Razorweld KUMJRRW145 Operating Manual Download

Page: 42 / 52

1: No arc

Possible Reason

Suggested Remedy

Incomplete welding circuit

Check earth lead is connected. Check all cable connections.

Wrong mode selected

Check the ARC selector switch is selected

No power supply

Check that the machine is switched on and has a power supply

2: Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Reason

Suggested Remedy

Arc length too long

Shorten the arc length

Work piece dirty, contaminated or

moisture

Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from

base metal

Damp electrodes

Use only dry electrodes

3: Excessive Spatter

Possible Reason

Suggested Remedy

Amperage too high

Decrease the amperage or choose a larger electrode

Arc length too long

Shorten the arc length

3: Weld sits on top, lack of fusion

Possible Reason

Suggested Remedy

Insufficient heat input

Increase the amperage or choose a larger electrode

Work piece dirty, contaminated or

moisture

Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from

base metal

Poor welding technique

Use the correct welding technique or seek assistance for the correct technique

4: Lack of penetration

Possible Reason

Suggested Remedy

Insufficient heat input

Increase the amperage 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 assis-

tance for the correct joint design and fit up

5: Excessive penetration - burn through

Possible Reason

Suggested Remedy

Excessive heat input

Reduce the amperage or use a smaller electrode

Incorrect travel speed

Try increasing the weld travel speed

6: Uneven weld appearance

Possible Reason

Suggested Remedy

Unsteady hand, wavering hand

Use two hands where possible to steady up, practice your technique

7: Distortion − movement of base metal during welding

Possible Reason

Suggested Remedy

Excessive heat input

Reduce the amperage or use a smaller electrode

Poor welding technique

Use the correct welding technique or seek assistance for the correct technique

Poor joint preparation and or joint

design

Check the joint design and fit up, make sure the material is not too thick. Seek assis-

tance for the correct joint design and fit up

7: Electrode welds with different or unusual arc characteristic

Possible Reason

Suggested Remedy

Incorrect polarity

Change the polarity, check the electrode manufacturer for correct polarity

The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction,

the manufacturer’s recommendations should be strictly adhered to and followed.

ARC(Stick) WELDING TROUBLE SHOOTING

Summary of Contents for KUMJRRW145

Page 1: ...erstand this instruction manual carefully before the installation and operation of this equipment YEARS Warranty Power Source 3 OPERATING MANUAL KUMJRRW145 KUMJRRW180 KUMJRRW210 JASIC Technologies America Inc 2013 Razorweld ...

Page 2: ...n history of welding knowledge and expertise giving vital input towards ensuring that our machines deliver control and performance to the utmost professional level We employ an expert team of profes sional sales marketing and technical personnel that provide us with market trends market feedback and customer comments and requirements Secondly they provide a customer support service that is second ...

Page 3: ... for Mig Torch Liner Installation 20 MIG Torch and Wire Feeder Set Up Guide for Aluminum MIG Wire 21 22 Installation Operation for MIG Welding with Spool Gun 23 24 MIG Metal Inert Gas Welding 25 26 Basic MIG Welding Guide 27 30 Installation Operation for TIG Welding 31 32 TIG Fusion Technique 33 Tungsten Electrodes Preparation 34 35 TWC2 MIG Torch Parts Breakdown 36 37 SPGRW200 Spool Gun Torch Par...

Page 4: ...atest IGBT inverter technology MIG MAG with Gas and Gasless wire function Excellent MIG welding with CO2 gas mixed gas Euro style MIG and TIG torch connection Internal wire feeder with solid construction Adjustable Burn Back Spool Gun Connection Stepless voltage and wire feed control Wire Inch Smart Set functionality Dual voltage 115 230V Hot Start Anti Stick Digital Readout Solid case constructio...

Page 5: ...ly functional multi system is a powerful portable and dual voltage machine ensuring smooth and trouble free welding and backed up by a big 3 year warranty Our Smart set function allows you to dial in your preferred wire size and gas mixture and you are ready to start welding The machine comes complete with Torch Regulator Adaptor and Arc lead set A real workhorse with a hight duty Cycle Razorweld ...

Page 6: ...uble free welding and backed up by a big 3 year warranty Our Smart set function allows you to dial in your preferred wire size and gas mixture and you are ready to start welding The machine comes complete with Torch Regulator Adaptor and Arc lead set A real workhorse with a high duty Cycle Razorweld MIG TIG ARC 210 Input voltage V Single phase AC230V 115V 15 50 60Hz Ieff 115V 21A 230V 22A Imax 115...

Page 7: ...put 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 We recommend RCD safety switch is used with this equipment to detect any leakage of current to earth Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harmful to...

Page 8: ...ecause 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 Insure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding electrode or earth clamp to touch the gas cylinder do not dr...

Page 9: ...ature inside the equipment The machine will be ready for use again when the internal temperature reaches safe level 2 3 Over Voltage Supply Regarding the power supply voltage range of the machine please refer to Main parameter table This equipment is of automatic voltage compensation which enables the maintaining of the voltage range within the given range In case that the voltage of input power s...

Page 10: ... Output terminal 8 Euro MIG TIG Torch Connector MIG MAG 9 Output terminal 10 SpoolGun Power Supply Connection 1 2 3 6 5 BACK PANEL LAYOUT 11 Power switch 12 Gas Inlet 13 Fan 14 Input power cable 15 Data Plate 14 12 15 11 INTERNAL PANEL LAYOUT 16 Spoolgun Standard selector switch 17 Inch wire feed button 18 Gas Check button 19 Spool holder assembly 20 Geared Wire feed assembly 17 20 19 4 7 8 9 10 1...

Page 11: ...ode connected to output socket DC Electrode connected to output socket 2 Turn the power source on and select the ARC function with the MIG TIG ARC selector switch 3 Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer 3 Set the welding current using the amperage control dial and adjust arcforce if required 6 Hold the electrode slig...

Page 12: ... 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 coating These electrodes are ...

Page 13: ...l 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 that will give the size of run requi...

Page 14: ...ation is selected press trigger Arc starts release trigger Arc stops burnback operation is automatic and preset When 4T operation is selected press and release trigger Arc starts press and release trigger Arc stops burnback operation is automatic and preset SmartSet by RazorWeld makes welding easy by taking the guess work out of MIG machine settings Simply select the correct wire diameter and gas ...

Page 15: ...valve and set the flow rate to between 11 21cfh 16 Set the welding parameters using the wire feed and voltage control knobs 17 Or use Smartset Smartset is a predefined setting based on Gas and wire used The machine will preselect Voltage and wire speed allowing the user to quickly find the best welding pa rameters for a given metal 12 Press and hold the inch wire button to feed the wire down the t...

Page 16: ...led into a cylinder to form the finished wire The wire cannot take too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied A knurled drive roller has been developed and it has small serrations in the groove the serrations grip the wire and assist to drive it without too much pressure from the top roller The down side to the knurled wire feed roller o...

Page 17: ...stment if required Carefully retighten the locking nut and screw to hold the new position NOTE MIG 180 145 not geared 4 Snip the wire carefully be sure to hold the wire to prevent the spool uncoiling Carefully feed the wire into the inlet guide tube of the wire feed unit 5 Feed the wire through the drive roller and into the outlet guide tube of the wire feeder NOTE MIG 180 145 not geared 6 Lock do...

Page 18: ...ect the earth lead to Positive socket 3 Connect the weld power lead to Negative socket 4 Turn the power source on and select the MIG function with the MIG TIG MMA selector switch 5 Set torch operation 2T 4T When 2T operation is selected press trigger Arc starts release trigger Arc stops burnback operation is automatic and preset When 4T operation is selected press and release trigger Arc starts pr...

Page 19: ...through to the torch neck release the inch button when the wire exits the torch neck 13 Fit the correct sized contact tip and feed the wire through it screw the contact tip into the tip holder of the torch head and nip it up tightly 14 Fit the gas nozzle to the torch head 15 Set the welding parameters using the wire feed and voltage control knobs 15 Set welding parameters using the voltage and wir...

Page 20: ...2 way 7 Leaving the torch straight snip the liner approximately 1 8in past the end of the torch neck 8 Place the tip holder over the end of the liner and screw into the torch neck trimming it up tight 9 Screw down the liner nut the remaining 1 2 and trim it up tight This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed 2 Remove ...

Page 21: ...with the liner o ring 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 9 Install a U groove drive roller of the correct size to match the wire diameter being used 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the liner 4 Carefully unravel the new liner 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 5 Care...

Page 22: ...to match the diameter of the wire being used 17 Fit the remaining front end parts to the torch neck ready for welding 17 Fit the remaining front end parts to the torch neck ready for welding 11 Install a U groove drive roller of the correct size for the diameter wire being used NOTE MIG 180 145not geared 7 Place aluminum wire onto spool holder Feed the wire through the inlet guide tube on to the d...

Page 23: ...nto the Spool Holder Note the spool retaining nut is Left Hand thread Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling 3 Connect earth lead to 1 Set Standard Spoolgun selector switch inside door to Spoolgun 5 Connect the gas line to the regulator and connect to the gas cylinder 6 Set MIG TIG MMA selector switch to MIG IMPORTANT When connecting the torch ...

Page 24: ...d close the wire spool cover 16 Carefully open the gas cylinder valve and set the flow rate to between 21 30cfh 17 Set the welding parameters using the wire feed and voltage control knobs 9 Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube Squeezing the tension arm adjustment knob to release the pressure of the tension arm will allow the ...

Page 25: ...roperties and corresponding advantages and limitations To perform MIG welding the basic necessary equip ment is a welding gun a wire feed unit a welding power supply an electrode wire and a shielding gas supply Short circuit transfer is the most common used method whereby the wire electrode is fed continuously down the welding torch through to and exiting the contact tip The wire touches the work ...

Page 26: ...eat and force of the arc flattens out the droplet into the weld pool The heat of the arc melts the end of the wire slightly as it feeds towards the base metal The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short circuit and repeat the cycle droplet separates arc flattens the droplet cycle repeats MIG Metal Inert Gas Welding Short Circuit Transfer Short ...

Page 27: ... bead profile and degree of weld penetration Push Technique The wire is located at the leading edge of the weld pool and pushed towards the un melted work surface This technique offers a better view of the weld joint and direction of the wire into the weld joint Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penet...

Page 28: ...ape prevents undercut uneven penetration poor gas shield and poor quality finished weld Correct angle Not enough angle Too much angle good level of control over the weld pool even flat weld less control over the weld pool more spatter poor control unstable arc less penetration lots of spatter Stick Out Stick out is the length of the unmelted wire protruding from the end of the contact tip A consta...

Page 29: ... resulting in a weld deposit of poor quality cold lap lack of fusion lack of joint penetration porosity large wide bead Too Slow Travel Speed Correct Travel Speed The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration fusion and wetting out of the weld pool producing a weld deposit of good quality good toe...

Page 30: ... welding zone from the atmosphere Too low flow will give inadequate coverage and result in weld defects and unstable arc conditions Too high flow can cause air to be drawn into the gas column and contaminate the weld zone Use the correct shielding gas Co2 is good for steel and offers good penetration characteristics the weld profile is narrower and slightly more raised than the weld profile obtain...

Page 31: ...eration is automatic to factory preset level When 4T operation is selected press and release trigger Gas starts touch and lift arc start press and release trigger Gas and Arc stops When 4T operation is selected with downslope time of either 1 to 10 seconds press and release trigger Gas starts touch and lift arc start Press and hold trigger after 1 to 10 seconds depending on the downslope time sele...

Page 32: ... Gas Cup on the work piece with the Tungsten Electrode 1 16 inm from the work piece Press the trigger button on TIG torch to start the gas flow 11 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 12 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 10 Lay the outside edge of the...

Page 33: ... 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 elect...

Page 34: ...e 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 metal...

Page 35: ...gthwise 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 longitudinal on ...

Page 36: ... DegreetNeck Assembly 3 U102 Block C W Spacer Screws 4 U244T Control Wire Terminals 5 UB5044 Hose Clamp 18 5mm 0 728 6 U141 6S Spring Cable Support Small Ball Joint 7 U200 10E Hyperflex C Assy X 10ft Euro U200 12E Hyperflex C Assy X 12ft Euro U200 15E Hyperflex C Assy X 15ft Euro U200 10 Hyperflex C Assy X 10ft U200 12 Hyperflex C Assy X 12ft U200 15 Hyperflex C Assy X 15ft 8 UP83 Handle With Hook...

Page 37: ...r Description QTY EAN CODE PRW52 Gas Diffuser QTY x 2 0680474943975 TWC2 Gas Insulator Part Number Description QTY EAN CODE PRW32 Insulator QTY x 2 0680474943999 TWC2 Torch Nozzle Part Number Description QTY EAN CODE PRW22 50 Nozzle Adjustable 13mm 33 67 QTY x2 0680474943951 PRW22 62 Nozzle Adjustable 16mm 5 8 QTY x2 0680474943968 Torch Model Description Part Number EAN CODE 15 FT Welding Torch Cl...

Page 38: ...7 LMZ2011 Motor Plate 8 LMZ2012 Suspension Screw 9 LMZ2013 Drive Roll Assembly 10 LMZ2016 Wire Nipple 11 LMT2101 Spool Shaft 12 LMH2112 Right Gun Case 13 LMH2113 Upper Gun Case 14 LMJ2101 Switch Part Number Description 15 LMZ2014 Potentiometer 16 LMZ2015 Push Roll 17 LMK2001 Conducting Board 18 EF1101 Conducting Tube 19 LML2140 Welding Cable 20 ES1201 Spring Support Back 21 EH2201 Adaptor Support ...

Page 39: ...0 040 QTY x5 0680474944071 PRW14H 45 Contact H D tip 1 2mm 0 045 QTY x5 0680474944088 TWC2 Gas Diffuser Part Number Description QTY EAN CODE PRW52 Gas Diffuser QTY x 2 0680474943975 TWC2 Gas Insulator Part Number Description QTY EAN CODE PRW32 Insulator QTY x 2 0680474943999 TWC2 Torch Nozzle Part Number Description QTY EAN CODE PRW22 50 Nozzle Adjustable 13mm 33 67 QTY x2 0680474943951 PRW22 62 N...

Page 40: ...ig Torch Package Euro Connection SRE17 13FTE 150A AIR COOLED TIG WELDING TORCH Rating 150A DC 105A AC 35 ducy cycle Spare Parts Part Number Description 1 WP17 Torch head WP17F Torch head flexible 2 57Y02 Back cap long 3 57Y03 Medium back cap 4 57Y04 Short back cap 5 UER1MS Momentary Kit 6 UERSWL4 Trigger Lead 12 5ft UERSWL8 Trigger Lead 25ft 7 UERSP1 Screw Pack 8 UERH100 Small Ergo Tig Handle 9 UE...

Page 41: ... Part Description 54N14 Gas lens ceramic 8 0mm 5 16 54N15 Gas lens ceramic 7 0mm 9 32 54N17 Gas lens ceramic 5 0mm 13 64 Compact Gas Lens Front End Parts Part Description TR0004 10 1 0mm x 175mm 0 040 x 6 57 64 thoriated tungsten electrode 2 TR0004 16 1 6mm x 175mm 1 16 x 6 57 64 thoriated tungsten electrode 2 TR0004 24 2 4mm x 175mm 3 32 x 6 57 64 thoriated tungsten electrode 2 TR0004 32 3 2mm x ...

Page 42: ... 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 assis tance for the correct joint design and fit up 5 Excessive penetration burn through Possible Reason Suggested Remedy Excessive heat input Reduce the amperage or use a smalle...

Page 43: ...e stubbing during welding Possible Reason Suggested Remedy Holding the torch too far away Bring the torch closer to the work and maintain stick out of 5 10mm Welding voltage set too low Increase the voltage Wire Speed set too high Decrease the wire feed speed 5 Lack of Fusion failure of weld metal to fuse completely with base metal or a proceeding weld bead Possible Reason Suggested Remedy Contami...

Page 44: ...ogged the most common causes of bad feeding Try to clear the liner by blowing out with compressed air as a temporary cure it is recommended to replace the liner Wrong size liner Install the correct size liner Blocked or worn inlet guide tube Clear or replace the inlet guide tube Wire misaligned in drive roller groove Locate the wire into the groove of the drive roller Incorrect drive roller size F...

Page 45: ...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 residue smoke on the alumina nozzle discoloured tungsten Possible Reason Suggested Remedy Incorrect Gas Use pure Argon gas Inadequate gas flow Set the g...

Page 46: ...kage 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 authorized representatives or agents of Jasic Technologies will not be liable or responsible for the loss of any gas ATTENTION CHECK...

Page 47: ...y the Manufacturer s Individual Warranty Contact the manufacturer 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 WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE ON ANY ORDER EXCE...

Page 48: ...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 handling fee of up to fifteen percent 15 of the value of the returned Goods plus any freight costs Whe...

Page 49: ...ple Central Plug Printed Circuit Board Gun Plug House Cable Sup port Gas Connector 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 Torch Body Gas Va...

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Page 52: ... GNED TRUSTE D I N A U S T R A L I A U NIMIG WELDE R S 1985 85 19 EST Razorweld JASIC Technologies America Inc 25503 74th Ave S Kent WA 98032 USA Phone 1 253 859 6277 1 253 859 6278 FAX 1 253 859 6286 EMAIL sales jasictechamerica com sales razorweld com Part of the JASIC group of companies MADE IN CHINA ...

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