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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 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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