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Related Manuals for Razorweld KUMJRRW160
Summary of Contents for Razorweld KUMJRRW160
- Page 1 Razorweld ™ ™ OPERATING MANUAL KUMJRRW160 KUMJRRW200 YEARS Warranty (Power Source) Please read and understand this instruction manual carefully before the installation and operation of this equipment. © JASIC Technologies America Inc 2013...
- Page 2 • Product will only be replaced if repair is not possible • Please view full Warranty term and conditions supplied with machine or at www.razorweld.com or at the back of this manual.
- Page 3 CONTENTS PAGE Warranty Safety - Cautions Technical Data, Product Information weld Program Sequence Control 9-12 Installation & Operation for MMA (Stick) Welding 13-14 MMA (Stick) Welding 15-16 Installation & Operation for DC TIG Welding 17-18 DC TIG Welding, DC Pulse TIG Welding 19-20 Set &...
- Page 4 SAFETY Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations. Read and understand this instruction manual carefully before the installation and operation of this equipment.
- Page 5 Fire hazard. Welding on closed containers, such as tanks,drums, or pipes, can cause them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
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Page 6: Working Environment
CAUTION 1. Working Environment. 1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity. 1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc; the temperature of working environment should be maintained within -14°F to +104°F. -
Page 7: Weld Program Sequence Control
DIGITAL DC INVERTER WELDER TIG/MMA - 160 Amp DC Inverter Welder Welds: Steels, Stainless, Cast Iron, Bronze, Copper KUMJRRW160 Features • Latest IGBT Inverter Technology • Digital Weld Program Sequence Control • DC TIG (DC tungsten inert gas welding) - HF Arc Ignition (prevents tungsten inclusion & tungsten damage) - Adjustable Pulse Frequency 0.5 - 200Hz... -
Page 8: Weld Program Sequence Control
DIGITAL DC INVERTER WELDER TIG/MMA - 200 Amp DC Inverter Welder Welds: Steels, Stainless, Cast Iron, Bronze, Copper KUMJRRW200 Features • Latest IGBT Inverter Technology • Digital Weld Program Sequence Control • DC TIG (DC tungsten inert gas welding) - HF Arc Ignition (prevents tungsten inclusion & tungsten damage) - Adjustable Pulse Frequency 0.5 - 200Hz - Peak Current, Base Current and Pulse Width Adjustment - 2/4T Trigger + Spot Time Adjustment... - Page 9 Front Panel Operation - Weld Program Sequence Control Front Panel Functions Indicates Action Selector Pad Mode Selector - Enables selection of required welding mode - MMA - DC TIG - DC PULSE TIG. DC Pulse Tig: Select by pushing DC Tig: Select by pushing the MMA: Select by pushing the selector pad to cycle through to selector button to cycle through to...
- Page 10 Continued - Front Panel Operation - Weld Program Sequence Control Weld Program - Provides selection weld program parameters Parameter selection: Select by pushing selector pad to cycle through to illuminate the icon of the parameter required. Each push of the selector pad will move the icon illumination in a clockwise cycle.
- Page 11 Continued - Front Panel Operation - Weld Program Sequence Control Down Slope Time - Sets the transition time from Welding Amperage to Finish Amperage The value selected shows on the digital Up Slope Time: Select by pushing selector Turn the Encoder to set display.
- Page 12 Continued - Front Panel Operation - Weld Program Sequence Control 4T - Selection provides 4 times function of the torch switch. (1) Pressing and holding on the torch switch activates Pre Gas then arc ignition initializing the set Start Amp level. Holding the torch switch on keeps the amperage output at the set Start Amp level. (2) Releasing the torch switch activates Up Slope allowing the amperage to increase during the set Up Slope time to reach the set Peak Amp level.
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Page 13: Mma (Stick) Welding
Set Up Procedure for MMA (Stick) Welding: Razor16O/2OO TIG-MMA (1) Connecting the Welding Lead Set: Various electrodes require a different polarity for optimum results refer to the electrode manufacturers information 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. -
Page 14: Mma (Stick) Welding
Continued - Set Up Procedure for MMA (Stick) Welding: Razor16O/2OO TIG-MMA Connect the Earth Clamp securely to Place and clamp an electrode into the Strike the electrode against the work the work piece or the work bench. Electrode Hand Piece piece to create an arc, lift slightly and hold the electrode steady to maintain the arc... - Page 15 MMA (Manual Metal Arc) Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
- Page 16 MMA (Stick) Welding Fundamentals Electrode Selection As a general rule, the selection of an electrode is straight forward,in that it is only a matter of selecting an electrode of similar composition to the parent metal. However, for some metals there is a choice of several electrodes, each of which has particular properties to suit specific classes of work.
- Page 17 Installation Set Up for DC TIG Welding: Razor16O/2OO TIG-MMA (1) Turn on the machine using the ON/OFF switch (2) Select the TIG function with the TIG/MMA selector switch (3) Connect the Tig Torch connector to the negative terminal and tighten it (4) Connect the Earth Cable connector into the positive terminal and tighten it (5) Connect the torch switch remote lead into the torch remote socket (6) Insert the torch gas connector into the quick lock gas receptacle...
- Page 18 DC HF TIG Welding Standard Operation: Razor16O/2OO TIG-MMA 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 the gas flow and the HF ignition result- ing in the arc igniting across the gap between the tungsten electrode and the work piece.
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Page 19: Dc Tig Welding
DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main elec- trical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical principle at work which should always be taken into account when using any DC circuit. -
Page 20: Dc Pulse Tig Welding
DC Pulse TIG Welding Pulse TIG welding is when the current output (amperage) changes between high and low current. Electronics within the welding machine create the pulse cycle. Welding is done during the high-amperage interval (this high amperage is referred to as peak current). During the low amperage period, the arc is maintained but the current output of the arc is reduced (this low amperage is referred to as base current). - Page 21 Set up and operation for DC PULSE TIG Welding Razor16O/2OO TIG-MMA 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 easy to set via the digital control panel.
- Page 22 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 electrode and the workpiece. Similar to Oxygen Acety- lene torch welding, Tig welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other.
- Page 23 Remote amperage controls allow for the welding current to adjusted remotely from the welding machine during welding. The Razor160 and Razor200 TIG - MMA machines are compatible with the ER1MS-H Remote Hand Amp Control supplied with the RazorWeld Tig Torch supplied with the machine. Type: ER1MS-H...
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Page 24: Tungsten Electrodes
Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 6170 degree Fahrenheit. Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare earth elements. -
Page 25: Tungsten Preparation
Tungsten Preparation Always use wheels when grinding and cutting. While tungsten is a very hard material, the surface of a DIAMOND diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects. - Page 26 SR17 ERGO TIG TORCH 150A AIR COOLED TIG WELDING TORCH Rating: 150A DC, 105A AC @35% ducy cycle. Wear Parts Identification Next Page Torch Model Description Part Number 13ft SR17 Pro-Grip Lite Tig Torch Package QF Gas Connect SR-17-13FTCP25 SR-17-13FTCP50 Spare Parts Part Number Description...
- Page 27 SR17 ERGO TIG TORCH Standard Front End Parts Part # Description Part # Description Part # Description 18CG Cup Gasket 10N30 Collet Body 1.0mm / 0.040” 10N49L Long Alumina Nozzle Ø 8mm / (5/16) 10N31 Collet Body 1.6mm / (1/16) 53N48L Long Alumina Nozzle Ø...
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Page 28: Tig Welding Trouble Shooting
TIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of TIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: Tungsten burning away quickly Possible Reason Suggested Remedy Incorrect Gas Check that pure Argon is being used No gas... - Page 29 continued- TIG WELDING TROUBLE SHOOTING 7: Arc wanders during DC welding Possible Reason Suggested Remedy Poor gas flow Check and set the gas flow between 20 - 35 CFH flow rate Incorrect arc length Lower torch so that the tungsten is off of the work piece 5/64” - 13/64” Tungsten incorrect or in poor condi- Check that correct type of tungsten is being used.
- Page 30 MMA (Stick) WELDING TROUBLE SHOOTING 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. 1: No arc Possible Reason Suggested Remedy Incomplete welding circuit Check earth lead is connected.
- Page 31 SPARE PARTS IDENTIFICATION - RAZOR 160 Part Number Description Part Number Description 1. 10043469 front plastic panel 11. 10007251 IGBT(FGH40N60 2. 10043476 handle 12. 10043417 main PCB: W216-22(PN-55-A1) 3. 10004636 panel socket DKJ35-50 13. 10044929 control PCB: W21201-21(PN-234-A1) 4. 10004636 panel socket DKJ35-50 14.
- Page 32 JASIC Technologies America Inc (‘Us’, ‘We’) warrants that the following products under RAZORWELD supplied by Us and purchased by you from an Authorised RAZORWELD Dealer throughout the U.S.A & Canada are free of Material and Faulty Workmanship defects except for those products listed under ‘Warranty Exclusions’.
- Page 33 WARRANTY / RETURNS / EXCHANGES We understand that sometimes a product may need to be returned. If you have purchased from the RAZORWELD Authorised Dealer Network, to assist you in following the correct procedure enclosed is the returns policy. Our Returns Policy includes the rights you have under the American consumer Law and other relevant laws.
- Page 34 Failure or any breakage caused by overload, dropping or abusive treatment or use by the customer • Repair, modifications or other work carried out on the product other than by an Authorised RAZORWELD Dealers Unless it is a manufacturing fault, this Warranty does not cover the following parts:...
- Page 35 NOTES...
- Page 36 © JASIC Technologies America Inc 2012 EST. 1985 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...