wilkinsonstar.com
MIG Series
MIG/MAG/MMA Separate wire feed welding machine
Order code ! JM-250S (MIG 250S)
OPERATOR MANUAL
Your new product
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 JM-250S is a portable inverter MIG/MAG/MMA
machine with the following features.
Advanced IGBT inverter technology
High inverter frequency design greatly reduces the size and
weight of the welder.
Reduction in magnetic and resistance loss enhances the
welding efficiency and energy saving effect.
Working frequency is beyond audio range, which almost
eliminates noise pollution.
Electronic control mode
Closed loop feedback control provides a stable voltage
output, and workable mains voltage fluctuation of ±15%.
Adjustable welding voltage matching the welding current
precisely gives excellent welding characteristics.
A unique welding dynamic characteristic control circuit
provides a stable arc, low spatter, high welding efficiency
and excellent weld appearance. .
Removing wire tip ball after welding; high no-load voltage
and soft start wire feeding results in a excellent arc ignition.
Welds a wide range of wires from 0.6~1.6mm diameter.
Improved functional design
With the wire feeder separate from the welding source, the
welding operation can be carried out at a wider range.
Lightweight and portable
Simple user friendly controls.
Both spot welding and continuous welding are optional, and
work piece burn-through can be avoided when welding
sheet metal in spot welding mode.
Both MMA and MIG/MAG (GMAW) are available, and
various welding requirements can be met.
2T and 4T welding modes
Wire inch button
5
Technical data
3
Product design may vary due to customer requirements.
6
JM-250S
Rated input voltage (V)
3-phase 400V AC±15%, 50/60Hz
Rated input current (A)
12.1
Rated power supply capacity (KVA)
8.4
Output current range (MMA)
10~220A
Welding current range (A)
35~250
Welding voltage range (V)
14~32
No-load voltage (V)
52
Wire feed speed range (m/min)
1.5~16
Wire diameter applicable (mm)
0.8/1.0
Rated duty cycle @ 400 C
250A@60%
Efficiency (%)
85
Power factor
0.93
Protection class
IP21S
Overall size (mm)
510×196×385
Weight (kg)
15
Controls
4
Front view
1. Spot welding/continuous welding switch
2. MMA/MIG switch
3. Voltmeter
4. Over current LED
5. Power LED
6. Overheating LED
7. Ammeter
8. Current control knob in MMA
9. Inductance control knob
10. “－” output terminal
11. Connector for the wire feeder
12. “＋” output terminalConnector for the wire feeder
7
!
Rear View
13! Power switch
14! Socket for the heater
15! Input power cord gland
16! Ground terminal
Wire feed control
1.! Welding current control knob
2.! Manual wire feeding switch
3. ! Welding voltage control knob
4.! 2T / 4T Selector switch
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.
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
Scratch Start TIG
When using the machine for scratch start TIG welding (set to
MMA mode) the TIG torch should be connected to the
negative terminal and the work return to the positive terminal
MIG / MAG (GMAW)
Connect the wire feeder to the welding source with the
interconnection control cable, and tighten the connector.
Connect one end of the welding cable to the “＋” output
terminal of the welding source and the other end to the back
panel of the wire feeder.
Insert the quick plug at one end of the work return cable into
the “－” socket on the front panel of the welding source, and
clamp the work piece with the work clamp at the other end
of the work return cable.
9
Input cable
!
Insert the welding torch into the “ ” output socket on the
front panel of the wire feeder, and tighten it. Manually thread
the welding wire into the torch body.
Insert the quick plug of the interconnection cable set into the
“+” output terminal of the welding machine, and tighten it
clockwise. Connect the other end of the interconnection on
the rear of the wire feed unit
Insert the multi pin plug of the interconnection cable set into
the control cable socket of the welding machine and connect
the other end of the control cable into the rear of the wire
feed unit
Installation of the wire spool
Install the wire spool on the spindle adapter on the wire
feeder, locating the hole on the wire spool to the fixing pin on
the spindle adapter.
Select the correct size feed drive roll according to the size of
welding wire.
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 inch wire feeding button to thread the wire out of
the torch head.
Installation of the cylinder
Connect the cylinder equipped with a regulator to the gas
inlet on the wire feeder with a hose, and tighten it with a
hose clamp.
Please note:
Avoid exces sive expos ure of the cy linde r to high
temperature or sunlight.
Always keep the cylinder in an upright position
Always fix the cylinder securely
Before the installation of gas regulator, open and close the
valve for several times in order to remove the dust on the
joint.
Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
Leakage of shield gas affects welding performance, so
tighten the cylinder valve joint with a spanner. Check for
leaks
10
Machine rear
Cable of the heater
Gas regulator
Input cable
Cylinder
Wire feeder
Gas hose
Welding torch
Workpiece
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 on the machine. The power LED will be lit and the
fan running.
Switch the MMA/MIG switch to MMA.
Set the amperage on the machine using the MMA current
control knob to a value suitable for the electrode being used.
Please see below a guide to amperages required. Ensure
you check that you have the electrode polarity correct.
Inductance can be adjusted using the inductance control on
the front panel of the machine
MIG/MAG
1)! After being installed as above, and the power switch
on the back panel being switched on, the machine is started.
At this time, the ammeter displays the preset wire feed
speed value, and the voltmeter displays the preset voltage
value. Open the cylinder valve, and switch the gas check
switch to the “GAS CHECK” position. Adjust the gas
regulator to get the correct gas flow. After setting, switch the
gas check switch to the “Welding” position.
2)! Get the correct arc conditions by adjusting the
inductance control knob. Turn the knob counterclockwise to
get lower inductance and harder arc; turn it clockwise to get
higher inductance and softer arc. Generally, select harder arc
at lower current, while select softer arc at higher currents.
3)! Select the correct welding current and welding
voltage by adjusting the current control knob and voltage
control knob on the wire feeder.
4! Select 2T or 4T operation mode. In 2T mode, the arc
is ignited by pushing the torch trigger, and arc stops by
releasing the torch trigger. In 4T mode, welding can be
continued when releasing the torch trigger after arc is
ignited, and at this time, welding instructions should be set
by adjusting the current control knob and voltage control
knob on the wire feeder. When pushing the torch trigger
again, the machine enters into crater welding, and at this
time. Crater parameters should be set by adjusting the
crater/welding current control knob and crater voltage
control knob on the front panel of the machine.
The actual current and voltage values are displayed on the
front panel of the machine. When the torch trigger is
released, welding ends. 2 seconds after welding ends, the
gas supply will be cut off.
Gas selection
Metal inert gas welding (MIG): Uses Argon (Ar), Helium (He)
or Ar-He mixtures as the shield gas, and it mainly used for
welding aluminium and its alloys.
Metal active gas welding (MAG): Uses Argon (Ar) mixed with
a certain amount of CO2 / O2 as the shield gas, and it usually
used in short circuit transfer and spray transfer. It can be
applicable to flat position welding, vertical position welding,
overhead position welding and all-position welding, and it
mainly used for welding carbon steel, high strength low alloy
steel and stainless steel. Welding robots mostly use the
MAG process.
CO2 (carbon dioxide) gas shielded arc welding (CO2
welding): It uses CO2 as the shield gas, and is usually used
in globular transfer and short circuit transfer to implement
welding. It can be used to weld in different positions. As
compared with other welding methods, CO2 welding has
many advantages, though it produces more spatters, CO2
welding is widely used for general metal structure welding.
1) Welding current setting
Set the welding current after the above preparation. Short
circuit transfer is mainly for electrode wires of diameter
0.6~1.2mm. As a guide for short circuit welding set the
welding current according to the table below.
2) Welding speed selection
The welding quality and productivity should be taken into
consideration for the selecting of welding speed. In the case
that the welding speed increases, it weakens the protection
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
Welding wire φ(mm)
Applicable current (A)
Optimal current (A)
0.8
50~120
70~100
1.0
70~180
80~120
1.2
80~350
100~200
effect and quickens the cooling. As a consequence, it is not
good for weld bead shaping. In the event that the speed is
too slow, the workpiece will be burned through, and a good
weld bead will be unavailable. In practical operation, the
welding speed should not exceed 50cm/min.
3) Wire Stick-out
The increase of the stick-out can improve the productivity,
but too long stick-out may lead to excessive spatter, wire
breaking and unstable welding. Generally, the stick-out
should be 10 times as the welding wire diameter.
4) Shield gas flow selection
The protection effect is the primary consideration. Besides,
the protection effect of inner-angle welding is better than
that of external-angle welding, so the gas flow in inner-angle
welding should be lower. Less or no shield gas is needed in
FCAW. Refer to the table below for the recommended gas
flow rates.
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
12
Welding mode
Welding with
thin wire
Welding with
thick wire
Welding with
thick wire
under high
current
Gas flow (L/min)
5~15
15~20
20~25
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.
Protection LED warnings
13
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.
Over current LED
If the over current LED is on during welding,
it indi cates that the mach ine fail s or
accidental interference occurs. Restart the
machine. If the phenomenon cannot be
eliminated, shut down the machine and
contact the service center of our company.
Overload LED
If the overload LED is on during welding, it
indicates that the main circuit is overheated
and the machine will stop welding.time that
welding.It is unnecessary to shut down the
machine, but just wait for the overload LED
to go out, and then welding can be
continued.
O.C
14
Malfunction Phenomena
Solution
The protection LED is on.
1.! Overheating protection
1)! Check the welding current and working time. Operate
according to the data shown in the operator’s
manual.
2)! Check the fan’s running status when welding. If the
fan does not work, check if there is a power supply of
230V: If the power supply is normal, check the fan; if
the power supply is abnormal, check the connecting
cable of the power supply.
3)! Replace the thermal switch if it is damaged.
2.! Over current protection: This indicates a machine fault or
an accidental break-off caused by interference. Restart
the machine. If over current problem still exists, contact
the service centre..
No response when pushing the torch trigger and the
protection LED is off.
1.! Check if the power LED and the digital meter illuminate.
2.! Check if the torch trigger is in good contact, and check if
the welding torch is correctly connected.
3.! Check if the wire feeder is correctly connected.
When the torch trigger is pushed, wire feeder works and gas
comes out, but there is no output current, and the protection
LED is off.
1.! Check if the work cable is in good contact.
2.! Check if the wire feeder cable is connected correctly.
3.! Check if the welding torch is damaged.
There is output current when pushing the torch trigger to
feed gas, but the wire feeder does not feed wire.
1.! Check if the control cable of the wire feeder is broken.
2.! Check if the wire feeder is blocked.
3.! Check if the wire feed PCB of the welding machine fails.
4.! Check if the wire feeder is damaged.
Welding can be carried out when pushing the torch trigger,
but the current is too high, the voltage can not be adjusted,
and the no-load voltage is too high.
1.! Check if the control cable of the wire feeder is broken.
2.! Check if the control PCB of the welding machine fails.
3.! Check if the voltage/current feedback wire breaks.
Welding can be carried out when pushing the torch trigger,
but the current is too high, the voltage can not be adjusted,
and the no-load voltage is too high.
1.! Check if the control cable of the wire feeder is broken.
2.! Check if the control PCB of the welding machine fails.
3.! Check if the voltage/current feedback wire breaks.
Weld bead is not well protected.
1.! Do not move the welding torch away immediately when
stopping welding, so that the shield gas can protect the
weld bead.
2.! Prolong the post-flow time of the shield gas, and contact
our company.
The gas regulator cannot be heated.
1.! Check if the plug of the heater is well plugged in.
2.! Check if the resettable fuse inside the machine is in
good condition.
3.! Check if the heater inside the gas regulator is damaged.
There is no gas flow when the torch trigger is pushed, but
the wire feeder works normally.
1.! The control PCB is damaged.
2.! The solenoid valve is clogged or damaged.
Excessive spatter in MMA.
The output polarity connection is incorrect. Exchange the
polarity.
Electrical schematic
7
15
Parts list
8
16
17
No.
Part no
Description
No.
Part no
Description
1
10007258
Rectifier
15
10002022
Reactor
2
10007258
IGBT
16
10016437
Diverter
3
10044601
Rectifier Plate
17
10044604
Fender apron
4
10002401
Thermal switch
18
10000920
Output absorbing board
5
10044603
Inverter board
19
10006075
Main transformer
6
10001867
Fan2010014690
Front Panel
7
10013342
Back panel
21
10001577
Indicator Light
8
10021881
Square sockets
22
10006795
Digital Meter
9
10004955
Power switch
23
10004944
Transform switch
10
10021912
Line button
24
10006507
MMA Current Potentiometer
11
10001146
Silicon bridge
25
10006507
Inductance Potentiometer
12
10044596
Power adapter plate
26
10021855
Quick socket
13
10042496
Transformer
27
10003254
Seven pin socket
14
10044595
Control board
WIRE FEED UNIT
18
No.
Part no
Description
No.
Part no
Description
1
10004893
Interconnection clamp
11
10004921
Knob
2
10044629
Solenoid valve
12
10044628
2T/4T switch
3
10044632
Socket1310015217
Control Panel
4
10021855
Output Terminal
14
10044630
10044640
Potentiometer
5
10044600
Wire Feeding PCB Board
15
10015526
CS501B Remote Plastic Box
6
10045742
Bottom panel
16
10012376
Wire Feeder Cover
7
10003814
Wire Feeder
17
10016524
Door Catch
8
10003831
Central socket
18
10015767
Platen
9
10015216
Front Panel
19
10016681
Spool for wire feede
10
10044633
Inching button
JM MIG Series MIG/MAG/MMA WELDING MACHINE
Order code ! JM-250S (MIG 250S)
© Wilkinson Star Limited
Issue 1 January 2014
Product is subject to change without notice
xix
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