Jasic TIG200, Operator'S Manual

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Page 2: ...t information should you require assistance or spare parts Date purchased ________________________________________ From where ________________________________________ Serial number ________________________________________ The serial number is normally located on the top or underside of the machine and will begin with AA For further information on your Jasic product warranty registration please vis...

Page 3: ...laration 8 LF declaration 8 Materials and their disposal 8 Product Overview 9 Technical Specifications 10 Description of Controls 11 Installation 12 Operation MMA 14 Operation TIG 15 Guide to MMA Welding 16 MMA Welding Problems 20 Guide to TIG Welding 21 TIG Welding Torch 26 Tig Welding Problems 27 Maintenance 29 Service Schedule Record 29 Troubleshooting 30 EC Declaration of Conformity 31 WEEE Di...

Page 4: ...e and overheating Never use worn damaged under sized or poorly jointed cables Insulate yourself from work and earth using dry insulating mats or covers big enough to prevent any physical contact Never touch the electrode if you are in contact with the work piece return Do not wrap cables over your body Ensure that you take additional safety precautions when you are welding in electrically hazardou...

Page 5: ...ulty welding helmets Always ensure there are adequate protective screens or barriers to protect others from flash glare and sparks from the welding area Ensure that there are adequate warnings that welding or cutting is taking place Wear suitable protective flame resistant clothing gloves and footwear Check and be sure the area is safe and clear of inflammable material before carrying out any weld...

Page 6: ...the the welding fume Ensure the welding zone is well ventilated and provision should be made for suitable local fume extraction system to be in place If ventilation is poor wear an approved airfed welding helmet or respirator Read and understand the Material Safety Data Sheets MSDS s and the manufacturer s instructions for metals consumable coatings cleaners and de greasers Do not weld in location...

Page 7: ...eated by high currents may affect the operation of pacemakers or elec tronically 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 Keep the torch cable and work re...

Page 8: ...ry current from the power supply network high power systems affect the quality of power provided by the network Consequently connection restrictions or maximum impedance requirements permitted by the network at the public network connection point must be applied to these systems In this case the installer or the user is responsible for ensuring the equipment can be connected consulting the electri...

Page 9: ...anel of the machine and the handle are coated with rubber oil so the machine has soft texture good hand feeling that feels warm and comfortable to hold Jasic TIG 180 and 200 Product Features Compact size lightweight and modern design 180DV has dual voltage inputs of 115V and 230V DC TIG with excellent HF arc ignition which offers reduced interference and high reliability Suitable for a wide range ...

Page 10: ...6 Rated input current Ieff 16 5 A 115V 18 5 230V 14 2 18 9 Welding current range TIG 10 180 MMA 10 160 A 115V TIG 10 120 115V MMA 10 100 230V TIG 10 180 230V MMA 10 160 TIG 10 200 MMA 10 180 No load voltage 65 V 65 65 Rated duty cycle 40 C TIG 180A 35 MMA 160A 35 115V TIG 120A 35 115V MMA 100A 35 230V TIG 180A 40 230V MMA 160A 40 TIG 200A 35 MMA 180A 35 Downslope time S 0 10 0 10 0 10 Post gas tim...

Page 11: ...ut terminal To connect the work clamp 6 Output terminal To connect the TIG torch 7 Gas terminal To connect the gas hose of the TIG torch 8 Control terminal To connect the trigger switch plug of the TIG torch trigger 9 Front grill for air intake 10 MMA TIG switch To toggle between MMA and TIG 11 2T 4T switch When the toggle switch is switched to 4T self lock function is available 12 Welding current...

Page 12: ...ing Never connect the machine to the mains supply with the panels removed Output connections Electrode polarity In general when using manual arc welding electrodes the electrode holder is connected to the positive terminal and the work return to the negative terminal output terminal For MMA connect the electrode holder output terminal For MMA connect the work return lead Always consult the electro...

Page 13: ...chine and tighten it clockwise Insert the cables plug of the TIG torch into the socket on the front panel of the machine and tighten clockwise Connect the gas quick connector into the outlet on the machine front Connect the torch switch plug into the socket on the front panel Example shown below Connect the gas hose to the regulator flowmeter located on the shield gas cylinder and connect the othe...

Page 14: ... contamination When the electrode is moved along the work piece at the correct speed the metal core deposits a uniformed layer called the weld bead After connecting the welding leads as detailed you will need to switch the power switch on the back panel to ON the machines power LED comes on and the fan is working Select MMA by switching to the MMA welding mode There is voltage output at both outpu...

Page 15: ...tch on the back panel to ON the machine is started with the power LED on and the fan working Switch the MMA TIG switch to TIG mode Open the gas valve of the cylinder and adjust the gas regulator to obtain the desired flow rate Press the torch trigger briefly the solenoid valve will operate and gas will flow Adjust the welding current according to the thickness of the work piece to be welded for a ...

Page 16: ...s across rather than to or from your body The electrode holder lead should always be clear of any obstruction so that you can move your arm freely along as the electrode burns down Some elders prefer to have the welding lead over their shoulder this allows greater freedom of movement and can reduce the weight from your hand Always inspect your welding equipment welding cables and electrode holder ...

Page 17: ...on as the electrode contacts the work piece The welder should always ensure a good connection of the work clamp The nearer the clamp is placed to the welding area the better When the arc is struck the distance between the end of the electrode and the work will determine the arc voltage and also affect the weld characteristic As a guide the arc length for electrodes up to 3 2mm diameter should be a...

Page 18: ...uit quickly lift up about 2 4mm and arc will be ignited This method is difficult to master Scratch technique Drag the electrode and scratch the work piece as if striking a match Scratching the electrode may cause the arc to burn along the scratch path so care should be taken to scratch in the weld zone When the arc is struck adopt the correct welding position Electrode positioning Horizontal or fl...

Page 19: ...ectrode 1 The electrode feeding to the molten pool along axis 2 The electrode swing right and left 3 The electrode moving in the weld direction The operator can choose the manipulation of electrode based on welding joint welding position electrode spec welding current and operation skill etc Weld characteristics A good weld bead should exhibit the following characteristics 1 Uniform weld bead 2 Go...

Page 20: ... speed Ensure the arc is on the leading edge of the weld puddle Porosity Small holes or cavities on the surface or within the weld material Work piece dirty Electrode is damp Arc length is excessive Remove all contaminant from the material i e oil grease rust moisture prior to welding Replace or dry the electrode Reduce the arc length Excessive penetration The weld metal is below the surface level...

Page 21: ...visibility of the arc A much larger diameter nozzle can be used which will produce a large blanket of shielding gas This can be very useful in welding material like titanium The gas lens will also enable the welder to reach joints with limited access such as inside corners Ceramic cups Gas cups are made of various types of heat resistant materials in different shapes diameters and lengths The cups...

Page 22: ...rode Colour Chart DC Tungsten Electrode Current Ranges Tungsten electrode preparation DC When welding at low current the electrode can be ground to a point At higher current a small flat on the end of the electrode is preferable as this helps with arc stability Electrode grinding It is important when grinding the electrode to take all necessary precautions such as wearing eye protection and ensuri...

Page 23: ...can use both non contact and contact methods to provide arc starting Depending on the Jasic model the options are indicated on a selector switch on the front control panel of the power source The most common method of arc starting is HF start This term is often used for a variety of starting methods and covers many different types of start Arc starting scratch start This system is where the electr...

Page 24: ...ption than scratch starting for mild and stainless steel although these methods of arc starting are not a good option when welding aluminium Arc starting HF start Non contact High Frequency HF start method is a high voltage and low amperage generated using a spark gap assembly and is the most popular and generally considered best TIG arc starting method The High Frequency HF start generates a high...

Page 25: ...torch angle is best kept at 15 20 from vertical away from the direction of travel This assists with visibility of the weld area and allows easier access for the filler material The filler metal should be fed in at a low angle to help avoid touching the tungsten electrode and contaminating it The TIG welding arc melts the base material and the molten puddle melts the filler rod it is important you ...

Page 26: ...F77 X Long Cup 3 8 Bore Secondary Consumables 23 SP9110 LH RH Handle Shell 24 SP9111 Handle Screw 25 SP9120 Single Button Switch SP9121 2 Button Switch SP9122 5K Potentiometer Switch SP9123 10K Potentiometer Switch SP9128 47K Potentiometer Switch SP9129 4 Button Switch 26 SP9113 Handle Ball Joint 27 SP9116 Leather Cover 800mm 28 SP9118 Cable Cover Joint not illustrated 29 18CG Standard Heat Shield...

Page 27: ...se No operation when torch switch is operated Torch switch or cable faulty Check the torch switch continuity and repair or replace as required ON OFF switch turned off Check position of ON OFF switch Mains fuses blown Check fuses and replace as required Fault inside the machine Call for a repair technician Low output current Loose or defective work clamp Tighten replace clamp Loose cable plug Chec...

Page 28: ...ad too small or insufficient penetration Welding travel speed too fast Reduce your welding travel speed Weld bead too wide or excessive bead build up Welding travel speed too slow Increase your welding travel speed Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod Tungsten melts or oxidises when welding arc is made TIG torch lead connected to Little or no gas f...

Page 29: ...it 5 minutes after power switch off before opening the case SERVICE SCHEDULE RECORD Period Maintenance item Daily examination Check the condition of the machine mains cables welding cables and connections Check for any warnings LEDs and machine operation Monthly examination Disconnect from the mains supply and wait for at least 5 minutes before removing the cover Check internal connections and tig...

Page 30: ...nally The fault LED is ON and the fan is running The machine is under over heating protection status and will recover automatically after the welding machine has cooled Check incoming mains supply to ensure it is within 230V 15 No high frequency is produced Process selection switch is set to manual metal arc MMA Torch trigger switch lead is disconnected or switch lead is faulty High frequency spar...

Page 31: ...rials Do not dispose of the equipment with normal waste The European Directive 2002 96 EC on Waste Electrical and Electronic Equipment states the electrical equipment that has reached its end of life must be collected separately and returned to an environmentally compatible recycling facility Jasic has a relevant recycling system which is compliant and registered in the UK with the environment age...

Page 32: ...he scope of the warranty Defects due to natural wear and tear Failure to observe the operating and maintenance instructions Connection to an incorrect or faulty mains supply Overloading during use Any modifications that are made to the product without the prior written consent Software errors due incorrect operation Any repairs that are carried out using non approved spare parts Any transport or s...

Page 33: ...33 SCHEMATIC ...

Page 34: ...ad Dinse Adaptor and Switch Plug JSP 01 TIG Torch Switch Plug 2 Pin WCS25 3WEL Welding Cable Set MMA 3m WC 2 03LD Electrode Holder and Lead 3m EC 2 03LD Work Return Lead and Clamp 3m CP3550 Cable Plug 35 50mm JSS 01 Jasic Carry Strap JSB 01 Jasic Site Bag JIT 01 Trolley JH HDX Jasic HD True Colour Auto Darkening Welding Helmet SSARG2G Single Stage 2 Gauge Argon Regulator WTLHK2 2m Gas Hose and Qui...

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Page 36: ...36 September 2020 Issue 4 ...