Wilkinson Star Jasic JT-500D Operator'S Manual Download | Manualshive

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Summary of Contents for Jasic JT-500D

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Page 2: ...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 ________________________________________ From where ________________________________________ Serial Number ________________________________________ The serial number will normally be located on the equipment top or underside of the machine and be...

Page 3: ... Controls 12 Installation 14 Operation MMA 16 Operation TIG 19 Torch Trigger Operation Modes 26 Remote Control Socket 27 Maintenance 28 Troubleshooting 29 Welding Troubleshooting 30 EC Declaration of Conformity 31 Disposal 31 RoHS Compliance Declaration 31 Statement of Warranty 32 Wilkinson Star Jasic Technology Contact Details 36 ...

Page 4: ...achine 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 ma...

Page 5: ... when the intervention is finished and before starting the equipment Take care to avoid getting fingers trapped when loading and feeding wire during set up and operation When feeding wire be careful to avoid pointing it at other people or towards your body Always ensure machine covers and protective devices are in operation Precautions against fire and explosion Avoid causing fires due to sparks a...

Page 6: ...ipment for the power supply requirements Due to the elevated absorbance of the primary current from the power supply network high power systems affect the quality of power provided by the network Consequently connection restrictions or maximum impedance requirements permitted by the network at the public network connection point must be applied to these systems In this case the installer or the us...

Page 7: ...4T trigger control Pre and post gas flow time full up and down slope control Pulse adjustment frequency pulse duty and arc force 100KHz frequency for reduced weight volume Adjustable AC frequency and AC wave balance Hot start arc ignition function which ensures excellent arc ignition in MMA for easier and more reliable arc starting Built in adjustable arc force technology which maintains the optim...

Page 8: ...nge A 10 500 Peak base current range A 20 500 Initial current range 10 500 Pulse frequency range Hz 0 5 200 Pulse duration range 10 90 AC Rated maximum output A V 500 30 Welding current range A 10 500 Peak base current range A 20 500 Initial current range 10 500 Pulse frequency range Hz 0 5 200 Pulse duration range 10 90 Initial current range A 5 400 Pilot arc current range A 5 400 Up slope time r...

Page 9: ...0 40 Environment Storage temperature range 0 C 25 55 Humidity 90 no water condensate Structure Enclosure ingress protection IP21S Cooling mode Forced air cooling Rated duty cycle MMA 30 TIG 50 Efficiency 85 Insulation grade F Overall size L W H 595 297 528 Weight Kg 30 ...

Page 10: ...oling 7 Remote control selector Selection of remote control 8 Air intake Air intake grill 9 output socket Connection of work return 10 Control socket Connection of torch switch or remote control 11 Power lamp Water cooler power indicator 12 Fuse Water cooler supply fuse 13 Water tank Water tank with filler cap 14 output socket Connection of TIG torch power cable 15 Gas connection Outlet for shield...

Page 11: ...e Function 19 Switch Mains power switch 20 Socket Water cooling unit supply 21 Ground point External ground point 22 Mains cable Mains cable inlet 23 Fuse holder Protection fuse 24 Fan guards Fan protection Rear View ...

Page 12: ... can be adjusted by turning the adjustment knob The digital meter displays the welding current during welding and parameters can be adjusted at this time as well The display also shows the parameter being adjusted and after 3 seconds will turn the display back to showing welding current B Press the key in this zone to shift the display of the digital meter between A S Hz V trigger mode and job rec...

Page 13: ...al current 3 Upslope time 4 Base current 5 Peak current 6 Downslope time 7 Final current 8 Post flow gas time 9 Pulse frequency 10 Pulse duration ratio 11 AC frequency 12 Wave balance 13 TIG welding parameter selection keys 5 MMA parameter selection area 1 Arc ignition current 2 Arc ignition time 3 Welding current 4 Arc force current 5 MMA parameter selection switch 6 Remote control selection Sele...

Page 14: ...Gas connections Connect the gas hose to the regulator flowmeter located on the shield gas cylinder and connect the other end to the machine Gas selection A shielding gas is necessary for TIG welding because it is important to keep oxygen away from the weld pool Shielding gas does this by replacing the oxygen around the weld pool Shielding gas for TIG welding is generally an inert gas with argon be...

Page 15: ...the indicated work clamp socket on the front panel of the welding machine and tighten it clockwise Insert the power connection plug of the TIG torch into the indicated torch socket on the front panel of the machine and tighten clockwise Connect the gas quick connector into the outlet on the machine front Connect the torch switch plug into the socket on the front panel Connect the water supply cabl...

Page 16: ... the weld from contamination When the electrode is moved along the work piece at the correct speed the metal core deposits a uniformed layer called the weld bead After connecting the welding leads as detailed you will need to switch the power switch on the back panel to ON Select MMA mode by switching to the welding mode selection key to either DC or AC depending on your welding application see pa...

Page 17: ... Changes in AC MMA Note t0 Standby section no welding current output no load voltage t1 Arc striking section the length adjusted according to hot arc striking time t2 Arcing section t3 Short circuit transition section I1 Arc strike current I2 Operating current I3 Arc force current U1 Operating voltage U0 No load voltage MMA AC mode outputs 50Hz sine wave Current I2 The current of the arcing sectio...

Page 18: ...Hot start current is beneficial to the arc strike as it reduces the tendency of welding rod and weld material to stick The size of the hot start striking current is generally determined according to rod type the specifications and welding current Rods with better arc striking performance and small diameter generally need lower hot start striking current higher welding current often will not need a...

Page 19: ...LED on and the fan working Select TIG mode by switching to the welding mode selection key to either TIG DC or TIG DC with pulse depending on your welding application see page 10 Open the gas valve of the cylinder and adjust the gas regulator and flow gas meter to obtain the desired flow rate Press the torch trigger briefly the solenoid valve will operate and gas will flow Adjust the welding curren...

Page 20: ...as hose is long Initial current I1 It is the current when arc is ignited by pushing the torch trigger and it should be set according to users own technical requirements If the initial current is high enough arc is easier to ignite However it should not be too high when welding thin plate so as to avoid burn through the work piece during arc ignition In some operation modes the current can stay at ...

Page 21: ... piece or illuminate the weld area Upslope Indicates the time taken for the current to rise from 0 to the preset value and it should be set according to users technical requirements Ip This parameter is set by the user according to process requirements and is the peak welding current when in pulse mode Ib This parameter is set by the user according to process requirements and is the background wel...

Page 22: ...nd gas will flow Adjust the welding current according to the thickness of the work piece to be welded for a guide to welding parameters please refer to the table below Hold the torch 2 4mm away from the work piece and then press the torch trigger After arc is ignited the HF discharge will cease the current will maintain the preset value and welding can be carried out After releasing the torch trig...

Page 23: ...age to the electrode due to overheating However this can be eliminated by the use of balance control which allows the time of the positive half cycle to be varied within the cycle time I0 Initial current I1 Welding current I2 Final current tu Upslope time td Downslope time tp AC period tc Cathode current time In AC square wave TIG welding the pre flow time and post flow time are the same as in DC ...

Page 24: ... square wave parameter selecting and setting please refer to the corresponding contents in AC square wave TIG welding For the pulse frequency and pulse duration ratio users may refer to the corresponding contents in DC pulsed TIG welding The pulse frequency 1 T can be adjusted between 0 5Hz and 5Hz The pulse duration ratio Tp T can be adjusted between 10 and 90 AC frequency The normal mains freque...

Page 25: ...hieved by placing the control to a position which will enable more time to be spent in the negative half cycle with respect to the positive half cycle This will allow for higher current to be used with smaller electrodes as more of the heat is in the positive work The increase in heat also results in deeper penetration when welding at the same travel speed as the balanced condition A reduced heat ...

Page 26: ...operation and current curve 0 Follow mode 1 Push the torch trigger Arc is ignited and current rises to the preset value 2 Release it Arc stops 2 Standard 2T mode 1 Push the torch trigger Arc is ignited and current rises gradually 2 Release the torch trigger Current drops gradually and arc stops 3 If the torch trigger is re operated again before arc stops the current will gradually rise again to st...

Page 27: ...lease note The maximum output current must be set on the power source control panel by the user prior to the foot control being connected 6 With the foot control connected the panel digital ammeter will only display minimum preview amps until the foot control is depressed then it displays actual welding current when the welding arc is established 7 Pressing the foot pedal increases the welding cur...

Page 28: ...connected before working on the machine Always wait 5 minutes after power switch off before opening the case Period Maintenance item Daily examination Check the condition of the machine mains cables welding cables and connections Check for any warnings LEDs and machine operation Monthly examination Disconnect from the mains supply and wait for at least 5 minutes before removing the cover Check int...

Page 29: ...ource input switch is switched OFF Loose connections internally The fault LED is ON and the fan is running The machine is under overheating protection status It can recover automatically after the welding machine is cooled Check incoming mains supply to ensure its within 400V 15 No high frequency is produced Process selection switch is set to manual metal arc MMA Torch trigger switch lead is disco...

Page 30: ...material Check correct filler material grade in use No operation when the torch switch is operated Torch switch faulty Check the torch switch continuity and replace if faulty Mains fuse blown Check circuit breakers or fuses and replace as necessary Fault inside the equipment Have a technician check the equipment Low or no output current Weld circuit broken Check all connections and cables continui...

Page 31: ... Do not dispose of the equipment with normal waste The European Directive 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 compatible recycling facility Wilkinson Star Jasic Technology has a relevant recycling system which is compliant and registered in the UK wit...

Page 32: ...he following falls outside the scope of the warranty Defects due to natural wear and tear Failure to observe the operating and maintenance instructions Connection to an incorrect or faulty mains supply Overloading during use Any modifications that are made to the product without the prior written consent Software errors due to incorrect operation Any repairs that are carried out using non approved...

Page 33: ...__________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ...

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Page 35: ...__________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ...

Page 36: ...36 Wilkinson Star Limited Shield Drive Wardley Industrial Estate Worsley Manchester United Kingdom M28 2WD Telephone 0044 0 161 728 7900 Mail sales wilkinsonstar com ...

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