Wilkinson Star Jasic TIG Series User manual

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
Secon Title Page
1Your new product 3
2Safety 4
3Product overview 6
4Panel layouts 7
5Control panel funcons 8
6Unpacking 11
7Input and output connecons 11
8MMA Welding 11
9TIG Welding 13
10 Maintenance and troubleshoong 16
11 Technical Parameters 19
Contents

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

Thank you for selecng 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 informaon provided paying parcular aenon to the
safety precauons. The informaon will help protect yourself and others against the potenal 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 operaon.
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 informaon 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 )



Disclaimer
Whilst every eort has been made to ensure that the informaon contained within this manual is
complete and accurate, no liability can be accepted for any errors or omissions. Please note products are
subject to connual development and may be subject to change without noce.
This manual should not be copied or reproduced without the wrien permission of Wilkinson Star
Limited

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

These general safety norms cover both arc welding
machines and plasma cung 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.

The equipment should be installed by a qualied
person and in accordance with current standards in
operaon. It is the users responsibility to ensure
that the equipment is connected to a suitable
power supply. Consult with your ulity 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 overheang. Do
not use worn, damaged, under sized, or poorly
jointed cables.
Ensure that you wear the correct protecve
clothing, gloves, head and eye protecon.
Insulate yourself from work and ground using dry
insulang 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
dierent machine.
Do not wrap cables over your body.
Ensure that you take addional safety precauons
when you are welding in electrically hazardous
condions such as damp environments, wearing
wet clothing, and metal structures. Try to avoid
welding in cramped or restricted posions.
Ensure that the equipment is well maintained.
Repair or replace damaged or defecve parts
immediately. Carry out any regular maintenance in
accordance with the manufacturers instrucons.

Locate the equipment in a well-venlated posion.
Keep your head out of the fumes. Do not breathe
the fumes.
Ensure the welding zone is in a well-venlated
area. If this is not possible provision should be
made for suitable fume extracon.
If venlaon is poor, wear an approved respirator.
Read and understand the Material Safety Data
Sheets (MSDS’s) and the manufacturer’s
instrucons for metals, consumable, coangs,
cleaners, and de-greasers.
Do not weld in locaons near any de-greasing,
cleaning, or spraying operaons. Be aware that
heat and rays of the arc can react with vapours to
form highly toxic and irritang gases.
Do not weld on coated metals, unless the coang is
removed from the weld area, the area is well
venlated, and while wearing an air-supplied
respirator. The coangs on many metals can give
o toxic fumes if welded.

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 WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
Wear approved safety glasses with side shields
under your helmet.
Never use broken or faulty welding helmets.
Always ensure there are adequate protecve
screens or barriers to protect others from ash,
glare and sparks from the welding area. Ensure
that there are adequate warnings that welding or
cung is taking place.
Wear suitable protecve ame resistant clothing.
The sparks and spaer 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, overheang, or re.
Check and be sure the area is safe and clear of
inammable material before carrying out any
welding.

Some welding and cung operaons may produce
noise.
Wear safety ear protecon to protect your hearing.

When the machine is in operaon keep away from
moving parts such as motors and fans. Moving
parts, such as the fan, may cut ngers and hands
and snag garments.
Protecons and coverings may be removed for
maintenance and controls only by qualied
personnel, aer rst disconnecng the power
supply cable.
Replace the coverings and protecons and close all
doors when the intervenon is nished, and before
starng the equipment.
Take care to avoid geng ngers trapped when
loading and feeding wire during set up and
operaon.
When feeding wire be careful to avoid poinng it at
other people or toward your body.
Always ensure machine covers and protecve
devices are in operaon.

Avoid causing res due to sparks and hot waste or
molten metal
Ensure that appropriate re safety devices are
available near the cung / welding area.
Remove all ammable and combusble materials
from the cung / 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
combusble or ammable material.
Do not work in atmospheres with high
concentraons of combusble fumes, ammable
gases and dust.
Always check the work area half an hour aer
cung to make sure that no res have begun.

The magnec elds created by high currents may
aect the operaon of pacemakers or
electronically controlled medical equipment.
Wearers of vital electronic equipment should
consult their physician before beginning any arc
welding, cung, gouging or spot welding
operaons.
Do not go near welding equipment with any
sensive electronic equipment as the magnec
elds may cause damage.

Equipment that complies with direcve 2004/108/
EC concerning electromagnec compability (EMC)

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
and the technical requirements of EN60974-10 is
designed for use in industrial buildings and not
those for domesc use where electricity is provided
via the low voltage public distribuon system.
Dicules may arise in assuring class A
electromagnec compability for systems installed
in domesc locaons due to conducted and
radiated emissions.
In the case of electromagnec problems, it is the
responsibility of the user to resolve the situaon. It
may be necessary to shield the equipment and t
suitable lters on the mains supply.

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 aect the quality of power provided by the
network. Consequently, connecon restricons or
maximum impedance requirements permied by
the network at the public network connecon point
must be applied to these systems.
In this case the installer or the user is responsible
for ensuring the equipment can be connected,
consulng the electricity provider if necessary.

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 separang components according to the
type of materials.
Do not dispose of the equipment with normal
waste. The European Direcve 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 compable recycling facility.
     

All cylinders and pressure regulators used in
welding operaons 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


Welding modes: DC TIG, Pulse TIG, DC MMA
Operang modes: Spot welding, 2T, 4T, Repeat
Equipped with HF and contact arc ignion.
MMA is equipped with an-sck and VRD.
Program storage in selected channels.
Energy saving intelligent cooling fan.
Advanced IGBT inverter technology
Digital MCU control mode
User friendly control panel
Can be used for a wide range of applicaons

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
No. Part name
1Protecve bar for front panel
2Scker on front panel
3Socket for the torch switch
4Socket for remote control
5“+” output terminal
6Rotary knob
7Gas outlet
8“-” output terminal
No. Part name
1Cable inlet
2Fuse holder
3Gas inlet
4Rubber foot
5Fan grill
6Back panel plasc enclosure
7Power switch




A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

1. Welding mode selecon zone
2. TIG welding parameters selecon zone
3. TIG welding mode selecon zone
4. MMA welding parameters selecon zone
5. Parameters adjustment rotary knob
6. Channel selecon buon
7. Parameters and protecon indicaon display zone
FUNCTIONS

Welding mode selecon zone contains welding
mode indicators and selecon key.
Welding modes include DC TIG, Pulse TIG, DIC
MMA(TIG400 has no pulse TIG funcon). Press the
welding mode selecon key to choose the
according welding mode. The welding mode being
selected LED will be lit when selected and there is
welding current owing.

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

This zone contains parameters selecon and VRD
switch-over
1.Press to switch MMA parameters; it can be
circulated among HOT START、CURRENT、ARC
FORCE
2.Press VRD and indicator is on; MMA will enter
VRD mode and OCV is 19V.



This zone contains display, parameters unit
indicator, warning indicator.
1. The window in the middle is a display to show
all parameters.
2. O.C on the le is over current protecon
indicator; O.H is over heat protecon indicator.
3. A、S、%、Hz on the right are parameters’
unit of current, me (second), duty cycle, HZ
respecvely.



This zone include 3 parts: TIG operang mode
selecon, water cooling switch key, arc ignion
switch key ( HF& contact)
1. TIG welding modes: 2T、4T、REPEAT、SPOT，
Press
to select the according welding mode.
2.TIG water cooling witch key
（1）press the key and indictor is on to enter water
cooling mode. In full set welding system, water
tank will give water ow signal and check whether
there is a water-lack; there is E-5 warning and is
with no output in case of water lack; please check
if everything is back to normal and observe
whether there is E-5 when under TIG.
（2）Every me operator presses this key, the gas
valve will work. Therefore, it can be used as gas
detecon.
3.Arc ignion type selecon.
（1）press this key and indicator is on to enter HF
arc ignion.
（2）press this key and indicator is o to enter li
arc ignion. When in this mode, place the torch to
contact workpiece; pull torch trigger then li the
torch slowly to achieve arc ignion.


A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

1. Press to circulate clockwise and select the
chosen TIG parameter.
2. Parameter descripon:
Tpre—Pre-ow me Is—Inial current
Tup—Up-slope me Ip—Peak current
Ib—Base current Tdown—Down-slope me
If—Final current Tpost—Post-ow me
Hz—Pulse frequency %--Pulse duty factor
Tspot—Spot welding me
Ib、Hz、% when in 
Ip is welding current.

Parameter adjustment rotary knob is
for all welding parameter seng.

For simple and ecient welding
processing, this machine is equipped
with 8 welding parameters storage
channels for DC TIG, Pulse TIG and DC
MMA.
The so-called channel is operator’s processing
specicaon plaorm (it contains welding funcon,
welding current, operang mode and other
parameters related with processing.) This machine
is working in certain channel when it’s powered on
and the channel it’s located in is the previous
working channel when the machine is turned o.
Check the channel number: press the channel key
when machine is under standby and the display
window will show the current working channel.
E.g.. When the current working channel is #6, then
the display will show “CH-6”.
To change the channel number: press the channel
key when machine is under standby and the display
window will show the current working channel.
Then adjust the rotary knob to change the working
channel from 1`8.
Exit channel management: re-press the CH key to
exit channel management.
Loading channel parameters ：press the channel
key when machine is under standby and the display
window will show the current working channel.
Then adjust the rotary knob to change the working
channel from 1`8. Re-press the CH key aer
selecng the required channel number and system
will show all the parameters under this channel for
operator’s usage.
Channel parameters’ storage: aer choosing the
required channel number and adjusng the
required welding parameters, the operator has to
start welding process to save the current
parameters.
：     
 ’    
      
      
        
      


The water cooler panel includes WORK indicator,
fuse,OUTPUT quick connector and INPUT quick
connector.
1. When WORK indicator is on, it means water
cooler is in operaon; when indicator is o, it
means water cooler is not working.
2. The water cooler operaon status is controlled
by the machine power source. When machine
power source is under TIG water cooling, which is

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
to say, the indicator is on, the opons
are:
（1）when there is current output from power
source, water cooler the WORK indicator is on.
（2）when the preset current is lower than 250A
and also there is no current output, the water
cooler will stop working aer 2 minutes and WORK
indicator will be o.
（3）when preset current is higher than 250A and
also there is no current output, the water cooler
will stop working aer 4 minutes and WORK
indicator will be o.
（4）when there is no water ow and also there is
no current output, the water cooler will stop
working aer 10 minutes and WORK indicator will
be o.
3. FUSE—The fuse rang is 5A.
4. OUTPUT (supply) quick connector has a blue
base and is connected to the water supply hose of
the welding torch (the torch’s blue quick
connector).
5. INPUT (return) quick connector has a red base
and is to connected water cooling return—
normally the torch power cable (the torch’s red
quick connector).

Check the packaging for any signs of damage.
Carefully remove the machine and retain the
packaging unl the installaon is complete.

The machine should be located in a suitable
posion 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 airow.


Before connecng 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
qualied competent person. Always ensure the
equipment has a proper grounding. Never connect
the machine to the mains supply with the panels
removed.

Electrode polarity
In general when using manual arc welding
electrodes the electrode holder is connected the
the posive terminal and the work return to the
negave 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 negave terminal
and the work return to the posive terminal.

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
     
      
     

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2


Switch the welding mode switch on the front panel
of the welding machine to “MMA” posion.
Turn on the power switch of the welding machine.
Then, the cooling fan will work, and the current
meter will display the preset welding current.
Adjust the welding parameters to the appropriate
values according to the welding requirements.
Aer the above steps are nished, welding can be
carried out. The current meter will display the actual
welding current when the arc is established
Aenon: This machine is equipped with an-
scking funcon. When arc voltage is too low and a
short circuit occurs the machine output is reduced
to 10A to prevent the electrode scking enabling it
to be broken away easily.

For more details always consult the electrode
material data sheet
Note: This table is suitable for mild steel welding. For other materials,
consult related materials and welding process for reference.

Adjustable
parameter
Adjusng
range Descripon
Arc ignion
current 0~200A
When the selected arc ignion
current is lower than the
welding current, it will output
the welding current
automacally when igning arc;
when the selected arc ignion
current is higher than the
welding current, it will output
the arc ignion current when
igning arc. If the arc ignion arc
is overly low, it is hard to ignite
arc and the success rate in arc
ignion is low; if the arc ignion
current is overly high, the
workpiece will be easily burned
through. Therefore, the arc
ignion current should be set
properly according to praccal
Welding
current 30~400A The output current for stable welding.
Arc force
current 0~200A
If the arc force current is overly
low, electrode scking will occur
during welding and the arc is
weak; if the arc force current is
overly high, excessive spaer
will be caused. Therefore, the
arc force current should be set
properly according to praccal
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

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

Insert the cable plug with the work clamp into the
“+” socket on the front panel of the welding
machine, and ghten it clockwise. Insert the cables
plug of the TIG torch into the “-” socket on the front
panel of the machine and ghten clockwise.
Connect the gas quick connector into the outlet on
the machine front.
Connect the torch switch plug into the socket on
the front panel.
Connect the gas hose to the regulator / owmeter
located on the shield gas cylinder and connect the
other end to the machine.

     
      
     


Switch the welding mode switch on the front panel
of the welding machine to “TIG” or “Pulse” posion.
Turn on the power switch of the welding machine.
Then, the cooling fan will work, and the current
meter will display the preset welding current.
Turn the gas-check/welding switch to “gas-check”
posion, and adjust the gas ow control knob on
the gas regulator to get the desired gas ow. Aer
that, turn the gas-check/welding switch to
“welding” posion.
Select the required operaon mode via the 2T/
repeang/4T / spot switch according to the welding
requirements.
Adjust the welding parameters to the appropriate
values according to the welding requirements.
Aer the above steps are nished, welding can be
carried out. The current meter will display the
actual welding current.



There are 4 operaon modes, namely 2T, 4T and

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
repeang are available for this machine in TIG
welding.
The adjustable TIG parameters are below.

In 2T mode, the gas valve opens aer the torch
switch is pressed down. Aer the pre-ow me
ends, discharge begins to ignite arc, and then the
current rises up to the welding current value
gradually. When the torch switch is released, the
current begins to drop gradually. When it drops to
the pilot arc current value, the current output is cut
o. The gas valve closes when the post-ow me
ends, and the welding process ends.
If the torch switch is pressed down during the
current downslope process, the current will rise up
to the welding current value, waing for the torch
switch to be released again.

In 4T mode, the gas valve opens aer the torch
switch is pressed down. Aer the pre-ow me
ends, HF discharge begins to ignite arc. Aer arc is
ignited successfully, the inial current is output.
Aer the torch switch is released, the current rises
up to the welding current value gradually and holds
there with the torch switch released. When the
torch switch is pressed down again, the current
begins to drop gradually to the pilot arc current
value. When the torch switch is released again, the
current output is cut o. Gas ows for the post ow
me
Adjustable
parameter
Adjusng
range Descripon
Pre-ow
me 0~15s
It is suggested to adjust it to
1s or an appropriate value
according to welding
requirements.
Post-ow
me 0~15s
It is suggested to adjust it to
5s or an appropriate value
according to welding
requirements.
Inial
current 5~100A
It is suggested to adjust it to
about 50% of the welding
current or an appropriate
value according to welding
requirements.
Up slope 0~10s To adjust the up slope me.
Welding
current 5~400A To adjust the welding current in DC TIG and to adjust the
Pulse
duraon
rao
10~90%
To adjust the percentage the
peak current holding in a
period in pulse TIG. Please set
it according to praccal
welding requirements.
Base
current 5~400A To adjust the base current value in pulse TIG.
Pulse
frequency 0.5~200Hz
To adjust pulse frequency. The
rst half of the knob is low
frequency range within
0.2~10Hz, and the second half
of the knob is high frequency
Downslope 0~10s To adjust the downslope me.
Pilot arc
current 5~400A
It is suggested to adjust it to a
lower value or an appropriate
value according to welding
requirements.

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

In repeang mode, the gas valve opens aer the
torch switch is pressed down. Aer the pre-ow
me ends, discharge begins to ignite arc. Aer arc
is ignited successfully, the pilot arc current is
output. Aer the torch switch is released, the
current rises up to the welding current value
gradually. When the torch switch is pressed down
again, the current begins to drop gradually to the
pilot arc current value. When the torch switch is
released again, the current rises up to the welding
current value gradually again. “Repeang” means
the welding current varies between the pilot arc
current value and the welding current value.
To exnguish arc, please keep the torch away
from workpiece to increase arc voltage, the arc
can be exnguished immediately and the current
output will be cut o. The gas valve closes when
the post-ow me ends, and the welding process
ends.

In spot welding mode discharge begins to ignite
arc aer the torch switch is pressed down. Aer
arc is ignited successfully, the welding current is
output . Now no maer if the torch switch is on or
o, the machine will sll output welding current.
When the spot welding me you have set is
over ,the arc will be exnguished. The gas valve
closes when the post-ow me ends, and the
welding process ends.
HF arc ignion is available for the above four
modes. This welder is also equipped with li arc
ignion. In this mode the tungsten is touched to
the work piece, the torch trigger operated and a
very low current ows. When the tungsten is lied
from the work piece the current will rise to the set
condion. Compared to HF ignion though it is
more dicult to get correct as many welders are
taught not to touch the electrode to the work
piece. Li arc ignion is not available in the spot
welding mode.

Shut o the cylinder valve and drain the gas in the
system. Turn of the power of the welding machine
3~5min aer the welding work is nished, so as to
cool the internal components of the machine.
Turn o the power switch on the welding machine
and then switch o the power at the mains
switching box.

Please do not dispose of electrical waste with
normal waste products. In accordance with the
European direcve 2002/96/EC regarding waste
electrical and electronic equipment and its
implementaon into naonal law any electrical or
electronic which has reached its end of life must
be collected separately and disposed of via a
suitable recycling facility.
The owner of the equipment is required to return
the equipment to a suitable recycling facility or to
Wilkinson Star Limited for the correct recycling of
the product.

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
 

    
     
     
       


In order to guarantee that the arc welding machine
works eciently and in safety, it must be
maintained regularly. Operators should understand
the maintenance methods and means of arc
welding machine operaon. This guide should
enable customers to carry on simple examinaon
and safeguarding by oneself, try to reduce the fault
rate and repair mes of the arc welding machine, so
as to lengthen service life of arc welding machine.











Items Checking requirements Remarks
Front
panel
Whether any of the
components are damaged or
loosely connected;
Whether the cables at the
boom are ghtly connected;
Whether the abnormity
indicator illuminates aer
starng the machine.
If qualied,
check the
interior of the
machine, and
ghten or
replace the
components.
Back
panel
Whether the input power
cable is in good condion;
Whether the air intake is
unobstructed.
Cover
Whether the handle is
damaged or loosely
connected.
If qualied,
ghten or
replace the
components.
Chassis
Whether any chassis
components are damaged or
loose
Fan
Whether the fan or fan guard
is distorted or damaged.
Whether the fan works or
sounds normal when the
machine is running;
If abnormal,
eliminate the
failures or
replace the
fan.
Gas
hose
Whether the gas hose joints
are ght and whether the gas
hose is damaged.
Tighten the
hose joints or
replace the
gas hose.

All maintenance and checking should be carried out
aer the power is completely cut o. Make sure the
power plug of the machine is pulled out before
uncovering the welding machine.
When the machine is powered on, keep hands, hair
and tools away from the moving parts such as the
fan to avoid personal injury or machine damage.

Check periodically whether inner circuit connecon
is in good condion (esp. plugs). Tighten the loose
connecon. If there is oxidizaon, remove it with
sandpaper and then reconnect. Check periodically
whether the insulang layer of all cables is in good
condion. If there is any dilapidaon, rewrap it or
replace it.

In order to protect the semiconductor components
and PCBs from the stac damage, please wear
anstac device or touch the metal part of the
enclosure to remove stac in advance before
contacng the conductors and PCBs of the machine
internal wiring.

Avoid rain, water and vapor inltrang the machine.
If there is, dry it and check the insulaon of the
welding machine (including that between the
connecons and that between the connecon and
the enclosure) with an ohmmeter. Only when there
are no abnormal phenomena anymore, can the
machine be used.
Put the machine into the original packing in dry
locaon if it is not to be used for a long me.

Periodic checks should be carried out to ensure the
long-term normal use of the machine. Be careful
when doing the periodic check, including the
inspecon and cleaning of the machine interior.
Generally, periodic check should be carried out
every 6 months, and it should be carried out every 3
months if the cung environment is dusty or with
heavy oily smoke.
Beware of corrosion
Please clean the plasc parts with neutral
detergent.

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

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 potenal 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 aer power
switch o before opening the case.

There are indicator alarms and meter alarm
funcons available for this machine when a
machine failure occurs.
When over current occurs, the over current
indicator on the front panel will illuminate and the
meter on the front panel will display “E-0”
When overheang occurs, the overheang
indicator on the front panel will illuminate and the
meter on the front panel will display “E-3”
When a problem occurs with the water cooling
system the meter on the front panel will display “E
– 5”

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2
Phenomena Cause Soluon
The fan does not work or works abnormally
and the meter does not display aer the
machine is started.
Phase failure of the mains power supply
or the power cable is not well
connected.
Solve the phase failure problem or reconnect
the power cable.
MMA
Hard to ignite arc The arc ignion current is too low or the
arc ignion me is too short.
Increase the arc ignion current or prolong
the arc ignion me properly.
Excessive spaer or
the molten pool is too
big.
The arc ignion current is too high or the
arc ignion me is too long.
Reduce the arc ignion current or shorten the
arc ignion me properly.
Normal arc can not be
started.
Phase failure of the mains power supply
or the power cord is not well connected.
Solve the phase failure problem or reconnect
the power cable.
Electrode scking The arc force current is too low. Increase the arc force current properly.
The electrode holder
becomes very hot.
The rated current of the electrode
holder is smaller than its actual working
current.
Replace it with a bigger rated current.
TIG
There is no current
output when pressing
down the torch
switch.
The torch switch circuit fails. Check the torch switch circuit.
The welding circuit is not in good
connecon.
Check the welding circuit and reconnect it if
necessary.
There is no HF
discharge when
pressing down the
torch switch in HF arc
ignion mode.
The torch switch is not connected well. Connect the torch switch well.
The HF discharge nozzle gap is too big. Adjust the discharge nozzle gap to about
1.0mm.
The electrode burns
quickly in TIG welding.
The output polarity connecon is
incorrect. Exchange the polarity.
TIG
Black weld bead The weld bead is not well protected and
is oxidized.
Make sure the gas valve of the cylinder is
open and the pressure inside the cylinder is
high enough. Generally, it is necessary to rell
the cylinder when the pressure is lower than
0.5MPa.
Check if the gas ow is normal. You may
select dierent gas ow according dierent
welding current. However low the current is,
the gas ow is recommended to be not less
than 5L/min. Otherwise, the weld bead may
not be fully covered for lack of shielded gas.
Check if the gas path is airproof and if the gas
is pure enough.
Check if the environment is with strong wind.
Arc is hard to start but
easy to break.
The electrode you use is of poor quality
or is badly oxidized.
Replace it with electrode of beer quality.
Remove the oxidized layer of the electrode.
Prolong the post-ow me to avoid
oxidizaon of the electrode.
Adjust the spark gap on the discharge board
to about 1.0mm.
Unstable current
during welding
Mains voltage uctuates badly, or the
input cable is loosely connected with the
mains power supply.
Check the mains power supply for normal
state, and reconnect the power cable.
There is serious interference from other
electric appliances
Do not connect the machine to the power
cable which is connected to other electric
appliances of serious interference.
Other failures Contact the service centre of our company.
POSSIBLE MACHINE FAILURES

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

Parameters Model
TIG400P (W322)
Input
Rated input power supply Three-phase AC400V 50/60Hz
Rated input capacity (KVA) 17.9
Power factor 0.96
MMA output
Rated no-load voltage (V) 68( 15V when under VRD)
Rated maximum output (A/V) 400/36
Welding current range (A) 30~400
Arc force current range (A) 0~200
Arc ignion current range (A) 0~200
Output characterisc CC
TIG output
Rated maximum output (A/V) 400/26
Welding current range (A) 5~400
Pre-ow me range (s) 0~15
Inial current range (A) 5~400
Pilot arc current range (A) 5~400
Up slope me range (s) 0~10
Base current range (A) 5~400
Peak current range (A) 5~400
Downslope me range (s) 0~10
Post-ow me range (s) 0~15
Pulse frequency range (Hz) 0.5~200
Pulse duraon rao range (%) 10~90
Spot welding me 0.1~10
Arc ignion mode HF /Li arc ignion
Output characterisc CC
Environment
Working temperature range (0C) -10~+40
Storage temperature range (0C) -25~+55
Humidity (%) ≤90% (no water condensate)
Structure Enclosure ingress protecon IP21S
Cooling mode Forced air cooling
Rated duty cycle (%) MMA:30 TIG:50
Eciency (%) 85
Insulaon grade F
Overall size (L*W*H) 595*297*528
Weight (Kg) 30

A WILKINSON STAR LIMITED PRODUCT 06-16 ISSUE 2

  -
