Jasic EVO 2.0 EM-160C Operator'S Manual Download

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DESCRIPTION OF SYMBOLS

Read this operation manual carefully before use.

Mixed gas welding (80% argon + 20% CO2) of carbon steel

Mixed gas welding (80% argon + 20% CO2) of flux

cored carbon steel

Self

shielded welding of carbon steel

100% argon shielding of aluminum magnesium alloy

Mixed gas welding (98% argon + 2% CO2) of stainless steel

Welding type selection: welding base metal and gas

Welding wire diameter

MIG/Lift TIG 2T operation

MIG/Lift TIG 4T operation

MIG torch

MIG spool torch

MIG synergic function

Inching wire feeding function

Gas check function

Summary of Contents for EVO 2.0 EM-160C

Page 1: ...1...

Page 2: ...rect information should you require assistance or spare parts Date purchased ________________________________________ From where ________________________________________ Serial number ________________...

Page 3: ...nel Description 19 Remote Control wired and wireless 28 Remote Control Socket 29 Operating MIG 30 Guide to MIG MAG Welding 38 Spool Gun Operation 45 MIG Welding Chart 46 MIG Welding Problems 47 MIG To...

Page 4: ...g should be regularly checked for damage and overheating Never use worn damaged under sized or poorly jointed cables Insulate yourself from work and earth using dry insulating mats or covers big enoug...

Page 5: ...cutting is taking place Wear suitable protective flame resistant clothing gloves and footwear Ensure adequate extraction and ventilation is in place prior to welding and cutting to protect users and...

Page 6: ...ding fume Ensure the welding zone is well ventilated and provision should be made for suitable local fume extraction system to be in place If ventilation is poor wear an approved airfed welding helmet...

Page 7: ...ated 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 ar...

Page 8: ...permanent damage to your hearing Noise from cutting and welding equipment can damage hearing Always protect your ears from noise and wear approved and appropriate ear protection if noise levels are hi...

Page 9: ...ONTENTS AND UNPACKING Supplied within your new Jasic EVO product package will be the following items with each model Use care when unpacking the contents and ensure all items are present and not damag...

Page 10: ...fective input current X Duty cycle The ratio of given duration time the full cycle time U0 No load voltage Open circuit voltage of secondary winding U2 Load voltage H Insulation class Do not dispose o...

Page 11: ...carbon steel Self shielded welding of carbon steel 100 argon shielding of aluminum magnesium alloy Mixed gas welding 98 argon 2 CO2 of stainless steel Welding type selection welding base metal and gas...

Page 12: ...er factor is the ratio of true power KW divided by reactive power kvar Power factor value is between 0 0 and 1 00 and if the power factor exceeds 0 8 the device is using mains input power efficiently...

Page 13: ...ange A MMA 20 100 MIG 30 120 TIG 5 100 MMA 20 140 MIG 30 160 TIG 5 160 MMA 20 110 MIG 30 140 TIG 5 140 MMA 20 180 MIG 30 200 TIG 5 200 MIG voltage range U2 V MIG 11 22 MIG 11 26 MIG 11 24 MIG 11 28 Ra...

Page 14: ...ains power cable 9 Shielding gas inlet hose Panel socket size is 35 50mm Rear view Jasic MIG EM 160C and EM 200C 10 Carry handle 11 Shielding gas inlet quick fitting 12 ON OFF power switch 13 Rear pan...

Page 15: ...ooved drive roller in place 6 Outlet feed adaptor Part of the Euro outlet connector which contains the inner outlet guide which ensures smooth wire feed from the drive assembly through to the MIG torc...

Page 16: ...p over Never use the machine on its side Most metals including stainless steel can give off toxic fume when welded or cut To protect the operator and others working in the area its important to have a...

Page 17: ...lator clean the cylinder valve outlet Match the regulator to cylinder and before connecting ensure the regulator and the regulator inlet and cylinder outlet match Connect the regulator inlet connectio...

Page 18: ...ou will require to fit the optional remote interface module Installation of the wireless receiver module 1 Remove the plastic cap A shown in the image right and fit the wireless receiver module as sho...

Page 19: ...or button preset according to material selected 7 Top digital display with rotary encoder for carrying out parameter adjustments including wire feed speed current control and material thickness depend...

Page 20: ...ckground settings In MIG Synergic mode MMA mode or Lift TIG mode current is displayed by default If Synergic is disabled in MIG mode the wire feed speed is displayed by default Top parameter adjustmen...

Page 21: ...various parameters of the welding equipment Depending on which welding process you have selected by either pressing or rotating the control knob this allows the operator to select the required paramet...

Page 22: ...er details Base metal and gas selecting zone This control allows you to select the base metal and welding gas mixture options which include Carbon steel with 80 Ar 20 CO2 Steel flux cored with 80 Ar 2...

Page 23: ...effective for MIG TIG and MMA operating Synergic Control Switch This button allows the user to turn synergic mode ON or OFF With Synergic mode turned on means the machine will automatically match the...

Page 24: ...arcode are the company s internal fixed numbers which are not displayed in the window Read the 9 groups of data and arrange them in order from left to right skipping the 12th 19th digits to get the ba...

Page 25: ...umbers function definitions and configuration values Upon selecting your chosen response time press the control dial to save the current settings Then press the welding mode button to complete the ope...

Page 26: ...ntering Welding Engineer Mode If the Welding Mode is MIG set the MIG post flow time with range 0 5 0 accuracy of 0 5 and unit of seconds If the Welding Mode is Lift TIG set the Lift TIG post flow time...

Page 27: ...he countdown ends the restore will not have taken place Factory settings are detailed and shown in the table below Welding Process Parameter Restored Parameter Value EVO EM 160C Restored Parameter Val...

Page 28: ...trol function button and the pairing button of the wireless remote controller at the same time hold for 2 seconds to perform wireless remote control pairing During pairing the blue indicator of wirele...

Page 29: ...ote LED will illuminate as shown left this indicates that the machine is ready to be used with a remote control device Pressing the remote button again will turn off remote control Lift TIG Torch Trig...

Page 30: ...l activate the feed motor only and will start to feed the wire through the torch until the wire comes through the contact tip You are now ready to start MIG welding MIG welding using gasless self shie...

Page 31: ...which also enhances the arc Connect the MIG torch leads as detailed on page 30 Work return lead to B and torch trailing lead to A Ensure that a suitable shielding gas supply is connected Switch the po...

Page 32: ...ng process you have previously selected Upon selecting your MIG wire size choice only that wire size icon will be illuminated The corresponding indicator will be lit according to selected operation me...

Page 33: ...and display area K is a combined rotary encoder and selection push button which when rotated in standard MIG mode gives the operator the ability to control wire feed speed Rotating the control dial c...

Page 34: ...2 seconds and the factory setting is 0 1 seconds MIG post gas selection and adjustment To select post flow gas time setting rotate the top adjustment dial until F04 is displayed by rotating the botto...

Page 35: ...hine being set up in synergic MIG mode and the following few pages will explain the setup steps of operation Following on from the standard MIG mode selecting synergic is easily actioned by pressing t...

Page 36: ...bility to adjust welding current and rotating the control dial clockwise increases not only the welding current but also the background wire feed speed and material thickness settings While rotating t...

Page 37: ...isplay the actual current and voltage respectively When torch trigger is pressed again stopping the arc is effected welding crater current and crater voltage parameters in the welding settings can adj...

Page 38: ...this process as CO welding Gases such as oxygen and carbon dioxide were added and are active constituents to the inert gas to improve the welding performance Although the MAG process is in common use...

Page 39: ...m contamination which also enhances the arc The MIG MAG process can be used to weld a wide variety of materials and is normally used in the horizontal position but can be used in vertical or overhead...

Page 40: ...es with the positive This means that the majority of the heat is in the electrode wire Certain special wires may require the polarity to be reversed i e electrode wire negative polarity Always consult...

Page 41: ...occurring This occurs when there is not enough energy in the weld puddle to fuse properly Another disadvantage is that this mode produces an increased amount of spatter due to the short circuits espe...

Page 42: ...the problems on thinner materials In basic terms pulsed MIG is a transfer method where material is transferred between the electrode and the weld puddle in controlled droplet form This is achieved by...

Page 43: ...clean and dry to avoid contamination such as oxidation and damp Inductance When MIG MAG welding in the dip transfer mode the welding wire electrode touches the work piece weld pool and this results in...

Page 44: ...e filled helping eliminate welding defects A spot welding timer will allow the time of the weld to be set and after the time has expired the operator will have to release the torch switch to restart t...

Page 45: ...ing mode A and spool gun mode B Set the welding voltage and other parameters via the machine control panel When the remote control function is enabled the Wire Feed Speed is adjusted by the potentiome...

Page 46: ...46 EVO MIG Set Up Guide Please Note This information is intended to act as a starting point guide only for standard MIG mode MIG WELDING GUIDE...

Page 47: ...ding tip Readjust the upper feed pressure Increase the pressure to eliminate burn back to tip Decrease pressure to eliminate bird nesting Replace torch liner Replace wire Check and replace welding tip...

Page 48: ...rior to welding Irregular weld bead and shape Incorrect voltage wire feed settings If it s convex voltage is too low and if it s concave then voltage is too high Insufficient or excessive heat input W...

Page 49: ...Note Package contents may very depending on country location and package part number purchased Please Note Package contents may very depending on country location and package part number purchased JE1...

Page 50: ...Note Package contents may very depending on country location and package part number purchased Please Note Package contents may very depending on country location and package part number purchased JE...

Page 51: ...electrode connected to the positive polarity Always consult the electrode manufacturer s data sheet if you have any doubts MMA welding 1 When connecting welding cables ensure that the machines ON OFF...

Page 52: ...t the rear panel of the machine place it to the ON position the panel indicator will then light up the fan may start to rotate as the welding machine powers up and the control panel will also light up...

Page 53: ...has been replaced on the lower display by the arc force current details You can now rotate the control dial B clockwise or anticlockwise which will increase or decrease the required arc force current...

Page 54: ...e electrodes of the welding arc is different When welding using DC power supply there are DCEN DC electrode negative and DCEP DC electrode positive connections The DCEN connection refers to the weldin...

Page 55: ...n as the electrode contacts the work piece The welder should always ensure a good connection of the work clamp The nearer the clamp is placed to the welding area the better When the arc is struck the...

Page 56: ...cuit quickly lift up about 2 4mm and arc will be ignited This method is difficult to master Scratch technique Drag the electrode and scratch the work piece as if striking a match Scratching the electr...

Page 57: ...rode 1 The electrode feeding to the molten pool along axes 2 The electrode swing right and left 3 The electrode moving in the weld direction The operator can choose the manipulation of electrode based...

Page 58: ...cross rather than to or from your body The electrode holder lead should always be clear of any obstruction so that you can move your arm freely along as the electrode burns down Some elders prefer to...

Page 59: ...el speed Ensure the arc is on the leading edge of the weld puddle Porosity Small holes or cavities on the surface or within the weld material Work piece dirty Electrode is damp Arc length is excessive...

Page 60: ...ckwise Insert the dinse plug on the work return cable into the socket on the front panel of the machine and rotate clockwise to tighten Attach the work clamp to the work piece Connect the supply gas h...

Page 61: ...background default parameters or functions To access WEM press and hold the top adjustment knob A for 5 seconds after pressing and holding this knob for 2 seconds the machine will show a count down f...

Page 62: ...the torch switch is pressed down during the current downslope period the current will rise up again to the preset welding current value and the slope out process will only start again once the torch...

Page 63: ...visibility of the arc A much larger diameter nozzle can be used which will produce a large blanket of shielding gas This can be very useful in welding material like titanium The gas lens will also ena...

Page 64: ...ode Colour Chart DC Tungsten Electrode Current Ranges Tungsten electrode preparation DC When welding at low current the electrode can be ground to a point At higher current a small flat on the end of...

Page 65: ...an use both non contact and contact methods to provide arc starting Depending on the Jasic model the options are indicated on a selector switch on the front control panel of the power source The most...

Page 66: ...ers Lift TIG mode utilising the TIG torch switch operation mode which starts the process with the internal gas valve opening to start the gas flow first Set the TIG welding current and other TIG weldi...

Page 67: ...1 6 2 4mm 5 9 Butt 80 110 3 32 2 4mm 1 6 2 4mm DC 1 6 2 4mm 5 9 Corner 80 110 3 32 2 4mm 1 6 2 4mm DC 1 6 2 4mm 5 9 Fillet 90 120 3 32 2 4mm 1 6 2 4mm DC 1 6 2 4mm 5 9 Lap 90 120 3 32 3 2mm 2 4mm DC...

Page 68: ...24 SP9111 Handle Screw 25 SP9120 Single Button Switch SP9121 2 Button Switch SP9122 5K Potentiometer Switch SP9123 10K Potentiometer Switch SP9128 47K Potentiometer Switch SP9129 4 Button Switch 26 SP...

Page 69: ...use No operation when torch switch is operated Torch switch or cable faulty Check the torch switch continuity and repair or replace as required ON OFF switch turned off Check position of ON OFF switc...

Page 70: ...bead too small or insufficient penetration Welding travel speed too fast Reduce your welding travel speed Weld bead too wide or excessive bead build up Welding travel speed too slow Increase your wel...

Page 71: ...ed joint reconnect and tighten the replaced gas inlet pipe or wrap up the damaged area The gas inlet pipe has been damaged by heat or aging Replace the gas inlet pipe Operator receiving a shock from t...

Page 72: ...gs LEDs and machine operation Monthly examination Disconnect from the mains supply and wait for at least 5 minutes before removing the cover Check internal connections and tighten if required Clean th...

Page 73: ...roved technician E32 Overvoltage protection The input mains voltage is too high Turn the machine off and back on again If the alarm continues check the input voltage If the input voltage is within spe...

Page 74: ...tally compatible recycling facility Jasic has a relevant recycling system which is compliant and registered in the UK with the environment agency Our registration reference is WEEMM3813AA In order to...

Page 75: ...75 UKCA Declaration of Conformity...

Page 76: ...76 EC DECLARATION OF CONFORMITY...

Page 77: ...an incorrect or faulty mains supply Overloading during use Any modifications that are made to the product without the prior written consent Software errors due incorrect operation Any repairs that are...

Page 78: ...78 SCHEMATIC...

Page 79: ...SP250 6 Spool Gun SP250 6m WP26 12JE WP26 Euro Style TIG Torch 4m JH HDX Jasic HD True Colour Auto Darkening Welding Helmet HRC 01 Wired hand held remote current control HRC 02 Wireless hand held remo...

Page 80: ...___________________ _____________________________________ _____________________________________ _____________________________________ Control Type Name Model Wireless Receiver Welding Mode Image Wired...

Page 81: ..._________ _____________________________________ _____________________________________ _____________________________________ _____________________________________ _____________________________________...

Page 82: ...82...

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