Jasic JT-200P-PFC Operator'S Manual Download

Page: 44 / 44

www.jasic.co.uk

Wilkinson Star Limited

Shield Drive

Wardley Industrial Estate

Worsley

Manchester

M28 2WD

+44 (0)161 793 8127

April 2020 Issue 3

Summary of Contents for JT-200P-PFC

Page 1: ...Operator Manual TIG Series TIG 200 Pulse PFC JT 200P PFC ...

Page 2: ...anty 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 is normally located on the top or underside of the machine and will begin with AA For further information on your ...

Page 3: ... 8 LF declaration 8 Materials and their disposal 8 Product Overview 9 Technical Specifications 10 Description of Controls 11 Installation 15 Operation MMA 17 Operation TIG 19 Remote Control Socket 24 Guide to MMA Welding 25 MMA Welding Problems 29 Guide to TIG Welding 30 TIG Welding Torch 35 TIG Welding Problems 36 Maintenance 38 Service Schedule Record 38 Troubleshooting 39 EC Declaration of Conf...

Page 4: ...e 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 enough to prevent any physical contact Never touch the electrode if you are in contact with the work piece return Do not wrap cables over your body Ensure that you take additional safety precautions when you are welding in electrically hazardou...

Page 5: ...ulty 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 gloves and footwear Check and be sure the area is safe and clear of inflammable material before carrying out any weld...

Page 6: ...the the welding 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 or 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 location...

Page 7: ...eated by high currents may affect the operation of pacemakers or elec tronically 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 Keep the torch cable and work re...

Page 8: ...ry 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 electri...

Page 9: ... the rear panel of the machine and the handle are coated with rubber oil so the machine has soft texture good hand feeling that feels warm and comfortable to hold Jasic TIG 200 Pulse PFC Product Features Compact size lightweight and modern design The 200P has wide voltage input of 95V 265V DC pulse TIG with excellent HF arc ignition which offers high reliability arc starting Suitable for a wide ra...

Page 10: ...125 115V A 10 180 230V TIG A 10 160 115V A 10 200 230V No load voltage MMA V 65 TIG 65 Duty cycle MMA 125 60 115V 180 25 230V TIG 160 60 115V 200 30 230V Pre flow time S 0 1 2 0 Initial current A 10 200 Upslope time A 0 10 Background current pulse mode 10 100 Pulse frequency Hz 0 5 200 Pulse width duty 10 90 Downslope time S 0 10 Final current A 10 200 Post flow time S 1 20 Spot Time S 0 2 5 0 Ove...

Page 11: ...Output terminal To connect the TIG torch 7 Gas outlet fitting for the gas hose of the TIG torch 8 5 pin remote connection 9 Cooling air vent 10 Adjustment encoder dial 11 Process LED s 12 Process selector switch 13 Mains and overheat LED s Panel socket size is 35 50mm Rear view Jasic TIG 200P PFC 14 Power switch 15 Mains input cable 16 Air vent and fan 17 Input shield gas ...

Page 12: ... choose the according welding mode The welding mode selected will be indicated by the corresponding LED being lit and there is welding current flowing 5 Adjustment knob Push to select and rotate to adjust parameters 6 Parameter selection area Pushing the adjustment knob will highlight the LED of the parameter to be adjusted in the selection area 7 Arc force LED When selected this will be lit and t...

Page 13: ...mode 2 DC TIG mode 3 DC MMA mode 4 2T mode 5 4T mode 6 Spot welding mode 7 Pre flow gas time LED 8 Start current LED 9 Slope up time LED 10 Peak current LED 11 Background current in pulse mode LED 12 Downslope time LED 13 Crater current LED 14 Post flow gas time LED 15 HF spot time LED 16 Arc force LED 17 Pulse frequency LED 18 Pulse duty LED 19 Overheat LED 20 Mains power LED ...

Page 14: ...des When the overcurrent indicator illuminates and the digital meter displays E 1 it indicates that overcurrent occurs Restart the machine and welding can be continued When the under voltage indicator illuminates and the digital meter displays E 2 it indicates that the mains voltage is overly low and welding can be recovered when the mains voltage goes into normal When the overheating indicator il...

Page 15: ...ing 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 to the positive terminal and the work return to the negative terminal output terminal For MMA connect the electrode holder output terminal For MMA connect the work return lead Always consult the electro...

Page 16: ...chine and tighten it clockwise Insert the cables plug of the TIG torch into the socket on the front panel of the machine and tighten clockwise Connect the gas quick connector into the outlet on the machine front Connect the torch switch plug into the socket on the front panel Connect the gas hose to the regulator flowmeter located on the shield gas cylinder and connect the other end to the machine...

Page 17: ...r metal is primarily obtained from the electrode core The electrodes outer coating called flux assists in creating the arc and provides a shielding gas on cooling forms a slag covering to protect the weld from contamination When the electrode is moved along the work piece at the correct speed the metal core deposits a uniformed layer called the weld bead MMA operation steps After connecting the we...

Page 18: ...can be set Arc ignition time setting can be carried out during welding Select the arc force current setting function by pressing the welding parameter selection key and arc force current in MMA can be set The arc force current setting can also be adjusted during welding If the secondary cables welding cable and earth cable are long select cable with larger cross section to reduce the voltage drop ...

Page 19: ...ctor so it is not necessary to turn the plug Insert the quick plug on the work return cable into the quick socket on the machine panel and tighten it clockwise Clamp the work clamp to the work piece Connect the gas hose of the TIG torch to the quick connector on the machine front Connect the gas hose to the gas inlet on the back panel of the machine The other end of the supply hose connects to the...

Page 20: ...ressing the operation mode selecting key Select the pre flow time setting function by pressing the welding parameter selecting key and set the pre flow time Select the initial current setting function by pressing the welding parameter selecting key and set the initial current Select the upslope time setting function by pressing the welding parameter selecting key and set the upslope time Select th...

Page 21: ...he gas regulator to the desired flow value Keep the torch 2 4mm away from the work piece and then press the torch trigger the solenoid valve will operate gas will flow and HF starts After arc is ignited the HF discharge rustling disappears the current rises up to the preset value and welding can be carried out After releasing the torch trigger the current begins to decrease automatically to the cr...

Page 22: ...ng function by pressing the welding parameter selecting key and set the pulse duty ratio Select pulse frequency setting function by pressing the welding parameter selecting key and set the pulse frequency After the parameters are set appropriately open the gas valve of the cylinder and adjust the gas regulator to the desired gas flow Keep the torch 2 4mm away from the work piece and then press the...

Page 23: ...s in 4T welding mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the operator can press and release the torch trigger and the output will remain active To stop welding the trigger switch must again be depressed and released This function eliminates the need for the operator to hold the torch trigger Spot welding Select the spot welding time set...

Page 24: ...nds until the front panel Arc Force indicator illuminates Remote current control is now active Setting the current to 200A allows full range current adjustment via the remote device connected Please note The maximum output current must be set on the power source control panel by the user prior to the foot control being connected Remote control deactivation is done by pressing the trigger switch fo...

Page 25: ...s across 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 have the welding lead over their shoulder this allows greater freedom of movement and can reduce the weight from your hand Always inspect your welding equipment welding cables and electrode holder ...

Page 26: ...on 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 distance between the end of the electrode and the work will determine the arc voltage and also affect the weld characteristic As a guide the arc length for electrodes up to 3 2mm diameter should be a...

Page 27: ...uit 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 electrode may cause the arc to burn along the scratch path so care should be taken to scratch in the weld zone When the arc is struck adopt the correct welding position Electrode positioning Horizontal or fl...

Page 28: ...ectrode 1 The electrode feeding to the molten pool along axis 2 The electrode swing right and left 3 The electrode moving in the weld direction The operator can choose the manipulation of electrode based on welding joint welding position electrode spec welding current and operation skill etc Weld characteristics A good weld bead should exhibit the following characteristics 1 Uniform weld bead 2 Go...

Page 29: ... 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 Remove all contaminant from the material i e oil grease rust moisture prior to welding Replace or dry the electrode Reduce the arc length Excessive penetration The weld metal is below the surface level...

Page 30: ...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 enable the welder to reach joints with limited access such as inside corners Ceramic cups Gas cups are made of various types of heat resistant materials in different shapes diameters and lengths The cups...

Page 31: ...rode 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 the electrode is preferable as this helps with arc stability Electrode grinding It is important when grinding the electrode to take all necessary precautions such as wearing eye protection and ensuri...

Page 32: ...can 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 common method of arc starting is HF start This term is often used for a variety of starting methods and covers many different types of start Arc starting scratch start This system is where the electr...

Page 33: ...better option than scratch starting for mild and stainless steel although these methods of arc starting are not a good option when welding aluminium Arc starting HF start Non contact High Frequency HF start method is a high voltage and low amperage generated using a spark gap assembly and is the most popular and generally considered best TIG arc starting method The High Frequency HF start generate...

Page 34: ...torch angle is best kept at 15 20 from vertical away from the direction of travel This assists with visibility of the weld area and allows easier access for the filler material The filler metal should be fed in at a low angle to help avoid touching the tungsten electrode and contaminating it The TIG welding arc melts the base material and the molten puddle melts the filler rod it is important you ...

Page 35: ...F77 X Long Cup 3 8 Bore Secondary Consumables 23 SP9110 LH RH Handle Shell 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 SP9113 Handle Ball Joint 27 SP9116 Leather Cover 800mm 28 SP9118 Cable Cover Joint not illustrated 29 18CG Standard Heat Shield...

Page 36: ...se 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 switch Mains fuses blown Check fuses and replace as required Fault inside the machine Call for a repair technician Low output current Loose or defective work clamp Tighten replace clamp Loose cable plug Chec...

Page 37: ...ad 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 welding travel speed Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod Tungsten melts or oxidises when welding arc is made TIG torch lead connected to Little or no gas f...

Page 38: ...it 5 minutes after power switch off before opening the case SERVICE SCHEDULE RECORD Period Maintenance item Daily examination Check the condition of the machine mains cables welding cables and connections Check for any warnings 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 tig...

Page 39: ...lly The fault LED is ON and the fan is running The machine is under over heating protection status and will recover automatically after the welding machine has cooled down Check incoming mains supply to ensure it is within 230V 15 No high frequency is produced Process selection switch is set to manual metal arc MMA Torch trigger switch lead is disconnected or switch lead is faulty High frequency s...

Page 40: ...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 Jasic has a relevant recycling system which is compliant and registered in the UK with the environment agency Our regis...

Page 41: ...he scope of the warranty Defects due to natural wear and tear Failure to observe the operating and maintenance instructions Connection to 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 carried out using non approved spare parts Any transport or s...

Page 42: ...Dinse Adaptor and Switch Plug JSP 01 TIG Torch Switch Plug 2 Pin WCS25 3WEL Welding Cable Set MMA 3m WC 2 03LD Electrode Holder and Lead 3m EC 2 03LD Work Return Lead and Clamp 3m CP3550 Cable Plug 35 50mm JSS 01 Jasic Carry Strap JSB 01 Jasic Site Bag JIT 01 Trolley JH HDX Jasic HD True Colour Auto Darkening Welding Helmet SSARG2G Single Stage 2 Gauge Argon Regulator WTLHK2 2m Gas Hose and Quick ...

Page 43: ...43 SCHEMATIC ...

Page 44: ...www jasic co uk Wilkinson Star Limited Shield Drive Wardley Industrial Estate Worsley Manchester UK M28 2WD 44 0 161 793 8127 April 2020 Issue 3 ...

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