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Safety Precautions

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These general safety norms cover both arc welding 
machines and plasma cutting machines unless 
otherwise noted.

The  equipment  must  only  be  used  for  the  purpose  it  was 
designed  for.  Using  it  in  any  other  way  could  result  in 
damage or injury and in breach of the safety rules.

Only suitably trained and competent persons should use the 
equipment.  Operators  should    respect  the  safety  of  other 
persons.

Prevention against electric shock

The equipment should be installed by a qualified person and 
in  accordance  with  current  standards  in  operation.It  is  the 
users  responsibility  to  ensure  that  the  equipment  is 
connected  to  a  suitable  power  supply.  Consult  with  your 
utility supplier if required

If  earth  grounding  of  the  work  piece  is  required,  ground  it 
directly with a separate cable. 

Do not use the equipment with the covers removed.

Do  not  touch  live  electrical  parts  or  parts  which  are 
electrically charged. 

Turn o

 all equipment when not in use. 

Cables  (both  primary  supply  and  welding)  should  be 
regularly  checked  for  damage  and  overheating.  Do  not  use 
worn, damaged, under sized, or poorly jointed cables.

Ensure that you wear the correct protective clothing, gloves, 
head and eye protection. 

Insulate yourself from work and ground using dry insulating 
mats or covers big enough to prevent any physical contact 
with the work ground. 

Never touch the electrode if you are in contact with the work 
ground, or another electrode from a di

erent machine. 

Do not wrap cables over your body. 

Ensure that you take additional safety precautions when you 
are  welding  in  electrically  hazardous  conditions  such  as 
damp  environments,  wearing  wet  clothing,  and  metal 
structures.  Try  to  avoid  welding  in  cramped  or  restricted 
positions. 

Ensure  that  the  equipment  is  well  maintained.  Repair  or 
replace damaged or   defective parts immediately. Carry out 
any  regular  maintenance  in  accordance  with  the 
manufacturers instructions.

Safety against fumes and welding gases

Locate the equipment in a well-ventilated position.

Keep your head out of the fumes. Do not breathe the fumes. 

Ensure the welding zone is in a well-ventilated area. If this is 
not  possible  provision  should  be  made  for  suitable  fume 
extraction. 

If ventilation is poor, wear an approved respirator. 

Read  and  understand  the  Material  Safety  Data  Sheets 
(MSDS’s)  and  the  manufacturer’s  instructions  for  metals, 
consumable, coatings, cleaners, and de-greasers. 

Do not weld in locations near any de-greasing, cleaning, or 
spraying operations.  Be aware that heat and rays of the arc 
can  react  with  vapours  to  form  highly  toxic  and  irritating 
gases. 

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Summary of Contents for Arc JA-140

Page 1: ...wilkinsonstar com Arc Series DC MMA LIFT TIG Welding machines Order codes JA 140 JA 160 JA 180 JA 200 JA 160DV JA 180DV Dual voltage OPERATOR MANUAL ...

Page 2: ...upplier of equipment in the UK and our products are supported by our extensive service network Call your distributor in the unlikely event of a problem occurring Please record below the details from your product as these will be required for warranty purposes and to ensure you get the correct information should you require assistance or spare parts Date purchased __________________________________...

Page 3: ...ye protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work ground Never touch the electrode if you are in contact with the work ground or another electrode from a different machine Do not wrap cables over your body Ensure that you take additional safety precautions when you are welding in electrically hazardous c...

Page 4: ... fan may cut fingers and hands and snag garments Protections and coverings may be removed for maintenance and controls only by qualified personnel after first disconnecting the power supply cable Replace the coverings and protections and close all doors when the intervention is finished and before starting the equipment Take care to avoid getting fingers trapped when loading and feeding wire durin...

Page 5: ...network at the public network connection point must be applied to these systems In this case the installer or the user is responsible for ensuring the equipment can be connected consulting the electricity provider if necessary Materials and their disposal The equipment is manufactured with materials which do not contain any toxic or poisonous materials dangerous to the operator When the equipment ...

Page 6: ...ing current if a short circuit occurs during welding Self adaptive arc force technology Maintains the optimum arc conditions during welding even with long cables Advanced scratch start arc ignition supports TIG welding without HF arc ignition circuit Product performance characteristics Advanced IGBT inverter technology Inverting frequency of 33 43 kHz greatly reduces the size and weight of the wel...

Page 7: ...rent range Welding current range A 10 140 10 160 10 180 10 200 Rated duty cycle Rated duty cycle 35 35 35 35 No load voltage No load voltage V 63 63 63 63 Overall efficiency Overall efficiency 85 85 85 85 Housing protection grade Housing protection grade IP 21 21 21 21 Power factor Power factor Cosφ 0 7 0 7 0 7 0 7 Insulation grade Insulation grade F F F F Noise Noise dB 70 70 80 80 Size without h...

Page 8: ...5 35 No load voltage No load voltage V 63 63 63 63 Overall efficiency Overall efficiency 85 85 85 85 Housing protection grade Housing protection grade IP 21 21 21 21 Power factor Power factor Cosφ 0 7 0 7 0 7 0 7 Insulation grade Insulation grade F F F F Noise Noise dB 70 70 80 80 Size without handle mm 313 130 206 313 130 206 313 130 206 313 130 206 Size with handle mm 313 130 250 313 130 250 313...

Page 9: ...us 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 8 ...

Page 10: ...ed Output connections Electrode polarity In general when using manual arc welding electrodes the electrode holder is connected the positive terminal and the work return to the negative terminal Always consult the electrode manufacturer s data sheet if you have any doubts When using the machine for TIG welding the TIG torch should be connected to the negative terminal and the work return to the pos...

Page 11: ...ork area Select the spot welding time setting function by pressing the welding parameter selecting key and set the spot welding time Operation steps in spot welding Press the torch trigger gas valve opens and HF arc ignition starts Keep the torch 2 4mm away from the work piece to TIG guides The recommended size of tungsten to be used can be selected from the table below Electrode type The correspo...

Page 12: ...of arc welding machine Especially check for build up of dust debris on intake grills main voltage transformer inductance IGBT module the fast recover diode and PCB etc Take care when blowing electronic components and do not dislodge any wiring connections Check the security of output connections and plugs Replace if signs of overheating Yearly examination Carry out an annual service Check earth co...

Page 13: ...Electrical schematic 7 12 Schematic for single voltage unit Schematic for dual voltage unit ...

Page 14: ... mode power supply transformer 6 10039735 Machine Cover 20 10037345 Silicon bridge 7 10037113 Bottom panel 21 10037146 TOP266KG 8 10037128 Front panel 22 10043910 Control board 9 10044029 Quick socket 23 10037734 High frequency transformer 10 10037561 Knob 24 10005801 Electrolytic capacitor 11 10037147 LM79L15ACMX 25 10006272 Rectifying tube 12 10006431 Thermal Resistor 26 10037078 Pin insulation ...

Page 15: ... 6 10039735 Machine Cover 20 10037147 LM79L15ACMX 7 10037113 Bottom Panel 21 10037146 TOP266KG 8 10037485 ARC160D Silicon bridge 22 10043914 ARC160D Control Board 9 10037431 ARC160D Rectifying Board 23 10037134 ARC160D High frequency transformer 10 10006248 ARC160D Rectifier Tube 24 10038719 ARC160D Electrolytic capacitor 11 10037836 Front Panel 25 10037561 Knob 12 10006431 Thermal Resistor 26 100...

Page 16: ...supply transformer 6 10037813 Machine Cover 20 10037147 LM79L15ACMX 7 10037811 Bottom panel 21 10037146 TOP266KG 8 10043405 Front Panel 22 10043912 Control Board 9 10044030 Quick Socket 23 10037735 High Frequency transformer 10 10037561 Knob 24 10038737 Electrolytic capacitor 11 10044538 Silicon Bridge board 25 10006248 Rectifier tube 12 10006431 Thermal Resistor 26 10037078 Pin insulation cover 1...

Page 17: ...r supply transformer 6 10037813 Machine Cover 20 10037147 LM79L15ACMX 7 10037706 Bottom Panel 21 10037146 TOP266KG 8 10043405 Front Panel 22 10043912 Control Board 9 10044030 Quick Socket 23 10037735 High Frequency transformer 10 10037561 Knob 24 10005848 Electrolytic capacitor 11 10037485 Silicon bridge board 25 10006248 Rectifying tube 12 10006431 Thermal Resistor 26 10037078 Pin insulation cove...

Page 18: ...17 ...

Page 19: ...A Arc series DC TIG MMA WELDING MACHINE Order code JA 140 JA 160 JA 180 JA 200 JA 160DV JA 180DV Dual voltage Wilkinson Star Limited Issue 1 January 2014 Product is subject to change without notice xviii ...

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