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TIG WELDING PROBLEMS

Before starting any welding activity ensure that you have suitable eye protection and

protective clothing. Also take the necessary steps to protect any persons within the welding

area.

TIG welding defects and prevention methods

Defect

Possible cause

Action

Excessive tungsten use

Set up for DCEP

Change to DCEN

Insufficient shield gas flow

Check for gas restriction and correct flow
rates. Check for drafts in the weld area.

Electrode size too small

Select correct size

Electrode contamination during
cooling time

Extend post flow gas time

Porosity/weld contamination

Loose torch or hose fitting

Check and tighten all fitting

Inadequate shield gas flow

Adjust flow rate

normally 8

12L/m

Incorrect shield gas

Use correct shield gas

Gas hose damaged

Check and repair any damaged hoses

Base material contaminated

Clean material properly

Incorrect filler material

Check correct filler wire for grade of 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 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

Check and tighten all plugs

Power source faulty

Call a repair technician

High frequency will not strike
the arc

Weld/power cable open circuit

Check all cables and connections for
continuity, especially the torch cables

No shield gas flowing

Check cylinder contents, regulator and
valves, also check the power source

Unstable arc when welding in
DC

Tungsten contaminated

Break off contaminated end and regrind
the tungsten

Arc length incorrect

Arc length should be between 3

6mm

Material contaminated

Clean all base and filler material

Electrode connected to the wrong
polarity

Reconnect to correct polarity

Arc is difficult to start

Incorrect tungsten type

Check and fit correct tungsten

Incorrect shield gas

Use argon shield gas

Содержание JT-300P

Страница 1: ......

Страница 2: ...t 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 Jasic product warranty registration please vis...

Страница 3: ...eclaration 8 Materials and their disposal 8 Product Overview 9 Technical Specifications 10 Description of Controls 11 Description of Functions 13 Installation 17 Operation MMA 19 Operation TIG 21 Remote Control Socket 29 Guide to MMA Welding 30 MMA Welding Problems 34 Guide to TIG Welding 35 TIG Welding Torch 2 TIG Welding Problems 44 Maintenance 46 Service Schedule Record 46 Troubleshooting 47 EC...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 9: ...gital display of output current Displays the output status of the welder Operating status is displayed by LED indicators dynamically and the current operating status is displayed constantly Hot start for manual welding Enables the arc striking during manual welding to be easier and more reliable starts VRD function Ensures the personal safety of the operator and prevents electric shock due to high...

Страница 10: ...ut characteristics Current output range A 5 300 No load voltage V 60 Initial current range A 5 300 Crater current range A 5 300 Peak current range A 5 300 Base current range A 5 300 Pulse frequency range Hz 0 5 200 Pulse duty cycle 10 90 Pre flow time S 0 15 Post flow time S 0 5 15 Upslope time S 0 10 Downslope time S 0 10 Spot welding time S 0 1 10 Arc ignition methods HF and lift arc start Duty ...

Страница 11: ...h or work clamp in MMA mode 4 9 pin remote connection See page 29 for further details 5 Gas Outlet used to connect the gas fitting hose of the TIG torch Rear view Jasic TIG 300P 6 Water cooler supply outlet The optional cooler plug will connect to this socket 7 Gas Inlet The gas supply hose connect to this inlet 8 Mains input supply cable 9 Control Fuse This fuse is for water cooler output and is ...

Страница 12: ...ion switch 5 will highlight the LED of the parameter to be adjusted in the selection area 5 Parameter selection button Press to select the required welding parameter to be adjusted 6 VRD voltage reduction device indicator 7 Adjustment control dial Rotating this dial will adjust selected parameter shown in the digital display 8 CH is the weld parameter recall storage channel selector 9 TIG torch sw...

Страница 13: ...y and parameter area This area contains the display meter unit parameters indicators and the warning indicator 1 The window in the middle is a display to show all user parameters 2 O C on the left is the over current protection LED 3 O C on the left is the over current protection LED 4 O H on the left is the over heat protection LED 5 The A LED on the right is current 6 The S LED on the right is t...

Страница 14: ...again and when the lift arc bottom indicator is On you have entered lift arc ignition When in this mode you place the torch to contact work piece pull torch trigger then lift the torch slowly to achieve arc ignition 4 Water cooling switch TIG mode only for the JT 300P air water cooled package By pressing the cooling key you will select the following cooling modes a When this indicator is lit it sh...

Страница 15: ...anagement just press the CH key again Storing channel weld parameters is done by first choosing the required channel number you wish to save too then adjust the required user welding parameters the operator then has to start the welding process to automatically save the current welding parameters PLEASE NOTE If the operator does not strike an arc after making weld parameter adjustments on a select...

Страница 16: ...er work indicator is on When there is no current output the water cooler will stop working after 15 minutes and the work indicator will be off 3 The cooler control fuse is located on the rear panel of the power source and is fuse rated of 5A 4 Output supply This quick connector socket has a blue base and is used to connect to the water supply hose of the TIG torch quick connect plug the TIG torch ...

Страница 17: ...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...

Страница 18: ...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 Examp...

Страница 19: ...rom 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 welding leads as detailed you will need to switch the power switch on the back panel of the machine to ON Select MMA mode by pressing the welding mode selecting key until the MMA LED illuminates and MMA can b...

Страница 20: ...he arc force setting function by pressing the welding parameter selection key until the arc force LED Illuminates The arc force parameter range is 0 60amps and is adjusted via the adjustment knob and the and the arc force additional amperage is indicated on the front panel digital display The arc force amperage setting can be carried out during welding If the secondary cables welding cable and ear...

Страница 21: ...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...

Страница 22: ...rent setting function by pressing the parameter selection key until the Is LED Illuminates The initial current range is 0 60amps and is adjusted via the control knob and the amperage is shown on the front panel digital display The initial current amperage can be adjusted during welding Select the upslope time setting function by pressing the parameter selection key until the Tup LED Illuminates Th...

Страница 23: ... flow time range is 0 5 15 seconds and is adjusted via the control knob and the post flow time is shown on the front panel digital display After the parameters are set appropriately open the gas valve of the cylinder and adjust the 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...

Страница 24: ...l display The base current amperage can be adjusted during welding Select the downslope time crater current and post flow gas time as standard TIG Select the pulse duty cycle setting function by pressing the parameter selection key until the LED Illuminates The pulse duty range is 10 90 and is adjusted via the control knob and the percentage is shown on the front panel digital display The pulse du...

Страница 25: ...lding can be carried out After releasing the torch trigger the current begins to decrease automatically to the crater current value Then the arc stops with the gas continuing to flow for the post flow time and welding ends Parameter autosaving The parameters having been adjusted will be autosaved in the parameter group currently used Please Note no autosaving will be done in the case that no weldi...

Страница 26: ...l the Lift arc ignition LED indicator is ON to enter lift TIG arc ignition function When in HF TIG mode 2T Keep the torch tungsten 2 4mm away from the work piece and then press and hold the torch trigger Gas will flow followed by the high frequency HF and the arc is ignited Once the arc is ignited the HF will cease and the current rises up to the preset values set by the user and welding is then c...

Страница 27: ...the welding process If 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 switch to be released 4T latch trigger control The 4T LED will illuminate when the power source is in 4T welding mode this trigger mode is mainly used for long welding runs to as...

Страница 28: ...alue again Cycle means the welding current varies between the final arc current value and the welding current value To extinguish the welding arc press and release the torch trigger briefly within 1 5 of a second and the arc will be extinguished immediately and the current output will be shut off The gas valve will then close when the post flow time ends and the welding process ends Spot welding m...

Страница 29: ...ne is ready for front panel current control Without welding press the remote until the remote LED is lit this indicates that the machine is ready for an analog potentiometer type type torch control Without welding press the remote until the foot pedal remote LED is lit this indicates that the machine is ready for a foot pedal type control Starparts Titanium Torch Trigger only wiring as follows Pin...

Страница 30: ...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 ...

Страница 31: ...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...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ... 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...

Страница 35: ...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...

Страница 36: ...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...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ...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 ...

Страница 40: ...panel image above as reference Depends on material thickness 30A per mm eg 3mm 90A Please Note Ensure you have set the water cooling option to ON OFF depending on TIG Torch type fitted Parameter Units Adjustable Range Guide Setting User Setting Job Material PRE GAS TIME Seconds 0 15 0 5 START CURRENT Amps 5 300 15 UP SLOPE TIME Seconds 0 10 0 PEAK CURRENT Amps 5 300 User defined DOWN SLOPE TIME Se...

Страница 41: ...follows using control panel image above as reference Depends on material thickness 30A per mm eg 3mm 90A Please Note Ensure you have set the water cooling option to ON OFF depending on TIG Torch type fitted Parameter Units Adjustable Range Guide Setting User Setting Job Material PRE GAS TIME Seconds 0 15 0 5 START CURRENT Amps 5 300 15 UP SLOPE TIME Seconds 0 10 0 PEAK CURRENT Amps 5 300 User defi...

Страница 42: ...42 TIG TORCH SPARE PARTS LIST TIG Welding Torch Air Cooled Model TIG 79ERGO Rating 200A DC 150A AC 60 Duty Cycle EN60974 7 0 5mm to 4 0mm Electrodes 9 PIN Torch plug Pt No JSG PLUG 9PIN ...

Страница 43: ...43 TIG TORCH SPARE PARTS LIST TIG Welding Torch Water Cooled Model TIG 83ERGO Rating 350A DC 260A AC 100 Duty Cycle EN60974 7 0 5mm to 4 0mm Electrodes 9 PIN Torch plug Pt No JSG PLUG 9PIN ...

Страница 44: ...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...

Страница 45: ...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...

Страница 46: ...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...

Страница 47: ...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...

Страница 48: ...rheated Temporarily turns off the main circuit The main circuit has been working for too long to the extent that exceeds its duty cycle Do not power off the machine Wait until the main circuit cools down and then resume the welding E30 Overvoltage undervoltage phase loss Permanently turns off the main circuit Phase loss may be caused by phase loss of the input power supply The voltage of input pow...

Страница 49: ...Do not 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 Ou...

Страница 50: ...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...

Страница 51: ...nse Adaptor Jasic Plug TIG 79ERGO FLEXI WP26F TIG Torch 12 5ft c w Dinse Adaptor Jasic Plug TIG 79ERGO 8M WP26 TIG Torch 25ft c w Dinse Adaptor Jasic Plug TIG 79ERGO 8MFLEXI WP26F TIG Torch 12 5ft c w Dinse Adaptor Jasic Plug Part Number Description JSG PLUG 9PIN TIG Torch Switch Plug 9 Pin JSG PLUG 9PIN Foot Pedal Plug 9 Pin WCS50 5 Welding Cable Set MMA 5m 50mm Cable WC 5 05 Electrode Holder and...

Страница 52: ...52 September 2020 Issue 4 ...

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