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Razorweld JRW200Pdi Instruction Manual

200 amp pulse pfc dc tig welding machine
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RAZORweld
JRW2ooPdi
200 AMP PULSE PFC DC TIG WELDING MACHINE
INSTRUCTION MANUAL - JRW200Pdi
October 2023

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Summary of Contents for Razorweld JRW200Pdi

  • Page 1  RAZORweld JRW2ooPdi 200 AMP PULSE PFC DC TIG WELDING MACHINE INSTRUCTION MANUAL - JRW200Pdi October 2023...
  • Page 2 Congratulations on choosing our equipment! This operating manual contains important information on the use and maintenance of this product, as well as safe handling of the product. Please refer to the technical parameters of the equipment in the Technical section located in this manual, and read the manual carefully before using the equipment for the first time.

  • Page 3: Table Of Contents

    Contents 1. Safety precautions ......................1.1. General safety ........................ 1.2. Other precautions ......................2. Description of symbols ....................... 3. Product overview ......................4. Technical parameters ....................... 5. Installation ........................5.1. External interface description ..................5.2. Power installation......................5.3. MMA/STICK electrode holder and earth cable connection ........... 5.4.
  • Page 4 For your safety, please read this manual carefully before installing and operating this JASIC equipment. Pay extra attention to all content marked with " ". All operations must be carried out by professional, suitably qualified persons! Page 4...

  • Page 5: Safety Precautions

    1. Safety precautions 1.1. General safety SAFETY INSTRUCTION These general safety norms cover both arc welding machines and plasma cutting machines unless otherwise noted. It is important that users of this equipment protect yourselves and others from harm or even death.
  • Page 6 Arc rays——May injure the eyes and burn the skin. Welding arc rays from all welding processes produce intense, visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. ·Wear an approved welding helmet fitted with an appropriate shade of filter lens to protect your face and eyes when welding or watching.
  • Page 7 Risks due to magnetic fields The magnetic fields created by high currents may affect the operation of pacemakers or electronically 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.

  • Page 8: Other Precautions

    1.2. Other precautions Warning! Location The machine should be located in a suitable position and environment. Care should be taken to avoid moisture, dust, steam, oil or corrosive gases. Place on a secure level surface and ensure that there is adequate clearance around the machine to ensure natural airflow.

  • Page 9: Description Of Symbols

    2. Description of symbols Read this operation manual carefully before use Operation warning Single-phase static frequency converter-transformer rectifier Single-phase AC power supply and rated frequency Can be used in environments with high risk of electric shock Degree of protection, such as IP23S. Rated AC input voltage (tolerance ±15%) Rated maximum input current 1max...
  • Page 10 Pulse frequency Duty cycle DC TIG mode DC pulse TIG mode MMA/STICK mode HF arc starting mode Lift arc starting mode MMA/STICK current Hot start current of MMA/STICK Arc force of MMA /STICK Welding mode switching Other function switching Remote control Smart gas VRD function indicator Overcurrent protection indicator...
  • Page 11 Wireless indicator Pairing of wireless simple remote controller Electric shock risk warning Page 11...

  • Page 12: Product Overview

    3. Product overview This is a digital control inverter DC welder with complete functionality, excellent performance and advanced technology, supporting DC TIG, DC pulse TIG, TIG spot welding, and SMAW. It can be widely used to weld common metals except aluminum and aluminum alloys. The unique electrical structure and air passage design inside the machine increases the dissipation of heat generated by the power device, thus improving its duty cycle.

  • Page 13: Technical Parameters

     Smart fan control: Saves energy, reduces noise, reduces dust entry, and prolongs the service life of the fan.  TIG arc starting mode: Supports HF and lift arc starting with a high success rate.  Multiple TIG operation modes: 2T, 4T, repeat, and spot welding. ...
  • Page 14 Pre-flow time Initial current 5~200 5~200 5~200 5~200 (AC230V) Initial current 5~160 5~160 (AC115V) Up-slope time 0~10 0~10 0~10 0~10 Down-slope 0~10 0~10 0~10 0~10 time Finish current 5~200 5~200 5~200 5~200 (AC230V) Finish current 5~160 5~160 (AC115V) 0~15 0~15 0~15 Post-flow time 0~15...
  • Page 15 Duty cycle 25% 10m 104F Power factor 0.99 0.99 0.68 0.68 Insulation class Protection class IP23S IP23S IP23S IP23S 18"X10"X12" Dimensions L*W*H Inch 453*150*313 413*150*311 413*150*311 Plus 20.0 8.97 7.92 7.92 weight Standard 18.5 8.37 7.51 7.51 Overall Plus 30.0 13.63 12.55 12.55...

  • Page 16: Installation

    5. Installation Warning! All connections shall be made with the power supply is turned off. Warning! Electric shock may cause death; after power failure, there is still a high voltage on the equipment, do not touch the live parts on the equipment. Warning! Incorrect input voltage may damage the equipment.

  • Page 17: Power Installation

    5.2. Power installation Warning! The electrical connection of equipment shall be carried out by suitably qualified personnel. Warning! All connections shall be made after the power supply is off. Warning! Incorrect voltage may damage the equipment. Ensure the input voltage value is within the specified input voltage range. Ensure that the power switch of the welder itself is turned off.

  • Page 18: Mma/Stick Electrode Holder And Earth Cable Connection

    5.3. ARC/STICK electrode holder and earth cable connection Figure 5-4 Electrode holder and earth cable Pay attention to the polarity of wiring before ARC welding. Generally, there are two connection method of DC welder: DCEN and DCEP. DCEN: The electrode holder is connected to the negative polarity, and the workpiece is connected to the positive polarity;...

  • Page 19: Tig Welding Torch And Earth Cable Connection

    5.4. TIG welding torch and earth cable connection 1) Ensure that the power switch is turned off. 2) Insert the cable plug with earth clamp into the positive socket on the front panel of the welder and tighten it clockwise. 3) Insert the cable plug of the welding torch into the corresponding negative socket on the front panel of the welder and tighten it clockwise.

  • Page 20: Wired Remote Control (Foot)

    5.5. TIG welding Remote connections ________________________9 Pin remote connection Use of Foot pedal controller 1. The foot remote controller consists internally of a switch and potentiometer. 2. Use the dedicated cable to connect the remote controller to the 5 pin Female aviation socket on the front panel of the welder.

  • Page 21: Wired Remote Control (Hand)

    5.6 TIG Torch Operation (Standard & Remote) 1. Your Machine comes complete with the foot control and our standard WP17-13-9P10KFC TIG torch is also provided as part Amperage of the package. If you wish to use a hand Amperage control On/Off Control Torch for your RAZORTIG 200 AC/DC ,the Model...

  • Page 22: Control Panel

    6.0 Optional remote control models Host Welding Type Name Model receiver Picture mode module Analog torch potentiometer None trigger Analog welding torch Digital torch Digital None trigger welding torch Wired Wired foot FC9P10K None remote controller Wired handheld HRC-01(P1S None MMA /STICK remote controller Wireless...

  • Page 23: Tig200P/Tig200P Pfc Hd Digital Panel

    6.2. TIG200P/TIG200P PFC HD digital panel Figure 6-4 HD digital panel 1. TIG parameter display 2. Parameter and error code display 3. Protection indicator 4. Welding mode selector 5. Arc start mode selector 6. Enable remote control (optional) 7. Smart gas 8.
  • Page 24 6.2.1 Display of TIG parameters Figure 6-5 TIG200P HD digital panel Pre-flow time indicator. When the indicator is on, it indicates the pre-flow protection time Initial current indicator. When the indicator is on, it indicates the initial current Up-slope time indicator. When the indicator is on, it indicates the time until the initial current reaches the peak current Peak current indicator.

  • Page 25: Other Functions

    6.2.4 Selection of welding mode 1) Before welding, press the welding mode key to switch among MMA/STICK, DC TIG and DC pulse TIG welding, and select the corresponding mode based on the process requirements. is on, it indicates the DC TIG mode is selected. 2) If the indicator is on, it indicates the DC pulse TIG mode is selected.
  • Page 26 Figure 6-6 Standby function indicator 6.3.2 Input overvoltage and undervoltage protection Figure 6-7 Enter the back-end 1) Press and hold the "Current Setting Encoder" key for 2s to start countdown. After the 3s countdown is over, the panel displays "F01". Rotate the "Current Setting Encoder" key clockwise to adjust the parameter to "F02", and press the key again to enter the input overvoltage and undervoltage protection settings.
  • Page 27 (The standard version only supports overvoltage protection function. This function is enabled by default.) 6.3.3 Restore factory settings Press and hold the welding mode key for 5s to restore factory settings. After holding for 1s, the display window will start to count down from 3. When the countdown ends, the factory settings are restored.
  • Page 28 6.3.4 Serial No. display :NB: Not applicable on some models Figure 6-9 View Serial no. Press and hold the "Current Setting Encoder" and "Welding Mode" keys simultaneously for 3s to view the machine Serial no.. Press any key or press the encoder to immediately exit the Serial no.

  • Page 29: Welding Function Operation

    7. Welding function operation Warning! Before turning on the power supply make sure that the electrode holder or welding torch is connected to the output, do not touch the workpiece and earth clamp. Otherwise, an unexpected arc may be started when the power is turned on in the case of MMA/STICK by default.
  • Page 30 7.1.2 Select manual welding mode Figure 7-2 MMA/STICK panel display The rotary encoder can adjust the welding current, hot start current and arc force current parameters. Welding current: The current of the arc section during welding, which is set by the user based on the type and diameter of the welding electrode and the process requirements.
  • Page 31 Hot start current: Stronger hot start current is conducive to arc start and reduces sticking between the welding electrode and workpiece during arc start. The magnitude of hot start current is generally determined based on the type, specification, and welding current of the welding electrode.

  • Page 32: Dc Tig Operation

    7.2. DC TIG operation 7.2.1 Turn on the power switch (Same as 7.1.1) 7.2.2 Select DC TIG welding mode Figure 7-4 DC TIG mode 7.2.3 Select the arc starting mode The arc starting mode includes lift arc starting and HF arc starting, which can be selected according to the actual conditions.
  • Page 33 Table 7-2 Welding method description Legend for commonly-used torch trigger operations ↓ Press the torch trigger ↑ Release the torch trigger Mode Torch trigger operation and typical DC TIG Operation Schedule current curve Press the torch Spot welding mode: trigger 1.
  • Page 34 Repeat mode: 1. Press the torch trigger to start the arc to the initial value 2. Release the trigger to slowly increase to the peak current 3. Press the trigger to slowly drop to the finish current 4. Release the trigger to slowly step up to the peak current 5.
  • Page 35 ● Up-slope time (t2): Refers to the time as the current slowly rises from the initial current to the peak current, which can be determined according to the usage and process requirements. ● Peak current (I3): Set by the user according to the actual process requirements. ●...

  • Page 36: Dc Pulse Tig Operation

    7.2.6 DC TIG welding Open the gas valve on the gas cylinder, adjust the argon gas flow, and realize TIG welding by lift arc starting or HF arc starting. During welding: 1) The TIG parameter indicator changes with the welding state 2) If the parameter indicator is in initial current, peak current, or finish current, directly press the encoder to adjust the value, and the parameter indicator will flash 3) If the parameter indicator is in pre-flow time, up-slope time or down-slope time, the value...
  • Page 37 7.3.4 Select welding method (Same as 7.2.4) 7.3.5 Set welding parameters The DC pulse TIG welding parameters are as shown in Figure 7-7. Figure 7-7 Current waveform of DC pulse TIG I1-Initial current t0-Pre-flow time I2-Current during up-slope time t1-Initial current period I3-Pre-set pulse current t2-Up-slope time I4-Current during down-slope time...
  • Page 38 Set all welding parameters according to the above steps. Choose the appropriate welding current, tungsten electrode, and shielding gas flow based on the welding requirements. Refer to the Table 7-3 for details. 7.3.6 DC pulse TIG welding Open the valve on the gas cylinder, adjust the argon flow, and realize TIG welding by lift arc starting or HF arc starting.

  • Page 39: Maintenance

    8. Maintenance Warning! The following operation requires sufficient professional knowledge on electric aspects and comprehensive safety knowledge. Make sure the input cable of the machine is disconnected from the electricity supply and wait for 5 minutes before removing the machine covers. Please note: The following should only be carried out by an authorised electrical technician.

  • Page 40: Welding Torch Maintenance

    8.2. Welding torch maintenance In Lift TIG mode, the TIG welding torch is used to clamp the electrode, conduct electricity and transport argon gas. Regular maintenance of welding torch is one of the most important measures to ensure its normal operation and improve its life. In order to ensure normal maintenance, the wearing parts of the torch should have spares, including the electrode holder, nozzle, sealing mesh, insulating washer, etc.

  • Page 41: Troubleshooting

    The nozzle is damaged or Replace with a new nozzle cracked The gas circuit in the welding Blow the circuit with compressed air torch is blocked to clear the blockage The gas screen has been damaged or lost during Replace with a new gas screen disassembly and assembly The argon gas is impure Replace with qualified argon gas...
  • Page 42 Arc hot start current Hard to start is low Increase arc start current or arc start Or the hot start time time the arc is short Unstable arc or Arc start current is excessive Reduce arc start current or start time high Or the arc start time penetration...
  • Page 43 (1) Ensure that the valve of argon cylinder is open and there is enough pressure. Generally, if the cylinder pressure is lower than 0.5 MPa, it must be refilled. (2) Check whether the argon flow rate is normal. You can select the flow rate according to the welding current condition, Welds are not Blackening of solder...

  • Page 44: Alarms And Solutions

    9.2. Alarms and solutions Error Category Possible cause Countermeasure code Continuously Restart the welder. If overcurrent protection Overcurrent output the alarm is still active, contact the after-sales maximum capacity protection department. current of welder Turn off the machine and restart it. If this the alarm cannot be eliminated and the grid voltage remains too low, check the power grid Undervoltage...

  • Page 45: Packaging, Transportation, Storage And Waste Disposal

    10. Packaging, transportation, storage and waste disposal 10.1. Transportation requirements In the process of handling the equipment, it should be handled with care, and should not be dropped or severely impacted. Avoid moisture and rain during transportation. 10.2. Storage conditions Storage temperature:-25 ℃...

  • Page 46: Appendix 1: Wiring Diagram Of Tig200P Pfc/Tig200Pfc

    Appendix 1: Wiring diagram of TIG200P PFC/TIG200PFC Page 46...

  • Page 47: Appendix 2: Wiring Diagram Of Tig200P/Tig200

    Appendix 2: Wiring diagram of TIG200P/TIG200 Page 47...

  • Page 48: Appendix 3: List Of Common Spare Parts

    Appendix 3: List of common spare parts Page 48...
  • Page 49 1.TIG200/TIG200P Material Material Name Quantity Name Quantity code code Solenoid Valve 51000375 Silicon button 51000022 (plus) Solenoid Valve 10083484 Knob 10056884 (standard) 51000648 Silicon button 10071118 Power switch HD digital panel 10083917 sticker 51000485 Power cord (TIG200) HD digital panel 10083915 sticker 10083651...
  • Page 50 Rear panel HF packaging 10083654 10083769 bracket board Main board PCB 51000583 (plus) 10083770 Wind shield Main board PCB 51001868 (standard) Front panel Pilot arc coil 10083653 51001879 bracket (standard) N/A（Standard） Pilot arc coil 51000715 Fast socket plug (plus) 10083486 (plus) Display PCB 51000631...
  • Page 51 Page 51...
  • Page 52 2.TIG200 PFC/TIG200P PFC Material Material Name Quantity SN Name Quantity code code 51000375 Silicon button 10071118 Power switch 10083484 Knob 51001928 Power cord 51000648 Silicon button 10083933 Right cover HD digital panel 10083940 sticker (TIG200P 10083930 Left cover PFC) HD digital panel sticker Upper cover 10083916...
  • Page 53 Rear panel Pilot arc coil 10083654 51000715 bracket (plus) Main board PCB Pilot arc coil 51000547 51001879 (plus) (standard) Main board PCB 51001872 (standard) 10083628 Diode heat sink Front panel 10083653 bracket Fast socket plug 10083486 10083635 Main transformer (plus) N/A(Standard) 10083629 IGBT heat sink...

  • Page 54: List Of Common Tig Torch Parts

    RAZORWELD Torch Model Description Part Number WP 17 TIG Torch Package WP17-13-9P10KHC with hand remote to suit JRW200Pdi WP 17 TIG Torch for 200 C/DC Power Supply to suit JRW200Pdi (Foot control) WP17-13-9P10KFC Cup Gasket Part # Description 18CG Cup Gasket...

  • Page 55: Notes

    NOTES: _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ Page 55...
  • Page 56 JASIC TECHNOLOGIES AMERICA INC 25503 74th Ave S, KENT WA 98032 USA WWW.RAZORWELD.COM SALES@RAZORWELD.COM...

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