Jasic JM-200CS, 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: ...ew 9 Technical Specifications 10 Description of Controls 11 Multifunctional Display Window 15 Installation 16 Operation MMA 18 Operation MIG MAG 19 Operation TIG 20 Guide to MMA Welding 21 MMA Welding Problems 25 Guide to MIG MAG Welding 26 MIG Set Up Guide 30 MIG Welding Problems 31 MIG Welding Torch 33 Guide to TIG Welding 34 TIG Welding Torch 38 TIG Welding Problems 39 Maintenance 41 Service Sc...

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 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 Keep the torch cable and work ret...

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: ...mfortable to hold Jasic MIG 200CS Product Features Advanced Synergic Control Pulse parameters are selected automatically Compact size lightweight and modern 40kHz advanced IGBT design inverter Multi process MIG MAG MMA and Lift TIG welding functions are available The JM 200CS is a single phase 230V 15 AC input machine Designed for gas gasless MIG welding wires with additional features as wire inch...

Page 10: ...d input voltage V AC230V 15 50 60Hz Rated input power kVA 9 4 Rated input current Imax A 35 6 Rated input current Ieff A 21 Welding current range A MIG 30 200 MMA 10 200 TIG 10 200 No load voltage V 53 Rated duty cycle 40 C MIG 200A 35 MMA 200A 35 TIG 200A 35 Efficiency 85 Power factor cosφ 0 7 Standard EN60974 1 Protection class IP IP21S Insulation class F Noise db 70 Operating temperature range ...

Page 11: ...orch trigger mode switch 8 Welding mode control switch 9 Voltage arc force and downslope time control dial Rear view Jasic MIG 200CS 10 Power switch The ON OFF mains switch for the machine 11 Gas inlet connection The gas inlet that allows you to connect the gas supply from the gas regulator 12 Cooling fans The entry for the air to access the cooling fans 13 Input cable gland The entry for the main...

Page 12: ...of the wire this is done by turning the central bolt with an Allen key clockwise to tighten or anti clockwise to loosen 4 Inlet wire guide The welding wire is fed through the inlet guide prior to feeding through the drive rollers 5 Wire feed roller and retaining nut Secures and holds the grooved drive roller in place 6 Outlet feed adaptor Part of the Euro outlet connector which contains the inner ...

Page 13: ...e power source and in MIG mode it adjusts the rate of speed metre per minute at which the filler metal is fed and consumed in the weld which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc See set up chart on page 29 for further information F Voltage arc force and downslope time control dial Welding voltage can be adjusted in MIG mode only and will...

Page 14: ... used with C0 gas 5 98 Ar 2 C0 0 8 In this position you have entered synergic MIG mode for 0 8mm dia welding wire when being used with gas mixture of 98 Argon and 2 C0 6 98 Ar 2 C0 1 0 In this position you have entered synergic MIG mode for 1 0mm dia welding wire when being used with gas mixture of 98 Argon and 2 C0 The inbuilt synergic control is used in this Jasic MIG 200CS in which the voltage ...

Page 15: ... the welding machine 2 When the display window displays release the 2T 4T switch key to enter into the system parameter adjusting interface 3 Select the welding mode which needs adjusting by turning the welding mode select switch select the parameter number through the current control knob and select the parameter value through the voltage control knob Please refer to the table below for the conte...

Page 16: ...of the machine or in the technical parameters shown in the manual The equipment should be connected by a suitably qualified competent person Always ensure the equipment has a proper grounding 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 positiv...

Page 17: ...e switch into the MIG position Press the wire inch button to thread the wire out of the torch through the contact tip You are now ready to start MIG welding Gasless self shielded MIG welding Insert the welding torch into the Euro connector for torch in MIG output socket on the front panel of the machine and tighten it Insert the work return cable plug C into the output terminal of the welding mach...

Page 18: ...ling forms a slag covering to protect the weld from 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 Using the welding mode switch select MMA by switching to the MMA position There is now op...

Page 19: ...as supply is connected Switch the power switch on the back panel to ON the machine is started with the power LED on and the fans are running Using the welding mode switch select MIG by switching to the MIG position Open the gas valve of the cylinder and adjust the gas regulator to obtain the desired flow rate Adjust the voltage control knob in MIG and wire feed speed control knob in MIG on the fro...

Page 20: ...socket on the front panel of the welding machine and fully tightened clockwise Connect the gas hose to the regulator flowmeter located on the shield gas cylinder and connect the other end to the machine 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 area Now you will need to s...

Page 21: ...oss 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 befor...

Page 22: ...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 23: ...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 24: ...ectrode 1 The electrode feeding to the molten pool along axes 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 25: ...peed 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 o...

Page 26: ... from contamination which also enhances the arc The MIG MAG process can be used to weld a wide variety of materials and is normally used in the horizontal position but can be used in vertical or overhead with the correct selection of machine wires and current In addition it can be used to weld at long distances from the power source subject to the correct cable sizing It is the dominant process us...

Page 27: ...cess as CO2 welding Gases such as oxygen and carbon dioxide were added and are active constituents to the inert gas to improve the welding performance Although the MAG process is in common use today it is still referred to as MIG welding although technically this is not correct The process began to prove itself as an alternative to stick electrode MMA and TIG GTAW offering high productivity and de...

Page 28: ...e positive This means that the majority of the heat is in the electrode wire Certain special wires may require the polarity to be reversed i e electrode wire negative polarity Always consult the manufacturer s data sheet for the best operating parameters The voltage is often referred to as the heat setting This will be altered dependent on the material type thickness gas type joint type and positi...

Page 29: ...by the operator Some quick reference handy tips for the MIG MAG welding process are When welding try to use an electrode stick out the distance between the weld and the contact tip of around 6 8mm When welding thin materials try and use smaller MIG wire diameters and for thicker materials use thicker wires Make sure you select the correct MIG wire type for the material to be welded Ensure the MIG ...

Page 30: ...30 MIG Set Up Guide Please Note This information is intended to act as a guide only MIG WELDING GUIDE ...

Page 31: ...lding tip Readjust the upper feed pressure Increase the pressure to eliminate burn back to tip Decrease pressure to eliminate bird nesting Replace torch liner Replace wire Check and replace welding tip No operation when the torch switch is operated Torch switch faulty Fuse blown Faulty PCB inside the equipment Check the torch switch continuity and replace if faulty Check fuses and replace if neces...

Page 32: ... to welding Irregular weld bead and shape Incorrect voltage wire feed settings If its convex then the voltage is too low and if its concave then the voltage is too high Insufficient or excessive heat input Wire is wandering Incorrect shielding gas Adjust voltage and or wire feed speed Adjust the wire feed speed dial or the voltage control Replace contact tip Check and change the shielding gas as r...

Page 33: ...33 MIG WELDING TORCH JM 200CS MIG Welding Torch Air Cooled Model T150 Rating 180A Co2 150A Mixed Gases 60 Duty Cycle EN60974 7 Wire Size 0 6mm to 1 0mm ...

Page 34: ...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 35: ...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 36: ...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 37: ... pure helium maybe used TIG welding arc starting Lift TIG lift arc Not to be confused with scratch start this arc starting method allows the tungsten to be in direct contact with the work piece first but with minimal current so as not to leave a tungsten deposit when the tungsten is lifted and an arc is established With lift TIG start the open circuit voltage OCV of the welder folds back to a very...

Page 38: ...H 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 30 54N01 Gas Lens Heat Shield 31 54N63 Large Gas Lens In...

Page 39: ...ade of use 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 p...

Page 40: ...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 41: ...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 42: ...en the MIG torch trigger switch is Check supply to wire feed motor depressed Possible motor PCB fault Output current reduces when welding Poor work lead connection to the work piece TIG electrode melts when arc is struck TIG torch is connected to the VE terminal No gas flow when the MIG torch trigger switch is depressed Empty gas cylinder Gas regulator is turned off Gas hose is blocked or cut Torc...

Page 43: ...spose 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 agency Our registr...

Page 44: ...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 45: ...45 SCHEMATIC ...

Page 46: ...JIT 01 Trolley JH HDX Jasic HD True Colour Auto Darkening Welding Helmet SSARG2G Single Stage 2 Gauge Argon Regulator WTLHK2 2mtr Gas Hose and Quick Gas Connecter 10048354 V Groove 0 6mm 0 8mm 10048356 V Groove 0 8mm 1 0mm 10048347 V Groove 1 0mm 1 2mm B6200ZZ Flat Pressure Roll 10048338 Knurled 0 8mm 1 0mm FCW 10048352 U Groove 0 6mm 0 8mm 10048349 U Groove 0 8mm 1 0mm 10048353 U Groove 1 0mm 1 2...

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Page 48: ...48 September 2020 Issue 5 ...