wilkinsonstar.com
MIG Series
MIG/MAG/MMA Compact welding machines
Order code ! JM-160C,JM-175C, JM-180C, JM-200C
OPERATOR MANUAL
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Thank you for selecting this Jasic Technology, Wilkinson Star product.
This product manual has been designed to ensure that you get the most from your new product. Please ensure that you are fully
conversant with the information provided paying particular attention to the safety precautions. The information will help protect
yourself and others against the potential hazards that you may come across.
Please ensure that you carry out daily and periodic maintenance checks to ensure years of reliable and trouble free operation.
Wilkinson Star Limited are a leading supplier 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! _____________________________________________________
From where ! ! _____________________________________________________
Serial Number! _____________________________________________________
(The serial number will normally be located on the equipment data plate on the underside of the machine or on the rear panel)
Please note products are subject to continual development and may be subject to change without notice
i
Safety Precautions
1
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 off 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 different 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 r e g u l ar ma i n t e n an c e in accordanc e 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.
2
Do not weld on coated metals, unless the coating is
removed from the weld area, the area is well ventilated, and
while wearing an air-supplied respirator. The coatings on
many metals can give off toxic fumes if welded.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin.
Wear an approved welding helmet fitted with a proper shade
of filter lens to protect your face and eyes when welding or
watching
Wear approved safety glasses with side shields under your
helmet.
Never use broken or faulty welding helmets.
Always ensure there are adequate protective screens or
barriers to protect others from flash, glare and sparks from
the welding area. Ensure that there are adequate warnings
that welding or cutting is taking place.
Wear suitable protective flame resistant clothing.
The sparks and spatter from welding, hot work pieces, and
hot equipment can cause fires and burns
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to explode.
Accidental contact of electrode to metal objects can cause
arcs, explosion, overheating, or fire.
Check and be sure the area is safe and clear of inflammable
material before carrying out any welding.
Protection against noise
Some welding and cutting operations may produce noise.
Wear safety ear protection to protect your hearing.
Protection from moving parts
When the machine is in operation keep away from moving
parts such as motors and fans. Moving parts, such as the
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 during set up and operation.
When feeding wire be careful to avoid pointing it at other
people or toward your body.
Always ensure machine covers and protective devices are in
operation.
Precautions against fire and explosion
Avoid causing fires due to sparks and hot waste or molten
metal
Ensure that appropriate fire safety devices are available near
the cutting / welding area.
Remove all flammable and combustible materials from the
cutting / welding zone and surrounding areas
Do not cut/weld fuel and lubricant containers, even if empty.
These must be carefully cleaned before they can be cut/
welded.
Always allow the cut/welded material to cool before touching
it or placing it in contact with combustible or flammable
material.
Do not work in atmospheres with high concentrations of
combustible fumes, flammable gases and dust.
Always check the work area half an hour after cutting to
make sure that no fires have begun.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the
operation of pacemakers or electronically controlled medical
equipment.
Wearers of vital electronic equipment should consult their
physician before beginning any arc welding, cutting, gouging
or spot welding operations.
Do not go near welding equipment with any sensitive
electronic equipment as the magnetic fields may cause
damage.
3
RF Declaration
Equipment that complies with directive 2004/108/EC
concerning electromagnetic compatibility (EMC) and the
technical requirements of EN60974-10 is designed for use in
industrial buildings and not those for domestic use where
electricity is provided via the low voltage public distribution
sy stem. Difficultie s ma y ari se in ass uring clas s A
electromagnetic compatibility for systems installed in
domestic locations due to conducted and radiated
emissions.
In the case of electromagnetic problems, it is the
responsibility of the user to resolve the situation. It may be
necessary to shield the equipment and fit suitable filters on
the mains supply.
LF Declaration
Consult the data plate on the equipment 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,
co n ne ct i on re s tr i ct io n s o r m ax i m u m i mp e da n ce
requirements permitted by the 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 is scrapped, it should be dismantled
separating components according to the type of materials.
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.
Handling of Compressed gas cylinders and
regulators
All cylinders and pressure regulators used in welding
operations should be handled with care.
Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
Always secure the cylinder safely
Never deface or alter any cylinder
4
Product Overview
2
The unique electronic structure and air channel design in
this series of machines provides efficient cooling of the
power devices as well as improving the duty cycles of the
machines. The design of the forced air-cooling system
channel can effectively prevent the power devices and
control circuits from being damaged by the dust introduced
into the machine by the fan. The reliability of the machine is
greatly improved as a result.
The streamline design means front and rear panels are
naturally integrated via large-radian transition. The front and
rear panels of the machine and the handle are coated with
rubber oil*, giving the machine a very tactile and
comfortable grip with an excellent appearance.
Note: *Designs may vary due to customer specific
requirements
Product functions
•
Both MMA and MIG are available, and TIG is optional.
•
Hot start arc ignition function: make the arc ignition in
MMA welding easier and more reliable.
•
VRD function: keep the operator safe when the machine
is idle.
•
Self-adaptive arc force technology: obviously improve the
performance of the machine in long-cable welding and
contribute to long-distance welding.
•
Advanced arc ignition by lifting: support TIG welding
without HF arc ignition circuit.
•
Manual wire feeding function: save the wire feeding time.
•
Burn-back control function: improves the crater filling
quality and welding quality.
Product performance characteristics
•
Advanced IGBT inverter technology
•
Inverting frequency of 33~43 kHz greatly reduces the size
and weight of the welder.
•
Great reduction in magnetic and resistance loss enhances
the welding efficiency and energy saving effect.
•
Working frequency is beyond the audio range, which
almost eliminates noise pollution.
•
Industry leading control system
•
Advanced control technology meets the various welding
applications and provides excellent welding performance.
•
It can be used with a wide range of welding electrodes.
•
Easy arc starting, less spatter, stable current and good
weld bead shaping.
•
Modern high tech design
•
Streamline design of front and rear panels.
•
Front and rear panels made of high-intensity plastics
suitable for working in severe conditions.
•
Excellent insulating property.
•
Water-resistant, antistatic and anticorrosion design.
5
Technical data
3
① Tested at the environment temperature of 400 C
② Product design may vary due to customer requirements.
6
Technical Parameter
Unit
Model
MIG160
(JM-160C)
MIG175
(JM-175C)
MIG180
(JM-180C)
MIG200
(JM-200C)
Rated input voltageVAC230V±15% 50/60HZ
Rated input power
KVA
7.1
7.9
8.2
9.4
Welding current range
A
10~160
10~175
10~180
10~200
V
20.4~26.4!
11~26
20.4~27!
11~26
20.4~27.2!
11~26
20.4~28!
11~28
Rated duty cycle
%
35
No-load voltage
V
53
Overall efficiency
%
85
Housing protection grade
IP 21S
Power factor
cosφ
0.7
Insulation grade
F
Standard
EN60974-1
Noise
db
70
Size
without handle
mm
485*185*315
with handle
485*185*370
Weight
kg
12.8
Applicable electrode
mm
1.6~4.0!
0.6/0.8/0.9
1.6~4.0!
0.6/0.8/0.9
1.6~5.0!
0.6/0.8/0.9/1.0
1.6~5.0!
0.6/0.8/0.9/1.0
Controls
4
Front view
1. Current control - MMA
2. Power on LED
3. Overheat LED
4. Voltage control - MIG
5. Wire speed control - MIG
6. MIG / MAG switch
7. Gas /No gas selector
8. Push pull control socket
9. “+” output terminal
10. Euro torch connector - MIG
11. “+” output terminal
Rear view
12.$ Input power cable
13.$ Gas inlet
14.$ Mains power switch
7
15$ Handle
16$ Push pull torch selector
17$ Burn back control
18$ Wire inch button
19$ Wire feed assembly
Socket 1$ Push pull torch power “+”
Socket 2$ Push pull torch power “-”
Socket 3-9$ Null
8
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
MIG Welding
Insert the welding torch into the “Euro connector for torch in
MIG” output socket on the front panel of the machine, and
tighten it.
Install the wire spool on the spindle adapter.
Connect the cylinder equipped with the gas regulator to the
gas inlet on the back panel of the machine with a gas hose.
Insert the cable
plug wi t h w o r k
clamp into the “-”
output terminal on
the front panel of
t h e w e l d i n g
m a c h i n e , a n d
t i g h t e n i t
clockwise.
Insert the quick
plug of the gas /
no gas selector
into the “+” output
ter m i nal of the
welding machine,
a n d t ig h t e n i t
clockwise.
Ensuring that the
groove size in the
9
feeding position on the drive roll matches the contact tip size
of the welding torch and the wire size being used. Release
the pressure arm of the wire feeder to thread the wire
through the guide tube, and into the drive roll groove. Adjust
the pressure arm, ensuring no sliding of the wire. Too high
pressure will lead to wire distortion, which will affect wire
feeding. Press the wire inch button to thread the wire out of
the torch contact tip.
Gas less Self Shielded Welding
Insert the welding torch into the “Euro connector for torch in
MIG” output socket on the front panel of the machine, and
tighten it.
Insert the cable plug with work clamp into the “+” output
terminal on the front panel of the welding machine, and
tighten it clockwise.
Insert the quick plug of the gas / no gas selector into the “-”
output terminal on the middle plate of the welding machine,
and tighten it clockwise.
Install the wire
spool on the
s p i n d l e
a d a p t e r ,
ensuring that
t h e g r o o v e
s i z e i n t h e
f e e d i n g
position on the
d r i v e r o l l
matc h e s t h e
c o n t a c t t i p
s i z e o f t h e
welding torch
and the wire
s i z e b e i n g
used. Release
the p ressure
arm of the wire
f e e d e r t o
thread the wire
through the guide tube, and into the drive roll groove.
Adjust the pressure arm, ensuring no sliding of the wire. Too
high pressure will lead to wire distortion, which will affect
wire feeding. Press the wire inch button to thread the wire
out of the torch contact tip.
10
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.
MIG/MAG
Connect the MIG torch leads as detailed above. Ensure that
a suitable inert gas supply is connected.
Switch the power switch on the back panel to “ON”, the
machine is started with the power LED on and the fan
working.
Switch the MMA/MIG switch to MIG mode.
Open the gas valve of the cylinder, and adjust the gas
regulator to obtain the desired flow rate.
Adjust the “voltage control knob in MIG” and “wire feed
speed control knob in MIG” on the front panel of the
machine to get the correct welding voltage and welding
current.
Operate the torch trigger, and welding can be carried out.
Where required adjust the burn-back time potentiometer
(above the feed unit inside the machine) to get the proper
electrode stick-out.
One second after the arc stops, the gas supply will be cut
off.
Gas less MIG
The operation method is the same to MIG operation except
that there are no gas options.
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
11
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
Maintenance and troubleshooting
6
The following operation requires sufficient professional
knowledge on electric aspects and comprehensive
safety knowledge. Make sure the input cable of the
machine is disconnected from the electricity supply and
wait for 5 minutes before removing the machine covers.
In order to guarantee that the arc welding machine works
efficiently and in safety, it must be maintained regularly.
Operators should understand the maintenance methods and
means of arc welding machine operation. This guide should
enable customers to carry on simple examination and
safeguarding by oneself, try to reduce the fault rate and
repair times of the arc welding machine, so as to lengthen
service life of arc welding machine
Troubleshooting
Before arc welding machines are dispatched from the
factory, they have already been checked thoroughly. The
machine should not be tampered with or altered.
Maintenance must be carried out carefully. If any wire
becomes loose or is misplaced, it maybe potential danger to
user!
Only professional maintenance personnel should repair the
machine!
Ensure the power is disconnected before working on the
machine. Always wait 5 minutes after power switch off
before opening the case.
12
Period
Maintenance item
Daily
examination
Carry out a full visual inspection. Check
for any damage to 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
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
continuity and insulation resistance of the
machine at the relevant points.
PLEASE NOTE THIS WORK SHOULD
BE CARRIED OUT BY A TRAINED
COMPETENT PERSON.
Symptom
Possible cause
Action
There is no response when
operating the torch trigger
and the alarm indicator does
not illuminate.
The welding torch is not
connected properly into the
power source.
Reconnect it.
The torch trigger is faulty.
Repair or replace the welding
torch.
When the torch trigger is
operated, there is gas
output, but there is no
output current, and the
alarm indicator does not
illuminate.
The earth cable is not
connected with the work piece.
Reconnect it.
The wire feeder or welding torch
fails.
Repair the wire feeder or
welding torch.
There is output current
when operating the torch
trigger to feed gas, but the
wire feeder does not work.
The wire feeder is clogged.
Unclog it.
The wire feeder fails.
Repair it.
The control PCB or wire feeding
power PCB inside the machine
fails.
Replace it.
The welding current is
unstable.
The pressure arm on the wire
feeder is not properly adjusted.
Adjust it to get proper
pressure.
The drive roll does not match
the wire size being used.
Make sure they match with
each other.
The contact tip of the welding
torch is badly worn.
Replace it.
The wire-feeding tube of the
welding torch is badly worn.
Replace it.
The electrode is of poor quality.
Use electrode of good quality.
Electrical schematic
7
13
Parts list
8
JM-160C
14
1
2
14
15
16
18
19
20
21
6
5
13
22
4
7
8
12
11
10
9
17
23
24
3
JM-200C
15
No.
Part no
Description
No.
Part no
Description
1
10044511
Main board
13
10041449
Spool for wire feeder
2
10041446
Fan1410044510
Control Board
3
10044512
Silicon bridge board
15
10041421
Wire feeder and line
4
10041723
Gas Nozzle
16
10041707
Fixing plate for control board
5
10041721
Silicon bridge heat sink
17
10037561
Knob610041727
Machine Cover
18
10037151
Plug & socket
7
10041730
Side cover
19
10043898
Quick socket cable
8
10016524
Door catch
20
10041419
Central socket and line
9
10041711
Back Panel
21
10041400
Socket
10
10041709
Central insulation board
22
10041417
Solenoid valve
11
10041724
Handle
23
10041708
Bottom Panel
12
10041715
Front Panel
24
10004949
Power switch
1
2
14
15
16
18
19
20
21
6
5
13
22
4
7
8
12
11
10
9
17
23
24
3
No.
Part no
Description
No.
Part no
Description
1
10043884
Main Board
13
10041449
Spool for wire feeder
2
10041446
Fan1410043885
Control Board
3
10041412
Silicon bridge board
15
10041421
Wire Feeder and line
4
10041723
Gas Nozzle
16
10041707
Fixing plate for control board
5
10041721
Silicon bridge heat sink
17
10037561
Knob610041727
Machine cover
18
10037151
Quick socket
7
10041730
Side cover
19
10043898
Quick socket cable
8
10016524
Door catch
20
10041419
Central socket and line
9
10041711
Back Panel
21
10041400
Socket
10
10041709
Central insulation board
22
10041417
Solenoid valve
11
10041724
Handle
23
10041708
Bottom panel
12
10041715
Front Panel
24
10004949
Power switch
16
JM MIG Series MIG/MAG/MMA WELDING MACHINE
Order code ! JM-160C (MIG 160) JM-200C (MIG 200)
© Wilkinson Star Limited
Issue 1 January 2014
Product is subject to change without notice
xvii
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