Wilkinson Star Jasic JT-200P-PFC User manual
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Your new product
Thank you for selecng 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 informaon provided paying parcular aenon to the
safety precauons. The informaon will help protect yourself and others against the potenal 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 operaon.
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 informaon 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 top or underside of the
machine )
PLEASE REGISTER YOUR PRODUCT ONLINE AT WWW.JASIC.CO.UK/REGISTER
When all entry elds are complete the system will show a short message thanking you for a successful
registraon.
Disclaimer
Whilst every eort has been made to ensure that the informaon contained within this manual is
complete and accurate, no liability can be accepted for any errors or omissions. Please note products are
subject to connual development and may be subject to change without noce.
This manual should not be copied or reproduced without the wrien permission of Wilkinson Star
Limited
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
SAFETY
These general safety norms cover both arc welding
machines and plasma cung 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.
Prevenon against electric shock
The equipment should be installed by a qualied
person and in accordance with current standards in
operaon. It is the users responsibility to ensure
that the equipment is connected to a suitable
power supply. Consult with your ulity 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 o all equipment when not in use.
Cables (both primary supply and welding) should
be
regularly checked for damage and overheang. Do
not use worn, damaged, under sized, or poorly
jointed cables.
Ensure that you wear the correct protecve
clothing, gloves, head and eye protecon.
Insulate yourself from work and ground using dry
insulang 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
dierent machine.
Do not wrap cables over your body.
Ensure that you take addional safety precauons
when you are welding in electrically hazardous
condions such as damp environments, wearing
wet clothing, and metal structures. Try to avoid
welding in cramped or restricted posions.
Ensure that the equipment is well maintained.
Repair or replace damaged or defecve parts
immediately. Carry out any regular maintenance in
accordance with the manufacturers instrucons.
Safety against fumes and welding gases
Locate the equipment in a well-venlated posion.
Keep your head out of the fumes. Do not breathe
the fumes.
Ensure the welding zone is in a well-venlated
area. If this is not possible provision should be
made for suitable fume extracon.
If venlaon is poor, wear an approved respirator.
Read and understand the Material Safety Data
Sheets (MSDS’s) and the manufacturer’s
instrucons for metals, consumable, coangs,
cleaners, and de-greasers.
Do not weld in locaons near any de-greasing,
cleaning, or spraying operaons. Be aware that
heat and rays of the arc can react with vapours to
form highly toxic and irritang gases.
Do not weld on coated metals, unless the coang is
removed from the weld area, the area is well
venlated, and while wearing an air-supplied
respirator. The coangs on many metals can give
o toxic fumes if welded.
Prevenon against burns and radiaon
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 ed with a
proper shade of lter lens to protect your face and
eyes when welding or watching.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Wear approved safety glasses with side shields
under your helmet.
Never use broken or faulty welding helmets.
Always ensure there are adequate protecve
screens or barriers to protect others from ash,
glare and sparks from the welding area. Ensure
that there are adequate warnings that welding or
cung is taking place.
Wear suitable protecve ame resistant clothing.
The sparks and spaer from welding, hot work
pieces, and hot equipment can cause res 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, overheang, or re.
Check and be sure the area is safe and clear of
inammable material before carrying out any
welding.
Protecon against noise
Some welding and cung operaons may produce
noise.
Wear safety ear protecon to protect your hearing.
Protecon from moving parts
When the machine is in operaon keep away from
moving parts such as motors and fans. Moving
parts, such as the fan, may cut ngers and hands
and snag garments.
Protecons and coverings may be removed for
maintenance and controls only by qualied
personnel, aer rst disconnecng the power
supply cable.
Replace the coverings and protecons and close all
doors when the intervenon is nished, and before
starng the equipment.
Take care to avoid geng ngers trapped when
loading and feeding wire during set up and
operaon.
When feeding wire be careful to avoid poinng it at
other people or toward your body.
Always ensure machine covers and protecve
devices are in operaon.
Precauons against re and explosion
Avoid causing res due to sparks and hot waste or
molten metal
Ensure that appropriate re safety devices are
available near the cung / welding area.
Remove all ammable and combusble materials
from the cung / 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
combusble or ammable material.
Do not work in atmospheres with high
concentraons of combusble fumes, ammable
gases and dust.
Always check the work area half an hour aer
cung to make sure that no res have begun.
Risks due to magnec elds
The magnec elds created by high currents may
aect the operaon of pacemakers or
electronically controlled medical equipment.
Wearers of vital electronic equipment should
consult their physician before beginning any arc
welding, cung, gouging or spot welding
operaons.
Do not go near welding equipment with any
sensive electronic equipment as the magnec
elds may cause damage.
RF Declaraon
Equipment that complies with direcve 2004/108/
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
EC concerning electromagnec compability (EMC)
and the technical requirements of EN60974-10 is
designed for use in industrial buildings and not
those for domesc use where electricity is provided
via the low voltage public distribuon system.
Dicules may arise in assuring class A
electromagnec compability for systems installed
in domesc locaons due to conducted and
radiated emissions.
In the case of electromagnec problems, it is the
responsibility of the user to resolve the situaon. It
may be necessary to shield the equipment and t
suitable lters on the mains supply.
LF Declaraon
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 aect the quality of power provided by the
network. Consequently, connecon restricons or
maximum impedance requirements permied by
the network at the public network connecon point
must be applied to these systems.
In this case the installer or the user is responsible
for ensuring the equipment can be connected,
consulng 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 separang components according to the
type of materials.
Do not dispose of the equipment with normal
waste. The European Direcve 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 compable recycling facility.
Handling of Compressed gas cylinders and
regulators
All cylinders and pressure regulators used in
welding operaons 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
PRODUCT OVERVIEW
Welding modes: DC TIG, Pulse TIG, DC MMA
Operang modes: Spot welding, 2T, 4T
MMA is equipped with automac an-sck.
Advanced IGBT inverter technology
User friendly control panel
Easy to use intuive digital control panel for seng
of parameters.
• LED display
• Rotary encoder control
• Self adapve Arc force current control
• Upslope, Downslope, pre and post-ow gas
funcon all adjustable
• Full control of pulse parameters
• Self-adapve arc force technology improves the
performance of the machine when using long-cable
welding.
• Excellent HF arc ignion: High reliability arc
striking.
• Over current, under-voltage and overheang
protecon funcons are standard.
• Fault memory display
• Memory funcon of last used parameters
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
No. Part name
1Digital meter
2Controls
3Selector switch
4Selector for 2T, 4T or spot mode
5“+” output terminal
6“-” output terminal
7Gas outlet
8Torch switch plug socket
9Air vent
10 Adjusng knob
11 Process LEDs
12 Process selector
13 Mains and overheat LEDs
No. Part name
14 Mains switch
15 Cable inlet
16 Air vent
17 Shield gas inlet
CONTROLS
Front view
Rear view
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Machine panel funcons
1DIGITAL METER—Displays parameters during set up and actual values when welding. Also used to
display any error message codes
2Overheat LED. Will be lit when the machine enters overheat condions. Welding will cease whilst
this LED is lit.
3Mains LED. This will be lit when mains supply is connected and the mains switch is on.
4Welding mode selecon zone. Welding mode selecon zone contains welding mode indicators and
selecon key. Welding modes include DC TIG, Pulse TIG, DIC MMA(TIG400 has no pulse TIG func-
on). Press the welding mode selecon key to choose the according welding mode. The welding
mode being selected LED will be lit when selected and there is welding current owing.
5Adjustment knob. Used to select and adjust parameters
6Parameter selecon area. Using the adjustment knob highlight the LED of the parameter to be
adjusted in the selecon area
7Arc force LED. When selected this will be lit and the arc force parameter can be adjusted.
8HF / Spot LED
9Use the selector to choose the mode 2T, 4T or Spot
10 Frequency LED. When lit the pulse frequency can be adjusted
11 Pulse duty LED . When lit the me on peak current during each pulse can be adjusted.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
FUNCTIONS
Press the selector unl the LED is lit
against the required parameter. The
parameter can the be adjusted
1DC Pulsed TIG mode
2DC TIG mode
3DC MMA mode
42T mode
54T mode
6Spot welding mode
7Pre ow gas me LED
8Start current LED
9Slope up me LED
10 Peak current LED
11 Background current (in pulse mode)
LED
12 Downslope me LED
13 Crater current LED
14 Post ow gas me LED
15 HF/ Spot me LED
16 Arc force LED
17 Pulse frequency LED
18 Pulse duty LED
19 Overheat LED
20 Mains power LED
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Parameter AutoSaving
The parameters having been adjusted will be AutoSaved in the parameter group currently used (no
AutoSaving will be done in the case that no operaon is done aer parameters are adjusted and the
machine was turned o in 5s’ me). When the machine is turned on next me, the parameters in this
parameter group are just the parameters used last me. When the welding mode and operaon mode
are reselected, AutoSaving will be done in 10s. No special save key and manual saving operaon is
available for this machine.
Protecon funcon
When the overcurrent indicator illuminates and the digital meter displays
“E-1”, it indicates that overcurrent occurs. Restart the machine, and
welding can be connued.
When the under-voltage indicator illuminates and the digital meter displays
“E-2”, it indicates that the mains voltage is overly low, and welding can be
recovered when the mains voltage goes into normal.
When the overheang indicator illuminates and the digital meter displays
“E-3”, it indicates that welding is forced to stop because the main circuit of
the machine gets overheated. In this condion, It is unnecessary to turn o
the machine, but just wait a few minutes, and then welding can be
connued.
When the current sensor fails and the digital meter displays “E-4”, welding
may sll be carried out. However, the current value at this me is
inaccurate.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Unpacking
Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging
unl the installaon is complete.
Locaon
The machine should be located in a suitable posion 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 airow.
Input connecon
Before connecng 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 qualied competent person. Always ensure the
equipment has a proper grounding. Never connect the machine to the mains supply with the panels
removed.
Output connecons
Electrode polarity
In general when using manual arc welding electrodes the electrode holder is connected the the posive
terminal and the work return to the negave 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 negave terminal and
the work return to the posive terminal.
MMA welding
Insert the cable plug with electrode holder into the “+” socket on the front
panel of the welding machine, and ghten it clockwise. Insert the cable
plug of the work return lead into the “-”ve socket on the front panel of the
welding machine, and ghten it clockwise
Before starng any welding acvity ensure that you have suitable eye protecon and protecve
clothing. Also take the necessary steps to protect any persons within the area.
MMA operaon steps
Select MMA mode by pressing the welding mode selecng key, and MMA can be
carries out. There is voltage output at both output terminals.
At this time, the voltage indicator illuminates, and welding can be carried out.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Select the welding current seng funcon by pressing the welding
parameter selecng key, and welding current in MMA can be set.
Welding current seng can be carried out during welding.
Select the arc ignion me seng funcon (This funcon changes into
spot welding me seng funcon in TIG spot welding mode.) by
pressing the welding parameter selecng key, and arc ignion me in
MMA can be set. Besides, arc ignion me seng can be carried out
during welding.
Select the arc force current seng funcon by pressing the welding
parameter selecng key, and arc force current in MMA can be set.
Besides, arc force current seng can be carried out during welding.
If the secondary cables (welding cable and earth cable) are long, select cable with larger cross-secon to
reduce the voltage drop.
Preset the welding current according to the type and size of the electrode, clip the electrode and then
welding can be carried out by short circuit arc ignion. For welding parameters, please refer to the below
table
.
Electrode diameter (mm) Recommended welding current (A) Recommended welding voltage (V)
1.0 20~60 20.8~22.4
1.6 44~84 21.76~23.36
2.0 60~100 22.4~24.0
2.5 80~120 23.2~24.8
3.2 108~148 24.32~24.92
4.0 140~180 24.6~27.2
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
TIG WELDING
Connect the TIG torch connector to the “-” quick socket on the machine panel, and ghten it clockwise.
Connect the switch plug on the TIG torch to the corresponding socket on the machine panel, this is a
quick connector so it is not necessary to turn the plug.
Insert the quick plug on the work return cable into the “+” quick socket on the machine panel, and
ghten it clockwise. Clamp the workpiece with the work clamp at the other end of the earth cable.
Connect the gas hose of the TIG torch to the quick connector on the machine front.
Connect the gas hose to the gas inlet on the back panel of the machine. The other end of the supply
hose connects to the gas regulator on the cylinder.
OPERATION
DC TIG
Select the DC TIG mode by pressing the welding mode selecng key,
Select the 2T mode by pressing the operaon mode selecng key.
Select the pre-ow me seng
funcon by pressing the welding
parameter selecng key, and set the
pre-ow me.
Select the inial current seng
funcon by pressing the welding
parameter selecng key, and set the
inial current.
Select the upslope me seng
funcon by pressing the welding
parameter selecng key, and set the
upslope me.
Select the welding current seng
funcon by pressing the welding
parameter selecng key, and set the
welding current.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Select the downslope me seng
funcon by pressing the welding
parameter selecng key, and set the
downslope me.
Select the crater current seng funcon
by pressing the welding parameter
selecng key, and set the pilot arc current.
Select the post-ow me seng
funcon by pressing the welding
parameter selecng key, and set the
post-ow me.
Aer the parameters are set appropriately, open the gas valve of the cylinder, and adjust the gas
regulator to the desired ow value.
Keep the torch 2~4mm away from the workpiece, and then press the torch trigger, the solenoid valve
will operate , gas will ow and HF starts.
Aer arc is ignited, the HF discharge rustling disappears, the current rises up to the preset value, and
welding can be carried out. Aer releasing the torch trigger, the current begin to decrease
automacally to the crater current value. Then, arc stops with gas kept owing for the post-ow me,
and welding ends.
PULSED TIG
Select the pulsed TIG mode by pressing the welding mode selecng key.
Select the 2T mode by pressing the operaon mode selecng key.
Proceed with the set up as for standard TIG. The welding current seng now becomes the peak
welding current of the pulse. The next step will allow seng of the base current. This is only allowed
when the pulse mode is selected.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Select the peak welding current seng
funcon by pressing the welding parameter
selecng key, and set the peak welding
current.
Select the base current seng funcon by
pressing the welding parameter selecng
key, and set the base current.
Select the downslope me, crater current ans post ow gas me as standard TIG.
Select pulse duty rao seng funcon by
pressing the welding parameter selecng
key, and set the pulse duty rao.
Select pulse frequency seng funcon by
pressing the welding parameter selecng
key, and set the pulse frequency.
SPOT WELDING
Select the spot welding me seng funcon by
pressing the welding parameter selecng key,
and set the spot welding me.
Aer the parameters are set appropriately, open the gas valve of the cylinder, and adjust the gas
regulator to the desired gas ow.
Keep the torch 2-4mm away from the workpiece, and then press the torch trigger. Gas will ow followed
by the HF and the arc is ignited. Once the arc is ignited the HF will cease and , the current rises up to the
preset value, and welding can be carried out. Aer releasing the torch trigger, the current begins to
decrease automacally to the crater current value. Then, arc stops with gas keeping owing for the post-
ow me, and welding ends.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
Operaon steps in spot welding:
Keep the torch 2-4mm away from the workpiece Press the torch trigger, gas valve opens, and HF starts
and this ignites the arc. When the arc is established the HF stops, and the current goes to the the preset
value. Welding begins, and it ends when the spot welding me is up. There is no current upslope and
downslope in spot welding mode.
TROUBLESHOOTING
The following operaons should only be carried out by suitably qualied competent persons. Make
sure the input cable of the machine is disconnected from the electricity supply before removing covers
from the welding machine.
Fault symptom Causes and Soluons
Turn on the machine, the power indicator
does not illuminate, the fan doesn't work,
and no welding output.
Check if the power switch is closed.
No input power.
Turn on the machine, the fan works, but
the output current is unstable and can't be
controlled by potenometer when welding.
The current potenometer fails. Replace it.
Check if any loose contact exists inside the machine. If any, reconnect.
Turn on the machine, the power indicator
illuminates, the fan works, but no welding
output.
Check if any loose contact exists inside the machine.
Open circuit or loose contact occurs at the joint of output terminal.
The overheang LED illuminates.
The machine is under overheang protecon status. It can recover
automacally aer the welding machine is cooled.
Check if the thermal switch is ok. Replace it if damaged.
Check if the thermal switch is loosely connected, and reconnect it if
The electrode holder becomes very hot. The rated current of the electrode holder is smaller than its actual working
Excessive spaer in MMA welding. The output polarity connecon is incorrect. Exchange the polarity.
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
TECHNICAL PARAMETERS
Technical Parameter Unit Model
TIG200P PFC
Rated input voltage VAC95-270V; 50/60HZ
Input current Ie
110V A27.7
230V 14.2
Welding current range
MMA A10—125 - 110V
A10—180 - 230V
TIG A10—160 - 110V
A10—200 - 230V
No-load voltage MMA V65
TIG 65
Duty cycle
MMA
%
125@60 - 110V
180@25 - 230V
160@60 - 110V
TIG 200 @30 - 230V
Post-ow me s0~15
Overall eciency %85
Housing protecon grade IP 21S
Power factor cosφ0.99
Insulaon grade F
Arc ignion mode HF arc ignion
Standard IEC60974-1
Noise db ＜70
Size without handle mm 420*135*235
with handle②420*135*277
Weight kg 7.5
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
ELECTRICAL SCHEMATIC
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
1
2
3
4
5
6
7
TIG TORCH COMPONENTS
1. Long back cap
2. Tungsten electrode
3. Collet body
4. Torch head
5. Collet
6. Ceramic nozzle
7. Insulated cap for torch head
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
NOTES
A WILKINSONSTAR PRODUCT 02-18 ISSUE 1
TIG Series
TIG 200P PFC Order code ZXJT-200P-PFC
© Wilkinson Star Limited
This manual suits for next models
2
Table of contents
Other Wilkinson Star Welding System manuals
