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Summary of Contents for Razorweld KUMJRRW110DC
- Page 1 Razorweld ™ ™ OPERATING MANUAL KUMJRRW110DC KUMJRRW170DC 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...
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Page 2: Table Of Contents
• 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: Safety
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 4 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 5: 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 6 California Proposition 65 WARNING: This product contains or produces a chemical known to the State of California to cause cancer and birth defects (or other reproductive harm) (California Health and Safety Code Section 25249.5 et seq.). WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemi- cals known to the State of California to cause birth defects and, in some cases, cancer (California Health and Safety Code Section 25249.5 et seq.).
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Page 7: Technical Data
MMA/TIG - 110Amp DC Welding Machine Small, Lightweight and Portable Welds: Steels, Stainless, Cast Iron, Bronze, Copper KUMJRRW110DC Features • 115 VOLT SINGLE PHASE • HOT START • ANTI STICK • ARC FORCE • DUTY CYCLE 20%@110AMPS MMA 104ºF (115V) 1 PHASE 30%@110AMPS TIG 104ºF (115V) 1 PHASE... - Page 8 MMA/TIG - 170Amp DC Welding Machine Small, Lightweight and Portable Welds: Steels, Stainless, Cast Iron, Bronze, Copper KUMJRRW170DC Features • DUAL VOLTAGE (115~230V) SINGLE PHASE • DUTY CYCLE 30%@170AMPS MMA 104ºF (230V) 1 PHASE 35%@170AMPS TIG 104ºF (230V) 1 PHASE •...
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Page 9: Machine Layout Descriptions
FRONT MAChINE LAYOUT DESCRIPTION Primary Power LED Thermal Alarm LED Amperage Control Dial MMA /TIG Selector Switch Negative Output Positive Output Terminal Terminal Rear Machine Layout Description Primary Input On /Off Power Switch Power Lead... - Page 10 INSTALLATION SET UP FOR MMA (STICk) WELDING WITh RAZOR 110-170 Please install the machine strictly according to the following steps. The protection class of this machine is IP21S, so avoid using it in rain. Connection of Input Cables Primary input cable is supplied with this welding equipment. Connect the primary input cable with power supply of required input voltage.
- Page 11 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 12 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 13 INSTALLATION AND SET UP FOR DC TIG WELDING FOR RAZOR 110-170 (1) Switch on the machine, select the TIG function with the TIG/MMA selector switch. (2) Insert the power cable plug of the TIG torch into the Negative socket on the front of the machine and tighten it.
- Page 14 LIFT ARC DC TIG OPERATION FOR RAZOR 110-170 Lift Arc ignition allows the arc to be started easily in DC TIG by simply touching the tungsten to the work piece and lifting it up to start the arc. This prevents the tungsten tip sticking to the work piece and breaking the tip from the tungsten electrode.
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Page 15: Dc Tig Welding
DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical 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 16: Tig Welding With Filler Wire Technique
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 Acetylene 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 17: 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 18: 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 19 17V TIG TORCH 150A AIR COOLED TIG WELDING TORCH Rating: 150Amp DC, 105Amp AC @35% duty cycle. For use with non gas solenoid machines Front end parts identification on opposite page Torch Model Description Part Number 13FT 17V Tig Torch Package c/w 6FT Gas Hose 17V-13FTCP25 17V-13FTCP50 Spare Parts Part Number Description VS2 Torch Body Gas valve WP17 Torch head 57Y02 Back cap long WP17V Torch head c/w valve 57Y03 Medium back cap WP17F Torch head flexible 57Y04 Short back cap HWP17 Torch handle HWP17 Torch Handle WP17VF Torch Head Flexi c/w valve...
- Page 20 17V TIG TORCH Standard Front End Parts Part # Description Part # Description Part # Description 18CG Cup Gasket 10N30 Collet Body 1.0mm / 0.039” 10N49L Long Alumina Nozzle Ø 8mm / 0.314” #5L 10N31 Collet Body 1.6mm / 0.062” 53N48L Long Alumina Nozzle Ø 10mm / 0.393” #6L 10N32 Collet Body 2.4mm / 0.094” 53N47L Long Alumina Nozzle Ø 11mm / 0.433” #7L 10N28 Collet Body 3.2mm / 0.125” Part # Description Part # Description 10N22 Collet 1.0mm / 0.039” 10N50 Alumina Nozzle Ø 6mm / 0.236” 10N23 Collet 1.6mm / 0.062”...
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Page 21: Mma (Stick) Welding Trouble Shooting
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 22: Tig Welding Trouble Shooting
TIG WELDING TROUBLE ShOOTING The following chart addresses some of the common problems of DC 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... - Page 23 continued- TIG WELDING TROUBLE ShOOTING 8: Arc difficult to start or will not start DC welding Possible Reason Suggested Remedy Incorrect machine set up Check machine set up is correct No gas, incorrect gas flow Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted.
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Page 24: Spare Part Identification
SPARE PARTS IDENTIFICATION - RAZOR 110DC Part Number Description Part Number Description 1. 10037836 front plastic panel 10. 10006650 Single-phase rectifier bridge 2. 10039824 handle 11. 10007251 IGBT 3. 10004966 TIG/MMA selector switch 12. 10039785 main PCB 4. 10037152 panel socket 16-25 13. - Page 25 Jasic Technologies America Inc (‘us’, ‘we’) warrants that the following products under Razorweld supplied by us and purchased by you from an authorized 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 26 We understand that sometimes a product may need to be returned. If you have purchased from an authorized RAZORWELD Dealer, the following is the correct procedure and returns policy. Our Returns Policy includes the rights you have under the American consumer Law and other relevant laws. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage.
- Page 27 This Warranty does not cover damage caused by: • Normal wear and tear due to usage • Misuse or abusive use of the RAZORWELD as outlined in the instructions supplied with the product. • Failure to clean or improper cleaning of the product •...
- Page 28 © 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...