Jasic Power Arc 160 PFC User manual
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 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 )
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
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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.
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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.
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.
A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
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/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
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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
The unique electronic structure and air channel design in this series of machines provides ecient
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 eecvely 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 transion. The front and rear panels of the machine and the handle are
coated with rubber oil*, giving the machine a very tacle and comfortable grip with an excellent
appearance.
Product funcons
• Hot start arc ignion funcons: ensure the arc ignion in MMA welding easier and more reliable.
• Wide input voltage range on the PFC models
• An-scking funcon: Reduces the welding current if a short circuit occurs during welding.
• Self-adapve arc force technology: Maintains the opmum arc condions during welding even with
long cables.
• Advanced scratch start arc ignion: supports TIG welding without HF arc ignion circuit.
• Oponal VRD funcon: Provides addional safety keep the operator safe when the machine is idle.
Product performance characteriscs
• Advanced IGBT inverter technology
• Inverng frequency of 33~43 kHz greatly reduces the size and weight of the welder.
• Great reducon in magnec and resistance loss enhances the welding eciency and energy saving
eect.
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• Working frequency is beyond the audio range, which almost eliminates noise polluon.
• Industry leading control system
• Advanced control technology meets the various welding applicaons and provides excellent welding
performance.
• It can be used with a wide range of welding electrodes.
• Easy arc starng, less spaer, 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 plascs suitable for working in severe condions.
• Excellent insulang property.
• Water-resistant, anstac and ancorrosion design.
CONTROLS
Front view
1. Overheang LED: Overheang LED on indicates that the
temperature inside the machine is too high and the machine is
under overheang protecon 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
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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 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
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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 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
Aer connecng 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
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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.
Aer 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 lied o aer 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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2
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