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Razorweld JRW200AC/DC Operating Manual

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Razorweld
™
™
Razor
2OOAC/DC
TIG-ARC
OPERATING MANUAL
JRW200AC/DC
3
YEARS
Warranty
(Power Source)
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
©
1
Welding Guns Of Australia PTY LTD 2015

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Summary of Contents for Razorweld JRW200AC/DC

  • Page 1 Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC OPERATING MANUAL JRW200AC/DC YEARS Warranty (Power Source) Please read and understand this instruction manual carefully before the installation and operation of this equipment. © Welding Guns Of Australia PTY LTD 2015...
  • 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 warranty.asp or at the back of this manual.

  • Page 3: Table Of Contents

    CONTENTS Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC Safety - Precautions Electrical Diagram Technical Data, Product Information Front Panel Layout 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...
  • 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 under- stand 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.
  • Page 6 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 -10°C to +40°C.(14 F-104 f ) 1.3 Keep this equipment 30cm distance from the wall.

  • Page 7: Electrical Diagram

    Razorweld Electrical Schematic Diagram ™ ™ Razor 2OOAC/DC TIG-ARC...
  • Page 8 RAZOR200ACDC is the new standard for Dual voltage welders making it the ideal choice for both the experienced professional welder and the weekend Warrior alike. Built to our specifications and manufactured in compliance to CAN/CSA 60974.1 MACHINE PACKAGE: JRW200AC/DC Standard option includes: RAZOR200AC/DC Machine, WP/SR17 TIG Torch x 13ft, Earth Lead 1" x 13ft,...
  • Page 9 Machine Layout Description Razor Razorweld 2OOAC/DC TIG-MMA ™ ™ Razor 2OOAC/DC TIG-ARC Front Machine Layout Description 1. Digital control panel 2. Postive output terminal 3. Negative output terminal 4. Quick lock gas connector * 5/8 NPT in USA 5. Torch switch - remote connector 5 Pin 6.
  • Page 10 Front Panel Operation Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC Front Panel Functions Indicates Active Selector Pad Mode Selector - Enables selection of required welding mode - AC TIG - AC PULSE TIG - DC TIG - DC PULSE TIG (Stick)
  • Page 11 Front Panel Operation - Weld Program Selection Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC Encoder Knob - provides digital adjustment of welding parameters and provides step by step motion through the weld cycle parameters. Encoder knob weld parameter value selection Turning the encoder will adjust the value of the parameters required.
  • Page 12 Continued - Weld Program Selection & Setting Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC Up Slope Time - Sets the transition time from Start Amperage to Welding Amperage The value selected shows on the digital Up Slope Time: Select by pushing the Turn the Encoder to set display.
  • Page 13 Continued - Weld Program Selection & Setting Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC Weld Program - Selection of further weld program parameters Parameter selection: Select by pushing the Encoder Knob repeatedly to cycle through the weld parameter icons. The icon will illuminate when selected.
  • Page 14 Razorweld Continued - Weld Program Selection & Setting ™ ™ Razor 2OOAC/DC TIG-ARC Spot - Provides selection of a pre-set time period for welding current output. Allows adjustment of the time that machine will deliver amperage output from trigger activation.
  • Page 15 Razorweld Set Up Procedure for ARC (Stick) Welding: ™ ™ Razor 2OOAC/DC TIG-ARC ARC (Stick Electrode) Welding Setup and Operation 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...
  • Page 16 Continued - Set Up Procedure for ARC (Stick) Weld- Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC 5) Strike the electrode against the work 4) Place the electrode into the electrode Connect the Earth Clamp securely to piece to create and arc and hold the elec- holder and clamp tight.
  • Page 17 Razorweld ARC (Manual Metal Arc) Welding ™ ™ Razor 2OOAC/DC TIG-ARC 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 shield- ing gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.

  • Page 18: Arc (Stick) Welding

    Razorweld ARC (Stick) Welding Fundamentals ™ ™ Razor 2OOAC/DC TIG-ARC 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 19 Installation Set Up for DC TIG Welding: Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC DC HF TIG Welding Setup and Operation 1. Connect the TIG Torch connector to the negative terminal and tighten it. 2. Install the threaded connector into into the gas fitting 3.
  • Page 20 DC HF TIG Welding Standard Set Up Procedure: Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC Front panel set up procedure for basic HF DC TIG welding 1. Select DC TIG Function. 2. Select Tungsten Diameter. 3. Set Pre-gas Time Select DC TIG by pressing the...

  • Page 21: Dc Tig Welding

    Razorweld DC TIG Welding ™ ™ Razor 2OOAC/DC TIG-ARC 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).

  • Page 22: Dc Pulse Tig Welding

    Razorweld DC Pulse TIG Welding ™ ™ Razor 2OOAC/DC TIG-ARC 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).
  • Page 23 DC Pulse TIG Welding Set Up Procedure The Razorweld 200 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 24 Razorweld Manual TIG Welding Technique ™ ™ TIG Welding Fusion Technique Razor 2OOAC/DC TIG-ARC 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.
  • Page 25 Razorweld Installation Set Up for AC TIG Welding: ™ ™ Razor 2OOAC/DC TIG-ARC AC HF TIG Welding Setup and Operation 1. Connect the TIG Torch connector to the negative terminal and tighten it. 2. Insert the torch gas connector into the quick lock gas receptacle.

  • Page 26: Set Up And Operation For Ac Tig Welding

    Razorweld Set up and operation for AC TIG Welding ™ ™ Razor 2OOAC/DC TIG-ARC Front panel set up procedure for basic AC HF TIG welding 1. Select AC TIG Function. 2. Select Tungsten Diameter. 3. Set Pre-gas Time button pushing the encoder...

  • Page 27: Set Up And Operation For Ac Tig Welding

    Razorweld continued - Set up and operation for AC TIG Welding ™ ™ Razor 2OOAC/DC TIG-ARC continued - Front panel set up procedure for basic AC TIG welding 10. Set Finish Amps 11. Set Post Gas Time the encoder the encoder...
  • Page 28 Razorweld AC TIG Welding - AC Wave Balance Control ™ ™ Razor 2OOAC/DC TIG-ARC AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminum, Magnesium and Aluminum Alloys. These materials have an insulating surface oxide layer that melts at a higher temperature than the base metal making it difficult to weld the base metal if the oxides are not removed.
  • Page 29 AC TIG Welding - AC Wave Balance Control Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC In older machines, a balanced current output wave was achieved using a large number of capacitors in series or a battery in the welding circuit. Modern TIG power sources use electronics to create and maintain a balanced wave and now most AC TIG power sources produce a square wave current output.
  • Page 30 AC Pulse Welding Set Up Procedure The Razorweld 200ACDC machine has digital Pulse Frequency Control. All the parameters for AC Pulse TIG welding - Peak Amp, Base Amp, Pulse Frequency and Pulse Width are easy to set via the digital con- trol panel.
  • Page 31 Razorweld Remote Amperage Control Operation Procedure ™ ™ Razor 2OOAC/DC TIG-ARC Remote amperage controls allow remote welding current adjustment from the welding machine during welding. Type: RWJFC-2D Type: ER1MS-10 Type: UER1MS-10H amperage on/off switch amperage on/off switch adjustment adjustment Connection and operation of the remote hand control 3.
  • Page 32 Razorweld Tungsten Electrodes ™ ™ Razor 2OOAC/DC TIG-ARC Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tung- sten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.
  • Page 33 Razorweld Tungsten Preparation ™ ™ Razor 2OOAC/DC TIG-ARC 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 aluminum 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 34 WP17 ERGO TIG TORCH WP17 TIG TORCH Distributor Pricing Standard Front End Parts WP17-13 Torch Model Description Part Number WP17 Pro-Grip Lite Tig Torch Package with hand remote WP17-13 WP 17 Eco- Grip Torch for 160/200/200 C/DC Power Supply ( use with Foot control) WP17-13FC Cup Gasket...

  • Page 35: Trouble Shooting Guide - Tig Welding

    TROUBLE SHOOTING - TIG WELDING TIG tROUBLE SHOOTING Razorweld TIG WELDING TROUBLE SHOOTING ™ ™ Razor 2OOAC/DC TIG-ARC 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.
  • Page 36 TROUBLE SHOOTING - TIG WELDING Razorweld continued- TIG WELDING TROUBLE SHOOTING ™ ™ Razor 2OOAC/DC TIG-ARC 7: Arc wanders during DC welding Possible Reason Suggested Remedy Poor gas flow Check and set the gas flow between 15-25 CFH flow rate...
  • Page 37 ARC (Stick) WELDING TROUBLE SHOOTING Razorweld ™ ™ Razor 2OOAC/DC TIG-ARC 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...

  • Page 38: Warranty

    JASIC Technologies America Inc (‘Us’ , ‘We’) warrants that the following products under RAZORWELD supplied by Us and pur- chased by you from an Authorised RAZORWELD Dealer throughout the U.S.A & Canada are free of Material and Faulty Work- manship defects except for those products listed under ‘Warranty Exclusions’ .
  • Page 39 TIG-ARC 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.
  • Page 40 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 41 NOTES.