Razorweld JRW200AC/DC User manual

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Razor2OOAC/DC TIG-ARC
Razorweld
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Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
OPERATING MANUAL
JRW200AC/DC
YEARS Warranty
(Power Source)
3
©Welding Guns Of Australia PTY LTD 2015

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Razor2OOAC/DC TIG-ARC
Razorweld
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WARRANTY
• 3 Years from date of purchase.
• JASIC TECHNOLOGIES AMERICA INC 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’s 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
warranty.asp or at the back of this manual.
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
condence that they will be well satised both now and in the future.
RAZORWELD welders are manufactured and compliant with - CAN/CSA 609741-1
guaranteeing you electrical safety and performance.

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Razor2OOAC/DC TIG-ARC
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CONTENTS
Safety - Precautions 4-6
Electrical Diagram 7
Technical Data, Product Information 8
Front Panel Layout 9
Operation - Weld Program Sequence Control 10-14
Installation & Operation for MMA (Stick) Welding 15-16
ARC (Stick) Welding 17-18
Installation & Operation for DC TIG Welding 19
DC HF TIG Welding Standard Operation 20
DC TIG Welding 21-22
DC Pulse TIG Welding 23-24
Set up and operation for AC TIG Welding 25-27
AC TIG Welding -Square Wave 27-30
Remote Controls - Installation and Operation 31
Tungsten Electrode Selection & Preparation 32-33
TIG Torch Parts Breakdown 34-35
Trouble Shooting Guide - TIG Welding 36-37
Trouble Shooting Guide - MMA (Stick) Welding 38
Warranty 39-42
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 ow rate on the regulator to approximately 20-30cfh
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 ow rate to 20-30cfh, 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 or spraying
with soapy water, bubbles will appear at the leakage point.
6. Tighten clamps or ttings 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 , authorised representatives or agents of
JASIC TECHNOLOGIES AMERICA INC will not be liable or responsible
for the loss of any gas.
ATTENTION! - CHECK FOR GAS LEAKS

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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 under-
stand this instruction manual carefully before the installation and operation of this equipment.
• 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 qualied.
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 USA AND /OR CANADIAN standards and regulations.
• 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. Use of a PAPR system is recommended.
• In conned 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 o 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 lter 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 ash,glare and sparks; warn others not to watch the arc.
Machine Operating Safety

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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
res and burns. Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or re. Check and be sure the area is safe before doing any welding.
• The welding sparks may cause re, therefore remove any ammable materials away from the working
area, at least 40ft from the welding arc. Cover ammable 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 ammable 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 ammable dust, gas, or liquid vapours (such as petrol)
• Have a re 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, oor, bulkhead, or partition can cause re on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylin-
der 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 ames,
sparks, and arcs.
• Ensure 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 o shielding gas supply when not in use.
• Always ventilate conned spaces or use approved air-supplied respirator.
Electronic magnetic elds. MAGNETIC FIELDS can aect 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.

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CAUTION
1. Working Environment.
1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive
chemicals, ammable 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 -10°C to +40°C.(14 F-104 f)
1.3 Keep this equipment 30cm distance 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 30 cm. Good ventilation is
of critical importance for the normal performance and service life of this equipment.
2.2 Thermal Overload protection.
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.
2.3 Over-Voltage Supply
Regarding the power supply voltage range of the machine, please refer to “Main Parameter” table.
This equipment will automatically compensate for input voltage variations within a specic range.
In circumstances where the voltage of the input power supply exceeds the stipulated value, it is |
possible to cause damage to the internal 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 pre-
vent 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 warranty; the warranty of this
welding equipment will be void if the machine has been modied or shows signs of attempts to open or take
apart the machine through damaging the factory-installed seal without the consent of an authorized repre-
sentative of the manufacturer.
TROUBLE SHOOTING
Caution: Only qualied 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:- 7KVA (9KVA Generator)
• Our equipment as described in this manual conforms to all applicable rules and regulations of the
‘LowVoltage Directive’(European Council Directive 73/23/EEC) as set out and am ended by Council
Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
• Our equipment as described in this manual conforms to all applicable rules and regulations of the
European Council Directive 89/336/EEC, (EMC Directive) and to the National legislation for he
enforcement of this Directive.

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Electrical Schematic Diagram
Razor2OOAC/DC TIG-ARC
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Razor2OOAC/DC TIG-MMA
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Welds: Aluminium, Magnesium, Zinc Alloys, Steels, Stainless,
Cast Iron, Bronze, Copper
RAZOR DIGITAL 200 AC/DC
TIG/ARC - Digital Inverter Welder
RWJFC-2D
Remote Foot Control as
Standard
MACHINE PACKAGE: JRW200AC/DC
Standard option includes: RAZOR200AC/DC Machine, WP/SR17 TIG Torch x 13ft, Earth Lead 1" x 13ft,
Argon Regulator, 6ft Gas Hose with ttings, Power Adaptor
TIG torch
Features
• Latest 43KHz Inverter Technology
• AC/DC HF TIG/ARC Function
- Arc Ignition HF Oscillation
- AC Square Wave 20 - 250Hz
- AC Balance Control Adjustable
- Pulse Frequency 1 - 200Hz
- Pulse Width 50%
- Base Current 5 - 200A
- Up Slope 0 -10 sec
- Down Slope 0 -15 sec
- Pre Gas 0 - 5 sec
- Post Gas 0.5 -20 sec
- Trigger Function 2/4T-Spot
• ARC
- Arc Ignition Current Automatic
- Arc Ignition Time Automatic
-Foot control as standard
TIG/ARC 200 Amp AC/DC Inverter
Welder Digital Control - 115/230V
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* Arc Set Optional
Overview
The RAZOR200ACDC is a Digital Controlled Square Wave AC/DC TIG inverter welder. Intelligent digital control of the main functions are realized by
intuitive software providing ease of operation and high accuracy. Full TIG functionality, oers simple step by step digital control of functions and
parameters providing complete professional control. HF arc ignition provides Pre Gas with instant arc ignition leaving no tungsten inclusion or
contamination of the tungsten electrode. Digital set of Pre Gas Time, Start Current, Up Slope and Down Slope Time, Finish Current Level and Post Gas
Time with the choice of 2T or 4T trigger function allows control of the welding process at a professional level from start to nish. Digital Pulse Control
gives full parameter setting of Peak & Base Current, Pulse Frequency & Pulse Width providing control of heat input, penetration & distortion. AC
Square Wave Balance gives control of the electron ow at the tungsten, the AC TIG arc can be adjusted from maximum oxide-layer cleaning on
aluminum through to a deeper penetrating weld. Remote Control Interface provides remote amperage control at the foot-pedal control. The
Selectable Tungsten feature allows the user to initiate softer arc starts when using small tungsten with thin metals avoiding burn through on their
work. When using a larger tungsten it requires a larger initial current and by selecting a larger tungsten size it avoids arc stutter or lack of arc
initiation. DC ARC welding delivers a smooth and stable arc for easy welding of electrodes producing high quality welds including cast Iron, stain-
less and low hydrogen. Arc Ignition and Arc Force control allows you to set the ideal arc condition no matter what electrode you choose.
Optimized auto protection of the power input provides auto shut down of the machine when large scale uctuations occur. Unique air channel
design increases the heat dissipation of the power device, control circuits, minimizes dust absorption, thereby greatly improving longevity and
reliability. RAZOR200ACDC is the new standard for Dual voltage welders making it the ideal choice for both the experienced professional welder and
the weekend Warrior alike. Built to our specications and manufactured in compliance to CAN/CSA 60974.1
MACHINE SPECIFICATIONS

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Razor2OOAC/DC TIG-MMA
Machine Layout Description
Razor2OOAC/DC TIG-ARC
1. Digital control panel
2. Postive output terminal
3. Negative output terminal
4. Quick lock gas connector * 5/8 NPT in USA
5. Torch switch - remote connector 5 Pin
6. Encoder knob
7. Handle
8. Power switch - on/o
9. Caution notice
10. Mains power input cable
11. Fan
12. Inlet gas connector * 5/8" NPT (USA)
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1
2
3
4 5
7
89
10
11 12
Front Machine Layout Description
Rear Machine Layout Description
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Front Panel Operation
Indicates Active
Selector Pad
AC TIG: Select by pushing the
selector pad to cycle through to
illuminate the AC icon.
DC ARC: Select by pushing the selector
button to cycle through to illuminate
the ARC icon.
1. Mode Selector - Enables selection of required welding mode - AC TIG - AC PULSE TIG - DC TIG - DC PULSE TIG
DC ARC (Stick)
Front Panel Functions
AC Pulse TIG: Select by pushing the
selector button to cycle through to
illuminate the AC PULSE icon.
DC TIG: Select by pushing the
selector button to cycle through to
illuminate the DC icon.
DC Pulse TIG: Select by pushing the
selector button to cycle through to
illuminate the DC PULSE icon.
1
3
2
3. Torch Switch Mode Selector - Controls the on/o cycle of the machine using the torch switch while
incorporating the weld program parameters selections.
2T: Select the 2T icon using the selector pad.
2T uses 2 actions of the torch switch while
incorporating the weld program parameter
selections.
(refer to page 10 for instruction of 2T function)
4T: Select the 4T icon using the selector pad.
4T uses 4 actions of the torch switch while
incorporating the weld program parameter
selections. 4T provides operator control of the
start and nish portions of the weld sequence.
(refer to page 11 for instruction of 4T function)
SPOT: Select the SPOT icon using the
selector pad.
Spot uses a single action of the torch switch
1) Pressing the torch switch gives arc ignition
and initializes the welding sequence for the
period of time set using the spot timer.
(refer to page 11 for instruction of SPOT
function)
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5

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Parameter selection: Select by pushing the Encoder Knob
repeatedly to cycle through the weld parameter icons. The
icon will illuminate when selected.
Each push of the encoder knob will move the icon illumina-
tion in a clockwise cycle.
Front Panel Operation - Weld Program Selection
Shows selected icon
4a - Weld Program - Selection weld program parameters
Turn the Encoder to set
the Start Amp value
(Range is 5-200A)
Start Amp: Select by pushing the encoder
to cycle through to illuminate the Start Amp
icon.
The value selected shows on the digital
display. It is the amount of amps the
machine will deliver at the start of the
welding sequence.
Start Amp - Provides selection for the amount of amps required at the start of the weld.
Turn the Encoder to set
the Pre-Gas Time
(Range is 0-3 Sec)
Pre Gas Time: Select by pushing the
encoder to cycle through to illuminate the
Pre Gas Timer icon.
The value selected shows on the digital
display. It is the length of time the gas
will ow before the arc starts.
Pre Gas Timer - Provides selection for gas ow time prior to the arc starting.
3. Encoder Knob - provides digital adjustment of welding parameters and provides step by step motion through the
weld cycle parameters.
Encoder knob weld parameter value selection
Turning the encoder will adjust the value of the parameters required.
The value selected will show in the digital display screen.
Encoder knob weld cycle function selection
Pushing the encoder will allow step by step selection of the weld cycle function.
The weld function selected will shown by the illuminated LED.
Turning the Encoder Knob will allow adjustment and setting of value for the weld function parameter
selected.
After selecting Starting Amperage you will be prompted to enter initial Arc "Soft Start" 0-20ms , after entering initial start amperage
start Amperage light will stay lit and display 0.0, select your desired initial delay from a range of 0-20ms.

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Continued-WeldProgramSelection&Setting
Turn the Encoder to set the
Finish Amp value
(Range is 10-200A)
Finish Amp: Select by pushing the encoder knob to
cycle through to illuminate the
Finish Amp icon.
The value selected shows on the digital dis-
play. It is the amount of amps the machine will
deliver at the nish of the welding sequence.
Finish Amp - Provides selection for the amount of amperage required at the end of the weld.
Turn the Encoder to set
the Down Slope time
(Range is 0-15 Sec)
The value selected shows on the digital
display. It is the amount of time it takes
for the welding amperage to drop down
to the set nish amperage.
Down Slope Time - Sets the transition time from Welding Amperage to Finish Amperage
Down Slope Time: Select by pushing the
encoder knob to cycle through to illuminate
the Down Slope icon.
Turn the Encoder to set
the Up Slope value
(Range is 0.5-15 Sec)
Post Gas Time: Select by pushing the encoder
knob to cycle through to illuminate the
Gas Timer
Post icon.
The value selected shows on the digital
display. It is the length of time the gas
will ow after the arc is nished.
Post Gas Timer - Provides selection for continued gas ow time at the end of the welding after the arc is out.
Turn the Encoder to set
the Up Slope value
(Range is 0-10 Sec)
Up Slope Time: Select by pushing the
encoder to cycle through to illuminate the
Up Slope icon.
The value selected shows on the digital
display. It is the amount of time the
welding current takes to climb from
start amperage to welding amperage.
Up Slope Time - Sets the transition time from Start Amperage to Welding Amperage
Turn the Encoder to set
the Peak Amp value
(Range is 10-200A)
Peak Amp: Select by pushing the encoder
to cycle through to illuminate the Peak
Amp icon.
The value selected shows on the digital
display. It is the maximum set value of
amperage the machine will deliver.
Peak Amp - Provides selection for the Maximum Welding Amperage required during welding.
Turn the Encoder to set
the Base Amp value
(Range is 5-200A)
Base Amp: Select by pushing the encoder
to cycle through to illuminate the Base
Amp icon.
The value selected shows on the digital
display. It is the set value of amperage
the machine will deliver during the Base
Amp period of the pulse cycle.
Base Amp - Provides selection for the Base Amperage during the Pulse Welding cycle.
After selecting nish Amperage you will be prompted to enter "Soft tailout" 0-20ms , after entering nish amperage the nish Amperage light
will stay lit and display 0.0, select your desired tailout from a range of 0-20ms.

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Continued - Weld Program Selection & Setting
Parameter selection: Select by pushing the Encoder Knob
repeatedly to cycle through the weld parameter icons. The
icon will illuminate when selected.
Each push of the encoder knob will move the icon illumina-
tion in a clockwise cycle.
Shows selected icon
4B Weld Program - Selection of further weld program parameters
Turn the Encoder to set
the AC Balance value
Range is (-15 to -50)
Start Amp: Select by pushing the encoder to cycle
through to illuminate the AC Balance icon.
The value selected shown on the digital
display represents a more penetrating arc
set at -15, a balanced arc at 0, or a more
oxide cleaning action arc at -50
AC Balance - Provides selection to adjust the balance of the AC wave form in AC TIG mode. Allows adjustment of
the arc to be balanced, penetrating or oxide cleaning during AC TIG welding.
Turn the Encoder to
adjust the AC Hz
(Range is 20-250Hz)
AC Hz: Select by pushing the encoder to
cycle through to illuminate the AC Hz icon.
The value selected shown on the digital
display represents the number of times
per second that the AC square wave
transitions from + to - cycle.
AC Hz - Provides selection to adjust the frequency of the AC square wave in AC TIG mode. Allows adjustment of
frequency of the AC square wave cycle (transistion from + to -) during AC TIG welding.
Turn the Encoder to
adjust the Pulse Hz
(Range is 0.02 - 200Hz)
Pulse Hz: Select by pushing the encoder
to cycle through to illuminate the Pulse Hz
icon.
The value selected shown on the digital
display represents the number of times
per second that the output welding current
switches from Peak Amp to Base Amp
Pulse Hz - Provides selection of the pulse frequency of the welding output current. Allows adjustment of frequency
that the output current transistions from Peak Amp to Base Amp.
Turn the Encoder to
adjust the % Pulse
(Range is 10-90%)
% Pulse: Select by pushing the encoder
to cycle through to illuminate the Pulse
Hz icon. Push the encoder a 2nd time to
access % Pulse adjustment mode
The value selected shown on the digital
display represents the % of time that the
Peak Amp is on during the pulse cycle.
% Pulse - Provides selection of the on time ratio of the Peak Amp during the pulse welding cycle (Pulse Width).
Allows adjustment of the % of time that the Peak Amp is on during each pulse cycle.

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Turn the Encoder to
adjust the Spot time
(Range is 0.5-10 sec)
Spot: Select SPOT using the Torch Mode Selector.
Select Spot time by pushing the encoder to cycle
through to illuminate the Spot icon. The Spot icon
will only activate when in TIG mode and SPOT torch
mode is selected.. Spot will NOT activate whilst the
power source is in remote mode.
The value selected shown on the digital
display represents the time in seconds that
the welding current will be delivered once
the torch switch is pressed.
Spot - Provides selection of a pre-set time period for welding current output.
Allows adjustment of the time that machine will deliver amperage output from trigger activation.
Turn the Encoder to
adjust the Arc Force
Spot: Select ARC using the Weld Mode Selector. Select
ARC FORCE by pushing the encoder to
cycle through the arc force icon illuminate
the Arc Force icon. It will only activate when in ARC mode.
The value selected shown on the digital
display represents extra current over time
applied to the electrode when short circuit is
about to occur. Low value allows a soft arc,
a higher value allows stronger digging arc.
Arc Force - Provides selection for adjustment of the ARC FORCE during ARC (Stick) welding.
Allows setting from a soft buttery arc characteristic through to a more digging, penetrating type of arc.
Continued-WeldProgramSelection&Setting
Icon selection: Select by pushing the Encoder Knob repeatedly to cycle
through the weld parameter icons. The icon will illuminate when selected.
4C - Other front panel Icon selection
Turn the encoder to set the
electrode Øinch value
Tungsten electrode : Select by pushing the
encoder knob to cycle through to illuminate the
Tungsten electrode Ømm icon.
The electrode diameter value
selected will in the digital display.
Tungsten electrode Øinch - for selection of Tungsten electrode and ARC electrode diameter
Remote - indicates remote control activation
The remote icon illuminates when the remote
function is active.
Remote Hand Control. Press the torch switch
and hold for 5 seconds the icon will illuminate
when remote function is activated.
Remote Foot Control. Remote function will be-
come active when the foot control is connected .
Parameter Warning - indicates weld parameters do not match
the electrode Øinch selection
The warning parameter icon illuminates when the
the weld parameter settings do not match the electrode
size selection.
The machine will still function but it is a warning to the
operator that the weld parameters chosen are outside
the generally accepted capabilties of the electrode size
selected. For example excessive amperage selected
may overheat and destroy the tungsten electrode.

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(5) Set the Arc Force by selecting the Arc Force
icon pressing the Encoder Knob until the Arc Force
icon illuminates.
Turn the encoder knob to set the Arc Force accord-
ing to the electrode type and size being used. The
set Arc Force will show in the digital display panel.
Refer to Page 12 for instruction and explanation on
Arc Force Control
(3) Select DC ARC Function.
Push the button until the DC icon
illuminates
1. Connecting the Welding Lead Set: Various electrodes require a dierent polarity for optimum results
refer to the electrode manufacturers information for the correct polarity. Most GP electrodes are
electrode connected to output socket, Earth Connected to the output socket
2. Turn the power source on using the on/o switch located on the rear machine panel.
Set Up Procedure for ARC (Stick) Welding:
(4) Set the amperage by selecting the Peak
Amp icon pressing the Encoder Knob until
the Peak Amp icon illuminates. Turn the
encoder knob to set the amperage according
to the electrode type and size being used as
recommended by the electrode manufacturer.
The set amperage will show in the digital
display panel.
(2) Turn on the Power source
using the on/o switch at the
rear of the machine
(1) Connect Electrode Lead
the terminal
(1) Connect the Earth Lead
lead to Terminal
ARC (Stick Electrode) Welding Setup and Operation
* ARC SET OPTIONAL

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Continued - Set Up Procedure for ARC (Stick) Weld-
6) Connect the Earth Clamp securely to
the work piece or the work bench.
4) Place the electrode into the electrode
holder and clamp tight.
5) Strike the electrode against the work
piece to create and arc and hold the elec-
trode 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 nish 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.
ARC FORCE - What is the Arc Force Control and what does it do?
During welding arc voltage drops as the arc gets tighter and can cause the electrode to stick/short circuit to the work piece. Arc
force should be set according to the electrode diameter, electrode type, welding current and the technical requirement. When you
set the arc force high the machine senses the drop in voltage, as the electrode is about to stick/short circuit to the work piece the
machine responds by increasing the arc voltage and welding current momentarily (per millisecond). This boost in arc voltage/cur-
rent blasts away base metal and electrode to prevent the electrode from sticking itself to the work piece. High arc force means
the molten droplet from the melting electrode is larger with quicker transistion preventing the electrode from sticking, however too
much arc force may create excessive spatter. Low arc force will result in a softer arc with minimal spatter and a nice shaped weld
bead, however it may lead to the electrode sticking to the work piece easier, therefore the arc force should be adjusted to provide
a smooth arc transistion between the electrode and workpiece without it sticking and without providing excessive spatter. Higher
Arc Force is more suited to thicker electrodes under low amperage settings, out of postion welding, low hydrogen type electrodes
where a forceful arc characteristic is preferred to maintain the arc and better control penetration. Lower Arc Force is better suited
to hardfacing and cast Iron electrodes where a soft buttery arc is preferred to prevent the electrode material diluting too much with
the base metal.
IMPORTANT NOTES - For ARC (Stick) Welding
ELECTRODE POLARITY - What is the electrode polarity and why is it important.
When using a DC power source, the question of whether to use electrode negative or positive polarity arises.
The rst important point is that not all electrodes can be used with all polarities. Electrode manufacturer information and specications such as
BS EN ISO 2560:2005 and AWS A5.1-2004, dene the polarity with which dierent electrodes may be used. The choice of polarity also depends
on the type of the material and joint design. A welding procedure should specify the polarity to be used for the electrode choice and joint
design.
Direct current ows in one direction in an electrical circuit and the direction of current ow and the composition of the elec-
trode coating will have a denite e󰀨ect on the welding arc and weld bead. Refer to the electrode manufacturers recommenda-
tion for polarity choice.
With DC electrode (+) positive (reverse) polarity, more heat is generated at the workpiece. This produces welds with deep penetration and a
narrower weld bead and can reduce the incidence of lack-of-fusion defects in the weld.
DC electrode (-) negative (straight) polarity generates more heat at the electrode and produces welds with shallower penetration. DC (-) nega-
tive electrode results in a higher burn o rate, and therefore a higher deposition rate at a given current. It is often used for welding thin sheet
materials, or joints with poor t-up, where more control of the weld pool is needed due to the increased risk of burn through.

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ARC (Manual Metal Arc) Welding
One of the most common types of arc welding is manual metal Arc welding (MMA) or stick welding. An electric current is used to
strike an arc between the base material and a consumable electrode rod or‘stick’. The electrode rod is made of a material that is
compatible with the base material being welded and is covered with a ux that gives o gaseous vapours that serve as a shield-
ing gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination. The electrode core
itself acts as ller material the residue from the ux that forms a slag covering over the weld metal must be chipped away after
welding.
Core wire
Flux coating
Gas shield from ux melt
Arc with core wire melt
Flux residue forms slag cover
Weld metal
Power Source
+
▬
• The arc is initiated by momentarily touching the electrode to the 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
Core wire
Flux coating
Base metal
Protective gas
Arc
Slag
Weld pool
Manual metal arc ( stick) electrodes have a solid metal wire core and a ux
coating. These electrodes are identied 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.
The covering on a shielded metal arc welding electrode is called Flux.
The ux on the electrode performs many dierent functions.
These include:
●producing a protective gas around the weld area
●providing uxing 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 ller metal to
the molten pool. These additional functions are provided mainly by the cover-
ing on the electrode.

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Electrode Size
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
base on using a general purpose type 6013 electrode.
Correct current selection for a particular job is an im-
portant factor in arc welding. With the current set too
low, diculty is experienced in striking and maintaining
a stable arc. The electrode tends to stick to the work,
penetration is poor and beads with a distinct rounded
prole will be deposited. Too high current is accompa-
nied by overheating of the electrode resulting 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.
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 nish to the weld. An exces-
sively 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, llet, 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, ame 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.
Welding Current (Amperage)
Electrode Size Current Range
ø Inch (Amps)
0.09 60 - 100
0.12 100 - 130
0.15 130 - 165
0.19 165 - 200
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 specic classes of work. It is recommend to con-
sult your welding supplier for the correct selection of electrode.
ARC (Stick) Welding Fundamentals
Average Thickness Maximum Recommended
of Material 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

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1. Connect the TIG Torch connector to the negative terminal and tighten it.
2. Install the threaded connector into into the gas tting
3. Connect the torch switch remote lead into the torch remote socket.
4. Connect the Earth Cable connector into the positive terminal and tighten it.
5. Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder.
Slowly open the valve on the gas cylinder and set gas ow to the required rate.
6. Connect the gas line to the 5/8" threaded gas inlet at the rear of the machine.
Check for gas leaks - JASIC Technologies America Inc nor it's representatives
will be responsible for any gas loss.
8. Switch on the machine using the On/O switch at the rear of the machine.
9. Set the weld parameters using the front panel set procedure on the following page.
5. Connect the regulator to the cylinder,
Connect the gas lead to the regulator.
Set the ow to 5-25 CFH * (To suit application)
4. Connect the Earth cable
connector to the terminal
3. Connect the torch switch lead
to the torch remote receptacle
8. Turn on the machine using the ON/OFF
switch at the rear of machine
1. Connect the TIG torch connector
to the terminal.
2. Install the threaded connector into
into the gas tting
InstallationSetUpforDCTIGWelding:
4. Lay the outside edge of the Gas Cup
on the work piece with the Tungsten
Electrode approx 1/16th of an inch
from the work 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 5/64th of an inch-
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 func-
tion 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
Weld start procedure for HF DC TIG welding
DC HF TIG Welding Setup and Operation
6. Connect the gas line to the 5/8" gas
threaded socket at the rear of the machine

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DC HF TIG Welding Standard Set Up Procedure:
Front panel set up procedure for basic HF DC TIG welding
Select DC TIG by pressing the button
1. Select DC TIG Function. 2. Select Tungsten Diameter.
Set the pre gas time by pushing the encoder
repeatedly, cycle through to illuminate the Pre
Gas icon. Set the time by turning the
encoder knob. The set time will appear in the
digital display
3. Set Pre-gas Time
Set the Start Amps by pressing the encoder
to cycle through to illuminate the Start Amp
icon. Set the start amps by turning the encoder
knob. The set start amps will appear in the
digital display
until the DC icon illuminates. Select 2T or 4T
trigger function as required by the pushing the
button to cycle through the trigger options.
The icon will illuminate for the selected trigger
option.
4. Set Start Amps
Set the Up Slope by pressing the encoder
to cycle through to illuminate the Up Slope
icon. Set the up slope time by turning the
encoder knob. The set up slope time will ap-
pear in the digital display
(2) Select the tungsten diameter required by
pushing the encoder r repeatedly, cycle
through to illuminate the Tungsten Electrode
icon. Set the size required by turning the
encoder knob. The set size will appear in the
digital display.
5. Set Up Slope Time
Set welding amps by pressing the encoder
to cycle through to illuminate the Peak Amp
icon. Set the amperage by turning the encoder
knob. The set welding amperage will appear in
the digital display
6. Set Welding Amperage
Set the down slope by pressing the encoder
to cycle through to illuminate the Down Slope
icon. Set the down slope time by turning
the encoder knob. The set down slope time
will appear in the digital display
7. Set Down Slope Time
Set the nish amps by pressing the encoder
to cycle through to illuminate the Finish Amps
icon. Set the nish amps by turning the en-
coder knob. The set nish amps will appear in
the digital display
8. Set Finish Amps
Set the post gas time by pressing the encoder
to cycle through to illuminate the Post Gas
icon. Set the post gas time by turning the
encoder knob. The set post gas time will ap-
pear in the digital display
9. Set Post Gas Time