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™
Razorweld
OPERATING MANUAL
™
KUMJRRW200ACDC-A
3YEARS Warranty
(Power Source)
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
1
© JASIC Technologies America Inc 2013
2
Thank you for your purchase of your RAZORWELD Welding Machine.
We are proud of our range of welding equipment that has a proven track record of innovation, performance
and reliability. Our product range represents the latest developments in Inverter technology put together
by our professional team of highly skilled engineers. The expertise gained from our long involvement with
inverter technology has proven to be invaluable towards the evolution and future development of our equipment range. This experience gives us the inside knowledge on what the arc characteristics, performance
and interface between man and machine should be. Within our team are specialist welders that have a
proven history of welding knowledge and expertise, giving vital input towards ensuring that our machines
deliver control and performance to the utmost professional level. We employ an expert team of professional sales, marketing and technical personnel that provide us with market trends, market feedback and
customer comments and requirements. Secondly they provide a customer support service that is second
to none, thus ensuring our customers have confidence that they will be well satisfied both now and in the
future.
RAZORWELD welders are manufactured and compliant with - CAN/CSA E60974-1 &
ANSI/IEC 60974-1, guaranteeing you electrical safety and performance.
™
Razorweld
™
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 chemicals 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.).
INFORMATION SOURCES
• California Health and Safety Code, Section 25249.4 through 25249.13.
• The California Office of Environmental Health Hazard Assessment, 301 Capitol Mall, Sacramento, CA
95814; telephone 916-445-6900.
• California Proposition 65 website: www.oehha.ca.gov/prop65.html.
• American National Standards Institute (ANSI). Product Safety Signs And Labels (ANSI Z535.4), available
from ANSI,
™ 25 West 43rd Street, New York, NY 10036; telephone: 212-642-4900; web site:
™ www.ansi.org.
Razorweld
WARRANTY
• 3 Years from date of purchase.
• JASIC Technologies America Inc Ltd warranties all goods as specified by the manufacturer
of those goods.
• This Warranty does not cover freight or goods that have been interfered with.
• All goods in question must be repaired by an authorised repair agent as appointed by this
company.
• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.
• New product will not be supplied unless JASIC Technologies America Inc has inspected
product returned for warranty and agree to replace product.
• 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.
3
CONTENTSPAGE
4
Warranty
3
Safety - Cautions
5-7
Technical Data, Product Information
8
Machine Layout & Descriptions
9
Front Panel Selector Switch Function Descriptions
10
Front Panel Control Dial Function Descriptions
11-12
Machine Installation & Operation
13
Installation & Operation for MMA (Stick) Welding
14-15
MMA (Stick) Welding 16-17
Installation & Operation for DC TIG Welding
18-19
DC TIG Welding, DC Pulse TIG Welding
20-22
TIG Welding Fusion and Filler Wire Technique
23
Installation & Operation for AC TIG Welding
24-25
AC TIG Welding, AC Pulse TIG Welding
26-28
Remote Controls - Installation and Operation
29
Tungsten Electrode Selection & Preparation
30-32
Trouble Shooting Guide - MMA (Stick) Welding 33
Trouble Shooting Guide - TIG Welding 34-35
TIG Torch Parts Breakdown
36-37
Machine Spare Parts Identification
38-39
Warranty Terms
40-42
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.
Machine Operating Safety
•Do not switch the function modes while the machine is operating. Switching of the function modes during
welding can damage the machine. Damage caused in this manner will not be covered under warranty.
•Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing
should the electrode be in contact with the work piece.
•Operators should be trained and or qualified.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe
burns. The electrode and work circuit is electrically live whenever the output is on. The input
power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding,
the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment is dangerous.
•Connect the primary input cable according to American standards and regulations. ANSI Z49.1..
•Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.
The operator must wear dry welding gloves while he/she performs the welding task.
•The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.
•Do not use damaged, under sized, or badly joined cables.
•Do not drape cables over your body.
Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can
be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health. •Do
not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
•Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
•In confined or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
•Do not weld in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.
•Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic
fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding process produce
intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
•Always
wear a welding helmet with correct shade of filter lens and suitable protective clothing including
welding gloves whilst the welding operation is performed.
•Measures should be taken to protect people in or near the surrounding working area. Use protective
screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
5
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. Check and be sure the area is safe before doing any welding.
•The
welding sparks may cause fire, therefore remove
any flammable materials away from the working
area, at least 12m from the welding arc. Cover flammable materials and containers with approved covers
if unable to be moved from the welding area.
•Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared
according to the required Safety Standards to insure that flammable or toxic vapors and substances are
totally removed, these can cause an explosion even though the vessel has been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
•Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)
•Have a fire extinguisher nearby and know how to use it. Be alert that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding
on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders are normally part of the welding process, be sure to
treat them carefully. CYLINDERS can explode if damaged.
•Protect
gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames,
sparks, and arcs.
•Insure cylinders are held secure and upright to prevent tipping or falling over.
•Never allow the welding electrode or earth clamp to touch the gas cylinder, do not drape welding cables
over the cylinder.
•Never weld on a pressurised gas cylinder, it will explode and kill you.
•Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.
Gas
build up. The build up of gas can causes a toxic environment, deplete the oxygen content
in the air resulting in death or injury. Many gases use in welding are invisible and odourless.
•Shut off shielding gas supply when not in use.
•Always ventilate confined spaces or use approved air-supplied respirator.
Electronic magnetic fields. MAGNETIC FIELDS can affect Implanted Medical Devices.
•Wearers of Pacemakers and other Implanted Medical Devices should keep away.
•Implanted Medical Device wearers should consult their doctor and the device manufacturer before going
near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
Hot parts. Items being welded generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the welding
gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns.
6
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..
1.3 Keep this equipment 1ft distant from the wall.
1.4 Ensure the working environment is well ventilated.
2. Safety Tips.
2.1 Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 1ft. Good ventilation is
of critical importance for the normal performance and service life of this equipment.
2.2
Thermal Overload protection.
2.3
Over-Voltage Supply
Should the machine be used to an excessive level, or in high temperature environment, poorly
ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the
machine will cease to operate. Under this circumstance, leave the machine switched on to keep the
built-in fan working to bring down the temperature inside the equipment. The machine will be ready for
use again when the internal temperature reaches safe level.
Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.
This equipment is of automatic voltage compensation, which enables the maintaining of the voltage
range within the given range. In case that the voltage of input power supply amperage exceeds the
stipulated value, it is possible to cause damage to the components of this equipment. Please ensure
your primary power supply is correct.
2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock
may possibly occur.
MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to prevent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and
dry compressed air of required pressure.
Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of
this welding equipment will be void if the machine has been modified, attempt to take apart the machine or
open the factory-made sealing of the machine without the consent of an authorized representative of the
manufacturer.
TROUBLE SHOOTING
Caution: Only qualified technicians are authorized to undertake the repair of this welding equipment.
For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.
Note:
Minimum Motor Generator Power Suggested:- 10KVA
7
TIG 200Amp AC/DC Welding Machine
Square Wave, Pulse, Remote Control
Welds: Aluminium, Zinc Alloy,Carbon Steels, Alloy Steels, Stainless,
Cast Iron, Bronze, Copper
™
Razorweld
TIG/MMA 200 Amp AC/DC Inverter Welder
HF, Pulse, 2/4T, Down Slope, Post Gas, Remote
Industrial Rated, Square Wave AC
Features
• Latest IGBT Inverter Technology
• AC/DC Tig
• HF Tig Function (provides easy arc start, prevents tungsten damage)
• 2/4T Trigger Function
• AC Square Wave with Adjustable AC Balance Control
• Adjustable Pulse Control - 0.5 - 300Hz
• Adjustable Base Current 10-90%
• Adjustable Down Slope 0-10 sec
• Adjustable Post Gas 0-10 sec
• MMA (stick electrode)
• Hot Start (improves electrode starting)
• Arc Force (stabilises the arc with difficult to use electrodes)
• Remote Amperage Control - Optional
Technical Data
Power Supply / Phases (V-Ph)
Rated Input Power (KVA) ieff (Amps)
Rated Input Current (A) Rated Output No-Load Voltage (V) Duty Cycle @ 40ºC as per AS/NZ60974
Efficiency (%) Power Factor Protection Class
Insulation Class Size (mm) Weight (kg) Warranty
230V - 1 ±15%
5.8
14.6 (TIG)
Standard Amperage Control for torch
24
20-170A/26.8V MMA
10-200A/17.4V TIG
56
20%@170Amps MMA
20%@200Amps TIG
85
0.93
IP21S
F
1 ft 8 5/64” x1 ft 63/64” x1 ft 2 11/64”
UTJRFC-3
66 pounds
Remote Foot Control Option
3 years on power source
Overview
The KUMJR200AAC/DC is a 230V square wave AC/DC TIG inverter welder incorporating full TIG functionality including AC balance
control, pre gas, down slope, post gas, variable pulse parameters, HF start with 2/4T trigger control. The HF arc start provides easy arc
ignition leaving no tungsten inclusion and no contamination of the tungsten electrode. The Down Slope and Post Gas combined with
the 2/4T trigger function gives you control of the welder allowing you to control the start and finish of the weld process at a
professional level. The addition of a fully adjustable pulse function of frequency, base current and pulse width gives you the added
capability to better control heat input into the work, control penetration & control distortion. AC balance control lets you set the AC TIG
arc for cleaning of the oxide layer on aluminium and adjustment for a deeper penetrating weld. Combining the functions of the
KUMJR200AAC/DC ensures comprehensive control of the welding parameters when welding both AC and DC weldable materials
giving you the ability to produce professional Tig welds. The DC MMA welding capability delivers a smooth and stable arc allowing
easy welding with electrodes obtaining high quality welds including cast Iron, stainless and low hydrogen. Addition of the optional Foot
Control provides variable amperage adjustment during welding. The KUMJR200AAC/DC has set the benchmark for 230V
single phase AC/DC welders and made it ideal for multiple applications; aluminium & stainless steel fabrication, light industrial use,
repair and maintenance applications.Robust & reliable, built to our specification and manufactured in compliance to
CAN/CSA E60974-1 & ANSI/IEC 60974-1
MACHINE PACKAGE: KUMJR200AAC/DC
Standard option includes: KUMJR200AC/DC Machine, SR26 Tig Torch x 13ft, Earth Lead & Arc Lead 25mm x 13ft,
Argon Regulator, 6ft Gas Hose with fittings
8
™
Front Machine Layout Description
Function Alarm
LED
Amperage Display
Thermal Alarm
VRD
LED
Voltage Reduction
Gas Pre Flow
Control Dial Peak Current
Control Dial
Base Current
Control Dial
Remote Control Selector
ON/OFF Switch
Down Slope
Control Dial
TIG/MMA Selector
Post Flow Gas
Control Dial
2T/4T Selector
AC Balance
Control Dial
AC/DC Selector
Pulse Width
Control Dial
Pulse Frequency
Control Dial
Pulse Selector
Negative Output Terminal
Arc Force
Control Dial
Gas Out
Connector
Torch Switch
Socket
Foot Amp
Control Socket
Torch Remote
Control Socket
Positive Output Terminal
Rear Machine Layout Description
Data Plate
Serial Number
Primary Power Input
Input Gas Connector
9
Selector Switch Function Descriptions
1
3
4
2
5
6
1
ON/OFF: This switch powers the machine up when switched to the on position
and powers the machine off when switched to the off position.
2
Remote: Provides selection of the remote output current (amps) control function
Selecting the ON position allows use of the remote current (amperage) controls
Selecting the OFF postion allows current (amperage) control from the front panel
Peak current control.
3
2T/4T: Provides control over the arc ignition, weld cycle and finishing of the weld
using the torch trigger switch.
2T Selection provides 2 times function of the torch switch
(1) Pressing the torch switch gives arc ignition and initializes the welding current
(2) Releasing the torch switch introduces down slope time to minimum current level
and then terminates the welding current and introduces the post flow gas
4T Selection provides 4 times function of the torch switch
(1) Pressing the torch switch gives arc ignition and initializes the weldingcurrent
(2) Releasing the torch switch continues the welding operation.
(3) Pressing the torch switch introduces down slope and current falls to
minimum current
(4) Releasing the torch switch terminates the welding operation and introduces the
post flow gas.
10
4
AC/DC: Provides selection of AC or DC Current.
Selecting the AC position provides for AC welding current output.
Selecting the DC position provides for DC welding current output.
5
Pulse Selector: Provides selection of Pulse welding mode.
Selecting the
position place the machine in Pulse welding mode.
Selecting the
position place the machine in standard (non Pulse) welding.
mode.
6
TIG/MMA: Provides selection of TIG or MMA (Stick) welding modes.
Selecting the TIG position provides for TIG welding function.
Selecting the MMA position provides for Manual Metal Arc (Stick)welding function.
Control Dial Function Descriptions
A
E
B
F
C
G
D
H
I
A
Gas Pre Flow: Provides a pre-flow of gas to purge tig torch gas line prior to the
initialisation of the arc. Helps arc ignition and prevents porosity in the weld start.
Adjustment is 0-1sec.
B
Peak Current: Provides adjustment and control of the main welding current.
Adjustment range 10-200 Amps.
C
Base Current: Provides adjustment and control of the base welding current during
pulse welding. Represents a percentage of the Peak welding current, for example
Peak current set at 100 amps - Base Current set at 20% (20 amps)it means the output
current (amps) during the pulse cycle will go from 100 amps down to 20 amps during
each pulse cycle.
Adjustment range 20 - 90%.
D
Down Slope: Provides adjustment of the down slope time at the end of the welding
cycle. At the end of the weld cycle the welding current will reduce down gradually
over the time set at the dial until it stops. This prevents craters and pin holes forming at
the end of the weld.
Adjustment is 0-10sec.
Note: When using the remote foot control set the dial to “0”.
E
Arc Force: Provides adjustment of the short circuit current during stick (MMA) welding.
Arc force control helps prevent the electrode sticking to the work by sensing a drop in
arc voltage and compensates by increasing the arc voltage.
The higher the dial is set the more forceful and digging the arc will be, the lower it is set
the more soft and buttery the arc characteristic will be.
11
Control Dial Function Descriptions - continued
12
F
Pulse Frequency: Provides adjustment and setting of the pulse frequency when the
machine is set in Pulse mode. It adjust the amount of times per second (Hz) the output
current switches from the Peak current setting to Base current setting.
Adjustment is 0.5-300Hz.
G
Pulse Width: Provides adjustment and setting of the on time for the Peak current
during a pulse cycle.
Example: Peak current set at 100 amps - Base Current set at 20% (20 amps)
(It means the output current (amps) will go from 100 amps to 20 amps duringeach
pulse cycle.) Set the Pulse Width control at for example 60% and the output current
(amps) will be on for 60% of the time of the pulse cycle at the Peak current and
40% of the time at the base current.
Adjustment is 10% – 90%.
H
AC Balance:
To understand how balance control works, you first need to understand why aluminium
and magnesium require an AC welding output. These materials have an insulating
surface oxide layer that melts at a higher temperature than the base metal and makes it
difficult to weld the base metal if the oxides are not removed. AC welding current is
ideal because the nature of the AC output assists in breaking the surface oxide layer.
The AC Balance dial is for adjusting the current flow time between positive (+) and
negative (-). When set at the middle the proportion is 50%. When set at the maximum
it is 80% (+) and at the minimum it is 10% (+ ). Adjusted in a clockwise direction, the
time that the tungsten is at (+) is longer and this promotes an aggressive cleaning
action of the oxide film from the material surface. Care should be taken as too much
time at the tungsten being (+) can drive too much energy to the tungsten causing it to
overheat. When the dial is set lower (below 50%) it tightens the arc and provides a
deeper penetrating arc characteristic.
I
Gas Post Flow: Provides adjustment and control of an after flow of gas when the
welding arc is extinguished. Post flow gas prevents contamination of the weld pool
during its cool down period from molten state to solid at the weld finish also keeping
the tungsten electrode protected from oxidising atmosphere during the cool down cycle.
The Gas Post flow time will depend of the tungsten size and welding current that is
being used, when the Gas Post Flow is set correctly the tungsten electrode will have a
clean shiny finish.
Adjustment 0-10sec.
INSTALLATION & OPERATION
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. Refer to data plate on machine for Input voltage, IMAX and IEFF.
ATTENTION! - CHECK FOR GAS LEAKS
At initial set up and at regular intervals we recommend to check for gas leakage
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 15-25CFH.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure
gauge on the regulator, if the needle drops away towards zero there is a gas leak.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the
regulator and line for an extended time period. In this situation it is recommended to open the cylinder valve, set the flow rate to 15-25CFH, close the cylinder valve and check after a
minimum of 15 minutes.
5.If there is a gas loss then check all connectors and clamps for leakage by brushing orspraying
with soapy water, bubbles will appear at the leakage point.
6. Tighten clamps or fittings to eliminate gas leakage.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to
operation of your machine. We recommend that you close the cylinder valve
when the machine is not in use.
JASIC Technologies America Inc Ltd, authorised representatives or agents of
JASIC Technologies America Inc Ltd will not be liable or responsible for the
loss of any gas.
13
Installation set up for MMA (Stick) Welding with KUMJR200AAC/DC
(1) Turn the power source on and select the MMA function with the Tig/MMA selector switch.
(2) Connection of Output Cables
Two sockets are available on this welding machine. For MMA welding the electrode holder is shown
be connected to the positive socket, while the earth lead (work piece) is connected to the negative
socket, this is known as DC+ polarity. However various electrodes require a different polarity for
optimum results and careful attention should be paid to the polarity, refer to the electrode
manufacturers information for the correct polarity.
DC+ Electrode connected to
output socket.
DC- Electrode connected to
output socket.
(1) Set Tig/MMA selector
switch to MMA
(3) Connect Earth Lead
the
terminal
14
(2) Connect the Electrode
lead to
terminal
continued set up and operation for MMA (Stick) Welding
(3) Set the welding current relevant to the electrode type and size being used as recommended by the
electrode manufacturer
(4) Place the electrode into the electrode holder and clamp tight
(5) Strike the electrode against the workpiece to create and arc and hold the electrode steady to maintain
the arc
(6) Hold the electrode slightly above the work piece to maintain the arc while travelling at an even speed
to create and even weld deposition
(7) To finish the weld, break the arc by quickly snapping the electrode away from the work piece.
(8) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal underneath
3) Set the welding current using the
amperage control dial
(4) Place the electrode into the electrode
holder and clamp tight.
(5) Strike the electrode against the workpiece
to create an arc and hold the electrode steady
to maintain the arc
(6) Hold the electrode slightly above the work
maintaining the arc while travelling at an even
speed.
(7) To finish the weld, break the arc by quickly
snapping the electrode away from the work
piece.
(8) Wait for the weld to cool and carefully chip
away the slag to reveal the weld metal below.
15
MMA (Manual Metal Arc) Welding General Description
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. The electrode core itself acts as filler material the residue from the flux that forms a slag
covering over the weld metal must be chipped away after welding.
Core wire
+
Flux coating
Gas shield from flux melt
Power Source
Arc with core wire melt
Flux residue forms slag cover
Weld metal
▬
• The arc is initiated by momentarily touching the electrode to the base metal.
Core wire
Flux coating
Base metal
• The heat of the arc melts the surface of the base metal to form a molten pool
at the end of the electrode.
• The melted electrode metal is transferred across the arc into the molten pool
and becomes the deposited weld metal.
• The deposit is covered and protected by a slag which comes from the
electrode coating.
• The arc and the immediate area are enveloped by an atmosphere of
protective gas
Protective gas
Arc
Manual metal arc ( stick) electrodes have a solid metal wire core and a flux
coating. These electrodes are identified by the wire diameter and by
a series of letters and numbers. The letters and numbers identify the metal
alloy and the intended use of the electrode.
The Metal Wire Core works as conductor of the current that maintains the arc.
The core wire melts and is deposited into the welding pool.
Slag
Weld pool
16
The covering on a shielded metal arc welding electrode is called Flux.
The flux on the electrode performs many different functions.
These include:
● producing a protective gas around the weld area
● providing fluxing elements and deoxidizers
● creating a protective slag coating over the weld as it cools
● establishing arc characteristics
● adding alloying elements.
Covered electrodes serve many purposes in addition to adding filler metal to
the molten pool. These additional functions are provided mainly by the covering on the electrode.
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. It is recommend to
consult your welding supplier for the correct selection of electrode.
Electrode Size
Average Thickness
of Material
Maximum Recommended
Electrode Diameter
0.03 - 0.07 inches
0.07 - 0.19 inches
0.19 - 0.31 inches
0.31 - > inches
0.09 inches
0.12 inches
0.15 inches
0.19 inches
The size of the electrode generally depends on the
thickness of the section being welded, and the thicker
the section the larger the electrode required. The table
gives the maximum size of electrodes that maybe used
for various thicknesses of section based on using a
general purpose type 6013 electrode.
Welding Current (Amperage)
Correct current selection for a particular job is an
important factor in arc welding. With the current set too
low, difficulty is experienced in striking and maintaining
a stable arc. The electrode tends to stick to the work,
0.09 inches
60 - 100
penetration is poor and beads with a distinct rounded
0.12 inches
100 - 130
profile will be deposited. Too high current is
0.15 inches
130 - 165
accompanied by overheating of the electrode resulting
0.19 inches
165 - 260
undercut and burning through of the base metal and
producing excessive spatter. Normal current for a particular job may be considered as the maximum, which
can be used without burning through the work, over-heating the electrode or producing a rough spattered
surface.The table shows current ranges generally recommended for a general purpose type 6013
electrode.
Electrode Size
ø mm
Current Range
(Amps)
Arc Length
To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a
simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An
arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld.
An excessively short arc will cause sticking of the electrode and result in poor quality welds. General rule of
thumb for down hand welding is to have an arc length no greater than the diameter of the core wire.
Electrode Angle
The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal.
When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5
and 15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should
be between 80 and 90 degrees to the work piece.
Travel Speed
The electrode should be moved along in the direction of the joint being welded at a speed that will give the
size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all
times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel
will frequently lead to arc instability,slag inclusions and poor mechanical properties.
Material and Joint Preparation
The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or
any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend
on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases
edges should be clean and free of any contaminates. The type of joint will be determined by the chosen
application.
17
Installation set up for DC TIG Welding with KUMJR200AAC/DC
(1) Turn on the machine using the ON/OFF switch
(2) Select the TIG function with the TIG/MMA selector switch.
(3) Select DC using the AC/DC selector switch.
(4) Connect the Tig Torch connector to the negative terminal and tighten it.
(5) Connect the Earth Cable connector into the positive terminal and tighten it.
(6) Connect the torch switch remote lead into the torch remote socket
(4) Insert the torch gas connector into the quick lock gas receptacle.
(4) Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder.
(8) Connect the regulator to the
cylinder, Connect the gas lead
to the regulator. Set the flow to
15-25CFH
(1) Turn on the machine using the
ON/OFF switch
(2) Select TIG using the TIG/MMA
selector switch
(7) Insert the torch gas connector into
the quick lock gas receptacle.
(3) Select DC using the
AC/DC selector switch
(4) Connect the TIG torch connector
to the
terminal.
(5) Connect the Earth cable
connector to the
terminal
(6) Connect the torch switch lead
to the torch remote receptacle
18
DC HF TIG Operation with KUMJR200AAC/DC
HF (high frequency) ignition allows the arc to be started in Tig welding without touching the tungsten to the
work piece. By pressing the torch switch the machine will activate the gas flow and the HF ignition
resulting in the arc igniting across the gap between the tungsten electrode and the work piece. The
distance between the electrode and the work piece can be up to 13/64”. This arc ignition method prevents
tungsten inclusion in the work piece, promotes longer tungsten life and offers better operator control over
the starting and stopping the arc.
(1) Assemble the front end torch parts use the correct size and type of tungsten electrode for the job,
the tungsten electrode requires a sharpened point for DC welding.
(2) Choose 2T or 4T trigger function preferred as per the descriptions below
2T Selection provides 2 times function of the torch switch.
(1) Pressing the torch switch gives arc ignition and initializes the welding current and the welding
current is maintained by the torch remaining on.
(2) Releasing the torch switch stops the welding by introducing down slope and the current falls to
minimum level and then terminates the welding current and introduces the post flow gas.
4T Selection provides 4 times function of the torch switch
(1) Pressing the torch switch gives arc ignition and initializes the welding current
(2) Releasing the torch switch continues the welding operation.
(3) Pressing the torch switch and holding introduces down slope and current falls to minimum current.
(4) Releasing the torch switch terminates the welding operation and introduces the post flow gas.
(3) Choose the preferred welding current (amperage) to suit the tungsten size material type and
thickness to be welded.
(4) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 3/64”- 1/8”
from the work piece this method will provide a clean positive arc ignition.
(5) Press the torch switch and the arc will ignite across the gap between the tungsten and work piece.
Hold even distance of about 5/64” gap between the tungsten and work piece to maintain the arc.
(6) Release the torch switch to bring in the end of the welding sequence dependant of 2T or 4T trigger
function choice.
(1) Assemble the front end torch parts use the
correct size and type of tungsten electrode
for the job, the tungsten electrode requires
a sharpened point for DC welding
(2) Select 2T or 4T trigger function as required
(3) Set the Peak Current (amps) to suit the
tungsten size material type and thickness
to be welded.
(4) Lay the outside edge of the Gas Cup on
the work piece with the Tungsten Electrode
1- 3mm from thework piece
(5) Press the torch switch and the arc will ignite
across the gap between the tungsten and
work piece. Hold even distance of about
2mm gap between the tungsten and work
piece to maintain the arc.
(6) Release the torch switch to bring in the end
of the welding sequence dependant of 2T
or 4T trigger function choice
19
DC TIG Welding
30%
70%
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.
With a DC circuit 70% of the energy (heat) is always on the positive side. This needs to
be understood because it determines what terminal the TIG torch will be connected to
(this rule applies to all the other forms of DC welding as well ).
argon gas
power source
low
current
nozzle
DC TIG welding is a process in which an arc is struck between a
TUNGSTEN electrode and the metal work piece. The weld area
is shielded by an inert gas flow to prevent contamination of the
tungsten, molten pool and weld area.When the TIG arc is struck the
inert gas is ionized and superheated changing it’s molecular structure
which converts it into a plasma stream. This plasma stream flowing
between the tungsten and the work piece is the TIG arc and can be as
hot as 34232°F. It is a very pure and concentrated arc which provides
the controlled melting of most metals into a weld pool. TIG welding
offers the user the greatest amount of flexibility to weld the widest
range of material and thickness and types. DC TIG welding is also the
cleanest weld with no sparks or spatter.
The intensity of the arc is proportional to the current that flows from the
tungsten. The welder regulates the welding current to adjust the power
of the arc. Typically thin material requires a less powerful arc with less
heat to melt the material so less current (amps) is required, thicker
material requires a more powerful arc with more heat so more current high
current
(amps) are necessary to melt the material.
HF ARC IGNITION for TIG (tungsten inert gas) Welding
HF (high frequency) ignition allows the arc to be started in Tig welding without touching the tungsten to the
work piece. By pressing the torch switch the machine will activate the gas flow and introduce the HF (high
frequency) (high voltage) spark, this “ionizes” the air gap making it conductive allowing an arc to be created
without touching the tungsten to the work piece. The gas molecules are superheated by the arc creating
a stream of super heated gas that changes the molecular structure into producing a plasma stream. This
plasma stream provides heat and energy that allows us to melt and fuse metals in an inert gas shielded
environment know as TIG (tungsten inert gas) welding.
gas flow
20
gas
molecules
. .
.... . ..
.. .. .
HF
plasma
stream
DC Pulse TIG Welding General Description
Pulse TIG welding is when the current output (amperage) changes between high and low current.
Electronics within the welding machine create the pulse cycle. Welding is done during the high-amperage
interval (this high amperage is referred to as peak current). During the low amperage period, the arc is
maintained but the current output of the arc is reduced (this low amperage is referred to as base current).
During pulse welding the weld pool cools during the low amperage period. This allows a lower overall heat
input into the base metal. It allows for controlled heating and cooling periods during welding providing better
control of heat input, weld penetration, operator control and weld appearance.
There are 4 variables within the pulse cycle:
Peak Current - Base Current - Pulse Frequency - Pulse Width
Setting and manipulation of these variables will determine the nature of the weld current output and is at the
discretion of the operator.
Peak Current is the main welding current (amps) set to melt the material being welded and works much the
same as setting maximum amperage values for regular DC TIG: as a guide use 30-40 amps for every 3/64”
of material thickness.
Base Current is the set level of background current (amps) which cools the weld puddle and affects overall
heat input. Background Amps is a percentage of peak amperage. As a rule, use enough background current to reduce the weld pool to about half its normal size while still keeping the weld pool fluid. As a guide
start by setting the background amperage at 20 to 30 percent of peak amperage.
Pulse Frequency is the control of the amount of times per second (Hz) that the welding current switches
from Peak Current to Base Current. DC Pulse TIG frequency generally ranges from 20 to 300 HZ
depending on the job application. Control of the pulse frequency also determines the appearance of the
weld.
Pulse Width is the control of the percentage of time during one pulsing cycle the power source spends at
the peak current (main amperage). Example is with the Pulse Width set at 80 percent and a rate of 1 pulse
per second (PPS), the machine will spend 80% of the pulse at peak amperage and 20% at the base current. Increasing the pulse width percentage adds more heat to the job, while decreasing pulse width percentage reduces heat
Current
peak
background
ON
OFF
Time
DC Pulse Tig welding allows faster welding speeds with better control of the heat input to the job, reducing
the heat input minimising distortion and warping of the work and is of particular advantage in the welding
of thin stainless steel and carbon steel applications. The high pulse frequency capability of the advanced
inverter agitates the weld puddle and allows you to move quickly without transferring too much heat to the
surrounding metal. Pulsing also constricts and focuses the arc thus increasing arc stability, penetration and
travel speeds.
high frequency
pulsing
no pulse
high frequency
pulsing
no pulse
21
EXAMPLE 1 OF PULSE DC TIG WELDING - SETUP PARAMETERS:
Material = Stainless Steel x 5*64” / Tungsten Electrode = 1/16” 2% Thoriated / Gas = Argon
The following steps are a guide as a starting point for you to set the machine up in Pulse mode to give an
example of welding in Pulse mode function. You can experiment by changing any of the variables to see
what effect it has over the welding and what the end result can be, but it is suggested to change only one
variable at a time and then check the welding to see what the result is, in this way you acquire a better
understanding of how each variable affects the welding current.
(1) (2) (3) (4) (5) Prepare the machine for DC TIG welding as per the DC HF TIG operating guide
Set the Peak Current at 110 Amps
Set the Base Current around 30% (Base Current is % of the Peak Current eg 30% of 110 = 33 Amps)
Set the Pulse Frequency around 2Hz (pulses per second)
Set the Pulse Width around 50% (the current will be 50% at Peak Current and 50% at Base Current)
Time = 1 second
Pulse Width
On
Time
Peak Current
Base
Current
110A
33A
110A
50%
33A
33A
50%
(2) Set the Peak Current at 110 Amps
(3) Set the Base Current at 30%
(5) Set the Pulse Width at 50%
(6) Set the Pulse Selector switch to Pulse
(4) Set the Pulse Frequency at 2 Hz
Example of Pulse vs Non Pulse weld finish
EXAMPLE 2 OF PULSE DC TIG WELDING - SETUP PARAMETERS:
Material = Mild Steel x 5/32”mm / Tungsten Electrode =3/32” 2% Thoriated / Gas = Argon
(1) (2) (3) (4) Set the Peak Current at 150 Amps
Set the Base Current around 20% (Base Current is % of the Peak Current eg 40% of 180 = 72 Amps)
Set the Pulse Frequency around 1Hz (pulse per second)
Set the Pulse Width around 80% (the current will spend 80% at Peak Current and 20% at Base Current)
Time = 1 second
Pulse Width
On
Time
Peak
Current
180A
Base
Current
72A
180A
180A
80%
72A
72A
20%
NOTE: Do not use a tugsten electrode that has been used on mild steel or stainless steel as it can
contaminate the welding material
22
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. However, some welds combining
thin materials can be accomplished without filler metal like edge, corner, and butt joints.
This is known as Fusion welding where the edges of the metal pieces are melted together using only the
heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until
a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired
size. Once the weld pool is established tilt the torch at about a 75° angle and move smoothly and evenly
along the joint while fusing the materials together.
75°
Travel direction
Form a weld pool
Angle torch
Move the torch slowly
and evenly forward
TIG Welding with Filler Wire Technique
It is necessary in many situations with TIG welding to add a filler wire into the weld
pool to build up weld reinforcement and create a strong weld. Once the arc is started
the torch tungsten is held in place until a weld pool is created, a circular movement
of the tungsten will assist is creating a weld pool of the desired size. Once the weld
pool is established tilt the torch at about a 75° angle and move smoothly and
evenly along the joint. The filler metal is introduced to the leading edge of the
weld pool. The filler wire is usually held at about a 15° angle and fed into the
leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is
moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the
wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly
and evenly forward. It is important during the welding to keep the molten end of the filler wire inside
the gas shield as this protects the end of the wire from being oxidised and contaminating the weld
pool.
75°
Travel direction
Form a weld pool
15°
Angle torch
Add Tig filler wire
gas
shield
Retract the filler wire
Move the torch forward to
the front of the weld pool
Repeat the process
23
Set up and operation for AC TIG Welding - KUMJR200AAC/DC
(1) Turn on the machine using the ON/OFF swicth
(2) Select the TIG function with the TIG/MMA selector switch.
(3) Select AC using the AC/DC selector switch.
(4) Connect the Tig Torch connector to the negative terminal and tighten it.
(5) Connect the Earth Cable connector into the positive terminal and tighten it.
(6) Connect the torch switch remote lead into the torch remote socket
(7) Insert the torch gas connector into the quick lock gas receptacle.
(8) Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder.
Carefully open the valve of the gas cylinder, set the flow to 15-25 CFH
(8) Connect the regulator to the
cylinder, Connect the gas lead
to the regulator. Set the flow to
15-25CFH
(1) Turn on the machine using the
ON/OFF switch
(2) Select TIG using the TIG/MMA
selector switch
(3) Select AC using the
AC/DC selector switch
(7) Insert the torch gas connector into
the quick lock gas receptacle.
(4) Connect the TIG torch connector
to the
terminal.
(5) Connect the Earth cable
connector to the
terminal
(6) Connect the torch switch lead
to the torch remote receptacle
24
continued - Set up and operation for AC TIG Welding - KUMJR200AAC/DC
AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminium, Aluminium Alloys and
Magnesium. These materials have an insulating surface oxide layer that melts at a higher temperature than
the base metal making it difficult to weld the base metal if the oxides are not removed. AC welding current
is ideal because the nature of the AC wave form assists in breaking the surface oxide layer. HF arc
ignition provides easy and precise starting of the arc,
(9) Assemble the front end torch parts using the correct size and type of tungsten electrode for the job.
(10) Choose 2T or 4T trigger function preferred as per the descriptions below
2T Selection provides 2 times function of the torch switch.
(1) Pressing the torch switch gives arc ignition and initializes the welding current and the welding
current is maintained by the torch remaining on.
(2) Releasing the torch switch stops the welding by introducing down slope and the current falls to
minimum level and then terminates the welding current and introduces the post flow gas.
4T Selection provides 4 times function of the torch switch
(1) Pressing the torch switch gives arc ignition and initializes the welding current
(2) Releasing the torch switch continues the welding operation.
(3) Pressing the torch switch and holding introduces down slope and current falls to minimum current.
(4) Releasing the torch switch terminates the welding operation and introduces the post flow gas.
(11) Choose the preferred welding current (amperage) to suit the tungsten size material type and
thickness to be welded.
(12) Set the AC Balance control to approximately 25%
(13) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 3/64”- 1/8” from the work piece this method will provide a clean positive arc ignition.
(14) Press the torch switch and the arc will ignite across the gap between the tungsten and work piece.
Hold even distance of about 2mm gap between the tungsten and work piece to maintain the arc.
(9) Assemble the front end torch parts usimg
thecorrect size and type of tungsten electrode
for the job, the tungsten electrode does not
require a sharpened point for AC welding
(12) Set the AC Balance Control to 25%
(10) Select 2T or 4T trigger function as required
(13) Lay the outside edge of the Gas Cup on
the work piece with the Tungsten
Electrode 3/64”- 1/8” from the work piece
(11) Set the Peak Current (amps) to suit the
tungsten size material type and thickness
to be welded.
(14) Press the torch switch and the arc will ignite
across the gap between the tungsten and
work piece. Hold even distance of about
2mm gap between the tungsten and work
piece to maintain the arc.
25
AC Welding
AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminium, Magnesium and Aluminium Alloys. These materials have an insulating surface oxide layer that melts at a higher temperature than
the base metal making it difficult to weld the base metal if the oxides are not removed. AC welding current
is ideal because the nature of the AC wave form assists in breaking the surface oxide layer.
AC (alternating current) has a current cycle that flows from + (direct) polarity to - (reverse) polarity.
The reversing of the polarity breaks the surface oxide while the direct polarity melts the base material.
current
direct polarity
reverse polarity
There are inherent problems that come with AC TIG arc rectification, arc stutter, arc wandering and arc
stoppage. These problems typically occur during the transition between + and - cycles.
The current is less (30%) during the half of the cycle when the electrode is positive and there is a resistance of the electron flow during this half cycle (rectification). The lack of current flow during this half cycle
makes the AC arc unstable.
current
direct polarity
30%
30%
reverse polarity
To overcome this lack of flow during one half of the cycle, a high-frequency (HF) voltage is generated and
fed into the welding circuit. The HF maintains the arc stability during the half cycle when the electrode is
positive.
UNBALANCED WAVE FORM
+
_
HF
current
direct polarity
30%
30%
reverse polarity
High-frequency voltage flows continually in the welding circuit and keeps the shielding arc in the welding
area in an ionized state. When the arc is ionized the arc is maintained during the half of the cycle when the
electrode is positive. However while the arc is maintained less current flows during this half of the AC cycle,
producing an unbalanced wave.
26
In older machines, a balanced current output wave was achieved using a large number of capacitors in
series or a battery in the welding circuit. Modern TIG power sources use electronics to create and maintain
a balanced wave and now most AC TIG power sources produce a square wave current output.
direct polarity
current
reverse polarity
A square wave power supply can change the current from electrode + positive to electrode - negative very
quickly. This produces high voltage as the current switches polarities allowing the arc to restart easily. The
arc can be maintained without the use of high-frequency or any other arc stabilising methods.
EVEN BALANCE
LESS POSITIVE
BALANCE
MORE POSITIVE
BALANCE
BALANCED
SQUARE WAVE FORM
direct polarity
current
Even Penetration - Stable Arc
reverse polarity
More Penetration - Faster Welding
More Electrode Capacity
Less Penetration - Oxide Cleaning
Less Electrode Capacity
The output current and voltage are controlled electronically so the amount of current electrode positive and
the amount of current electrode negative can be adjusted. This allows the welder to adjust the amount of
cleaning and the amount of penetration. This is achieved electronically by adjusting the balance control dial
on the welding machine. More current flow from the + direct polarity produces stronger arc energy and current flow from the tungsten and is good for removing the oxidized surface of the work piece. However too
much + current flow can drive too much energy to the tungsten causing it to overheat and melt the tungsten
electrode.
LESS POSITIVE
BALANCE
MORE POSITIVE
BALANCE
Balance Adjusted for More Penetration - Cooler Tungsten
25%
direct polarity
current
Arc
More Penetration - Faster Welding
More Electrode Capacity
MORE POSITIVE
BALANCE
reverse polarity
Less Penetration - Oxide Cleaning
Less Electrode Capacity
Balance Adjusted for More Oxide Cleansing Action - Hotter Tungsten
25%
current
direct polarity
reverse polarity
Less Penetration - Oxide Cleaning
Less Electrode Capacity
27
EXAMPLE 1: PULSE AC TIG WELDING - SETUP PARAMETERS:
Material = Aluminium x 1/8” / Tungsten Electrode = 3/32” Zirconiated / Gas = Argon
The following steps are a guide as a starting point for you to set the machine up in AC Pulse mode to give
an example of welding in AC Pulse TIG function. You can experiment by changing any of the variables to
see what effect it has over the welding and what the end result can be, but it is suggested to change only
one variable at a time and then check the welding to see what the result is, in this way you acquire a better
understanding of how each variable affects the welding current.
(1) (2) (3) (4) (5) Prepare the machine for AC TIG welding as per the AC TIG operating guide
Set the Peak Current at 150 Amps
Set the Base Current around 40% (Base Current is % of the Peak Current eg 40% of 150 = 60 Amps)
Set the Pulse Frequency around 1Hz (pulses per second)
Set the Pulse Width around 60% (the current will spend 60% at Peak Current & 40% at Base Current)
Time = 1 second
Pulse Width
On
Time
Peak
Current
150A
Base
Current
150A
60A
28
150A
60%
60A
60A
40%
(2) Set the Peak Current at 110 Amps
(3) Set the Base Current at 30%
(4) Set the Pulse Frequency at 2 Hz
(5) Set the Pulse Width at 50%
(6) Set the Pulse Selector switch to Pulse
Example of Pulsed weld finish
Remote Amperage Controls - Installation and Operation
Remote amperage controls allow for the welding current to adjusted remotely from the welding machine
during welding. Generally there several types of remote amperage control available;
(1) Hand amperage control located in the torch handle allowing the operator to adjust the welding current
by rolling the potentiometer wheel to increase or decrease the amount of amperage desired.
(2) Foot amperage control that is a foot pedal that allows the operator to adjust the welding current by
depressing the pedal to increase the amperage desired and releasing the pedal to decrease.
(3) Box amperage control that is small box housing a potentiometer with a knob that the operator can
adjust the welding current turning the knob to increase or decrease the amount of amperage desired.
Type: SRMS-10
Type: UTJRFC
foot amperage
adjustment
amperage
adjustment
on/off
switch
hand amperage
adjustment
Connection and operation of the remote hand control
(1) Place the remote selector switch on
the front panel of machine in the remote
position. This bypasses the current
control on the machine giving the current
control to the remote control.
(2) Connect the remote control 7 pin
plug from the Tig Torch switch lead to
the 7 pin remote receptacle on the front
panel of the machine.
(3) Press the switch to activate the machine.
Rotate the amp control potentiometer to
select the desired welding current.
Connection and operation of the remote foot control
(1) Place the remote selector switch on
the front panel of machine in the remote
position. This bypasses the current
control on the machine giving the current
control to the remote control.
(2) Connect the remote control 7 pin
plug from the Tig Torch switch lead to
the 7 pin remote receptacle on the front
panel of the machine.
(3) Set the dial on the foot control to the
desired setting eg - Max = Maximum current
output, 50% = 50% of the maximum current
output of the machine. Depress the foot pedal
to activate the machine, further depressing
the pedal will increase the current level to the
maximum set by the dial on the foot control.
29
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. Choosing the correct tungsten depends on the material being
welded, the amount of amps required and whether you are using AC or DC welding current.
Tungsten electrodes are colour-coded at the end for easy identification.
Below are the most commonly used tungsten electrodes.
Thoriated
Thoriated tungsten electrodes (AWS classification EWTh-2) contain a minimum of 97.30 percent tungsten and 1.70
to 2.20 percent thorium and are called 2 percent thoriated. They are the most commonly used electrodes today and
are preferred for their longevity and ease of use. Thorium increases the electron emission qualities of the electrode,
which improves arc starts and allows for a higher current-carrying capacity. This electrode operates far below its
melting temperature, which results in a considerably lower rate of consumption and eliminates arc wandering for
greater stability. Compared with other electrodes, thoriated electrodes deposit less tungsten into the weld puddle, so
they cause less weld contamination.
Thorium however is a low-level radioactive hazard and many users have switched to other alternatives.
Regarding the radioactivity, thorium is an alpha emitter but when it is enclosed in a tungsten matrix the risks are
negligible. Thus holding a stick of Thoriated tungsten in your hand should not pose a great threat unless a welder has
open cuts on their skin. Thoriated tungsten should not get in contact with open cuts or wounds. The more significant
danger to welders can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours
during welding or from ingestion of material/dust in the grinding of the tungsten. Follow the manufacturer’s warnings,
instructions, and the Material Safety Data Sheet (MSDS) for its use.
Ceriated (Color Code: Orange)
Ceriated tungsten electrodes (AWS classification EWCe-2) contain a minimum of 97.30 percent tungsten and 1.80 to
2.20 percent cerium and are referred to as 2 percent ceriated. Ceriated tungstens perform best in DC welding at low
current settings. They have excellent arc starts at low amperages and become popular in such applications as orbital
tube welding, thin sheet metal work. They are best used to weld carbon steel, stainless steel, nickel alloys, and
titanium, and in some cases it can replace 2 percent thoriated electrodes. Ceriated tungsten is best suited for lower
amperages it should last longer than Thoriated tungsten higher amperage applications are best left to Thoriated or
Lanthanated tungsten.
Lanthanated (Color Code: Gold)
Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of 97.80 percent tungsten and
1.30 percent to 1.70 percent lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent
arc starting, a low burn off rate, good arc stability, and excellent re-ignition characteristics. Lanthanated tungstens
also share the conductivity characteristics of 2 percent thoriated tungsten. Lanthanated tungsten electrodes are ideal
if you want to optimise your welding capabilities. They work well on AC or DC electrode negative with a pointed end,
or they can be balled for use with AC sine wave power sources. Lanthanated tungsten maintains a sharpened point
well, which is an advantage for welding steel and stainless steel on DC or AC from square wave power sources.
Zirconiated (Color Code: White)
Zirconiated tungsten electrodes (AWS classification EWZr-1) contain a minimum of 99.10 percent tungsten and 0.15
to 0.40 percent zirconium. Most commonly used for AC welding Zirconiated tungsten produces a very stable arc and
is resistant to tungsten spitting. It is ideal for AC welding because it retains a balled tip and has a high resistance to
contamination. Its current-carrying capacity is equal to or greater than that of thoriated tungsten. Zirconiated tungsten
is not recommended for DC welding.
Tungsten Electrodes Rating for Welding Currents
Tungsten
Diameter
mm
3/64” (0.040”)
1/16” (.062” & .060”)
3/32” (.93”)
1/8” (.125”)
5/32” (.156”)
30
DC Current Amps
Torch Negative
2% Thoriated
AC Current Amps
Un-Balanced Wave
0.8% Zirconiated
AC Current Amps
Balanced Wave
0.8% Zirconiated
15 - 80
70 -150
150- 250
250 - 400
400 - 500
15 - 80
70 - 150
140 - 235
225 - 325
300 - 400
20 - 60
60 - 120
100 - 180
160 - 250
200 - 320
Tungsten Preparation
Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a
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.
Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel. Tungsten electrodes are
manufactured with the molecular structure of the grain running lengthwise and thus grinding crosswise is “grinding
against the grain.” If electrodes are ground crosswise, the electrons have to jump across the grinding marks and the
arc can start before the tip and wander. Grinding longitudinally with the grain, the electrons flow steadily and easily to
the end of the tungsten tip. The arc starts straight and remains narrow, concentrated, and stable.
grind longitudinal on the
grinding wheel
don’t grind across
the grinding wheel
Electrode Tip/Flat
The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection
of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur
and the more difficult it will be to arc start. However, increasing the flat to the maximum level that still allows arc start
and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders still grind
electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from
melting at the tip and the possibility of the point falling off into the weld pool.
2.5 times tungsten diameter
pointed tip
flat tip
Electrode Included Angle/Taper - DC Welding
Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a
specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and
offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide
the following benefits:
• Last Longer
flat spot diameter
• Have better weld penetration
• Have a narrower arc shape
• Can handle more amperage without eroding.
included angle
Sharper electrodes with smaller included angle provide:
• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration
increases and bead width decreases.
Tungsten
Diameter
Diameter at
the Tip - mm
Constant Included
Angle - Degrees
Current Range
Amps
Current Range
Pulsed Amps
3/64” (0.040”)
1/16” (.062” & .060”)
1/16” (.062” & .060”)
3/32” (.93”)
3/32” (.93”)
1/8” (.125”)
1/8” (.125”)
.250
.500
.800
.800
1.100
1.100
1.500
20
25
30
35
45
60
90
05 - 30
08 - 50
10 - 70
12 - 90
15 - 150
20 - 200
25 - 250
05 - 60
05 - 100
10 - 140
12 - 180
15 - 250
20 - 300
25 - 350
31
Tungsten preparation AC Welding
To obtain full current capacity from a pure or zirconiated tungsten electrode when used with AC current output the
electrode is not ground to a point. The welding during positive polarity melts the point of the tungsten that becomes
rounded. The ball shape formed at the end of the tungsten is desirable because it reduces current rectification and
allows the arc to flow more easily.
balled tip
Arc shape from balled
tungsten AC welding
Safety with tungsten electrodes
Arc shape from ground
pointed tungsten DC
welding
Tungsten welding electrodes should never be manually ground on an abrasive belt or wheel (particularly silicone
carbide). Always use diamond wheels when grinding and cutting tungstens. The risk of injury when hand (manually)
grinding a very hard brittle material like tungsten is quite high. It is important to always follow standard safety guidelines when operating high speed grinding equipment.
• Wear approved safety glasses
• No loose clothing which may get caught in moving parts
• Wear protective hair covering to contain long hair
• Wear safety shoes with non-slip sole
• A vacuum system is recommended to remove tungsten, especially thorium dust
• Never operate power tools when tired, intoxicated or when taking medication that causes drowsiness
The most common injuries to the manual tungsten electrode grinder are eye and finger related. Holding and grinding
the tungsten electrode by hand has resulted in burned fingers, laceration to fingers and splintered tungsten electrodes
in hand or fingers. Eye injury generally occurs from manually grinding tungsten electrodes without a safety shield or
safety glasses. Small slivers of tungsten electrode may become stuck in the operator’s eye.
32
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. Check all cable connections.
Wrong mode selected
Check the MMA selector switch is selected
No power supply
Check that the machine is switched on and has a power supply
Possible Reason
Suggested Remedy
Arc length too long
Check that pure Argon is being used
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Damp electrodes
Use only dry electrodes
Possible Reason
Suggested Remedy
Amperage too high
Decrease the amperage or choose a larger electrode
Arc length too long
Shorten the arc length
2: Porosity − small cavities or holes resulting from gas pockets in weld metal.
3: Excessive Spatter
3: Weld sits on top, lack of fusion
Possible Reason
Suggested Remedy
Insufficient heat input
Increase the amperage or choose a larger electrode
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
4: Lack of penetration
Possible Reason
Suggested Remedy
Insufficient heat input
Increase the amperage or choose a larger electrode
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation
Check the joint design and fit up, make sure the material is not too thick.
Seek assistance for the correct joint design and fit up
5: Excessive penetration - burn through
Possible Reason
Suggested Remedy
Excessive heat input
Reduce the amperage or use a smaller electrode
Incorrect travel speed
Try increasing the weld travl speed
Possible Reason
Suggested Remedy
Unsteady hand, wavering hand
Use two hands where possible to steady up, practise your technique
Possible Reason
Suggested Remedy
Excessive heat input
Reduce the amperage or use a smaller electrode
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation and or joint
design
Check the joint design and fit up, make sure the material is not too thick.
Seek assistance for the correct joint design and fit up
6: Uneven weld appearance
7: Distortion − movement of base metal during welding
7: Electrode welds with different or unusual arc characteristic
Possible Reason
Suggested Remedy
Incorrect polarity
Change the polarity, check the electrode manufacturer for correct polarity
33
TIG WELDING TROUBLE SHOOTING
The following chart addresses some of the common problems of 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
No gas
Check the gas cylinder contains gas and is connected
Inadequate gas flow
Check the gas is connected, check hoses, gas valve and torch are not restricted. Set
the gas flow between 20 - 35 CFH flow rate
Back cap not fitted correctly
Make sure the torch back cap is fitted so that the o-ring is inside the torch body
Torch connected to DC +
Connect the torch to the DC- output terminal
Incorrect tungsten being used
Check and change the tungsten type if necessary
Tungsten being oxidised after weld
is finished
Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10
amps of weld current.
Tungsten melting back into the
nozzle on AC welding
Check that correct type of tungsten is being used. Check the balance control is not set
too high on the balance - reduce to a lower setting
2: Contaminated tungsten
Possible Reason
Suggested Remedy
Touching tungsten into the weld
pool
Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of
the work piece 5/64” - 13/64”
Touching the filler wire to the tungsten
Keep the filler wire from touching the tungsten during welding, feed the filler wire into the
leading edge of the weld pool in front of the tungsten
Tungsten melting into the weld pool
Check that correct type of tungsten is being used. Too much current for the tungsten
size so reduce the amps or change to a larger tungsten
3: Porosity - poor weld appearance and colour
Possible Reason
Suggested Remedy
Incorrect Gas
Check that pure Argon is being used
Inadequate gas flow / gas leaks
Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the
gas flow between 20 - 35 CFH flow rate. Check hoses and fittings for holes, leaks etc.,
Moisture on the base metal
Remove all moisture from base metal before welding
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Contaminated filler wire
Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire
Check the filler wire and change if necessary
4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten
Possible Reason
Suggested Remedy
Incorrect Gas
Use pure Argon gas
Inadequate gas flow
Set the gas flow between 20 - 35 CFH flow rate
Inadequate post flow gas
Increase the post flow gas time
Alumina gas nozzle too small for size Increase the size of the alumina gas nozzle
of tungsten being used
5: Unstable Arc during DC welding
Possible Reason
Suggested Remedy
Torch connected to DC +
Connect the torch to the DC- output terminal
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long
Lower torch so that the tungsten is off of the work piece 5/64” - 13/64”
Incorrect gas or inadequate gas flow
Check that pure Argon is being used. Check the gas is connected, check hoses, gas
valve and torch are not restricted. Set the gas flow between 20 - 35 CFH flow rate flow
rate
Incorrect tungsten being used
Check and change the tungsten type if necessary
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Improperly prepared tungsten
Use a pointed tungsten with AC Squarewave inverter machines. The point will round off
after welding.
Excessive rectification in the base
metal
Increase balance control. Increase travel speed. Add filler wire during welding
Unstable Arc during AC welding
34
6: HF present but no welding power
Possible Reason
Suggested Remedy
Incomplete welding circuit
Check earth lead is connected. Check all cable connections. If using a water cooled
torch check that the power cable is not separated.
No gas
Check the gas is connected and cylinder valve open, check hoses, gas valve and torch
are not restricted. Set the gas flow between 20 - 35 CFH flow rate
Tungsten melting into the weld pool
Check that correct type of tungsten is being used. Too much current for the tungsten
size so reduce the amps or change to a larger tungsten
7: Arc wanders during DC welding
Possible Reason
Suggested Remedy
Poor gas flow
Check and set the gas flow between 20 - 35 CFH flow rate
Incorrect arc length
Lower torch so that the tungsten is off of the work piece 5/64” - 13/64”
Tungsten incorrect or in poor condition
Check that correct type of tungsten is being used. Remove 10mm from the weld end of
the tungsten and re sharpen the tungsten
Poorly prepared tungsten
Grind marks should run lengthwise with tungsten, not circular. Use proper grinding
method and wheel.
Contaminated base metal
Remove contaminating materials like paint, grease, oil, and dirt, including mill scale from
base metal.
Contaminated filler wire
Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire
Check the filler wire and change if necessary
Possible Reason
Suggested Remedy
Inadequate gas flow
Set the gas flow between 20 - 35 CFH flow rate
Incorrect arc length
Set the torch so that the tungsten is off of the work piece 5/64” - 13/64”
Tungsten is contaminated
Remove 25/64” of contaminated tungsten and re grind the tungsten. Use a pointed
tungsten with AC Squarewave and inverter machines. The point will round off after
welding
Incorrect tungsten size and or tungsten being used
Check and change the size and or the tungsten if required
Excessive rectification in the base
metal
Increase balance control. Increase travel speed. Add filler wire during welding
Contaminated base metal
Remove contaminating materials like paint, grease, oil, and dirt, including mill scale from
base metal.
Arc wanders during AC welding
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. Set the gas flow between 20 - 35 CFH flow rate flow rate
Tungsten is contaminated
Remove 25/64” of contaminated tungsten and re grind the tungsten
Incorrect tungsten size and or tungsten being used
Check and change the size and or the tungsten if required
Loose connection
Check all connectors and tighten
Earth clamp not connected to work
Connect the earth clamp directly to the work piece wherever possible
Loss of high frequency
Check torch and cables for cracked insulation or bad connections. Check spark gaps
and adjust if necessary
Arc difficult to start or will not start AC welding
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. Set the gas flow between 20 - 35 CFH flow rate flow rate
Incorrect tungsten size and or tungsten being used
Check and change the size and or the tungsten if requir
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten. Use a pointed tungsten with AC Squarewave and inverter machines. The point will round off after welding
Loose connection
Check all connectors and tighten
Earth clamp not connected to work
Connect the earth clamp directly to the work piece wherever possible
Loss of high frequency
Check torch and cables for cracked insulation or bad connections. Check spark gaps
and adjust if necessary
SR26 ERGO TIG TORCH
5
8
3
2
180A AIR COOLED TIG WELDING TORCH
Rating:180Amp DC, 125Amp AC @35% duty cycle.
4
6
7
s
serie
ens
as L
s
s
erie
ns s
e
as L
serie
s
serie
dard
ries
s se
Len
by G
eG
Larg
Gas
Stan
by
Stub
b
Stu
9
10
11
13
12
20
*
Wear Parts Identification Next Page
16
17
14
15
7
18
19
Torch Model
Description
Part Number
13FT
SR26 Pro-Grip Lite Tig Torch Package c/w QF Gas Connect
SR-26-13FTCP50
Spare Parts
Part Number
Description
Part Number
Description
1
2
3
4
5
6
7
8
9
10
11
WP26
WP26F
57Y02
57Y03
57Y04
UER1MS
UERSWL4
UERSWL8
UERSP1
UERH200
UERKJ200
UERLC200-08
UERJK200
Torch head
Torch head flexible
Back cap long
Medium back cap
Short back cap
Momentary Kit
Trigger Lead 12.5ft
Trigger Lead 25ft
Screw Pack
Large Ergo Tig Handle
Large Knuckle Joint
Leather Cover X 0.8mt / 2ft
Jointing Repair Kit
12
13
14
15
16
17
18
19
20
UERNCL-32
UERNCL-72
UERCO200-40
UERCO200-80
USLH26-S USLH26-H
USLH26-C
USL46V28AR
USL46V30AR
USL3550
USL-1-GS4
10004667
Neoprene Cover X 3.2mt / 10ft
Neoprene Cover X 7.2mt / 23ft
Sheath X 12.5ft Inc Leather Cover
Sheath X 25ft Inc Leather Cover
Cable Support Large
“Surelok “ Housing Large
“Surelok “ Housing Cover
Power Cable X 12.5ft “Surelok “ Rubber
Power Cable X 25ft “Surelok “ Rubber
“Surelok “ Body & Support
Gas Supply Hose
7 Pin Plug
©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means,
electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.
Standard Front End Parts
SR26 ERGO TIG TORCH
Part #
18CG
Description
Cup Gasket
Part #
10N30
10N31
10N32
10N28
Part #
10N22
10N23
10N24
10N25
Description
Collet Body 1.0mm / 0.040”
Collet Body 1.6mm / (1/16)
Collet Body 2.4mm / (3/32)
Collet Body 3.2mm / (1/8)
Description
Collet 1.0mm / 0.040”
Collet 1.6mm / ((1/6)
Collet 2.4mm / (3/32)
Collet 3.2mm / (1/8)
Part #
10N50
10N49
10N48
10N47
10N46
10N45
10N44
Part #
10N49L
53N48L
53N47L
Description
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Description
Long Alumina Nozzle Ø8mm / (5/16) #5L
Long Alumina Nozzle Ø 10mm / (25/64)#6L
Long Alumina Nozzle Ø 11mm / (7/16) #7L
Ø 6mm / (15/64) Ø 8mm / (5/16)
Ø 10mm / (25/64)
Ø 11mm / (7/16)
Ø 13mm / (33/64)
Ø 16mm / (5/8)
Ø 19mm / (3/4)
#4
#5
#6
#7
#8
#10
#12
Compact Gas Lens Front End Parts
Part #
54N01
Description
Gas Lens Gasket
Part #
45V25
45V26
45V27
Description
Gas Lens Body 1.6mm / (1/16)
Gas Lens Body 2.4mm / (3/32)
Gas Lens Body 3.2mm /(1/8)
Part #
54N14
54N15
54N17
Description
Gas lens ceramic 8.0mm / (5/16)
Gas lens ceramic 7.0mm / (9/32)
Gas lens ceramic 5.0mm / (13/64)
TR0004-16
RED
ANSI/AWS A5.12-98
ISO 6848 WT20
2% Thoriated: Best stability
at medium currents, good arc
starts, medium tendency to spit,
medium erosion rate.
Commonly used for steel and
stainless steel applications
Part #
TR0004-10
TR0004-16
TR0004-24
TR0004-32
Description
1.0mm x 175mm
1.6mm x 175mm
2.4mm x 175mm
3.2mm x 175mm
/
/
/
/
0.040” x 6 57/64” thoriated tungsten electrode 2%
(1/16) x 6 57/64” thoriated tungsten electrode 2%
(3/32) x 6 57/64” thoriated tungsten electrode 2%
(1/8) x 6 57/64” thoriated tungsten electrode 2%
1/16 x 7” (1.6mm x 175mm)
3/32 x 7” (2.4mm x 175mm)
1/8 x 7” (3.2mm x 175mm)
TR0006-16
WHITE
ANSI/AWS A5.12 M-98
ISO 6848 WZ8
.8% Zirconiated: Balls well, handles
higher current with less spitting, better
arc starts and arc stability than pure
tungsten
Commonly used for
aluminium applications
Part #
TR0006-10
TR0006-16
TR0006-24
TR0006-32
Description
1.0mm x 175mm
1.6mm x 175mm
2.4mm x 175mm
3.2mm x 175mm
/
/
/
/
0.040” x 6 57/64” zirconiated tungsten electrode 1%
(1/16) x 6 57/64” zirconiated tungsten electrode 1%
(3/32) x 6 57/64” zirconiated tungsten electrode 1%
(1/8) x 6 57/64” zirconiated tungsten electrode 1%
1/16 x 7” (1.6mm x 175mm)
3/32 x 7” (2.4mm x 175mm)
1/8 x 7” (3.2mm x 175mm)
©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means,
electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.
37
Spare Parts Identification
1
18
2
19
15
3
4
5
6
7
8
16
21
20
17
9
10
11 12 13 14
24
23
22
25
32
26
27 28
29
30
31
34
35
38
36
33
37 38
39
40
Spare Parts Identification
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Part Number J10A10
D20006
C16017
B22310
B22329
B22311
B22330
B22328
C02066
J24011
J21009
C04022
C04023
C04045
C14021
P00706
C02066
J24020
J06260
C13010
J21050
B04045
B01160
D28078
B06051
B10361
B08003-1
B06036
B02044
B03308
B06197
B17011
B16060
B04290
D16212
B05003
B16061
D03955
B07010
D01532
Description
Front Plastic Panel Digital Display Meter
On/Off Switch
Remote Control Selector Switch
2T/4T Trigger Selector Switch
Tig/MMA Selector Switch
AC/DC Selector Switch
Pulse Mode Selector Switch
Panel Socket 35-50
Rubber Foot
Gas Connector Quick Fit - Female Panel Mount
2 Pin Connector - Female Panel Mount
5 Pin Connector - Female Panel Mount
7 Pin Connector - Female Panel Mount
Knob
Front Panel Adhesive Sticker
Panel Socket 35-50
Handle
Rear Plastic Panel
Cable Support Assembly
Gas Connector Quick Fit - Female Panel Mount
Low Voltage - Long Strip PCB
Top PCB
Fan
Power Transfer PCB
Gas Solenoid
Bridge Rectifier
Protection (EMC) PCB
Middle PCB
Bottom PCB
ACDC Series Hand Switch PCB
Arc Strike Coil
ACDC200P Secondary Inverter PCB (B)
Control PCB
Reactor
AC Driver PCB
ACDC200P Secondary Inverter PCB (A)
Transformer
Industrial FrequencyTransformer
Glaze Resistor
39
25503 74th Ave S Kent WA 98032 USA
Phone: +1 253-859-6277
+1 253-859-6278
FAX:
+1 253-859-6286
EMAIL: [email protected]
[email protected]
™
Razorweld
™
JASIC Technologies America Inc
WARRANTY
JASIC Technologies America Inc (‘Us’, ‘We’) warrants that the following products under RAZORWELD supplied by Us
and purchased by you from an Authorised RAZORWELD Dealer throughout the U.S.A & Canada are free of Material
and Faulty Workmanship defects except for those products listed under ‘Warranty Exclusions’.
These terms and conditions supersede and exclude all former and other representations and arrangements relating
to any warranties on these products.
WARRANTY PERIOD
We offer the following ‘Warranty Periods’ from ‘date of purchase’:
An Extended Warranty Period of 6 months total shall apply only to Machinery where offered and warranty
is registered online.
RAZORWELD WELDING MACHINES
RAZORWELD DIY Series (Power Source Only)
3 Years
RAZORWELD JASIC Inverter MIG (Power Source Only)
3 Years
RAZORWELD JASIC Inverter MIG SWF (Power Source / Separate Wire Feeder Only) 3 Years
RAZORWELD JASIC Inverter TIG (Power Source Only)
3 Years
RAZORWELD Water Cooler
1 Year
RAZORWELD JASIC Series (Power Source Only)
3 Years
UNI-FLAME Regulators Argon/ Acetylene / Oxygen / LPG / Bobbin Flowmeter
1 Year
UNI-FLAME Automatic Welding Helmet
2 Years
RAZORWELD Automatic Welding Helmets
2 Years
TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,
INTERCONNECTING CABLES, GAS HOSE
3 Months
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3
(Clause 3)
(Clause 3)
(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB,
and all other components.
(Clause 2) Gas Hose, Flashbacks are subject to and covered by the Manufacturer’s Individual Warranty, Contact
the manufacturer for details
(Clause 3) This only Covers Manufactures defaults on all accessories for the first three months after date of
purchase.
• SELLER MAKES NO WARRANTIES EXPRESSED OR IMPLIED, INCLUDING BUT NOT BY WAY OF LIMITATION,
ANY IMPLIED WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE, ON ANY ORDER EXCEPT THAT SELLER WARRANTS TITLE TO ALL GOODS FURNISHED
BY SELLER AND EXCEPT THAT SELLER WARRANTS FOR A PERIOD OF ONE YEAR FROM THE DATE MARK
LOCATED ON THE SELLER’S IDENTIFICATION TAG THAT ALL GOODS DESCRIBED ON SELLER’S
ACKNOWLEDGMENT OF PURCHASER’S PURCHASE ORDER WILL BE MANUFACTURED IN ACCORDANCE WITH
THE SPECIFICATIONS, IF ANY, SET FORTH IN SAID PURCHASE ORDER AND EXPRESSLY ACCEPTED IN
SELLER’S ACKNOWLEDGMENT SUBJECT TO SELLER’S STANDARD MANUFACTURING VARIATIONS AND
PRACTICES. IN THE CASE OF COMPONENTS OR ACCESSORIES FURNISHED BY SUPPLIERS TO SELLER,
PURCHASER’S WARRANTY FROM SELLER SHALL BE LIMITED TO THE WARRANTY OF THE COMPONENT OR
ACCESSORY SUPPLIER. THE FOREGOING WARRANTIES ARE THE SOLE AND EXCLUSIVE WARRANTIES
APPLICABLE TO THE GOODS DELIVERED, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY, ARE HEREBY EXPRESSLY DISCLAIMED AND
NEGATED. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, PURCHASER ACKNOWLEDGES THAT
SELLER’S PRODUCTS ARE NOT PACKAGED OR PROTECTED FOR LONG PERIODS OF STORAGE AND THUS
MAY CORRODE OR RUST OVER TIME..
40
WARRANTY / RETURNS / EXCHANGES
We understand that sometimes a product may need to be returned. If you have purchased from the RAZORWELD
Authorised Dealer Network, to assist you in following the correct procedure enclosed is the 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. You are also entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure.
• You shall inspect the Goods on delivery and shall within seven (7) days of delivery (time being of the essence) notify
JASIC Technologies America Inc of any alleged defect, shortage in quantity, damage or failure to comply with the
description or quote.
• You shall also afford JASIC Technologies America Inc the opportunity to inspect the Goods within a reasonable
time following delivery if you believe the Goods are defective in any way.
• If you shall fail to comply with these provisions the Goods shall be presumed to be free from any defect or damage.
For defective Goods, Which JASIC Technologies America Inc has agreed in writing that you are entitled to reject,
JASIC Technologies America Inc ‘s liability is limited to, at the discretion of JASIC Technologies America Inc
either replacing the Goods or repairing the Goods except where you have acquired Goods as a consumer within the
meaning of the relevant State legislation and trade act policies and is therefore also entitled to, at the consumer’s
discretion either a refund of the purchase price of the Goods, or repair of the Goods, or replacement of the Goods.
Returns will only be accepted provided that:
(a) You have complied with the provisions outlined above, and
(b) where the Goods are unable to be repaired, the Goods are returned at your cost within thirty (30) days of the
delivery date, and
(c) JASIC Technologies America inc will not be liable for Goods which have not been stored or used in a proper
manner, and
(d) the Goods are returned in the condition in which they were delivered and with all packaging material, brochures
and instruction material in as new condition as is reasonably possible in the circumstances.
• JASIC Technologies America Inc Accepts no responsibility for products lost, damaged or mislaid whilst in transit
• JASIC Technologies America Inc may (at their sole discretion) accept the return of Goods for credit but this may
incur a handling fee of up to fifteen percent (15%) of the value of the returned Goods plus any freight costs.
• Where a failure does not amount to a major failure, JASIC Technologies America Inc is entitled to choose
between providing you with a repair, replacement or other suitable remedy.
PURCHASER’S REMEDIES :
WITH RESPECT TO ANY CLAIM ARISING OUT OF ANY ORDER, ANY GOODS DELIVERED PURSUANT TO ANY
ORDER AND EXPRESSLY ACCEPTED IN SELLER’S ACKNOWLEDGMENT, OR SELLER’S PERFORMANCE IN
CONNECTION WITH ANY ORDER, INCLUDING, WITHOUT LIMITATION, ANY CLAIM ARISING OUT OF ANY
RECALL, DEFECT OR ALLEGED DEFECT IN ANY GOODS OR SERVICES FURNISHED BY SELLER, SHALL BE
LIMITED EXCLUSIVELY TO THE RIGHT OF REPAIR OR REPLACEMENT OF SUCH GOODS OR SERVICES, AT
SELLER’S OPTION. WITHOUT IN ANY WAY LIMITING THE GENERALITY OF THE FOREGOING, IN NO EVENT
SHALL SELLER BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING, WITHOUT
LIMITATION, ANY LOSS OF ANTICIPATED PROFITS INCURRED BY PURCHASER WITH RESPECT TO ANY GOODS
OR SERVICES FURNISHED BY SELLER, OR ANY DAMAGES ARISING FROM INJURIES TO PERSONS AS A
RESULT OF PURCHASER’S OR A THIRD PARTY’S NEGLIGENCE. SELLER’S WARRANTY DOES NOT COVER
FAILURES RESULTING FROM THE IMPROPER INSTALLATION, MOUNTING DESIGN OR APPLICATION OR FROM
CORROSION. THE PROVISIONS OF THIS PARAGRAPH ARE A MATERIAL TERM OF THIS TRANSACTION.
MAKING A CLAIM
If you wish to make a claim under this Warranty, you should:
• Return the product to the point of purchase either in person or on a prepaid courier; or
• Contact Us by Telephone on (+1) 253-859-6277, 253-859-6278 or e-mail [email protected]
• When returned, the product must be accompanied with the original invoice including the purchase price and
disclosing the purchase date
• All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the Customer.
• To the extent permitted by law, our total liability for loss or damage of every kind related to the product in any way
whatsoever is limited to the amount paid to the retailer by you for the product or the value of the product.
No responsibility will be taken for products lost, damaged or mislaid whilst in transit.
41
WARRANTY EXCLUSIONS
This Warranty covers Material and Faulty Workmanship defects only.
This Warranty does not cover damage caused by:
•
Normal wear and tear due to usage
•
Misuse or abusive use of the RAZORWELD instructions supplied with the product.
•
Failure to clean or improper cleaning of the product
•
Failure to maintain the equipment such as regular services etc
•
Incorrect voltage or non-authorised electrical connections
•
Improper installation
•
Use of non-authorised/non-standard parts
•
Abnormal product performance caused by any ancillary equipment interference or other external factors
•
Failure or any breakage caused by overload, dropping or abusive treatment or use by the customer
•
Repair, modifications or other work carried out on the product other than by an Authorised RAZORWELD
Dealers
Unless it is a manufacturing fault, this Warranty does not cover the following parts:
MIG Welding Torches and Consumables to suit, such as:
Gas Nozzles, Gas Diffusers, Contact Tip holder, Contact tip, Swan Necks, Trigger, Handle, Liners,
Wire Guide, Drive Roller, Gas Nozzle Spring. Neck Spring, Connector Block, Insulator, Gas Nipple, Cap, Euro Block,
Head Assembly, Gas Block, Trigger Spring, Spring Cable Support, Neck Insulator, Shroud Spring,
Gun Plug Cover, Lock Nut, Snap On Head, Spring Cap, Ball, Motor 42 Volt, Pot 10K standard, Knob, Drive Roll Seat,
Washer, Bow, Ball Bearing, Wire Conduit Nipple, Central Plug, Printed Circuit Board, Gun Plug House, Cable Support, Gas Connector, Handle To Suit PP36 with Knobs, & Electrodes, Arc Leads, Welding Cable, Electrode Holder,
Earth Clamps
.
TIG Welding Torches and Consumables to suit, such as:
Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled,
Torch Head Flexible,Back Caps, Gas Lens, Torch Handle, Cup Gasket, Torch Body Gas Valve, O-ring,
Arc Leads, Welding Cable, Electrode Holder, Earth Clamps.
PLASMA Cutting Torches and Consumables to suit, such as:
All Cutting Tips, All Diffuser/Swirl Ring, All Electrode, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps,
All Air and Power Cables, All Switches, All O-rings, All Springs, All Circle Guides and Cutting Kits, Torch Bodies, Air
Filter Regulator, Arc Leads, Welding Cable, Electrode Holder, Eatch Clamps
STRAIGHT LINE CUTTING MACHINES and Consumables to suit, such as:
Hoses, Fittings, Track, Cutting Nozzles.
HIT-8SS Welding Carriage Consumables to suit, such as:
Input Cord, Inter-connecting Cord, Triggering Cable.
This Warranty does not cover products purchased:
• • • From a non-authorized Dealer (such as purchases from unauthorized retailers and purchases over the
Internet from unauthorized local/international sellers or sites such as EBay)
At an auction;
From a private seller Unless it is a manufacturing fault, this Warranty does not apply to any products
sold to Hire Companies.
These conditions may only be varied with the written approval of the Directors of JASIC Technologies America Inc
REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.
.
Notes
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© JASIC Technologies America Inc 2012
G W ELD
E
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: [email protected]
[email protected]
Part of the JASIC group of companies
MADE IN CHINA
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