Razorweld KUMJRRW160 Operating Manual Download

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Please read and understand this instruction manual carefully
before the installation and operation of this equipment.

OPERATING MANUAL

KUMJRRW160
KUMJRRW200

JASIC Technologies America Inc

2013

YEARS

Warranty

(Power Source)

Razorweld

Razor

weld

™

Summary of Contents for KUMJRRW160

Page 1: ...d understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KUMJRRW160 KUMJRRW200 JASIC Technologies America Inc 2013 YEARS Warranty Power Source 3 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: ...G Welding 17 18 DC TIG Welding DC Pulse TIG Welding 19 20 Set Operation for Pulse DC TIG with TIG160 200 21 TIG Welding Fusion and Filler Wire Technique 22 Remote Controls Installation and Operation 23 Tungsten Electrode Selection Preparation 24 25 TIG Torch Parts Breakdown 26 27 Trouble Shooting Guide TIG Welding 28 29 Trouble Shooting Guide MMA Stick Welding 30 Machine Spare Parts Identification...

Page 4: ...ected from hot metal 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 gase...

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 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 cylinde...

Page 6: ...ent 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 supply amperage exceeds the stipulated value it is possible to cause damage to the 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 ope...

Page 7: ...of the tungsten electrode Digital set of Pre Gas Time Start Current Level Up Slope Time Down Slope Time Finish Current Level and Post Gas Time combined with the choice of 2 or 4T trigger function allows you to control the start and finish of the weld process at the highest professional level The Digital Control Pulse Frequency allows full parameter setting of Peak Current Base Current Pulse Freque...

Page 8: ... and no contamination of the tungsten electrode Digital set of Pre Gas Time Start Current Level Up Slope Time Down Slope Time Finish Current Level and Post Gas Time combined with the choice of 2 or 4T trigger function allows you to control the start and finish of the weld process at the highest professional level The Digital Control Pulse Frequency allows full parameter setting of Peak Current Bas...

Page 9: ...e incorporating weld program parameter selections 4T provides operator control of the Start and Finish periods of the weld sequence refer to page 12 for instruction of 4T function SPOT Select the SPOT icon using the selector pad Spot uses a single action of the torch switch 1 Pressing the torch switch gives arc igni tion and initializes the welding sequence for a period of time set using the spot ...

Page 10: ... set the Start Amp value Range is 10 200A Pre Gas Time Select by pushing selector pad to cycle through to illuminate the Start Amp icon The value selected shows on the digital display It is the amount of amps the machine will deliver at the start of the welding sequence Turn the Encoder to set the Up Slope value Range is 0 60 Sec Up Slope Time Select by pushing selector pad to cycle through to ill...

Page 11: ... set the Up Slope value Range is 0 60 Sec The value selected shows on the digital display It is the amount of time it takes for the welding amperage to drop down to the set Finish Amperage Continued Front Panel Operation Weld Program Sequence Control Up Slope Time Select by pushing selector pad to cycle through to illuminate the Up Slope icon Post Gas Timer Provides selection for continued gas flo...

Page 12: ... MMA function Select by pushing selector pad to cycle through to illuminate the IGNITION icon Allows to set the time period of the arc ignition 4T Selection provides 4 times function of the torch switch SPOT Selection provides a set weld sequence time IGNITION TIME For MMA Stick welding only Selection allows for high amperage start for a selected time period ARC FORCE Select MMA by pushing selecto...

Page 13: ...ct DC MMA Function Push the button until the DC icon illuminates green 4 Set the weld amperage by rotating the Adjustment Encoder Knob Set the amper age according to the electrode type and size being used as recommended by the electrode manufacturer The Peak Amp icon will be illuminated and the set amperage will show in the Digital Display 5 Select Ignition and Arc Force Push the button until the ...

Page 14: ... the weld to cool and carefully chip away the slag to reveal the weld metal below Continued Set Up Procedure for MMA Stick Welding Razor16O 2OO TIG MMA 6 Connect the Earth Clamp securely to the work piece or the work bench 7 Place and clamp an electrode into the Electrode Hand Piece 8 Strike the electrode against the work piece to create an arc lift slightly and hold the electrode steady to mainta...

Page 15: ...cross 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 coating These electr...

Page 16: ... have an arc length no greater than the diameter of the core wire Electrode Angle The angle that the electrode makes with the work is important to ensure 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...

Page 17: ...nect the gas regulator to the Gas Cylinder Connect the gas line to the quick lock gas inlet connector at the rear of the machine 7 Connect the regulator to the cylinder Connect the gas lead to the regulator Set the flow to 17 25 CFH 4 Connect the Earth cable connector to the terminal 5 Connect the torch switch lead to the torch remote receptacle 1 Turn on the machine using the ON OFF switch at the...

Page 18: ...g the torch switch terminates the welding operation and introduces the post flow gas 3 Choose the preferred welding current amperage to suit the tungsten size material type and thickness to be welded 4 Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 0 040 1 8 from the work piece this method will provide a clean positive arc ignition 5 Press the torch switch and th...

Page 19: ...ers 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 machine will activate...

Page 20: ...mps is a percentage of peak amperage 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 Current DC P...

Page 21: ...h 8 Select the Pulse Frequency by pushing the selector button to cycle through to illuminate the Hz Pulse Icon 9 Rotate the Adjustment Encoder Knob to set the Pulse Frequency to 2 Hz 0 5 200Hz Peak Amp Base Amp 100A 60 30A 40 100A 60 30A 40 The Razorweld TIG machine has digital pulse frequency control All the parameters for DC Pulse Tig welding Peak Amp Base Amp Pulse Frequency and Pulse Width are...

Page 22: ... 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 23: ...emote control 7 pin plug from the Tig Torch switch lead to the 7 pin remote receptacle on the front panel of the machine 3 Activate the remote control Press and hold down the torch switch for 5 seconds The machine will give an audible beep single indicate the remote is activated Repeat the procedure to de activate the remote control 4 The thermal LED will illuminate RED to indicate the machine is ...

Page 24: ...nge 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 work They are best used ...

Page 25: ...thwise 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 t...

Page 26: ...niarc the copyright holder 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 UERKJ100 Small Knuckle Joint 10 UERLC200 08 Leather Cover X 0 8mt 2ft 11 UERJK100 Jointing ...

Page 27: ... retrieval system or transmitted by any means electronic mechanical photocopying or otherwise without the prior permission of Uniarc the copyright holder 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 28: ... 20 35 CFH 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 ...

Page 29: ... 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 20 35 CFH flow rate Tungsten...

Page 30: ...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 assistance 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 31: ...0 Spare Parts Identification RAZOR 160 Spare Parts Identification RAZOR 200 2 2 3 3 4 4 1 1 5 5 6 6 7 7 19 19 8 8 9 9 15 15 Part Number Description 1 10043469 front plastic panel 2 10043476 handle 3 10004636 panel socket DKJ35 50 4 10004636 panel socket DKJ35 50 5 10043442 front panel adhesive sticker 6 30000151 Amperage knob 7 10043418 power cord without cable support 8 10043460 rear plastic pane...

Page 32: ...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 33: ...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 34: ...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...

Page 35: ...NOTES ...

Page 36: ... 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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