Wilkinson Star Jasic JM-250C User manual

Operator Manual
www.jasic.co.uk
MIG Series
|MIG 250 Compact (JM-250C) |

Your new product
Thank you for selecting this Jasic Technology, Wilkinson Star product.
This product manual has been designed to ensure that you get the most from your new product. Please ensure that you are fully
conversant with the information provided paying particular attention to the safety precautions. The information will help protect
yourself and others against the potential hazards that you may come across.
Please ensure that you carry out daily and periodic maintenance checks to ensure years of reliable and trouble free operation.
Wilkinson Star Limited are a leading supplier of equipment in the UK and our products are supported by our extensive service
network. Call your distributor in the unlikely event of a problem occurring. Please record below the details from your product as
these will be required for warranty purposes and to ensure you get the correct information should you require assistance or
spare parts.
Date purchased!_____________________________________________________
From where ! ! _____________________________________________________
Serial Number!_____________________________________________________
(The serial number will normally be located on the equipment data plate on the underside of the machine or on the rear panel)
Please note products are subject to continual development and may be subject to change without notice
i

Safety Precautions
1
These general safety norms cover both arc welding
machines and plasma cutting machines unless
otherwise noted.
The equipment must only be used for the purpose it was
designed for. Using it in any other way could result in
damage or injury and in breach of the safety rules.
Only suitably trained and competent persons should use the
equipment. Operators should respect the safety of other
persons.
Prevention against electric shock
The equipment should be installed by a qualified person and
in accordance with current standards in operation.It is the
users responsibility to ensure that the equipment is
connected to a suitable power supply. Consult with your
utility supplier if required
If earth grounding of the work piece is required, ground it
directly with a separate cable.
Do not use the equipment with the covers removed.
Do not touch live electrical parts or parts which are
electrically charged.
Turn offall equipment when not in use.
Cables (both primary supply and welding) should be
regularly checked for damage and overheating. Do not use
worn, damaged, under sized, or poorly jointed cables.
Ensure that you wear the correct protective clothing, gloves,
head and eye protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact
with the work ground.
Never touch the electrode if you are in contact with the work
ground, or another electrode from a different machine.
Do not wrap cables over your body.
Ensure that you take additional safety precautions when you
are welding in electrically hazardous conditions such as
damp environments, wearing wet clothing, and metal
structures. Try to avoid welding in cramped or restricted
positions.
Ensure that the equipment is well maintained. Repair or
replace damaged or defective parts immediately. Carry out
any regular maintenance in accordance with the
manufacturers instructions.
Safety against fumes and welding gases
Locate the equipment in a well-ventilated position.
Keep your head out of the fumes. Do not breathe the fumes.
Ensure the welding zone is in a well-ventilated area. If this is
not possible provision should be made for suitable fume
extraction.
If ventilation is poor, wear an approved respirator.
Read and understand the Material Safety Data Sheets
(MSDS’s) and the manufacturer’s instructions for metals,
consumable, coatings, cleaners, and de-greasers.
Do not weld in locations near any de-greasing, cleaning, or
spraying operations. Be aware that heat and rays of the arc
can react with vapours to form highly toxic and irritating
gases.
2

Do not weld on coated metals, unless the coating is
removed from the weld area, the area is well ventilated, and
while wearing an air-supplied respirator. The coatings on
many metals can give offtoxic fumes if welded.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin.
Wear an approved welding helmet fitted with a proper shade
of filter lens to protect your face and eyes when welding or
watching
Wear approved safety glasses with side shields under your
helmet.
Never use broken or faulty welding helmets.
Always ensure there are adequate protective screens or
barriers to protect others from flash, glare and sparks from
the welding area. Ensure that there are adequate warnings
that welding or cutting is taking place.
Wear suitable protective flame resistant clothing.
The sparks and spatter from welding, hot work pieces, and
hot equipment can cause fires and burns
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to explode.
Accidental contact of electrode to metal objects can cause
arcs, explosion, overheating, or fire.
Check and be sure the area is safe and clear of inflammable
material before carrying out any welding.
Protection against noise
Some welding and cutting operations may produce noise.
Wear safety ear protection to protect your hearing.
Protection from moving parts
When the machine is in operation keep away from moving
parts such as motors and fans. Moving parts, such as the
fan, may cut fingers and hands and snag garments.
Protections and coverings may be removed for maintenance
and controls only by qualified personnel, after first
disconnecting the power supply cable.
Replace the coverings and protections and close all doors
when the intervention is finished, and before starting the
equipment.
Take care to avoid getting fingers trapped when loading and
feeding wire during set up and operation.
When feeding wire be careful to avoid pointing it at other
people or toward your body.
Always ensure machine covers and protective devices are in
operation.
Precautions against fire and explosion
Avoid causing fires due to sparks and hot waste or molten
metal
Ensure that appropriate fire safety devices are available near
the cutting / welding area.
Remove all flammable and combustible materials from the
cutting / welding zone and surrounding areas
Do not cut/weld fuel and lubricant containers, even if empty.
These must be carefully cleaned before they can be cut/
welded.
Always allow the cut/welded material to cool before touching
it or placing it in contact with combustible or flammable
material.
Do not work in atmospheres with high concentrations of
combustible fumes, flammable gases and dust.
Always check the work area half an hour after cutting to
make sure that no fires have begun.
Risks due to magnetic fields
The magnetic fields created by high currents may affect
the operation of pacemakers or electronically controlled
medical equipment.
Wearers of vital electronic equipment should consult their
physician before beginning any arc welding, cutting, gouging
or spot welding operations.
Do not go near welding equipment with any sensitive
electronic equipment as the magnetic fields may cause
damage.
3

RF Declaration
Equipment that complies with directive 2004/108/EC
concerning electromagnetic compatibility (EMC) and the
technical requirements of EN60974-10 is designed for use in
industrial buildings and not those for domestic use where
electricity is provided via the low voltage public distribution
system. Difficulties may arise in assuring class A
electromagnetic compatibility for systems installed in
domestic locations due to conducted and radiated
emissions.
In the case of electromagnetic problems, it is the
responsibility of the user to resolve the situation. It may be
necessary to shield the equipment and fit suitable filters on
the mains supply.
LF Declaration
Consult the data plate on the equipment for the power
supply requirements.
Due to the elevated absorbance of the primary current from
the power supply network, high power systems affect the
quality of power provided by the network. Consequently,
connection restrictions or maximum impedance
requirements permitted by the network at the public network
connection point must be applied to these systems.
In this case the installer or the user is responsible for
ensuring the equipment can be connected, consulting the
electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not
contain any toxic or poisonous materials dangerous to the
operator.
When the equipment is scrapped, it should be dismantled
separating components according to the type of materials.
Do not dispose of the equipment with normal waste. The
European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment states the electrical equipment that
has reached its end of life must be collected separately and
returned to an environmentally compatible recycling facility.
Handling of Compressed gas cylinders and
regulators
All cylinders and pressure regulators used in welding
operations should be handled with care.
Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
Always secure the cylinder safely
Never deface or alter any cylinder
4

Product Overview
2
The MIG 250 is an inverter power source that can provide
MIG, MMA and gas less self- shielded welding welding
options.
Its IGBT power device with unique control mode provides
excellent reliability with a high duty cycle.
The system has a closed loop feedback control, constant
voltage output, which allows it to operate with a wide
tolerance to mains fluctuation, within ±15%.
It has continuously adjustable welding voltage and current,
to provide excellent welding characteristics.
Adopting a unique welding dynamic characteristic control
circuit in MIG, provides a stable arc, low spatter, excellent
weld appearance and high welding efficiency.
By removing the ball at the end of the wire after welding, a
high no-load voltage, and slow wire feed at the start
presents exceptional arc starting.
The machine also has a very stable welding current in MMA,
excellent arc ignition, and can be used with a wide variety of
welding electrodes.
Its high inverter frequency greatly reduces the volume and
weight of the welder and the great reduction in magnetic
and resistance loss obviously enhances the welding
efficiency and energy saving effect.
Switching frequency is beyond audio range, which almost
eliminates noise pollution.
5

Technical data
3
Tested at the environment temperature of 400 C
Product design may vary due to customer requirements.
6
MODEL
MIG250
Input voltage (V)
Single-phase
AC230V±15%，50/60Hz
Rated input current (A)
45
Rated power supply capacity (KVA)
10.4
Recommended fuse capacity (A)
70
MMA welding current range (A)
10󺹱250
MIG current range (A)
25󺹱250
MIG voltage range (V)
11󺹱29
No-load voltage (V)
54
Wire feed speed range（m/min）
1.5󺹱16
Electrode diameter applicable (mm)
0.6/0.8/0.9 /1.0
Rated duty cycle
250A @35%
Efficiency (%)
85
Power factor
0.75
Protection class
IP21S
Insulation class
F
Size (mm)
880×296×616
Weight (Kg)
47

Controls
4
Front view
1. Power LED
2. Overheating LED
3. Wire inching button
4. Current control knob in MMA
5. Voltage control knob in MIG
6. Wire feed control knob in MIG
7. Voltage meter
8. Current meter
9. MMA/MIG switch
10. Pull torch switch
11. Socket of wire pull torch control cable
12. “＋” output terminal
13. “－” output terminal
14. Euro connector of the welding torch in MIG
15. Polarity selector cable
7

Rear View
16.!Power switch
17.!Input cable
18.!Power socket
19.!Fan
20.!Ground connection
21.!Gas solenoid inlet fitting
21.!Burn back control
8
!

Installation
5
Unpacking
Check the packaging for any signs of damage.
Carefully remove the machine and retain the packaging until
the installation is complete.
Location
The machine should be located in a suitable position and
environment. Care should be taken to avoid moisture, dust,
steam, oil or corrosive gases
Place on a secure level surface and ensure that there is
adequate clearance around the machine to ensure natural
airflow.
Input connection
Before connecting the machine you should ensure that the
correct supply is available. Details of the machine
requirements can be found on the data plate of the machine
or in the technical parameters shown in the manual.
The equipment should be connected by a suitably qualified
competent person. Always ensure the equipment has a
proper grounding.
Never connect the machine to the mains supply with the
panels removed.
Output connections
Electrode polarity
In general when using manual arc welding electrodes the
electrode holder is connected the the positive terminal and
the work return to the negative terminal. Always consult the
electrode manufacturer’s data sheet if you have any doubts.
When using the machine for TIG welding the TIG torch
should be connected to the negative terminal and the work
return to the positive terminal
MMA welding
Insert the cable plug with electrode holder into the “+”
socket on the
front panel of
the welding
machine, and
tighten it
clockwise.
Insert the cable
plug of the work
return lead into
the “-”ve socket
o n t h e f r o n t
panel of the
welding
machine, and
tighten it
clockwise
MIG Welding
Insert the welding torch into the “Euro connector for torch in
MIG” output socket on the front panel of the machine, and
tighten it.
Install the wire spool on the spindle adapter.
Connect the cylinder equipped with the gas regulator to the
gas inlet on the back panel of the machine with a gas hose.
Insert the cable plug with work clamp into the “-” output
terminal on the front panel of the welding machine, and
tighten it clockwise.
Insert the quick plug of the gas / no gas selector into the “+”
output terminal of the welding machine, and tighten it
clockwise.
Ensuring that the groove size in the feeding position on the
drive roll matches the contact tip size of the welding torch
and the wire size being used. Release the pressure arm of
the wire feeder to thread the wire through the guide tube,
9
!
SWITCHING BOX

and into the drive roll groove. Adjust the pressure arm,
ensuring no sliding of the wire. Too high pressure will lead to
wire distortion, which will affect wire feeding. Press the wire
inch button to thread the wire out of the torch contact tip.
Gas less Self Shielded Welding
Insert the welding torch into the “Euro connector for torch in
MIG” output socket on the front panel of the machine, and
tighten it.
Insert the cable plug with work clamp into the “+” output
terminal on the front panel of the welding machine, and
tighten it clockwise.
Insert the quick plug of the gas / no gas selector into the “-”
output terminal on the middle plate of the welding machine,
and tighten it clockwise.
Install the wire spool on the spindle adapter, ensuring that
the groove size in the feeding position on the drive roll
matches the contact tip size of the welding torch and the
wire size being used. Release the pressure arm of the wire
feeder to thread the wire through the guide tube, and into the
drive roll groove. Adjust the pressure arm, ensuring no
sliding of the wire. Too high pressure will lead to wire
distortion, which will affect wire feeding. Press the wire inch
button to thread the wire out of the torch contact tip.
10
GAS HOSE
SWITCHING BOX
SWITCHING BOX
!

Operation
Before starting any welding activity ensure that you have
suitable eye protection and protective clothing. Also take
the necessary steps to protect any persons within the
area.
MMA
After connecting the welding leads as detailed you will need
to switch on the machine. The power LED will be lit and the
fan running.
Switch the MMA/MIG switch to MMA.
Set the amperage on the machine using the MMA current
control knob to a value suitable for the electrode being used.
Please see below a guide to amperages required. Ensure
you check that you have the electrode polarity correct.
MIG/MAG
Connect the MIG torch leads as detailed above. Ensure that
a suitable inert gas supply is connected.
Switch the power switch on the back panel to “ON”, the
machine is started with the power LED on and the fan
working.
Switch the MMA/MIG switch to MIG mode.
Select pull position if using a remote torch
Open the gas valve of the cylinder, and adjust the gas
regulator to obtain the desired flow rate.
Adjust the “voltage control knob in MIG” and “wire feed
speed control knob in MIG” on the front panel of the
machine to get the correct welding voltage and welding
current.
Operate the torch trigger, and welding can be carried out.
Where required adjust the burn-back time potentiometer
(above the feed unit inside the machine) to get the proper
electrode stick-out.
One second after the arc stops, the gas supply will be cut
off.
Gas less MIG
The operation method is the same to MIG operation except
that there are no gas options.
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
11
Electrode Diameter (mm)
Recommended Welding Current (A)
1.0
20~60
1.6
44~84
2.0
60~100
2.5
80~120
3.2
108~148
4.0
140~180
5.0
180~220
6.0
220~260

Maintenance and troubleshooting
6
The following operation requires sufficient professional
knowledge on electric aspects and comprehensive
safety knowledge. Make sure the input cable of the
machine is disconnected from the electricity supply and
wait for 5 minutes before removing the machine covers.
In order to guarantee that the arc welding machine works
efficiently and in safety, it must be maintained regularly.
Operators should understand the maintenance methods and
means of arc welding machine operation. This guide should
enable customers to carry on simple examination and
safeguarding by oneself, try to reduce the fault rate and
repair times of the arc welding machine, so as to lengthen
service life of arc welding machine
Troubleshooting
Before arc welding machines are dispatched from the
factory, they have already been checked thoroughly. The
machine should not be tampered with or altered.
Maintenance must be carried out carefully. If any wire
becomes loose or is misplaced, it maybe potential danger to
user!
Only professional maintenance personnel should repair the
machine!
Ensure the power is disconnected before working on the
machine. Always wait 5 minutes after power switch off
before opening the case.
12
Period
Maintenance item
Daily
examination
Carry out a full visual inspection. Check
for any damage to the machine, leads,
cables and connections. Replace where
necessary.
Switch on the machine and check for any
warning Led’s and general operation
Monthly
examination
Using the dry compressed air to clean the
inside of arc welding machine. Especially
check for build up of dust / debris on
intake grills, main voltage transformer,
inductance, IGBT module, the fast recover
diode and PCB, etc. Take care when
blowing electronic components and do not
dislodge any wiring connections
Check the security of output connections
and plugs. Replace if signs of overheating.
Yearly
examination
Carry out an annual service. Check earth
continuity and insulation resistance of the
machine at the relevant points.
PLEASE NOTE THIS WORK SHOULD
BE CARRIED OUT BY A TRAINED
COMPETENT PERSON.

Symptom
Solution
The overheat LED is on.
1. Check the welding current and welding time. Refer to the manual, and
operate according to the specifications.!
2. Check the running status of the fan when welding. If the fan does not
work, check if the power supply of the fan is 230V: If the power
supply is normal, check the fan; if the power supply is abnormal,
check the connecting cable of the power supply.!
3. Replace the thermal switch if it is damaged or faulty.
The power LED is off, and
there is no output current.
1. Check if the fan works. If it does not work, it indicates that the power
supply is not present. Check any fuses cables and supply switches!
2. If the fan works, it indicates that the control PCB PK-63 inside the
machine may be defective.
There is no response when
operating the torch trigger, and
the protection LED is off.
1. Check if the torch trigger is working.!
2. Check if the welding torch is well connected to the Euro connector,
and check the connections of the Euro connector. !
3. The control PCB PK-63 inside the machine may be defective.
The wire feeder feeds wire
when operating the torch
trigger, gas feeds, but there is
no output current, and the
protection LED is off.
1. Check if the work return connected to the workpiece is in good
condition.!
2. Check if the quick plug is connected to correct quick socket.!
3. Check if the euro connector is intact.!
4. Check the welding torch for damage.!
5. The control PCB PK-63 inside the machine may be defective.
There is output current when
operating the torch trigger to
feed gas, but the wire feeder
does not feed wire.
1. Check the wire feeder for clogging or damage.!
2. Check the contact tip of welding torch for clogging or damage.!
3. The control PCB PK-63 inside the machine may be defective.
Welding can be carried out
when pushing the torch trigger,
but the voltage cannot be
adjusted.
1. Check if the voltage feedback wire inside the machine is in good
condition.!
2. The control PCB PK-63 inside the machine may be defective.
Welding current is unstable.
1. Check the pressure arm on the wire feeder for proper pressure.!
2. Check if the drive roll matches the wire size being used.!
3. Check the contact tip of the welding torch for wear. Replace it and
tighten it if necessary.!
4. Check the welding wire for good quality.!
5. Check the torch.!
6. Check if the quick plug is loose.
Weld bead is not well shielded.
1. Do not move the welding torch away immediately when stopping
welding, so that the shielded gas can protect the weld bead.!
2. Prolong the post-flow time of the shielded gas.
13

Electrical schematic
7
14
A

Parts list
8
15

16
No.
Part no
Description
No.
Part no
Description
1
10020951
Fan
18
10016534
Swivel wheel
2
10021881
Square sockets
19
10006625
Silicon bridge
3
10021912
Line button
20
10020611
Output absorbing board
4
10004951
Air Switch
21
10020477
Filter board
5
10020512
Control Board
22
10006231
Power supply transformer
6
10001256
Burn back potentiometer
23
10020408
Secondary Rectifier board
7
10002343
Output absorbing board
24
10020582
Power Panel
8
10021665
Wire Feeder motor
25
10006064
Main transformer
9
10006505
Wire feed rate
potentiometer
26
10029695
IGBT
10
10003588
Inching button
27
10020994
Inverter board
11
10003828
Euro connector socket
28
10006559
Reactor
12
10016486
Insulated flange
29
10020626
Peak current feedback board
13
10003238
Four pin socket
30
10023147
Flexible ring for axle
14
10021846
Quick socket
31
10016699
Spool
15
10003348
Quick socket cable
32
10016535
Wheel
16
10006797
Digital Meter
33
10001346
Solenoid value
17
10004956
Switch
34
10016685
Spool holder

JM MIG Series MIG/MAG/MMA WELDING MACHINE
Order code !JM-250C (MIG 250)
© Wilkinson Star Limited
Issue 1 January 2014
Product is subject to change without notice
xvii