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Razorweld JRW200AC/DC, Operating Manual

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Razorweld JRW200AC/DC Operating Manual Download Page 3

3

Razor

2OOAC/DC

 TIG-ARC

Razorweld

Razor

weld

™

™

™

™

CONTENTS

 

Safety - Precautions 

4-6

Electrical Diagram 

7

Technical Data, Product Information 

8

Front Panel Layout 

9 

Operation - Weld Program Sequence Control 

10-14

Installation & Operation for MMA (Stick) Welding 

15-16

ARC (Stick) Welding  

17-18

Installation & Operation for DC TIG Welding 

19 

DC HF TIG Welding Standard Operation 

20

DC TIG Welding 

21-22

DC Pulse TIG Welding 

23-24

Set up and operation for AC TIG Welding 

25-27

AC TIG Welding -Square Wave 

27-30

Remote Controls - Installation and Operation 

31 

Tungsten Electrode Selection & Preparation 

32-33

TIG Torch Parts Breakdown 

34-35

Trouble Shooting Guide - TIG Welding   

36-37

Trouble Shooting Guide - MMA (Stick) Welding   

38

Warranty

39-42

At initial set up and at regular intervals we recommend to check for gas leakage.
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 20-30cfh
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the

regulator, if the needle drops away towards zero there is a gas leak.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator
and line for an extended time period.  In this situation it is recommended to open the cylinder valve, set
the flow rate to 20-30cfh, close the cylinder valve and check after a minimum of 15 minutes.

5. If there is a gas loss then check all connectors and clamps for leakage by brushing or 

spraying

with soapy water, bubbles will appear at the leakage point.

6. Tighten clamps or fittings to eliminate gas leakage.

IMPORTANT! -  We strongly recommend that you check for gas leakage prior to 

 

operation of your machine.  We recommend that you close the cylinder valve when the 

machine is not in use. 

JASIC TECHNOLOGIES AMERICA INC , authorised representatives or agents of 

JASIC TECHNOLOGIES AMERICA INC will not be liable or responsible 

 for the loss of any gas.

ATTENTION! - CHECK FOR GAS LEAKS

Summary of Contents for JRW200AC/DC

Page 1: ... Razorweld Please read and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL JRW200AC DC YEARS Warranty Power Source 3 Welding Guns Of Australia PTY LTD 2015 ...

Page 2: ...ity Our product range represents the latest developments in Inverter technology put together by our professional team of highly skilled engineers The expertise gained from our long involvement with inverter technology has proven to be invaluable towards the evolution and future development of our equipment range This experience gives us the inside knowledge on what the arc characteristics performa...

Page 3: ...inder valve 3 Set the flow rate on the regulator to approximately 20 30cfh 4 Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the regulator if the needle drops away towards zero there is a gas leak Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator and line for an extended time period In thi...

Page 4: ...tal and sparks Frequently inspect input power cable for wear and tear replace the cable immediately if damaged bare wiring is dangerous and can kill Do not use damaged under sized or badly joined cables Do not drape cables over your body Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harmful to people s health Welding produces fumes and gases Breathing these...

Page 5: ...n explode Because gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damaged Protect gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Ensure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding electrode or earth clamp to touch the gas cylinde...

Page 6: ...ill automatically compensate for input voltage variations within a specific range In circumstances where the voltage of the input power supply exceeds the stipulated value it is possible to cause damage to the internal components of this equipment Please ensure your primary power supply is correct 2 4 Do not come into contact with the output terminals while the machine is in operation An electric ...

Page 7: ...7 Electrical Schematic Diagram Razor2OOAC DC TIG ARC Razorweld ...

Page 8: ... Current Level and Post Gas Time with the choice of 2T or 4T trigger function allows control of the welding process at a professional level from start to finish Digital Pulse Control gives full parameter setting of Peak Base Current Pulse Frequency Pulse Width providing control of heat input penetration distortion AC Square Wave Balance gives control of the electron flow at the tungsten the AC TIG...

Page 9: ...ve output terminal 4 Quick lock gas connector 5 8 NPT in USA 5 Torch switch remote connector 5 Pin 6 Encoder knob 7 Handle 8 Power switch on off 9 Caution notice 10 Mains power input cable 11 Fan 12 Inlet gas connector 5 8 NPT USA 6 1 2 3 4 5 7 8 9 10 11 12 Front Machine Layout Description Rear Machine Layout Description Razorweld ...

Page 10: ... Torch Switch Mode Selector Controls the on off cycle of the machine using the torch switch while incorporating the weld program parameters selections 2T Select the 2T icon using the selector pad 2T uses 2 actions of the torch switch while incorporating the weld program parameter selections refer to page 10 for instruction of 2T function 4T Select the 4T icon using the selector pad 4T uses 4 actio...

Page 11: ...ugh to illuminate the Pre Gas Timer icon The value selected shows on the digital display It is the length of time the gas will flow before the arc starts Pre Gas Timer Provides selection for gas flow time prior to the arc starting 3 Encoder Knob provides digital adjustment of welding parameters and provides step by step motion through the weld cycle parameters Encoder knob weld parameter value sel...

Page 12: ...gas flow time at the end of the welding after the arc is out Turn the Encoder to set the Up Slope value Range is 0 10 Sec Up Slope Time Select by pushing the encoder to cycle through to illuminate the Up Slope icon The value selected shows on the digital display It is the amount of time the welding current takes to climb from start amperage to welding amperage Up Slope Time Sets the transition tim...

Page 13: ...ay represents the number of times per second that the AC square wave transitions from to cycle AC Hz Provides selection to adjust the frequency of the AC square wave in AC TIG mode Allows adjustment of frequency of the AC square wave cycle transistion from to during AC TIG welding Turn the Encoder to adjust the Pulse Hz Range is 0 02 200Hz Pulse Hz Select by pushing the encoder to cycle through to...

Page 14: ... Allows setting from a soft buttery arc characteristic through to a more digging penetrating type of arc Continued WeldProgramSelection Setting Icon selection Select by pushing the Encoder Knob repeatedly to cycle through the weld parameter icons The icon will illuminate when selected 4C Other front panel Icon selection Turn the encoder to set the electrode Ø inch value Tungsten electrode Select b...

Page 15: ...nformation for the correct polarity Most GP electrodes are electrode connected to output socket Earth Connected to the output socket 2 Turn the power source on using the on off switch located on the rear machine panel Set Up Procedure for ARC Stick Welding 4 Set the amperage by selecting the Peak Amp icon pressing the Encoder Knob until the Peak Amp icon illuminates Turn the encoder knob to set th...

Page 16: ...ut it sticking and without providing excessive spatter Higher Arc Force is more suited to thicker electrodes under low amperage settings out of postion welding low hydrogen type electrodes where a forceful arc characteristic is preferred to maintain the arc and better control penetration Lower Arc Force is better suited to hardfacing and cast Iron electrodes where a soft buttery arc is preferred t...

Page 17: ...is transferred across the arc into the molten pool and becomes the deposited weld metal The deposit is covered and protected by a slag which comes from the electrode coating The arc and the immediate area are enveloped by an atmosphere of protective gas Core wire Flux coating Base metal Protective gas Arc Slag Weld pool Manual metal arc stick electrodes have a solid metal wire core and a flux coat...

Page 18: ...re a smooth even transfer of metal When welding in down hand fillet horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel When vertical up welding the angle of the electrode should be between 80 and 90 degrees to the work piece Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed tha...

Page 19: ... CFH To suit application 4 Connect the Earth cable connector to the terminal 3 Connect the torch switch lead to the torch remote receptacle 8 Turn on the machine using the ON OFF switch at the rear of machine 1 Connect the TIG torch connector to the terminal 2 Install the threaded connector into into the gas fitting InstallationSetUpforDCTIGWelding 4 Lay the outside edge of the Gas Cup on the work...

Page 20: ...t up slope time will ap pear in the digital display 2 Select the tungsten diameter required by pushing the encoder r repeatedly cycle through to illuminate the Tungsten Electrode icon Set the size required by turning the encoder knob The set size will appear in the digital display 5 Set Up Slope Time Set welding amps by pressing the encoder to cycle through to illuminate the Peak Amp icon Set the ...

Page 21: ... TIG welding offers the user the greatest amount of flexibility to weld the widest range of material and thickness and types DC TIG welding is also the cleanest weld with no sparks or spatter HF ARC IGNITION for TIG tungsten inert gas Welding HF high frequency ignition allows the arc to be started in Tig welding without touching the tungsten to the work piece By pressing the torch switch the machi...

Page 22: ... weld puddle and affects over all heat input As a rule use enough background current to reduce the weld pool to about half its normal size while still keeping the weld pool fluid As a guide start by setting the background amperage at 20 to 30 percent of peak amperage Pulse Frequency is the control of the amount of times per second Hz that the welding current switches from Peak Current to Base Curr...

Page 23: ... the welding current 1 Select DC Pulse by pushing selector button to cycle through to illuminate DC Pulse icon 2 Select Peak Amp by pressing the encoder knob to cycle through to illuminate the Peak Amp Icon 3 Rotate the Encoder Knob to set the Peak Amp at 100A it will show in the digital display Range is 5 200 Amps 4 Select the Base Amp by pushing the encoder knob to cycle through to illuminate th...

Page 24: ...ld pool Travel direction Angle torch Add Tig filler wire Retract the filler wire Move the torch forward to the front of the weld pool Repeat the process gas shield TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes Because the welder must maintain a short arc length great care and skill are required to prevent contact between the ele...

Page 25: ...connector into the positive terminal and tighten it 5 Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder Slowly open the valve on the gas cylinder and set gas flow to the required rate 6 Connect the gas line to the quick lock gas inlet connector at the rear of the machine Check for gas leaks JASIC Technologies America Inc nor it s representatives will be responsibl...

Page 26: ...y 4 Set Start Amps Set the Up Slope by pressing the encoder to cycle through to illuminate the Up Slope icon Set the up slope time by turning the encoder knob The set up slope time will ap pear in the digital display Set welding amps by pressing the encoder to cycle through to illuminate the Peak Amp icon Set the amperage by turning the encoder knob The set welding amperage will appear in the digi...

Page 27: ...be adjusted from 20Hz 20 times per second to 200Hz Increasing frequency Hz causes the current to change direction more often which means that it spends less time per cycle in both DC electrode negative and DC electrode positive mode By spending less time at each polarity the arc cone has less time to expand A higher frequency produces a narrower arc cone producing an arc that is tighter with more ...

Page 28: ...c rectification arc stutter arc wandering and arc stoppage These problems typically occur during the transition between and cycles The current is less 30 during the half of the cycle when the electrode is positive and there is a resist ance of the electron flow during this half cycle rectification The lack of current flow during this half cycle makes the AC arc unstable To overcome this lack of fl...

Page 29: ...electronically by adjusting the balance control dial on the welding machine More current flow from the polarity produces stronger arc energy and current flow from the tungsten and is good for removing the oxidized surface of the work piece However too much current flow can drive too much energy to the tungsten causing it to overheat and melt the tungsten electrode BALANCED SQUARE WAVE FORM Balance...

Page 30: ...s the welding current 1 Select AC Pulse by pushing selector button to cycle through to illuminate AC Pulse icon 2 Select Peak Amp by pressing the encoder knob to cycle through to illuminate the Peak Amp Icon 3 Rotate the Encoder Knob to set the Peak Amp at 150A it will show in the digital display Range is 5 200 Amps 4 Select the Base Amp by pushing the encoder knob to cycle through to illuminate t...

Page 31: ...e can be used static or during welding to adjust the amps up or down 6 The amps set by the remote control will show in the Digital Display of the machine 2 Select 4T trigger function by pushing the button to cycle through until the 4T icon illuminates as the chosen option 1 Connect the remote control 5 pin plug from the Tig Torch switch lead to the 5 pin remote receptacle on the front panel of the...

Page 32: ... use Ceriated Color Code Orange Ceriated tungsten electrodes AWS classification EWCe 2 contain a minimum of 97 30 percent tungsten and 1 80 to 2 20 percent cerium and are referred to as 2 percent ceriated Ceriated tungstens perform best in DC welding at low current settings They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding thin sheet me...

Page 33: ...ain running lengthwise and thus grinding crosswise is grinding against the grain If electrodes are ground crosswise the electrons have to jump across the grinding marks and the arc can start before the tip and wander Grinding longitudinally with the grain the electrons flow steadily and easily to the end of the tungsten tip The arc starts straight and remains narrow concentrated and stable grind l...

Page 34: ...8 2 10N45 Alumina Nozzle Ø 16mm 5 8 10 2 10N44 Alumina Nozzle Ø 19mm 3 4 12 2 Back Cap Part Description QTY 57y02 Back Cap 2 Gas Lens Gasket Part Description QTY 54N01 Gas Lens Gasket 2 Gas Lens Body Part Description QTY 45V25 Gas Lens Body 1 6mm 1 16 2 45V26 Gas Lens Body 2 4mm 3 32 2 45V27 Gas Lens Body 3 2mm 1 8 2 Gas Lens Part Description QTY 54N14 Gas lens ceramic 8 0mm 5 16 2 54N15 Gas lens ...

Page 35: ...n flow rate Check hoses and fittings for holes leaks etc Moisture on the base metal Remove all moisture from base metal before welding Contaminated base metal Remove materials like paint grease oil and dirt including mill scale from base metal Contaminated filler wire Remove all grease oil or moisture from filler metal Incorrect filler wire Check the filler wire and change if necessary 4 Yellowish...

Page 36: ...metal Incorrect filler wire Check the filler wire and change if necessary 8 Arc difficult to start or will not start DC welding Possible Reason Suggested Remedy Incorrect machine set up Check machine set up is correct No gas incorrect gas flow Check the gas is connected and cylinder valve open check hoses gas valve and torch are not restricted Set the gas flow between 15 25CFH flow rate Tungsten i...

Page 37: ...rage or choose a larger electrode Poor welding technique Use the correct welding technique or seek assistance for the correct technique Poor joint preparation Check the joint design and fit up make sure the material is not too thick Seek assist ance for the correct joint design and fit up 5 Excessive penetration burn through Possible Reason Suggested Remedy Excessive heat input Reduce the amperage...

Page 38: ... and covered by the Manufacturer s Individual Warranty Contact the manufac turer for details Clause 3 This only Covers Manufactures defaults on all accessories for the first three months after date of purchase SELLER MAKES NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT BY WAY OF LIMITATION ANY IMPLIED WAR RANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE O...

Page 39: ...ction material in as new condition as is reasonably possible in the circumstances JASIC Technologies America Inc Accepts no responsibility for products lost damaged or mislaid whilst in transit JASIC Technologies America Inc may at their sole discretion accept the return of Goods for credit but this may incur a han dling fee of up to fifteen percent 15 of the value of the returned Goods plus any f...

Page 40: ... Wire Conduit Nipple Central Plug Printed Circuit Board Gun Plug House Cable Support Gas Con nector Handle To Suit PP36 with Knobs Electrodes Arc Leads Welding Cable Electrode Holder Earth Clamps TIG Welding Torches and Consumables to suit such as Tungsten Electrodes Collet Collet Body Alumina Nozzle Torch Head Torch Head water Cooled Torch Head Flexible Back Caps Gas Lens Torch Handle Cup Gasket ...

Page 41: ...NOTES ...

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