wilkinsonstar.

com

Arc Series
DC MMA / LIFT TIG Welding machines
Order codes !JA-140, JA-160, JA-180, JA-200
! ! ! ! JA-160DV, JA-180DV - Dual voltage

OPERATOR MANUAL
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 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

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Safety Precautions

These general safety norms cover both arc welding Insulate yourself from work and ground using dry insulating
machines and plasma cutting machines unless mats or covers big enough to prevent any physical contact
with the work ground.
otherwise noted.
Never touch the electrode if you are in contact with the work
The equipment must only be used for the purpose it was ground, or another electrode from a different machine.
designed for. Using it in any other way could result in
damage or injury and in breach of the safety rules. Do not wrap cables over your body.

Ensure that you take additional safety precautions when you

Only suitably trained and competent persons should use the
are welding in electrically hazardous conditions such as
equipment. Operators should respect the safety of other damp environments, wearing wet clothing, and metal
persons. structures. Try to avoid welding in cramped or restricted
positions.

Prevention against electric shock

Ensure that the equipment is well maintained. Repair or
replace damaged or defective parts immediately. Carry out
The equipment should be installed by a qualified person and any regular maintenance in accordance with the
in accordance with current standards in operation.It is the manufacturers instructions.
users responsibility to ensure that the equipment is
connected to a suitable power supply. Consult with your Safety against fumes and welding gases
utility supplier if required

If earth grounding of the work piece is required, ground it

Locate the equipment in a well-ventilated position.
directly with a separate cable.

Keep your head out of the fumes. Do not breathe the fumes.
Do not use the equipment with the covers removed.

Ensure the welding zone is in a well-ventilated area. If this is

Do not touch live electrical parts or parts which are
not possible provision should be made for suitable fume
electrically charged.
extraction.

Turn off all equipment when not in use.

If ventilation is poor, wear an approved respirator.

Cables (both primary supply and welding) should be

Read and understand the Material Safety Data Sheets
regularly checked for damage and overheating. Do not use
(MSDS’s) and the manufacturer’s instructions for metals,
worn, damaged, under sized, or poorly jointed cables.
consumable, coatings, cleaners, and de-greasers.

Ensure that you wear the correct protective clothing, gloves,

Do not weld in locations near any de-greasing, cleaning, or
head and eye protection.
spraying operations. Be aware that heat and rays of the arc
can react with vapours to form highly toxic and irritating
gases.

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 Do not weld on coated metals, unless the coating is Replace the coverings and protections and close all doors
removed from the weld area, the area is well ventilated, and when the intervention is finished, and before starting the
while wearing an air-supplied respirator. The coatings on equipment.
many metals can give off toxic fumes if welded.
Take care to avoid getting fingers trapped when loading and
Prevention against burns and radiation feeding wire during set up and operation.

Arc rays from the welding process produce intense, visible When feeding wire be careful to avoid pointing it at other
and invisible (ultraviolet and infrared) rays that can burn eyes people or toward your body.
and skin.
Always ensure machine covers and protective devices are in
Wear an approved welding helmet fitted with a proper shade operation.
of filter lens to protect your face and eyes when welding or
watching Precautions against fire and explosion

Wear approved safety glasses with side shields under your Avoid causing fires due to sparks and hot waste or molten
helmet. metal

Never use broken or faulty welding helmets. Ensure that appropriate fire safety devices are available near
the cutting / welding area.
Always ensure there are adequate protective screens or
barriers to protect others from flash, glare and sparks from Remove all flammable and combustible materials from the
the welding area. Ensure that there are adequate warnings cutting / welding zone and surrounding areas
that welding or cutting is taking place.
Do not cut/weld fuel and lubricant containers, even if empty.
Wear suitable protective flame resistant clothing. These must be carefully cleaned before they can be cut/
welded.
The sparks and spatter from welding, hot work pieces, and
hot equipment can cause fires and burns Always allow the cut/welded material to cool before touching
it or placing it in contact with combustible or flammable
Welding on closed containers, such as tanks, drums, or material.
pipes, can cause them to explode.
Do not work in atmospheres with high concentrations of
Accidental contact of electrode to metal objects can cause combustible fumes, flammable gases and dust.
arcs, explosion, overheating, or fire.
Always check the work area half an hour after cutting to
Check and be sure the area is safe and clear of inflammable make sure that no fires have begun.
material before carrying out any welding.
Risks due to magnetic fields
Protection against noise
The magnetic fields created by high currents may affect the
Some welding and cutting operations may produce noise. operation of pacemakers or electronically controlled medical
equipment.
Wear safety ear protection to protect your hearing.
Wearers of vital electronic equipment should consult their
Protection from moving parts physician before beginning any arc welding, cutting, gouging
or spot welding operations.

When the machine is in operation keep away from moving Do not go near welding equipment with any sensitive
parts such as motors and fans. Moving parts, such as the electronic equipment as the magnetic fields may cause
fan, may cut fingers and hands and snag garments. damage.

Protections and coverings may be removed for maintenance

and controls only by qualified personnel, after first
disconnecting the power supply cable.

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 RF Declaration Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
Equipment that complies with directive 2004/108/EC
concerning electromagnetic compatibility (EMC) and the Keep your head and face away from the cylinder valve outlet
technical requirements of EN60974-10 is designed for use in when opening the cylinder valve.
industrial buildings and not those for domestic use where
electricity is provided via the low voltage public distribution Always secure the cylinder safely
system. Difficulties may arise in assuring class A
electromagnetic compatibility for systems installed in
domestic locations due to conducted and radiated Never deface or alter any cylinder
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,
c o n n e c t i o n re s t r i c t i o n s o r m a x i m u m i m p e d a n c 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.

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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.

Product functions
• Easy arc starting, less spatter, stable current and good
• Hot start arc ignition functions: ensure the arc ignition in weld bead shaping.
MMA welding easier and more reliable.
• Modern high tech design
• VRD function: Provides additional safety keep the
operator safe when the machine is idle.
• Streamline design of front and rear panels.
• Anti-sticking function: Reduces the welding current if a
short circuit occurs during welding. • Front and rear panels made of high-intensity plastics
suitable for working in severe conditions.
• Self-adaptive arc force technology: Maintains the
optimum arc conditions during welding even with long • Excellent insulating property.
cables.
• Water-resistant, antistatic and anticorrosion design.
• Advanced scratch start arc ignition: supports TIG welding
without HF arc ignition circuit.
• It can be used with a wide range of welding electrodes.

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.

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Technical data

Single voltage units

Technical Parameter Unit Model

ARC140 (JA-140) ARC160 (JA-160) ARC180 (JA-180) ARC200 (JA-200)

Rated input voltage V AC230V±15% 50/60HZ

Rated input power KVA 6 7.11 8 9.4

Welding current range A 10~140 10~160 10~180 10~200

Rated duty cycle % 35

No-load voltage V 63

Overall efficiency % 85

Housing protection grade IP 21

Power factor Cosφ 0.7

Insulation grade F

Noise dB ＜70 ＜70 ＜80 ＜80

without handle 313*130*206 313*130*206 313*130*206 351*130*206

Size mm
with handle* 313*130*250 313*130*250 313*130*250 351*130*250

Weight Kg 4.7 4.7 4.7 5.2

Applicable electrode size mm 1.0~4.0 1.0~4.0 1.0~5.0 1.0~5.0

Tested at the environment temperature of 400 C

Product design may vary due to customer requirements.

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 Dual voltage units

Technical Parameter Unit Model

ARC160DV (JA-160DV) ARC180DV (JA-180DV)

Rated input voltage V AC230V±15% 50/60HZ AC110V±15% 50/60HZ AC230V±15% 50/60HZ AC115V±15% 50/60HZ

Rated input power KVA 7.11 5 8 6

Welding current range A 10~160 10~120 10~180 10~140

Rated duty cycle % 35

No-load voltage V 63

Overall efficiency % 85

Housing protection grade IP 21

Power factor Cosφ 0.7

Insulation grade F

Noise dB ＜70 ＜70 ＜80 ＜80

without handle 313*130*206

Size mm
with handle* 313*130*250

Weight Kg 4.7 5.2

Applicable electrode size mm 1.0~4.0 1.0~5.0

Tested at the environment temperature of 400 C

Product design may vary due to customer requirements.

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Controls

Front view

1. Overheating LED: Overheating LED on indicates that the temperature

inside the machine is too high and the machine is under overheating
protection status.

2. Power LED: Power LED on indicates that the power switch of the
machine is on.

3. MMA/TIG switch: To toggle between MMA and TIG.

4. "+" Output terminal: To connect the electrode holder.

5. "-" Output terminal: To connect the work clamp.

6. Trademark

7. Welding current knob: To adjust the output current.

8. Handle

Rear view

9 Power switch

10 Warning label

11 Input cable gland

12 Cooling fan

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Installation

Unpacking MMA welding

Check the packaging for any signs of damage. Insert the cable plug with electrode holder into the “+”
socket on the front panel of the welding machine, and
Carefully remove the machine and retain the packaging until tighten it clockwise.
the installation is complete.
Insert the cable plug of the work return lead into the “-”ve
Location socket on the front panel of the welding machine, and
tighten it clockwise
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 TIG Welding
or in the technical parameters shown in the manual.
Insert the cable plug with the work clamp into the “+” socket
on the front panel of the welding machine, and tighten it
The equipment should be connected by a suitably qualified clockwise.
competent person. Always ensure the equipment has a
proper grounding. Insert the cables plug of the TIG torch into the “-” socket on
the front panel of the machine and tighten clockwise.
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 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 Connect the gas hose to the regulator / flowmeter located on
return to the positive terminal the shield gas cylinder and connect the other end to the
machine.

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 Operation
Before starting any welding activity ensure that you have TIG guides
suitable eye protection and protective clothing. Also take
the necessary steps to protect any persons within the The recommended size of tungsten to be used can be
area. selected from the table below

MMA The welding current reference for different electrode diameter

Electrode diameter /mm 1.6 2.0 2.5 3.2
After connecting the welding leads as detailed you will need
Welding current /A 25-40 40-60 50-80 100-130
to switch the power switch on the back panel to “ON”

Electrode type
Select MMA by switching to the MMA welding mode. There
is voltage output at both output terminals.
Type Mode Colour
Set the amperage on the machine suitable for the electrode
being used. Please see below a guide to amperages DC welding of steel, stainless
required. Ensure you check that you have the electrode Thoriated 2% Red
steel and copper
polarity correct.
DC welding of steel, stainless
Ceriated Grey
steel and copper
Electrode Diameter (mm) Recommended Welding Current (A)
1.0 20~60
DC welding of steel, stainless
1.6 44~84 Lanthanated Black
2.0 60~100
steel and copper
2.5 80~120
3.2 108~148
The corresponding relationship between gas nozzle
4.0 140~180
5.0 180~220 diameter and electrode diameter
6.0 220~260

Gas nozzle diameter/mm Electrode diameter/mm

TIG mode
6.4 0.5

Connect the TIG torch leads as detailed above. Ensure that a 8 1.0
suitable inert gas supply is connected.
9.5 1.6 or 2.4
Switch the power switch on the back panel to “ON”
11.1 3.2

Select the TIG welding mode using the selector switch.

For welder training please visit our Academy
There is voltage output at both output terminals. website at

After the parameters are set appropriately, open the gas www.wilkinson-welding-academy.com
valve of the cylinder, the gas valve on the torch and adjust
the gas regulator to obtain the desired flow rate.

The arc will start when the tungsten electrode touches the
work piece and is lifted off after touching by between 2-4mm

The arc will cease when the electrode (torch) is moved away
from the work area

Select the spot welding time setting function by pressing

the welding parameter selecting key, and set the spot
welding time. Operation steps in spot welding:

Press the torch trigger, gas valve opens, and HF arc ignition
starts; Keep the torch 2~4mm away from the work piece to

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Maintenance and troubleshooting

The following operation requires sufficient professional Troubleshooting

knowledge on electric aspects and comprehensive
Before arc welding machines are dispatched from the
safety knowledge. Make sure the input cable of the
factory, they have already been checked thoroughly. The
machine is disconnected from the electricity supply and machine should not be tampered with or altered.
wait for 5 minutes before removing the machine covers.
Maintenance must be carried out carefully. If any wire
becomes loose or is misplaced, it maybe potential danger to
In order to guarantee that the arc welding machine works user!
efficiently and in safety, it must be maintained regularly.
Operators should understand the maintenance methods and Only professional maintenance personnel should repair the
means of arc welding machine operation. This guide should machine!
enable customers to carry on simple examination and
Ensure the power is disconnected before working on the
safeguarding by oneself, try to reduce the fault rate and
machine. Always wait 5 minutes after power switch off
repair times of the arc welding machine, so as to lengthen before opening the case.
service life of arc welding machine
Malfunction symptom Causes and Solutions
Period Maintenance item Turn on the machine, the power LED
1 Check if the power switch is closed.
Carry out a full visual inspection. Check is off, the fan doesn't work, and no
2 No input power.
for any damage to the machine, leads, welding output.
cables and connections. Replace where Turn on the machine, the fan works, 1 The current potentiometer fails. Replace
Daily but the output current is unstable
necessary. it.
examination and can't be controlled by 2 Check if any loose contact exists inside
potentiometer when welding. the machine. If any, reconnect.
Switch on the machine and check for any
1 Check if any loose contact exists inside
warning Led’s and general operation the machine.
Using the dry compressed air to clean the 2 Open circuit or loose contact occurs at the
inside of arc welding machine. Especially joint of output terminal.
3 The overheating LED is on.
check for build up of dust / debris on
intake grills, main voltage transformer, Turn on the machine,, the fan works, The machine is under over-heating
protection status. It can recover
inductance, IGBT module, the fast recover but no welding output. automatically after the welding machine is
Monthly
diode and PCB, etc. Take care when cooled.
examination 4 Check if the thermal switch is ok. Replace
blowing electronic components and do not it if damaged.
dislodge any wiring connections 5 Check if the thermal switch is loosely
connected, and reconnect it if necessary.
Check the security of output connections
and plugs. Replace if signs of overheating. The rated current of the electrode holder is
Carry out an annual service. Check earth The electrode holder becomes very smaller than its actual working current.
continuity and insulation resistance of the hot. Replace it with a higher rated current
Yearly machine at the relevant points. capacity.
examination PLEASE NOTE THIS WORK SHOULD
BE CARRIED OUT BY A TRAINED Excessive spatter in MMA welding.
The output polarity connection is incorrect.
Exchange the polarity.
COMPETENT PERSON.

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Electrical schematic

Schematic for single voltage unit

Schematic for dual voltage unit

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Parts list

Arc Pro 140 - (JA-140)

No. Part no Description No. Part no Description

1 10004957 Power switch 15 10037859 Thermal Switch
2 10037125 Back panel 16 10037135 Driver transformer
3 10044817 Fan 17 10006282 IRF9Z24N
4 10043477 Handle 18 10006282 IRFZ24N
5 10043689 Louver 19 10037134 Switching mode power supply transformer
6 10039735 Machine Cover 20 10037345 Silicon bridge
7 10037113 Bottom panel 21 10037146 TOP266KG
8 10037128 Front panel 22 10043910 Control board
9 10044029 Quick socket 23 10037734 High frequency transformer
10 10037561 Knob 24 10005801 Electrolytic capacitor
11 10037147 LM79L15ACMX 25 10006272 Rectifying tube
12 10006431 Thermal Resistor 26 10037078 Pin insulation cover
13 10006474 Electric Relay 27 10037432 Rectifier Plate
14 10007251 IGBT 28 10037858 Power line

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 Arc Pro 160 - (JA-160DV)

No. Part no Description No. Part no Description

1 10004957 Power switch 15 10037859 Thermal Switch

2 10037125 Back Panel 16 10037135 Drive Transformer
3 10044817 Fan 17 10006282 IRF9Z24N
4 10043477 Handle 18 10006282 IRFZ24N
5 10043689 Louver 19 10037134 Switching mode power supply transformer
6 10039735 Machine Cover 20 10037147 LM79L15ACMX
7 10037113 Bottom Panel 21 10037146 TOP266KG
8 10037485 ARC160D Silicon bridge 22 10043914 ARC160D Control Board
9 10037431 ARC160D Rectifying Board 23 10037134 ARC160D High frequency transformer
10 10006248 ARC160D Rectifier Tube 24 10038719 ARC160D Electrolytic capacitor
11 10037836 Front Panel 25 10037561 Knob
12 10006431 Thermal Resistor 26 10037078 Pin insulation cover
13 10006474 Electric Relay 27 10037152 Quick socket
14 10007251 IGBT 28 10037858 Power line

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 Arc Pro 180 - (JA-180DV)

No. Part no Description No. Part no Description

1 10004957 Power switch 15 10037852 Thermal Switch
2 10037837 Back Panel 16 10037135 Driver transformer
3 10044009 Fan 17 10006282 IRF9Z24N
4 10043477 Handle 18 10006282 IRFZ24N
Switching mode power supply
5 10043689 Louver 19 10037134
transformer
6 10037813 Machine Cover 20 10037147 LM79L15ACMX
7 10037811 Bottom panel 21 10037146 TOP266KG
8 10043405 Front Panel 22 10043912 Control Board
9 10044030 Quick Socket 23 10037735 High Frequency transformer
10 10037561 Knob 24 10038737 Electrolytic capacitor
11 10044538 Silicon Bridge board 25 10006248 Rectifier tube
12 10006431 Thermal Resistor 26 10037078 Pin insulation cover
13 10006474 Electric Relay 27 10037429 Rectifying board
14 10029693 IGBT 28 10037853 Power line

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 Arc Pro 200 - (JA-200)

No. Part no Description No. Part no Description

1 10004957 Power switch 15 10037852 Thermal Switch

2 10037837 Back panel 16 10037135 Drive Transformer

3 10044009 Fan 17 10006282 IRF9Z24N

4 10043477 Handle 18 10006282 IRFZ24N

5 10043689 Louver 19 10037134 Switching mode power supply transformer

6 10037813 Machine Cover 20 10037147 LM79L15ACMX

7 10037706 Bottom Panel 21 10037146 TOP266KG

8 10043405 Front Panel 22 10043912 Control Board

9 10044030 Quick Socket 23 10037735 High Frequency transformer

10 10037561 Knob 24 10005848 Electrolytic capacitor

11 10037485 Silicon bridge board 25 10006248 Rectifying tube

12 10006431 Thermal Resistor 26 10037078 Pin insulation cover

13 10006474 Electric Relay 27 10037429 Rectifier Plate

14 10029693 IGBT 28 10037853 Power line

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 JA Arc series DC TIG/MMA WELDING MACHINE
Order code ! JA-140, JA-160, JA-180, JA-200
! ! ! ! JA-160DV, JA-180DV - Dual voltage

© Wilkinson Star Limited

Issue 1 January 2014

Product is subject to change without notice

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