wilkinsonstar.com
OPERATOR MANUAL
MIG Series
MIG/MAG/MMA Compact welding machines
Order code ! JM-200CS
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
1
Safety Precautions
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
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 reg ula r mai nte nan ce in ac cord anc e wit h the
manufacturers instructions.
Safety against fumes and welding gases
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.
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
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.
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.
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.
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.
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.
Protections and coverings may be removed for maintenance
and controls only by qualified personnel, after first
disconnecting the power supply cable.
3
RF Declaration
Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
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
system. Diffi culties may arise in assuring class 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.
Always secure the cylinder safely
Never deface or alter any cylinder
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 n e ct i o n re s t ri c t i on s o r m a xi m u m i mp e d a nc e
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.
4
2
Product Overview
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
MMA, TIG and MIG function are available.
•
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.
•
Simple adjusting function: four groups of MIG
•
parameters for CO2, and mixed gas, using Φ0.8 and
Φ1.0 wires are provided.
2T / 4T mode
•
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: improves the
•
performance of the machine when using long welding
cables.
Advanced Lift arc ignition in TIG mode.
•
Manual wire feeding function.
•
Self-adaptive crater filling function: manual adjusting
•
is unnecessary.
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.
5
3
Parameter
Unit
MIG 200CS
Rated input voltage
V
230V AC +/- 15%
Rated input power
KVA
9.4 MMA
Recommended fuse
A
30
A
MMA 10 - 200 MIG 30 - 200
Welding current range
V
MMA 20.4 -28 MIG 15.5 - 24
Rated duty cycle
%
200A @ 35%
No load voltage
V
53
Overall efficiency
%85Housing protection grade
IP21S
Power factor
Cos
0.7
Insulation grade
F
Standard
EN60974-1
Noisedb<80
Size (without handle)
485 x 185 x 315
Size (with handle)
mm
485 x 185 x 370
Weightkg12.8
MMA - 1.6~5.0
Applicable electrodes
mm
MIG - 0.6/0.8/0.9/1.0
Technical data
① Tested at the environment temperature of 400 C
6
4
9
10
7
8
15
14
1312
11
1 2
3 4
5
6
Controls
Front view
1. Current/wire feed speed control knob
2. Current display window
3. 2T indicator
4. 4T indicator
5. 2T/4T switch key
6. Welding mode selecting switch
7. Gas/no gas switch
8. Socket for spool gun torch (optional)
9. "+" output terminal
10. Euro connector for torch
11. "-" output terminal
12. VRD ON
13. VRD OFF
14. Voltage/arc force/downslope time control knob
15. Voltage display window
7
Optional spool gun socket
!
1
2
3
4
1
2
3
Socket 1: Push-pull torch power source ”+”
Socket 2: Push-pull torch power source ”-”
Socket 3~9: Null
Rear view
1% Input power cord
2.% Gas inlet
3% Power switch
Side view
1.% Handle
2.% Wire-inch button
3.% Gas-check button
4% Wire feed system
8
5
!
!
Installation
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
with work clamp into
the “-” output terminal
on the front panel of
the welding machine,
a n d t i g h t e n i t
clockwise.
Insert the quick plug of
t h e g a s / n o g a s
9
selector into the “+” output terminal of the welding machine,
!
!
and tighten it clockwise.
Ensuring that the groove size in the 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.
2)% Connect the cylinder to the gas inlet on the back
panel of the machine, adjust the gas flow to the appropriate
value, and open the gas valve. Please note that the joint
should be tightened to prevent gas leakage.
Using valve type torch - No trigger
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 spindle adapter, ensuring that
the groove size in the 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.
1)% Connect the TIG torch and the work clamp
respectively. Connect the TIG torch to the “-” output terminal
on the front panel, and connect the workpiece to the “+”
output terminal on the front panel, and tighten the quick
plugs clockwise.
2)% Connect the cylinder to the gas inlet on the back
panel of the machine, adjust the gas flow to the appropriate
value, and open the gas valve. Please note that the joint
should be tightened to prevent gas leakage.
TIG Welding
Using the optional Euro TIG torch
1)% Connect the TIG torch and the work clamp
respectively. Connect the TIG torch to the Euro connector on
the machine and connect the workpiece to the “+” output
terminal on the front panel, and tighten the plugs clockwise.
10
Operation
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
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.
Gas less MIG
The operation method is the same to MIG operation except
that there are no gas options.
TIG Welding
1) After being installed correctly as shown in the installation
section, switch the power switch on the back panel to
“ON”, the machine is started and the fan operates. The
display window displays the rated capacity and software
version firstly, and then displays the relevant parameters
after several seconds.
Using the Euro TIG torch
2) Switch the welding mode selection switch to “TIG”.
3) Select the desired operating mode using the 2T/4T switch
key.
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.
2T: After pressing down the torch trigger, gas flows for the
pre-flow time, and then welding begins. Initially, the arc is
ignited by touch and lift at low current. The current rises to
the initial current, and then it increases gradually (according
to the upslope time) to the preset current. After releasing the
torch trigger, the current drops gradually (according to the
downslope time) to “0”, and welding ends.
4T: After pressing down the torch trigger, gas flows for the
pre-flow time, and then welding begins. Initially, the arc is
ignited by touch and lift at low current. The current rises to
the initial current, and then it increases gradually (according
to the upslope time) to the preset current. The torch trigger
can be released during welding. When pressing down the
torch trigger again, the current drops gradually (according to
the downslope time) to the pilot arc current. After the torch
trigger is released, gas keeps flowing for the post-flow time,
and welding ends.
4) Select the correct welding current using the current
control knob according to the thickness of the workpiece,
and the current display window displays this preset value.
Set the downslope time through the downslope time
control knob.
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.
Using valve type torch with no trigger
Arc ignition mode:
This mode adopts contact arc ignition in TIG. The operator
should bring the tungsten electrode into contact with the
workpiece.When there is current, lift the electrode a little
immediately to enter into normal welding. Using this torch
there is no 2T or 4T operation and no downslope
11
Multifunctional display window
Welding mode
Current display
window
Voltage display
window
MMA
Preset current (A)
VRD voltage (V)/
arc force (A/MS)*
MIG (including
unified adjusting)
Preset wire feed
speed (m/min)
Preset voltage (V)
TIG
Preset current (A)
Downslope time (s)
MMA
MIG
TIG
P1
Ignition current (A)
Crater filling speed (m/min)
Initial current (A)
P2
Ignition time (s)
Crater filling voltage (V)
Pilot arc current (A)
P3
Capacity setting (A)
Downslope time (s)
Upslope time (s)
P4
Return to the default
parameter (0: No; 1: Yes)
Pre-flow time (s)
Pre-flow time (s)
P5
Post-flow time (s)
Post-flow time (s)
During welding, the current display window displays the
practical welding current value, and the voltage display
window displays the practical welding voltage value. In
standby mode, the windows display as follows.
4)% After the parameter adjustment is done, press the 2T/
4T switch key again to store the system parameters. Then,
the machine enters into standby mode.
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
*-It displays VRD voltage when not turning the voltage
control knob, and displays the arc force when turning the
voltage control knob.
System parameters setting
This machine uses a group of welding parameters in
common use as default. If the user wants to alter these
parameters, he or she can realize this by altering the system
parameters.
The method to alter the system parameter is as follows:
1)% Press the 2T/4T switch key on the panel and do not
release it. Then, turn on the power switch of the welding
machine.
2)% When the display window displays “--- ---“, release
the 2T/4T switch key to enter into the system parameter
adjusting interface.
3) Select the welding mode which needs adjusting by turning
the welding mode select switch, select the parameter
number through the current control knob, and select the
parameter value through the voltage control knob.
Please refer to the table below for the contents of system
parameters.
12
6
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
Possible solution
There is no current
The power cord is
not connected.
Reconnect the power cord.
There is no current
after turning on the
machine.
The welding
machine fails.
Contact the service
department
The fan does not
The fan supply is
not connected.
Reconnect the supply for the
fan.
The fan does not
work during
welding.
Auxiliary power or
the fan fails.
Contact the service
department
The window
displays “Err 0”.
The power device
is under over
current or is
damaged.
Contact the service
department
The window
displays “Err 1”.
The mains voltage
is too low.
Disconnect the machine with
the mains power supply, and
reconnect it after the mains
voltage recovers.
The window
displays “Err 1”.
The auxiliary
power fails
Replace the auxiliary power
PCB.
The window
displays “Err 2”.
Overheating
protection occurs.
It will recover automatically
after the machine is cooled
down.
The window
displays “Err 3”.
Overload
protection occurs.
Restart the machine. If the
problem remains, contact the
service department.
The overheating
LED is on.
The overheating
protection circuit
works.
It will recover after the
machine cools down.
Maintenance and troubleshooting
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.
13
7
!
Electrical schematic
14
8
1
2
14
15
16
18
19
20
21
6
5
13
22
4
7
8
12
11
10
9
17
23
24
3
27
25
26
Parts list
15
No.
Part no
Description
No.
Part no
Description
1
10045881
Inverter
15
10041421
Wire feed system
2
10041446
Fan
16
10045805
Display panel mounting
3
10037485
Rectifier board
17
10043904
Knob
4
10041723
Gas Connector
18
10037151
Quick Socket
5
10041721
Silicon bridge heat sink
19
10041427
Handle Line
6
10046146
Machine Cover
20
10041419
Torch connector body
7
10046145
Side cover
21
10041400
Spool gun connector (optional)
8
10016524
Door catch
22
10040667
Solenoid valve
9
10041711
Back Panel
23
10041708
Bottom Panel
10
10045740
Central panel
24
10004949
Power switch
11
10041724
Handle
25
10045705
Bracket
12
10041715
Front Panel
26
10045878
Control board
13
10041449
Wire hub assembly
27
10045882
Voltage sampling board
14
10045879
Display panel
16
JM MIG Series MIG/MAG/MMA WELDING MACHINE
Order code ! JM-200CS (MIG 200CS)
© Wilkinson Star Limited
Issue 1 May 2014
Product is subject to change without notice
xvii
Loading...