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Installation

5

Unpacking

Check the packaging for any signs of damage.

Carefully remove the machine and retain the packaging until 
the installation is complete.

Location

The  machine  should  be  located  in  a  suitable  position  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 
airflow.

Input connection

Before  connecting  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 qualified 
competent  person.  Always  ensure  the  equipment  has  a 
proper grounding.

Never  connect  the  machine  to  the  mains  supply  with  the 
panels removed.

Output connections 

Electrode polarity

In  general  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  plug  with 
electrode  holder  into  the  “+” 
socket  on  the  front  panel  of 
the  welding  machine,  and 
tighten it clockwise.

Insert  the  cable  plug  of  the 
work  return  lead  into  the  “-” 
socket  on  the  front  panel  of 
the  welding  machine,  and 
tighten it clockwise

TIG Welding

Insert the cable plug with the work clamp into the “+” socket 

on  the  front  panel  of  the  welding  machine,  and  tighten  it 

clockwise.

Insert the cables plug of the TIG torch into the “-” socket on 

the front panel of the machine and tighten clockwise.

Connect the gas hose to the regulator / flowmeter located on 

the  shield  gas  cylinder  and  connect  the  other  end  to  the 

machine.

Open the valve on the TIG torch and “scratch” the electrode 

on the work piece to start the arc.

8

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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