Jasic Power Arc 160 PFC Bedienungsanleitung

Operator Manual

www.jasic.co.uk

Power Arc Series

|Power Arc 160 PFC (JPA-160PFC) |Power Arc 180 (JPA-180SE) |

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

Your new product

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 12-16 ISSUE 1

SAFETY

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.

Prevenon against electric shock

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.

Safety against fumes and welding gases

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.

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

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.

Prevenon against burns and radiaon

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.

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.

Protecon against noise

Some welding and cung operaons may produce noise.

Wear safety ear protecon to protect your hearing.

Protecon from moving parts

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.

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

Always ensure machine covers and protecve devices are in operaon.

Precauons 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 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.

Risks due to magnec elds

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.

RF Declaraon

Equipment that complies with direcve 2004/108/EC concerning electromagnec compability (EMC)

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.

LF Declaraon

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.

Materials and their disposal

The equipment is manufactured with materials, which do not contain any toxic or poisonous materials

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

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.

Handling of Compressed gas cylinders and regulators

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

Never deface or alter any cylinder

PRODUCT OVERVIEW

The unique electronic structure and air channel design in this series of machines provides ecient

cooling of the power devices as well as improving the duty cycles of the machines. The design of the

forced air-cooling system channel can eecvely prevent the power devices and control circuits from

being damaged by the dust introduced into the machine by the fan. The reliability of the machine is

greatly improved as a result. The streamline design means front and rear panels are naturally

Integrated via large radian transion. The front and rear panels of the machine and the handle are

coated with rubber oil*, giving the machine a very tacle and comfortable grip with an excellent

appearance.

Product funcons

• Hot start arc ignion funcons: ensure the arc ignion in MMA welding easier and more reliable.

• Wide input voltage range on the PFC models

• An-scking funcon: Reduces the welding current if a short circuit occurs during welding.

• Self-adapve arc force technology: Maintains the opmum arc condions during welding even with

long cables.

• Advanced scratch start arc ignion: supports TIG welding without HF arc ignion circuit.

• Oponal VRD funcon: Provides addional safety keep the operator safe when the machine is idle.

Product performance characteriscs

• Advanced IGBT inverter technology

• Inverng frequency of 33~43 kHz greatly reduces the size and weight of the welder.

• Great reducon in magnec and resistance loss enhances the welding eciency and energy saving

eect.

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

• Working frequency is beyond the audio range, which almost eliminates noise polluon.

• Industry leading control system

• Advanced control technology meets the various welding applicaons and provides excellent welding

performance.

• It can be used with a wide range of welding electrodes.

• Easy arc starng, less spaer, stable current and good weld bead shaping.

• Modern high tech design

• Streamline design of front and rear panels.

• Front and rear panels made of high-intensity plascs suitable for working in severe condions.

• Excellent insulang property.

• Water-resistant, anstac and ancorrosion design.

CONTROLS

Front view

1. Overheang LED: Overheang LED on indicates that the

temperature inside the machine is too high and the machine is

under overheang protecon status.

2. Power LED: Power LED on indicates that the power switch of the

machine is on.

3. MMA/TIG switch: To toggle between MMA and TIG.

4. "+" Output terminal: To connect the electrode holder.

5. "-" Output terminal: To connect the work clamp.

6. Trademark

7. Welding current knob: To adjust the output current.

8. Handle

Rear view

9 Power switch

10 Warning label

11 Input cable gland

12 Cooling fan

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

Unpacking

Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging

unl the installaon is complete.

Locaon

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.

Input connecon

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.

Output connecons

Electrode polarity

In general when using manual arc welding electrodes the electrode holder is connected 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.

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

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

TIG Welding

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 hose to the regulator / owmeter located on the shield gas cylinder and connect the

other end to the machine.

OPERATION

Before starng any welding acvity ensure that you have suitable eye protecon and protecve

clothing. Also take the necessary steps to protect any persons within the area.

MMA

Aer connecng the welding leads as detailed you will need to switch the power switch on the back

panel to “ON” . Select MMA by switching to the MMA welding mode. There is voltage output at both

output terminals. Set the amperage on the machine suitable for the electrode being used. Please see

below a guide to amperages required. Ensure you check that you have the electrode polarity correct.

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

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1

TIG mode

Connect the TIG torch leads as detailed above. Ensure that a suitable inert gas supply is connected.

Switch the power switch on the back panel to “ON”. Select the TIG welding mode using the selector

switch. There is voltage output at both output terminals.

Aer the parameters are set appropriately, open the gas valve of the cylinder, the gas valve on the torch

and adjust the gas regulator to obtain the desired ow rate. The arc will start when the tungsten elec-

trode touches the work piece and is lied o aer touching by between 2-4mm The arc will cease when

the electrode (torch) is moved away from the work area.

TIG guides

The recommended size of tungsten to be used can be selected from the table below

Electrode types

Gas nozzle sizes

For welder training please contact our welding academy at

www.wilkinson-welding-academy.com

Electrode diameter /mm 1.0 1.6 2.4 3.2

Welding current /A 15-80 70-150 150-250 250-400

Type Material to be welded Colour

Thoriated 2% DC welding of steel, stainless

steel and copper

Red

Ceriated DC welding of steel, stainless

steel and copper

Grey

Lanthanated DC welding of steel, stainless

steel and copper

Black

Gas nozzle diameter/mm Electrode diameter/mm

81.0

9.5 1.6 / 2.4

11.1 3.2

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