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Operation

Before starting any welding activity ensure that you have 
suitable eye protection and protective clothing. Also take 
the  necessary  steps  to  protect  any  persons  within  the 
area.

MMA

After connecting 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.

The  arc  ignition  time  (hot  start)  is  set  internally  in  the 
machine  in  accordance  with  the  table  below.  This  should 
only  be  carried  out  by  a  competent  trained  person  as  it 
involves removing the machine cover. 

Always  disconnect  the  machine  from  the  mains  supply 
before setting this time position

Tips

It is generally recommended that the Arc ignition current is to 
be  adjusted  to  a  larger  value  to  facilitate  good  arc  ignition 
but  it  can  also  be  reduced  to  a  lower  value  to  prevent  the 
burning of the workpiece when the workpiece is too thin or 
to reduce spatter during arc ignition.

The arc force current should be adjusted appropriately. If the 
arc  force  current  is  high  enough,  electrode  sticking  seldom 
occurs.  However,  if  the  arc  force  current  is  too  high,  the 
spatter increases. It is very important to choose the correct 
arc force current especially welding with thin electrodes or in 
all-position welding. Specific parameters are determined by 
the welding application requirements.

Remote control

This  series  of  machines  has  the  capability  of  two  types  of 
remote control:

 

A remote control with cable 

 

A  carrier  wave  remote  control  which  eliminates  the 

need for a connection cable. 

When using the remote control with cable, insert the control 
plug on the remote control cable into the control plug socket 
of  remote  control  at  the  bottom  on  the  front  panel  of  the 
welding  machine,  and  tighten  it  clockwise.  After  switching 
the  remote  control/local  control  switch  to  “

!

”  position,  the 

current control knob and arc force control knob on the front 
panel of the machine are ine

ective, while the current control 

knob  and  arc  force  control  knob  on  the  remote  control 
functions.

When  using  the  wave  carrier  remote  control,  wave  carrier 
receiving  board  should  be  installed  inside  the  machine. 
Switch  the  remote  control/local  control  switch  on  the  front 
panel to “

!

” position, and connect the two wires of the wave 

carrier remote control respectively with the electrode holder 
and work clamp. And then the welding current and arc force 
current can be adjusted with the remote control. 

For  details,  please  consult  the  operator’s  manual  for  wave 
carrier remote control.

When not to use remote control, please switch the “remote 
control/Local  control”  switch  on  the  front  panel  to  “

!

” 

position to ensure normal welding.

Note: Either remote control is an optional item.

For welder training please visit our Academy website at

 

www.wilkinson-welding-academy.com

 

9

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

SW1 status

Arc ignition 

time

SW1 status

Arc ignition 

time

  300ms

  150ms

  200ms

  70ms (factory 

default)

Summary of Contents for ARC400

Page 1: ...wilkinsonstar com Arc 400 DC MMA LIFT TIG Welding machines Order code JA 400 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 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 High Inverting frequency greatly reduces the size and weight of the welder Great reduction in magnetic and resistance loss enhan...

Page 7: ...urrent range A 20 400 25 500 30 630 Arc force current range A 20 200 20 200 20 200 No load voltage V 65 67 80 Arc ignition current range A 50 320A 63 400A 75 480A Rated duty cycle 60 400 500 630 Overall size mm 540 275 510 650 330 624 650 355 624 Weight kg 31 38 52 Protection class IP21S IP21S IP21S Tested at the environment temperature of 400 C Product design may vary due to customer requirements...

Page 8: ...al To connect the electrode holder 7 Remote control socket 8 Output terminal To connect the work clamp 9 Hot start ignition control 10 Local remote switch 11 Digital voltmeter 12 Overheating LED on indicates that the temperature inside the machine is too high and the machine is under overheating protection status Rear view 13 Mains input cable gland 14 Data plate 15 Mains switch 7 ...

Page 9: ...eral when using manual arc welding electrodes the electrode holder is connected the 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 positive terminal MMA welding Insert the cable...

Page 10: ...d by the welding application requirements Remote control This series of machines has the capability of two types of remote control A remote control with cable A carrier wave remote control which eliminates the need for a connection cable When using the remote control with cable insert the control plug on the remote control cable into the control plug socket of remote control at the bottom on the f...

Page 11: ... the machine leads cables and connections Replace where necessary Switch on the machine and check for any warning Led s and general operation Monthly examination Using the dry compressed air to clean the inside 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 blowin...

Page 12: ...ains voltage is too low Welding can be carried out after the mains voltage recovers The no load voltage is 0 and the under voltage LED is on The mains voltage is too low Welding can be carried out after the mains voltage recovers The no load voltage is 0 and the under voltage LED is on Auxiliary power fails Replace the fault circuit board of the auxiliary power The no load voltage is 0 and the ove...

Page 13: ...Electrical schematic 7 12 ...

Page 14: ...Parts list 8 Arc 400 JA 400 13 41 36 35 34 37 38 39 40 33 32 31 30 29 28 3 4 5 6 7 8 10 11 12 13 14 23 22 24 25 26 27 20 19 18 17 21 2 1 9 15 16 ...

Page 15: ...1 Current POT 9 10043869 The partition 30 10015882 Copper interconnects 10 10004925 Power switch 31 10007237 IGBT module 11 10027473 Stator 32 10006443 Thermal switch 12 10016621 Cable fixing plate 33 10002016 Electric reactor 13 10027470 Waterproof cover 34 10043838 Front panel Steel 14 10004895 Cable buckle 35 10028782 Quick outlet 15 10039141 Back panel plastic 36 10044144 Five pin socket 16 10...

Page 16: ...JA Arc 400 DC TIG MMA WELDING MACHINE Order code JA 400 Wilkinson Star Limited Issue 1 January 2014 Product is subject to change without notice xv ...

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