wilkinsonstar.com
TIG Series
DC MMA / TIG Welding machines
Order code ! TIG180（JT-180 / TIG200 (JT-200）
!!!!TIG180（JT-180DV / TIG200 (JT-200DV）
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
system. Difficulties 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.
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 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
•
Hot start arc ignition function: makes the arc ignition in
TIG under low current easier and more reliable.
•
2T/4T function.
•
Downslope and post-flow gas function
•
Self-ada ptive arc force technology imp roves the
performance of the machine when using long-cable
welding.
•
Excellent HF arc ignition: High reliability arc striking.
•
Advanced arc ignition by lift arc: TIG welding without HF
arc ignition circuit.
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.
•
Digital amp and voltmeter
5
Technical data
3
Tested at the environment temperature of 400 C
Product design may vary due to customer requirements.
6
Model
Model
Model
Technical Parameter
Unit
TIG180 (JT-180)
TIG 200 (JT-200)
TIG180DV (JT-180DV)
TIG 200DV (JT-200DV)
Rated input voltage
V
AC230V±15%
50/60HZ
AC230V±15%
50/60HZ
AC115V±15%
50/60HZ
AC230V±15%
50/60HZ
AC115V±15%
50/60HZ
AC230V±15%
50/60HZ
Rated input
MMA
7.1
8.2
4.1
7.158.2
Rated input
power
TIG
KVA
5.2
6
2.1
5.246
Current
MMA
10~160
10~180
10~100
10~160
10~120
10~180
Current
range
TIGA10~180
10~200
10~120
10~180
10~150
10~200
Rated duty cycle
*
*
%
35
35
35
No-load
MMA
60
60
60
No-load
voltage
TIG
V
65
65
65
Downslope time
s
0~10
0~10
0~10
Post-flow time
s
0~15
0~15
0~15
Overall efficiency
%
85
85
85
Housing protection grade
IP
21S
21S
21S
Power factor
cosφ
0.7
0.7
0.7
Insulation grade
F
F
F
Arc ignition mode
HF arc ignition
HF arc ignition
HF arc ignition
Standard
IEC60974-1
IEC60974-1
IEC60974-1
Noise
db
＜70
＜70
＜70
without
handle
365*135*235
365*135*235
365*135*235
Size
with
handle
mm
365*135*277
365*135*277
365*135*277
Weightkg5.94
6.125
5.94
6.125
Controls
4
Front view
1. Overheating LED to indicate overheating.
2. Power LED to indicate the power is on.
3. Downslope time control: 1~10s.
4. Post-flow time control: 1~10s.
5. "+" output terminal: To connect the work clamp.
6. "-" output terminal: To connect the TIG torch.
7. Torch switch plug connection.
8. Gas terminal: To connect the gas hose of the TIG torch.
9. 2T/4T switch: When the toggle switch is switched to 4T, self-lock function is
available.
10. MMA/TIG selector switch.
11. Welding current adjustment knob.
12. Handle
Rear view
13$ Power switch
14$ Warning label
15$ Input cable gland
16$ Cooling fan
17$ Gas inlet
7
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 t h e cable
plug with electrode
holder into the “+”
socket on the front
p a n e l o f t h e
welding machine,
a n d t i g h t e n i t
clockwise.
Insert t h e cable
plug of the work
return lead into the
“-”ve socket on the
front panel of the
welding machine,
a n d t i g h t e n i t
clockwise
TIG Welding
Insert the cable plug with the work clamp into the “+” socket
on the front panel of the welding machine, and tighten it
clockwise.
I n s e r t t h e
cables p l u g
o f th e T I G
torch into the
“-” socket on
t h e f r o n t
panel of the
machine and
t i g h t e n
clockwise.
Connect the
gas hose to
the regulator /
fl o w m e t e r
l o ca t ed o n
the shield gas
cylinder and
connec t th e
other end to
the machine.
8
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.
TIG
Connect the TIG torch leads as detailed above. Ensure that a
suitable inert gas supply is connected.
Switch the MMA/TIG switch to TIG mode.
Open the gas valve of the cylinder, and adjust the gas
regulator to obtain the desired flow rate.
Switch the power switch on the back panel to “ON”, the
machine is started with the power LED on and the fan
working.
Press the torch trigger briefly, the solenoid valve will operate
and 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 tables 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 trigger, the current begins to down
slope automatically to the minimum value. Then, the arc
stops with gas kept flowing for the post-flow time, and
welding ends.
Adjust the downslope time potentiometer to change the time
according to the welding process requirements.
If the torch trigger is pressed again during the downslope
period, the welding current will immediately rise to the preset
value.
Operation of 2T/4T switch
2T:
Press the torch trigger, gas valve opens, and HF arc ignition
starts; Keep the torch 2~4mm away from the work piece to
ignite the arc. When the arc is established the HF stops, and
current rises to the preset value; Release the torch trigger,
current decreases to the minimum value, and then arc stops;
Gas keeps flowing for the post-flow time, and welding ends.
4T:
Press the torch trigger, gas valve opens, and HF arc ignition
starts; Keep the torch 2~4mm away from the work piece to
ignite the arc. When the arc is established the HF stops, and
current rises to the preset value; Release the torch trigger,
and welding continues at the preset current level. Press the
torch trigger again and release it, current begins to decrease
to the minimum value, and then arc stops; Gas keeps
flowing fo r the post-flow time, an d we lding ends.%
For either the above modes, the HF discharge will remain on
in the case that the torch trigger is pressed but arc is not
ignited successfully. After arc is ignited, HF discharge will
end automatically. Whenever the arc is broken due to
external causes, HF discharge will restart automatically in
order to reignite the arc, and the HF discharge will not end
until either arc is ignited successfully or the torch trigger is
released.
Upslope time control
This function can be added upon customers’ requirements.
It is used to adjust the current increasing speed when the
current rises from the minimum value to the preset value
after arc is ignited successfully. If this function is not added,
the upslope time is 0.1s fixed.
TIG Tips
9
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
The welding current reference for different electrode diameters
Electrode diameter /mm
1.6
2.0
2.5
3.2
Welding current /A
25-40
40-60
50-80
100-130
Electrode type
The corresponding relationship between gas nozzle diameter and electrode diameter
TIG of stainless steel (single run welding)
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
10
Type
Mode
Colour
Thoriated 2%
DC welding of steel, stainless steel and copper
Red
Ceriated
DC welding of steel, stainless steel and copper
Grey
Lanthanated
DC welding of steel, stainless steel and copper
Black
Gas nozzle diameter/mm
Electrode diameter/mm
6.4
0.5
8
1.0
9.5
1.6 or 2.4
11.1
3.2
Work piece
thickness
mm
Joint form
Tungsten electrode
diameter/mm
Welding wire
diameter/mm
Argon gas
flow rate
(L per·min)
Welding
current
Welding
speed
cm·min-1
0.8
Butt joint
1.0
1.6
5
20-50
66
1.0
Butt joint
1.6
1.6
5
50-80
56
1.5
Butt joint
1.6
1.6
7
65-105
30
1.5
Corner joint
1.6
1.6
7
75-125
25
2.4
Butt joint
1.6
2.4
7
85-125
30
2.4
Corner joint
1.6
2.4
7
95-135
25
3.2
Butt joint
1.6
2.4
7
100-135
30
3.2
Corner joint
1.6
2.4
7
115-145
25
4.8
Butt joint
2.4
3.2
8
150-225
25
4.8
Corner joint
3.2
3.2
9
175-250
20
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.
11
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.
Malfunction symptom
Causes and Solutions
Turn on the machine, the power
LED is off, the fan doesn't work, and
no welding output.
Check if the power switch is closed.
No input power.
Turn on the machine, the fan works,
but the output current is unstable
and can't be controlled by
potentiometer when welding.
The current potentiometer fails.
Replace it.
Check if any loose contact exists
inside the machine. If any,
reconnect.
Turn on the machine, the power
LED is on, the fan works, but no
welding output.
Check if any loose contact exists
inside the machine.
Open circuit or loose contact occurs
at the joint of output terminal.
The overheating LED is on.
The machine is under over-heating
protection status. It can recover
automatically after the welding
machine is cooled.
Check if the thermal switch is ok.
Replace it if damaged.
Check if the thermal switch is
loosely connected, and reconnect it
if necessary.
The electrode holder becomes very
hot.
The rated current of the electrode
holder is smaller than its actual
working current. Replace it with a
higher rated current capacity.
Excessive spatter in MMA welding.
The output polarity connection is
incorrect. Exchange the polarity.
12
Symptom
Cause
Solution
Difficult to ignite the arc
The arc ignition current is too low or the arc
ignition time is too short.
Increase the arc ignition current or prolong the arc starting
time.
No arc can be started
Phase failure of the mains power supply or
the mains supply cable is not connected.
Solve the phase failure problem or reconnect the mains supply
cable.
Electrode sticking
The arc force current is too low.
Increase the arc force current
The mains power supply or the mains
supply cable is not connected.
Reconnect the mains supply cable.
The fan does not work or it works
abnormally.
Phase failure
Solve the phase failure problem.
The fan does not work or it works
abnormally.
The mains voltage is too low.
Welding can be carried out after the mains voltage recovers.
The no-load voltage is “0”, and the under
The mains voltage is too low.
Welding can be carried out after the mains voltage recovers.
The no-load voltage is “0”, and the under
voltage LED is on.
Auxiliary power fails.
Replace the fault circuit board of the auxiliary power.
The no-load voltage is “0”, and the
overheating LED is on.
Over heating protection
It will recover automatically after the welding machine is
cooled.
The no-load voltage is “0”, and the over
current LED is on.
Over current or damage of power parts
Restart the machine. If over current problem still exists, contact
the service centre of your distributor
The electrode holder becomes very hot.
The rated current of the electrode holder is
lower than its actual working current.
Replace it with a higher rated current holder.
Other malfunction
Contact the service centre of your distributor.
Electrical schematic
7
13
Parts list
8
14
15
No.
Part no
Description
No.
Part no
Description
1
10004949
Power switch
22
10041436
Thermal Switch
2
10041432
Power line
23
10037134
Switching mode power supply transformer
3
10042342
Connector for input gas
24
10006477
12V Electric Relay
10044817
TIG180/TIG180 Dual Voltage Fan
25
10037146
TOP266KG
4
10044009
TIG200 Fan
26
10006673
KA7915510043460
Back Panel
27
10040667
Solenoid value
6
10043476
Handle2810037078
Pin insulation cover
7
10043689
Louver
10005833
TIG180 Electrolytic capacitor
8
10042320
Bottom Panel
29
10028332
TIG200 Electrolytic capacitor
9
10041327
Isolation transformer
29
10037137
TGI180 Dual voltage electrolytic capacitor
10
10021853
Quick socket
10006650
TIG180/ TIG 180 Dual voltage silicon bridge
11
10043469
Front Panel
30
10037485
TIG200 Silicon bridge board
12
10042014
Small Knob
10007251
TIG180/TIG180 Dual Voltage IGBT
13
10037561
Knob3110029693
TIG200 IGBT/TIG200 IGBT
14
10040688
EPC connection between hose
and gas connector
32
10041361
TIG180/TIG180 Dual voltage control board
15
10040709
Hose3210041372
TIG200 Control board
16
10004684
Air socket
33
10040708
TIG180/TIG 180 Dual voltage high frequency
transformer
17
10042323
Machine Cover
33
10041725
TIG200 High frequency transformer
18
10006474
Electric Relay
34
10041326
Arc coil1910006282
IRF9Z24N
35
10037431
Rectifier board
20
10006282
IRFZ24N
36
10041436
Thermal resistor
21
10037135
Driver transformer
JT DC TIG Series DC TIG/MMA WELDING MACHINE
Order code ! TIG180（JT-180 / TIG200 (JT-200）
!!!!TIG180（JT-180DV / TIG200 (JT-200DV）
© Wilkinson Star Limited
Issue 1 January 2014
Product is subject to change without notice
xvi
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