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Related Manuals for Jasic JM-500S
Summary of Contents for Jasic JM-500S
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Page 2: Your New Product
Please ensure that you carry out daily and periodic maintenance checks to ensure years of reliable and trouble free operation. Please call your Jasic distributor in the unlikely event of a problem occurring. Please record below the details from your product as these will be required for warranty purposes and to ensure you get the correct information should you require assistance or spare parts. -
Page 3: Table Of Contents
MIG Welding Problems MIG Water Cooled Welding Torch Maintenance Service Schedule Record Troubleshooting Error codes WEEE Disposal RoHS Compliance Declaration UKCA Declaration of Conformity EC Declaration of Conformity Statement of Warranty Wiring diagrams Options and Accessories Notes Jasic Contact Details... -
Page 4: Safety Instruction
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. The equipment must only be used for the purpose it was designed for. Using it in any other way could result in damage or injury and in breach of the safety rules. -
Page 5: Welding Processes Lens Shade Selector Guide
SAFETY INSTRUCTION Use of Personal Protective Equipment (PPE) 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 6: Fume And Welding Gases
SAFETY INSTRUCTION Safety against fumes and welding gases The HSE have identified welders as being an ‘at risk’ group for occupational diseases arising from exposure to dusts, gases, vapours and welding fumes. The main identified health effects are pneumonia, asthma, chronic obstructive pulmonary disease (COPD), lung and kidney cancer, metal fume fever (MFF) and lung function changes. -
Page 7: The Working Environment
SAFETY INSTRUCTION The working environment Ensure the machine is mounted in a safe and stable position allowing for cooling air circulation. Do not operate equipment in an environment outside the laid down operating parameters. The welding power source is not suitable for use in rain or snow. Always store the machine in a clean, dry space. -
Page 8: Rf Declaration
SAFETY INSTRUCTION RF Declaration Equipment that complies with directive 2014/30/EU concerning electromagnetic compatibility (EMC) and the technical requirements of EN60974-10 is designed for use in industrial buildings and not those for domestic use where electricity is provided via the low voltage public distribution system. Difficulties may arise in assuring class A electromagnetic compatibility for systems installed in domestic locations due to conducted and radiated emissions. -
Page 9: Product Overview
PRODUCT OVERVIEW Jasic MIG JM-500S Product Features: The Jasic MIG 500S Synergic is a powerful MIG/MAG synergic welding system and is suitable for use in the most demanding situations and its digital controls and display make it easy to use. -
Page 10: Technical Specifications
TECHNICAL SPECIFICATIONS Parameter Unit Jasic MIG JM-500S Rated input voltage AC400V±20% 50/60HZ Rated input power 28.2 Rated input current I max 40.6 Rated input current I eff 28.7 MIG 60 ~ 500 Welding current range MMA 30 ~ 500 No-load voltage... -
Page 11: Panel Layouts
PANEL LAYOUT Front view Jasic MIG JM-500S Power Source and cooler 1. Digital ammeter 2. Selector button for Amps, Wire speed or material thickness and time 3. Parameter selector button. Pressing this button moves the selector to light the LED of the parameter to be adjusted 4. - Page 12 WIRE FEED UNIT LAYOUT Jasic MIG JM-500S wire feed unit Front view 21. Digital display 22. Wire speed control dial 23. Wire inch button 24. Euro style MIG torch connector 25. Digital display 26. Voltage control dial and Voltage trim in synergic mode 27.
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Page 13: Installation
Installation Unpacking Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging until the installation is complete. 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 14 Installation MIG welding Insert the welding torch into the “Euro connector for torch in MIG” output socket on the front panel of the wire feed unit and tighten it. Insert the quick plug of the interconnection cable set into the “+” output terminal of the welding machine and tighten it clockwise (ensure to connect the other end connection to the rear of the wire feed unit).
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Page 15: Controls
CONTROLS Front control panel view Jasic MIG JM-500S 1. Digital display 2. Selector button for Amps, Wire speed or material thickness and time 3. Selector button for process mode: allows user to select MIG or MMA 4. Rotary encoder: For carrying out adjustments 5. -
Page 16: Control Panel
Time (s) - Pre flow, post flow and spot only * Please note: On the JM-500S the default factory setting is set to wire feed, if you require the adjustment to be material thickness then you are required to enter the background menu to change the default, see page 34 for further information. - Page 17 CONTROL PANEL Parameter adjustment knob All welding parameters are set by adjusting the shown control potentiometer knobs A or B. The adjustment indicator tells users that the knob is effective when the corresponding parameter LED in the current column or voltage column flashes. Dial A will general make adjustments to the left display and dial B will generally make adjustments to the right hand display.
- Page 18 Synergic means that when a single setting is adjusted i.e. voltage or material thickness for example other settings like current or wire speed will also change. On the JM-500S machine, there are a multitude of pre-configured settings being changed by the software to provide the best weld possible.
- Page 19 Note: This function is not applicable when MMA mode . Front control panel view of wire feed unit (Jasic MIG JM-500S) 1. Digital display meter (ammeter) 2. Digital display meter (voltmeter in standard MIG mode and trim in synergic mode) 3.
- Page 20 CONTROL PANEL Saving welding Jobs via the Job No mode For the simple and effective management of welding programs, the JM-500S machine is equipped with 20 channels (0 ~ 19) for storage of general MIG/MAG, synergic MIG/MAG and MMA welding programs.
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Page 21: Operating Parameters
OPERATING PARAMETERS Parameter Value Jasic MIG JM-500S Welding current range Amps 30 ~ 500 Arc force current range Amps 0 ~ 250 Arc ignition current range Amps 0 ~ 250 Arc ignition time Seconds 500ms MIG/MAG Pre-flow time Seconds 0 ~ 1... -
Page 22: Operation
OPERATION 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. MMA Welding Mode MMA (Manual Metal Arc), SMAW (Shielded Metal Arc Welding) or just Stick Welding. Stick welding is an arc welding process which melts and joins metals by heating them with an arc between a covered metal electrode and the work. -
Page 23: Operation Mma
OPERATION (MMA) 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. MMA Welding Mode - Parameters in MMA There are 3 adjustable parameters in MMA welding, namely arc ignition current , arc welding current and arc force. -
Page 24: Guide To Mma Welding
GUIDE TO MMA WELDING 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. Notes for the welding beginner This section is designed to give the beginner who has not yet done any welding some information to get them going. - Page 25 GUIDE TO MMA WELDING 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. MMA process tips and guides Typical welder set up 1.
- Page 26 GUIDE TO MMA WELDING 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. MMA arc striking Tap technique Lift the electrode upright and bring it down to strike the work piece. After forming short circuit, quickly lift up about 2~4mm and arc will be ignited.
- Page 27 GUIDE TO MMA WELDING 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. Fillet welding The electrode should be positioned to split the angle i.e. 45º. Again the electrode should be inclined in the direction of travel at around 10º-30º.
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Page 28: Mma Welding Problems
MMA 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. Arc welding defects and prevention methods Defect Possible cause Action Excessive spatter (beads of metal Amperage too high for the... - Page 29 OPERATION (MIG/MAG) 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. MIG/MAG Welding Mode MIG - Metal Inert Gas Welding, MAG - Metal Active Gas Welding, GMAW - Gas Metal Arc Welding MIG welding was developed to help meet production demands of the war and post war economy which is an arc welding process in which a continuous solid wire electrode is fed through a MIG welding gun and...
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Page 30: Operation Mig/Mag
OPERATION (MIG/MAG) 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. Control panel operation and setup After the machine is powered on, the system will be under the functional state that was used last time the machine was powered off. - Page 31 OPERATION (MIG/MAG) 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. Wire feed unit control panel operation and setup Wire feed unit control Once the machine has been set up, the operator does have the ability to make some welding adjustments via the wire feed unit panel.
- Page 32 OPERATION (MIG/MAG) 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. MIG/MAG Welding Mode - Parameters in MIG There are 5 adjustable parameters in standard MIG/MAG welding, namely pre-flow time, peak current, crater current, crater voltage and post-flow time.
- Page 33 OPERATION (MIG/MAG) 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. Torch trigger functions Mode Operation Torch trigger operation and Number current curve 1T/Spot welding mode: 1.
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Page 34: Submenu Functions
Factory preset is 0 (metric) 1 = English unit Temperature of inverter - The digital display meter will show A facility for the local Jasic service center to check the temperature of inverter. accuracy of the inverter temperature Maximum wire feed speed calibration... -
Page 35: Guide To Mig/Mag Welding
GUIDE TO MIG/MAG WELDING 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. MIG process description The MIG process was first patented for the welding of aluminium in 1949 in the USA. The process uses the heat that is generated by an electric arc formed between a bare consumable wire electrode and the work piece. - Page 36 GUIDE TO MIG/MAG WELDING 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. Notes for the welding beginner This section is designed to give the beginner who has not yet done any welding some information to get them going.
- Page 37 GUIDE TO MIG/MAG WELDING 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. Modes of Transfer Dip or short circuit mode In the dip or short circuit, the wire (electrode) touches the work piece and a short circuit is created.
- Page 38 GUIDE TO MIG/MAG WELDING 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. Modes of Transfer Globular Transfer Mode The globular transfer method is in effect an uncontrolled short circuit which occurs when the voltage and wire are above the dip range but too low for spray.
- Page 39 GUIDE TO MIG/MAG WELDING 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. SYNERGIC AND STANDARD MODES Synergic Mode When a welding machine is referred to as synergic it means that when a single setting is adjusted (most commonly voltage or material thickness) other settings like current or wire speed also change.
- Page 40 GUIDE TO MIG/MAG WELDING 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. Inductance When MIG/MAG welding in the dip transfer mode the welding wire electrode touches the work piece/ weld pool and this results in a short circuit.
- Page 41 GUIDE TO MIG/MAG WELDING 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. MIG/MAG system checks Shielding gas nozzle This nozzle must be periodically cleaned to remove weld spatter. Replace if distorted or squashed. Contact Tip Only a good contact between this contact tip and the wire can ensure a stable arc and optimum current output;...
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Page 42: Mig Welding Guide
MIG WELDING GUIDE... -
Page 43: Mig Welding Problems
MIG 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. MIG welding defects and prevention methods Defect Possible cause Action Porosity (within or outside the bead) Poor material Check the material is clean... - Page 44 MIG 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. MIG welding defects and prevention methods Defect Possible cause Action Burning through –...
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Page 45: Mig Water Cooled Welding Torch
MIG TORCH SPARE PARTS LIST JM-500S Water Cooled MIG Welding Torch Water Cooled - Model: T501 Rating 500A C°2/450A Mixed Gases @ 100% Duty Cycle EN60974-7 Wire Size 1.0mm to 1.6mm... -
Page 46: Maintenance
MAINTENANCE 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. In order to guarantee that the arc welding machine works efficiently and in safety, it must be maintained regularly. -
Page 47: Troubleshooting
TROUBLESHOOTING 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. Before arc welding machines are dispatched from the factory, they have already been checked thoroughly. -
Page 48: Error Codes
Error code Possible cause Possible solution Over current or failed power components Restart the machine; if over-current error still exists, please contact your local Jasic service center Low mains supply voltage The machine will resume when the mains Failure on the auxiliary power supply... -
Page 49: Weee Disposal
Jasic has a relevant recycling system which is compliant and registered in the UK with the environment agency. Our registration reference is WEEMM3813AA. -
Page 50: Ec Declaration Of Conformity
EC Declaration of Conformity... -
Page 51: Statement Of Warranty
This should be carried out by a suitably qualified competent person. In the unlikely event of a problem, this should be reported to Jasic technical support team to review the claim. -
Page 52: Wiring Diagrams
WIRING DIAGRAM Power Source Wire Feed Unit Water Cooler... -
Page 53: Options And Accessories
Work Return Lead 70mm and Clamp 5m CP3550 Cable Plug 35-50mm CP5070 Cable Plug 50-70mm JH-HDX Jasic HD True Colour Auto Darkening Welding Helmet SSARG2G Single Stage 2 Gauge Argon Regulator JM-WF500SYN-5 5M Interconnecting Cable - Air/Water Cooled JM-WF500SYN-10 10M Interconnecting Cable - Air/Water Cooled... -
Page 54: Notes
NOTES ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________... - Page 55 NOTES ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________...
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Page 56: Jasic Contact Details
November 2021 Issue 4...
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