Razor 200 AC/DC Pulse Manual

Razor 200 AC/DC Pulse Manual

Razorweld

Razor weld

Razor

2OOAC/DC TIG-MMA

OPERATING MANUAL

KUMJRRZ200AC/DC

Please read and understand this instruction manual carefully

3

YEARS Warranty

(Power Source)

©

Welding Guns Of Australia PTY LTD 2015

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2OOAC/DC TIG-MMA

Thank you for your purchase of your UNI-MIG 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.

UNI-MIG welders are manufactured and compliant with - AS/NZ60974.1 2006 - AS60974-6:2006 guaranteeing you electrical safety and performance.

WARRANTY

• 3 Years from date of purchase.

• Welding Guns Of Australia PTY LTD 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 Welding Guns Of Australia PTY LTD 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.unimig.com.au/

warranty.asp or at the back of this manual.

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CONTENTS

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4-6 Safety - Precautions

Electrical Diagram

Technical Data, Product Information

Front Panel Layout

Operation - Weld Program Sequence Control

Installation & Operation for MMA (Stick) Welding

MMA (Stick) Welding

Installation & Operation for DC TIG Welding

DC HF TIG Welding Standard Operation

DC TIG Welding

DC Pulse TIG Welding

Set up and operation for AC TIG Welding

AC TIG Welding -Square Wave

Remote Controls - Installation and Operation

Tungsten Electrode Selection & Preparation

TIG Torch Parts Breakdown

Trouble Shooting Guide - TIG Welding

Trouble Shooting Guide - MMA (Stick) Welding

Warranty 39-42

21-22

23-24

25-27

27-30

31

32-33

34-35

36-37

38

7

8

9

10-14

15-16

17-18

19

20

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 8-10 l/min.

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 8-10 l/min, 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 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.

Welding Guns Of Australia PTY LTD, authorised representatives or agents of

Welding Guns Of Australia PTY LTD will not be liable or responsible

for the loss of any gas.

3

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 Australian and New Zealand 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 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.

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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 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.

• 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 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.

5

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 -10°C to +40°C.

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 specific 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 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 warranty; the warranty of this welding equipment will be void if the machine has been modified or shows signs of attempts to open or take apart the machine through damaging the factory-installed seal 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:- 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

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RAZOR DIGITAL 200 AC/DC

TIG/MMA - Digital Inverter Welder

Welds: Aluminium, Magnesium, Zinc Alloys, Steels, Stainless,

Cast Iron, Bronze, Copper

TIG/MMA 200 Amp AC/DC Inverter Welder

Digital Control - 240V Single Phase

Features

• Latest 43KHz Inverter Technology

• AC/DC HF TIG/MMA Function

- Arc Ignition HF Oscillation

- AC Square Wave 20 - 250Hz

- AC Balance Control Adjustable

- Pulse Frequency 0.2 - 200Hz

- Pulse Width 10 - 90%

- Base Current 5 - 200A

- Up Slope 0 -10 sec

- Down Slope 0 -15 sec

- Pre Gas 0 - 3 sec

- Post Gas 0.5 -15 sec

- Trigger Function 2/4T-Spot

• MMA

- Arc Ignition Current Automatic

- Arc Ignition Time Automatic

- Arc Force Current 0 - 40A

• Remote Amperage Foot & Hand Control

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Technical Data

Power Supply / Phases (V-Ph)

Rated Input Power (KVA) ieff (Amps) iMax (Amps)

Rated Output

No-Load Voltage (V)

Duty Cycle @ 40ºC as per AS/NZ60974

Effciency (%)

Power Factor

Protection Class

Insulation Class

Size (mm)

Weight (kg)

Warranty

Certification Approval

240V - 1 ±15%

7.0 (Genrator 9KVA)

15

29

10-160A/26.4V MMA

10-200A/18.0V TIG

68

30%@160Amps MMA

25%@200Amps TIG

85

0.70

IP21S

B

426x162x326

10Kg

3 years machine only

AS/NZ60974.1

Standard Amperage Control for torch

UTJRFC-4

Remote Foot Control Option

Overview

The RAZOR200ACDC is a Digital Controlled Square Wave AC/DC TIG inverter welder. Intelligent digital control of the main functions are realised by software providing ease of operation and high accuracy, software upgrade is possible by simple download function. Full TIG functionality, offering 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 finish. 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 flow at the tungsten, the AC TIG arc can be adjusted from maximum oxide-layer cleaning on aluminium through to a deeper penetrating weld. Remote Control Interface provides optional remote amperage control at the torch or foot-pedal control. DC MMA welding delivers a smooth and stable arc for easy welding of electrodes producing high quality welds including cast Iron, stainless and low hydrogen. Arc Ignition and Arc Force control allows you to set the ideal arc condition no matter what electrode you choose. Optimised auto protection of the power input provides auto shut down of the machine when large scale flucuations occur. Unique air channel design increases the heat dissaption of the power device, control circuits, minimises dust absorbtion, thereby greatly improv-ing longevity and reliabilty. RAZOR200ACDC is the new standard for 240V AC/DC welders making it the ideal choice for experienced or novice welders of Aluminium, Stainless and Steel materials. Built to our specification and manufactured in compliance to AS/NZ60974.1

MACHINE PACKAGE: KUMJRRZ200AC/DC

Standard option includes: RAZOR200AC/DC Machine, SR26 TIG Torch x 4m, Earth Lead & Arc Lead 25mm x 4m,

UNI-FLAME Argon Regulator, 2M Gas Hose with fittings

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Machine Layout Description

Front Machine Layout Description

1. Digital control panel

2. Postive output terminal

3. Negative output terminal

4. Quick lock gas connector

5. Torch switch - remote connector

6. Encoder knob

7. Handle

1

2

3

4

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6

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Rear Machine Layout Description

8. Power switch - on/off

9. Caution notice

10. Mains power input cable

11. Fan

12. Inlet gas connector

9

10

11

8

12

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Front Panel Operation

Front Panel Functions

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4

3

5

Indicates Active

Selector Pad

1

2

1.

Mode Selector -

Enables selection of required welding mode -

AC TIG - AC PULSE TIG - DC TIG - DC PULSE TIG

DC MMA

(Stick)

AC TIG: Select by pushing the selector pad to cycle through to illuminate the

AC icon.

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.

DC MMA: Select by pushing the selector button to cycle through to illuminate the MMA icon.

3.

Torch Switch Mode Selector -

Controls the on/off 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 finish 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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Front Panel Operation - Weld Program Selection

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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.

4a

- Weld Program -

Selection weld program parameters

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 illumination in a clockwise cycle.

Shows selected icon

Pre Gas Timer -

Provides selection for gas flow time prior to the arc starting.

Pre Gas Time: Select by pushing the encoder to cycle through to illuminate the

Pre Gas Timer icon.

Turn the Encoder to set the Pre-Gas Time

(Range is 0-3 Sec)

The value selected shows on the digital display. It is the length of time the gas will flow before the arc starts.

Start Amp -

Provides selection for the amount of amps required at the start of the weld.

Start Amp: Select by pushing the encoder to cycle through to illuminate the Start Amp icon.

Turn the Encoder to set the Start Amp value

(Range is 10-200A)

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.

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Continued - Weld Program Selection & Setting

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Up Slope Time -

Sets the transition time from Start Amperage to Welding Amperage

Up Slope Time: Select by pushing the encoder to cycle through to illuminate the

Up Slope icon.

Turn the Encoder to set the Up Slope value

(Range is 0-10 Sec)

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.

Peak Amp -

Provides selection for the Maximum Welding Amperage required during welding.

Peak Amp: Select by pushing the encoder to cycle through to illuminate the Peak

Amp icon.

Turn the Encoder to set the Peak Amp value

(Range is 10-200A)

The value selected shows on the digital display. It is the maximum set value of amperage the machine will deliver.

Base Amp -

Provides selection for the Base Amperage during the Pulse Welding cycle.

Base Amp: Select by pushing the encoder to cycle through to illuminate the Base

Amp icon.

Turn the Encoder to set the Base Amp value

(Range is 5-200A)

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.

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 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 finish amperage.

Finish Amp -

Provides selection for the amount of amperage required at the end of the weld.

Finish Amp: Select by pushing the encoder knob to cycle through to illuminate the

Finish Amp icon.

Turn the Encoder to set the Finish Amp value

(Range is 10-200A)

The value selected shows on the digital display. It is the amount of amps the machine will deliver at the finish of the welding sequence.

Post Gas Timer -

Provides selection for continued gas flow time at the end of the welding after the arc is out.

Post Gas Time: Select by pushing the encoder knob to cycle through to illuminate the

Post Gas Timer icon.

Turn the Encoder to set the Up Slope value

(Range is 0.5-15 Sec)

12

The value selected shows on the digital display. It is the length of time the gas will flow after the arc is finished.

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Continued - Weld Program Selection & Setting

4B

Weld Program -

Selection of further weld program parameters

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 illumination in a clockwise cycle.

Shows selected icon

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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.

Start Amp: Select by pushing the encoder to cycle through to illuminate the AC Balance icon.

Turn the Encoder to set the AC Balance value

Range is (-5-0-5+ )

The value selected shown on the digital display represents a more penetrating arc set at -5, a balanced arc at 0, or a more oxide cleaning action arc at 5+

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.

AC Hz: Select by pushing the encoder to cycle through to illuminate the AC Hz icon.

Turn the Encoder to adjust the AC Hz

(Range is 20-250Hz)

The value selected shown on the digital display represents the number of times per second that the AC square wave transitions from + to - cycle.

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.

Pulse Hz: Select by pushing the encoder to cycle through to illuminate the Pulse Hz icon.

Turn the Encoder to adjust the Pulse Hz

(Range is 0.02 - 200Hz)

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 -

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.

% 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

Turn the Encoder to adjust the % Pulse

(Range is 10-90%)

13

The value selected shown on the digital display represents the % of time that the

Peak Amp is on during the pulse cycle.

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Continued - Weld Program Selection & Setting

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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.

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..

Turn the Encoder to adjust the Spot time

(Range is 0.5-10 sec)

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.

Arc Force -

Provides selection for adjustment of the ARC FORCE during MMA (Stick) welding.

Allows setting from a soft buttery arc characteristic through to a more digging, penetrating type of arc.

Spot: Select MMA using the Weld Mode Selector.

Select ARC FORCE by pushing the encoder to cycle through to illuminate the Arc Force icon.

The Arc Force icon will only activate when in MMA mode.

Turn the Encoder to adjust the Arc Force

(Range is 0-40)

4C -

Other front panel Icon selection

Icon selection: Select by pushing the Encoder Knob repeatedly to cycle through the weld parameter icons. The icon will illuminate when selected.

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.

Tungsten electrode Ømm -

for selection of Tungsten electrode and MMA electrode diameter

Tungsten electrode : Select by pushing the encoder knob to cycle through to illuminate the

Tungsten electrode

Ømm icon.

Turn the encoder to set the electrode

Ømm value

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 become active when the foot control is connected .

The electrode diameter value selected will in the digital display.

Parameter Warning -

indicates weld parameters do not match the electrode

Ømm

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 opertor 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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Set Up Procedure for MMA (Stick) Welding:

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MMA (Stick Electrode) Welding Setup and Operation

1. Connecting the Welding Lead Set: Various electrodes require a different 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/off switch located on the rear machine panel.

(2) Turn on the Power source using the on/off switch at the rear of the machine

(1) Connect the Earth Lead lead to terminal

(1) Connect Electrode Lead the terminal

(3)

Select DC MMA Function.

Push the button until the

DC icon illuminates

(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.

(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 according 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

15

Continued - Set Up Procedure for MMA (Stick) Welding:

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2OOAC/DC TIG-MMA

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 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 below.

IMPORTANT NOTES -

For MMA (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 first important point is that not all electrodes can be used with all polarities. Electrode manufacturer information and specifications such as BS EN ISO 2560:2005 and AWS A5.1-2004, define the polarity with which different 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 flows in one direction in an electrical circuit and the direction of current flow and the composition of the electrode coating will have a definite effect on the welding arc and weld bead. Refer to the electrode manufacturers recommendation 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 (-) negative electrode results in a higher burn off rate, and therefore a higher deposition rate at a given current. It is often used for welding thin sheet materials, or joints with poor fit-up, where more control of the weld pool is needed due to the increased risk of burn through.

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/current 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.

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MMA (Manual Metal Arc) Welding

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2OOAC/DC TIG-MMA

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.

+

Power Source

Core wire

Flux coating

Gas shield from flux melt

Arc with core wire melt

Flux residue forms slag cover

Weld metal

Core wire

Flux coating

Base metal

• 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

Protective gas

Arc

Slag

Weld pool

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.

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.

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MMA (Stick) Welding Fundamentals

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2OOAC/DC TIG-MMA

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 Maximum Recommended of Material Electrode Diameter

1.0 - 2.0mm

2.0 - 5.0mm

5.0 - 8.0mm

8.0 - > mm

2.5mm

3.2mm

4.0mm

5.0mm

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.

Welding Current (Amperage)

Electrode Size

ø mm

2.5mm

3.2mm

4.0mm

5.0mm

Current Range

(Amps)

60 - 95

100 - 130

130 - 165

165 - 260

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, penetration is poor and beads with a distinct rounded profile will be deposited. Too high current is accompanied 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 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.

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Installation Set Up for DC TIG Welding:

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Razor

2OOAC/DC TIG-MMA

DC HF TIG Welding Setup and Operation

1. Connect the TIG Torch connector to the negative terminal and tighten it.

2. Insert the torch gas connector into the quick lock gas receptacle.

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 flow to the required rate.

6. Connect the gas line to the quick lock gas inlet connector at the rear of the machine.

Check for gas leaks Welding Guns of Australia PTY LTD nor it's representatives will be responsible for any gas loss.

8. Switch on the machine using the On/Off switch at the rear of the machine.

9. Set the weld parameters using the front panel set procedure on the following page.

6. Connect the gas line to the quick lock gas connector at the rear of the machine

5. Connect the regulator to the cylinder,

Connect the gas lead to the regulator.

Set the flow to 8-12 l/min

8. Turn on the machine using the ON/OFF

switch at the rear of machine

2. Insert the torch gas connector

into the quick lock gas receptacle.

1. Connect the TIG torch connector

to the terminal.

4. Connect the Earth cable

connector to the terminal

3. Connect the torch switch lead to the torch remote receptacle

Weld start procedure for HF DC TIG welding

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

4. Lay the outside edge of the Gas

Cup on the work piece with the

Tungsten Electrode 1- 3mm 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 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

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DC HF TIG Welding Standard Set Up Procedure:

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2OOAC/DC TIG-MMA

Front panel set up procedure for basic HF DC TIG welding

1. Select DC TIG Function.

2. Select Tungsten Diameter.

3. Set Pre-gas Time

Select DC TIG by pressing the button 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.

(2) Select the tungsten diameter required by pushing the encoder 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.

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

4. Set Start Amps 5. Set Up Slope Time 6. Set Welding Amperage

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

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 appear in the digital display

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

7. Set Down Slope Time 8. Set Finish Amps 9. Set Post Gas Time

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

S et the finish amps by pressing

the encoder to cycle through to illuminate the Finish Amps icon. Set the finish amps by turning the encoder knob. The set finish amps will appear in the digital display

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 appear in the digital display

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DC TIG Welding

70%

30% power source

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Razor

2OOAC/DC TIG-MMA

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 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 19,000°C. 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. low current

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

(amps) are necessary to melt the material.

high current

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 gas molecules .

.

HF plasma stream

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DC Pulse TIG Welding

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2OOAC/DC TIG-MMA

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 1mm of material thickness.

Base Current is the set level of background current (amps) which cools the weld puddle and affects overall heat input. 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, the machine will spend 80% of the pulse at peak amperage and 20% at the base amperage. Increasing the pulse width percentage adds more heat to the job, while decreasing pulse width percentage reduces heat

Current peak amps base amps

Time

ON OFF

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

22

high frequency pulsing no pulse

Razorweld

Set up and operation for DC PULSE TIG Welding

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Razor

2OOAC/DC TIG-MMA

DC Pulse TIG Welding Set Up Procedure

The Razorweld 200 machine has digital pulse frequency control. All the parameters for DC Pulse Tig welding - Peak Amp, Base Amp, Pulse Frequency and Pulse Width are easy to set via the digital control panel.

EXAMPLE OF PULSE DC TIG WELDING - SETUP PARAMETERS:

Material = Stainless Steel x 2.0mm / Tungsten Electrode = 1.6mm 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. Select DC Pulse by pushing selector button to cycle through to illuminate DC Pulse icon.

4. Select the Base Amp by pushing the encoder knob to cycle through to illuminate the Base Amp Icon

2. Select Peak Amp by pressing the encoder knob to cycle through to illuminate the Peak

Amp Icon

3. Rotate the Encoder Knob to set the Peak

Amp at 100A, it will show in the digital display.

(Range is 10-200 Amps)

Peak

Amp

100A

Base

Amp

30A

5. Rotate the Encoder Knob to set the Base Amp at 30A - (Range is 5-200 Amps)

Time = 1 Second (Hz)

100A 100A

30A 30A

6. Select the Pulse Frequency by pushing the encoder knob to cycle through to illuminate the

Pulse Hz Icon

7. Rotate the Adjustment Encoder Knob to set the

Pulse Frequency to 2 Hz - (0.5 - 200Hz)

Pulse Width

100A

30A

8. Select the Pulse Width (on time of the

Peak Amp) by pushing the selector button to cycle through to illuminate the % Pulse Icon

9. Rotate the Adjustment Encoder Knob to set the

Pulse Width at 60% - (Range is 10 - 90%).

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Manual TIG Welding Technique

TIG Welding Fusion Technique

Razor weld

Razor

2OOAC/DC TIG-MMA

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.

Travel direction

Form a weld pool

Retract the filler wire

Angle torch

75° gas shield

Move the torch forward to the front of the weld pool

24

15°

Add Tig filler wire

Repeat the process

Razorweld

Installation Set Up for AC TIG Welding:

Razor weld

Razor

2OOAC/DC TIG-MMA

AC HF TIG Welding Setup and Operation

1. Connect the TIG Torch connector to the negative terminal and tighten it.

2. Insert the torch gas connector into the quick lock gas receptacle.

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 flow to the required rate.

6. Connect the gas line to the quick lock gas inlet connector at the rear of the machine.

Check for gas leaks Welding Guns of Australia PTY LTD nor it's representatives will be responsible for any gas loss.

8. Switch on the machine using the On/Off switch at the rear of the machine.

9. Set the weld parameters using the front panel set procedure on the following page.

6. Connect the gas line to the quick lock gas connector at the rear of the machine

5. Connect the regulator to the cylinder,

Connect the gas lead to the regulator.

Set the flow to 8-12 l/min

(1) Turn on the machine using the ON/OFF

switch at the rear of machine

2. Insert the torch gas connector

into the quick lock gas receptacle.

1. Connect the TIG torch connector

to the terminal.

4. Connect the Earth cable

connector to the terminal

3. Connect the torch switch lead to the torch remote receptacle

Weld start procedure for HF AC TIG welding

1. Assemble the front end torch parts use the correct size and type of tungsten electrode for the job. Use a tungsten type suitable for AC welding.

4. Lay the outside edge of the Gas

Cup on the work piece with the

Tungsten Electrode 1- 3mm 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 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

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Set up and operation for AC TIG Welding

Razor weld

Razor

2OOAC/DC TIG-MMA

Front panel set up procedure for basic AC HF TIG welding

1. Select AC TIG Function.

2. Select Tungsten Diameter.

3. Set Pre-gas Time

Select AC TIG by pressing the button until the AC 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.

(2) Select the tungsten diameter required by pushing the encoder 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.

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

4. Set Start Amps 5. Set Up Slope Time 6. Set Welding Amperage

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

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 appear in the digital display

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

7. Set AC Square Wave Frequency (AC Hz) 8. Set AC Balance

9. Set Down Slope Time

Set the AC Hz by pressing the encoder cycle through to illuminate the AC Hz icon. Set the AC Hz by turning the encoder knob. The set AC Hz will appear in the digital display

Set the AC Balance by pressing the encoder to cycle through to illuminate the AC Balance

icon. Set the AC Balance by turning the encoder knob. The set AC balance will appear in the digital display

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

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continued - Set up and operation for AC TIG Welding

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Razor

2OOAC/DC TIG-MMA

continued - Front panel set up procedure for basic AC TIG welding

10. Set Finish Amps 11. Set Post Gas Time

S et the finish amps by pressing

the encoder to cycle through to illuminate the Finish Amps icon. Set the finish amps by turning the encoder knob. The set finish amps will appear in the digital display

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 appear in the digital display

AC TIG Welding - AC Square Wave Frequency Control

It is possible with the RAZOR200ACDC machine to adjust the frequency of the AC Square Wave output. It means that the amount of time that it takes the AC square wave to complete a full cycle switch from postive (+) to negative (-) can be adjusted from 20Hz (20 times per second) to 200Hz

Increasing frequency (Hz) causes the current to change direction more often, which means that it spends less time per cycle in both DC electrode negative and DC electrode positive mode. By spending less time at each polarity, the arc cone has less time to expand.

A higher frequency produces a narrower arc cone producing an arc that is tighter with more focus at the exact spot the electrode is pointing. The result is improved arc stability, ideal for fillet welds and other fit ups requiring precise penetration.

Decreasing the frequency softens the arc and broadens the weld pool producing a wider bead, produces good overall penetration and ideal for build up applications.

AC Square Wave Hz

Current

Increasing Square Wave Frequency

Slower AC Square Wave Hz

Slower AC Square Wave Hz

Wider Cleaning

Action

Wider Weld Bead

Current

Wider Arc

Broader Weld Pool

Faster AC Square Wave Hz

Faster AC Square Wave Hz

Current

Narrower Cleaning

Action

Narrower Weld Bead

Faster Weld Speed

Narrow Arc

Narrower Weld Pool

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AC TIG Welding - AC Wave Balance Control

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Razor

2OOAC/DC TIG-MMA

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 reverse polarity straight 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.

30% 30% current

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

30% 30% current

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.

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AC TIG Welding - AC Wave Balance Control

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Razor

2OOAC/DC TIG-MMA

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.

current reverse polarity straight 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

BALANCED SQUARE WAVE FORM

EVEN BALANCE

EVEN BALANCE current reverse polarity straight polarity

Even Penetration - Stable Arc More Penetration - Faster Welding

More Electrode Capacity

Less Penetration - Oxide Cleaning

Less Electrode Capacity

The output current and voltage are controlled electronically so the balance between 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 + 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 Adjusted for More Penetration - Cooler Tungsten

25%

Even Penetration - Stable Arc

LESS POSITIVE

BALANCE

More Penetration - Faster Welding

More Electrode Capacity

MORE POSITIVE

BALANCE current

Less Penetration - Oxide Cleaning

Less Electrode Capacity current

Balance Adjusted for More Oxide Cleansing Action - Hotter Tungsten

25%

Even Penetration - Stable Arc

More Penetration - Faster Welding

More Electrode Capacity

Less Penetration - Oxide Cleaning

Less Electrode Capacity

29

Razorweld

Set up and operation for AC PULSE TIG Welding

Razor weld

Razor

2OOAC/DC TIG-MMA

AC Pulse Welding Set Up Procedure

The Razorweld 200ACDC machine has digital Pulse Frequency Control. All the parameters for AC Pulse

TIG welding - Peak Amp, Base Amp, Pulse Frequency and Pulse Width are easy to set via the digital control panel.

EXAMPLE OF PULSE AC TIG WELDING - SETUP PARAMETERS:

Material = Aluminium x 3.0mm / Tungsten Electrode = 2.4mm Zirconiated / 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. Select AC Pulse by pushing selector button to cycle through to illuminate AC Pulse icon.

4. Select the Base Amp by pushing the encoder knob to cycle through to illuminate the Base Amp Icon

2. Select Peak Amp by pressing the encoder knob to cycle through to illuminate the Peak

Amp Icon

3. Rotate the Encoder Knob to set the Peak

Amp at 150A, it will show in the digital display.

(Range is 10-200 Amps)

Peak

Amp

150A

Base

Amp

60A

5. Rotate the Encoder Knob to set the Base Amp at 60A - (Range is 5-200 Amps)

Time = 1 Second (Hz)

150A 150A

30A 30A

6. Select the Pulse Frequency by pushing the encoder knob to cycle through to illuminate the

Pulse Hz Icon

7. Rotate the Adjustment Encoder Knob to set the

Pulse Frequency to 2 Hz - (0.5 - 200Hz)

Peak

Amp

150A

Base

Amp

60A

Pulse Width

8. Select the Pulse Width (on time of the

Peak Amp) by pushing the selector button to cycle through to illuminate the % Pulse Icon

9. Rotate the Adjustment Encoder Knob to set the

Pulse Width at 60% - (Range is 10 - 90%).

30

Razorweld

Remote Amperage Control Operation Procedure

Razor weld

Razor

2OOAC/DC TIG-MMA

Remote amperage controls allow remote welding current adjustment from the welding machine during welding.

Type: ER1MS-10H

on/off switch amperage adjustment

Type: ER1MS-10

amperage adjustment on/off switch

Type: UTJRFC-4

Connection and operation of the remote hand control

1. 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.

2. Select

4T trigger function by pushing the button to cycle through until the 4T icon illuminates as the chosen option.

3. Activate the remote control.

Press and hold the torch switch for 5 second until the machine beeps to indicate the remote function has activated. Repeat the procedure to de-activate the remote control.

(4) The thermal LED will illuminate Green to indicate the machine is in remote control mode. Note: The machine will default to nonremote mode when switched off.

5. Rotate the Remote Control Knobto adjust the amperage output of the machine. The remote can be used static or during welding to adjust the amps up or down.

6. The amps set by the remote control will show in the Digital Display of the machine.

Connection and operation of the remote foot control

1. 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.

2. Select 2T trigger function by pushing the button to cycle through until the

2T

icon illuminates

3. Activate by holding down the foot pedal for

5 seconds, the remote icon will illuminate. Up

& down travel of the foot pedal will adjust the welding amperage during welding. The side potentiometer knob will allow manual set and adjustment.

31

Razorweld

Tungsten Electrodes

Razor weld

Razor

2OOAC/DC TIG-MMA

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, 3,410 degrees Celsius.

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 found in the New Zealand and Australian market.

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

DC Current Amps

Torch Negative

2% Thoriated

AC Current Amps

Un-Balanced Wave

0.8% Zirconiated

AC Current Amps

Balanced Wave

0.8% Zirconiated

1.0mm

1.6mm

2.4mm

3.2mm

4.0mm

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

32

Razorweld

Tungsten Preparation

Razor weld

Razor

2OOAC/DC TIG-MMA

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 whee l

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 flat tip pointed 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

• Have better weld penetration

• Have a narrower arc shape

• Can handle more amperage without eroding. flat spot diameter

Sharper electrodes with smaller included angle provide:

• Offer less arc weld

• Have a wider arc

• Have a more consistent arc included angle

The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration increases and bead width decreases.

Tungsten

Diameter

1.0mm

1.6mm

1.6mm

2.4mm

2.4mm

3.2mm

3.2mm

Diameter at the Tip - mm

.250

.500

.800

.800

1.100

1.100

1.500

Constant Included

Angle - Degrees

20

25

30

35

45

60

90

Current Range

Amps

05 - 30

08 - 50

10 - 70

12 - 90

15 - 150

20 - 200

25 - 250

Current Range

Pulsed Amps

05 - 60

05 - 100

10 - 140

12 - 180

15 - 250

20 - 300

25 - 350

33

Suregrip Series

SR26 ERGO TIG TORCH

8

5

4

3

2

180A AIR COOLED TIG WELDING TORCH

Rating:180Amp DC, 125Amp AC @35% duty cycle.

6

7

9

Stubby

series

Standa rd

series

G as

L en s s eri es

La rge

Gas

Lens

series

Stubby

Gas

Lens

series

10

11

12

13

20

16

17

14

7

15

18

19

1

5

6

7

2

3

4

8

9

10

11

Torch Model

Description

Part Number

4m

SR26 Suregrip Tig Torch Package c/w QF Gas Connect

SR-26-4MCP25

SR-26-4MCP50

Spare Parts

Part Number

WP26

WP26F

57Y02

57Y03

57Y04

UER1MS

UERSWL4

UERSWL8

UERSP1

UERH200

UERKJ200

UERLC200-08

UERJK200

Description

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

Jointing Repair Kit

12

15

16

17

13

14

18

19

20

Part Number

UERNCL-32

UERNCL-72

UERCO200-40

UERCO200-80

USLH26-S

USLH26-H

USLH26-C

USL46V28AR

USL46V30AR

USL3550

USL-1-GS4

10004667

8m

SR-26-8MCP25

SR-26-8MCP50

Description

Neoprene Cover X 3.2mt

Neoprene Cover X 7.2mt

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

34

©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.

Suregrip Series

SR26 ERGO TIG TORCH

Standard Front End Parts

Part # Description

18CG Cup Gasket

Part # Description

10N30 Collet Body 1.0mm

10N31 Collet Body 1.6mm

10N32 Collet Body 2.4mm

10N28 Collet Body 3.2mm

Part # Description

10N49L Long Alumina Nozzle Ø 8mm #5L

53N48L Long Alumina Nozzle Ø 10mm #6L

53N47L Long Alumina Nozzle Ø 11mm #7L

Part # Description

10N22 Collet 1.0mm

10N23 Collet 1.6mm

10N24 Collet 2.4mm

10N25 Collet 3.2mm

Part # Description

10N50 Alumina Nozzle Ø 6mm #4

10N49 Alumina Nozzle Ø 8mm #5

10N48 Alumina Nozzle Ø 10mm #6

10N47 Alumina Nozzle Ø 11mm #7

10N46 Alumina Nozzle Ø 13mm #8

10N45 Alumina Nozzle Ø 16mm #10

10N44 Alumina Nozzle Ø 19mm #12

Compact Gas Lens Front End Parts

Part #

54N01

Description

Gas Lens Gasket

Part #

45V25

45V26

45V27

Description

Gas Lens Body 1.6mm

Gas Lens Body 2.4mm

Gas Lens Body 3.2mm

Part # Description

54N14 Gas lens ceramic 8.0mm

54N15 Gas lens ceramic 7.0mm

54N17 Gas lens ceramic 5.0mm

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

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

1/16 x 7” (1.6mm x 175mm)

3/32 x 7” (2.4mm x 175mm)

1/8 x 7” (3.2mm x 175mm)

Part #

TR0004-10

TR0004-16

TR0004-24

TR0004-32

Description

1.0mm x 175mm thoriated tungsten electrode 2%

1.6mm x 175mm thoriated tungsten electrode 2%

2.4mm x 175mm thoriated tungsten electrode 2%

3.2mm x 175mm thoriated tungsten electrode 2%

Part #

TR0006-10

TR0006-16

TR0006-24

TR0006-32

Description

1.0mm x 175mm zirconiated tungsten electrode 1%

1.6mm x 175mm zirconiated tungsten electrode 1%

2.4mm x 175mm zirconiated tungsten electrode 1%

3.2mm x 175mm zirconiated tungsten electrode 1%

©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.

35

Razorweld

TIG WELDING TROUBLE SHOOTING

Razor weld

Razor

2OOAC/DC TIG-MMA

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

No gas

Inadequate gas flow

Back cap not fitted correctly

Torch connected to DC +

Incorrect tungsten being used

Tungsten being oxidised after weld is finished

Tungsten melting back into the nozzle on AC welding

2: Contaminated tungsten

Possible Reason

Check that pure Argon is being used

Check the gas cylinder contains gas and is connected

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 10 - 15 l/min flow rate

Make sure the torch back cap is fitted so that the o-ring is inside the torch body

Connect the torch to the DC- output terminal

Check and change the tungsten type if necessary

Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10 amps of weld current.

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

Suggested Remedy

Touching tungsten into the weld pool

Touching the filler wire to the tungsten

Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work piece 2 - 5mm

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

Inadequate gas flow / gas leaks

Moisture on the base metal

Contaminated base metal

Contaminated filler wire

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 10 - 15 l/min flow rate. Check hoses and fittings for holes, leaks etc.,

Remove all moisture from base metal before welding

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal

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

Inadequate gas flow

Inadequate post flow gas

Use pure Argon gas

Set the gas flow between 10 - 15 l/min flow rate

Increase the post flow gas time

Alumina gas nozzle too small for size of tungsten being used

Increase the size of the alumina gas nozzle

5: Unstable Arc during DC welding

Possible Reason Suggested Remedy

Torch connected to DC +

Contaminated base metal

Tungsten is contaminated

Arc length too long

Connect the torch to the DC- output terminal

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.

Remove 10mm of contaminated tungsten and re grind the tungsten

Lower torch so that the tungsten is off of the work piece 2 - 5mm

6: HF present but no welding power

Possible Reason Suggested Remedy

Incomplete welding circuit

No gas

Check earth lead is connected. Check all cable connections. If using a water cooled torch check that the power cable is not separated.

Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted. Set the gas flow between 10 - 15 l/min 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

36

Razorweld

continued- TIG WELDING TROUBLE SHOOTING

Razor weld

Razor

2OOAC/DC TIG-MMA

7: Arc wanders during DC welding

Possible Reason Suggested Remedy

Poor gas flow

Incorrect arc length

Tungsten incorrect or in poor condition

Poorly prepared tungsten

Check and set the gas flow between 10 - 15 l/min flow rate

Lower torch so that the tungsten is off of the work piece 2 - 5mm

Check that correct type of tungsten is being used. Remove 10mm from the weld end of the tungsten and re sharpen the tungsten

Grind marks should run lengthwise with tungsten, not circular. Use proper grinding method and wheel.

Contaminated base metal

Contaminated filler wire

Remove contaminating materials like paint, grease, oil, and dirt, including mill scale from base metal.

Remove all grease, oil, or moisture from filler metal.

Incorrect filler wire Check the filler wire and change if necessary

8: Arc difficult to start or will not start DC welding

Possible Reason Suggested Remedy

Incorrect machine set up

No gas, incorrect gas flow

Tungsten is contaminated

Incorrect tungsten size and or tungsten being used

Loose connection

Earth clamp not connected to work

Loss of high frequency

Check machine set up is correct

Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted. Set the gas flow between 10 - 15 l/min flow rate

Remove 10mm of contaminated tungsten and re grind the tungsten

Check and change the size and or the tungsten if required

Check all connectors and tighten

Connect the earth clamp directly to the work piece wherever possible

Check torch and cables for cracked insulation or bad connections. Check spark gaps and adjust if necessary

37

Razorweld

MMA (Stick) WELDING TROUBLE SHOOTING

Razor weld

Razor

2OOAC/DC TIG-MMA

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

Incomplete welding circuit Check earth lead is connected. Check all cable connections.

Wrong mode selected

No power supply

Check the MMA selector switch is selected

Check that the machine is switched on and has a power supply

2: Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Reason Suggested Remedy

Arc length too long

Work piece dirty, contaminated or moisture

Damp electrodes

3: Excessive Spatter

Possible Reason

Suggested Remedy

Shorten the arc length

Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal

Use only dry electrodes

Suggested Remedy

Amperage too high Decrease the amperage or choose a larger electrode

Arc length too long Shorten the arc length

3: Weld sits on top, lack of fusion

Possible Reason Suggested Remedy

Insufficient heat input

Work piece dirty, contaminated or moisture

Poor welding technique

4: Lack of penetration

Possible Reason

Increase the amperage or choose a larger electrode

Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal

Use the correct welding technique or seek assistance for the correct technique

Suggested Remedy

Insufficient heat input Increase the amperage or choose a larger electrode

Poor welding technique

Poor joint preparation

Use the correct welding technique or seek assistance for the correct technique

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

Incorrect travel speed

6: Uneven weld appearance

Possible Reason

Reduce the amperage or use a smaller electrode

Try increasing the weld travl speed

Suggested Remedy

Unsteady hand, wavering hand Use two hands where possible to steady up, practise your technique

7: Distortion − movement of base metal during welding

Possible Reason Suggested Remedy

Excessive heat input Reduce the amperage or use a smaller electrode

Poor welding technique

Poor joint preparation and or joint design

Use the correct welding technique or seek assistance for the correct technique

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

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

38

PO Box 3033, Lansvale NSW 2166, AUSTRALIA

112 Christina Rd, Villawood, NSW 2163

Phone: (02) 9780 4200

Fax: (02) 9780 4244

Email: [email protected] / Web: www.unimig.com.au

Welding Guns Of Australia Pty Ltd

ABN: 14 001 804 422

Welding Guns Of Australia Pty Ltd (‘Us’, ‘We’) warrants that the following products under UNI-MIG, UNI-TIG,

UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA, supplied by Us and purchased by you from an Authorised

UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA Dealer throughout Australia 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.

UNI-MIG WELDING MACHINES

UNI-MIG DIY Series (Power Source Only)

RAZORWELD Series (Power Source Only)

UNI-MIG Procraft Series (Power Source Only)

UNI-MIG Trade Series (Power Source Only)

UNI-MIG Trade Series SWF (Power Source / Seperate Wire Feeder Only)

UNI-MIG Workshop Series (Power Source Only)

UNI-MIG Workshop Series SWF (Power Source / Separate Wire Feeder Only)

UNI-MIG Jasic Inverter MIG (Power Source Only)

UNI-MIG Jasic Inverter MIG SWF (Power Source / Separate Wire Feeder Only)

UNI-TIG Jasic Inverter TIG (Power Source Only)

UNI-MIG Water Cooler

T&R Pulse MIG (Power Source Only)

T&R Pulse MIG SWF (Power Source / Separate Wire Feeder Only)

UNI-PLAS (Power Source Only)

UNI-PLAS Jasic Series (Power Source Only)

UNI-PLAS Site Cut Series (Power Source Only)

UNI-FLAME Gas Cutting and Welding Kits

UNI-FLAME Straight Line & Gas Cutting Machines (Power Source Only)

UNI-FLAME Regulators Argon/ Acetylene / Oxygen / LPG / Bobbin Flowmeter

UNI-FLAME Automatic Welding Helmet

UNI-MIG Automatic Welding Helmets

TECNA (Power Source Only)

HIT-8SS Automatic Carriage (Power Source Only)

ROTA 102 Rotating table

HOTBOX ElectrodeOven

SPOTCAR 3500

TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,

INTERCONNECTING CABLES, GAS HOSE

2 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

1 Year

2 Year

2 Year

3 Years

2 Years

1 Year

(Clause 3)

(Clause 1&3)

(Clause 1&3)

(Clause 1&3)

(Clause 1&3))

(Clause 1&3)

(Clause 1&3)

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

3 Months (Clause 2&3)

1 Year (Clause 3)

1 Year

2 Years

2 Years

1 Year (Clause 3)

(Clause 3) 1 Year

1 Year

1 Year

1 Year (Clause 3)

3 Months (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 Manufacture’s Individual Warranty, Contact the manufacturer for details

(Clause 3) This only Covers Manufactures defaults on all accesories for the first three months after date of purchase.

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WARRANTY / RETURNS / EXCHANGES

We understand that sometimes you may need to return a product you have purchased from Welding Guns Of

Australia PTY LTD Authorised Dealer Network, to assist you, we have set out below the Welding Guns Of Australia

PTY LTD Returns Policy that you should know.

Our Returns Policy includes the rights you have under the Australian Consumer Law and other relevant laws.

Your Rights under the Australian Consumer Law - Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. 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 Welding Guns Of Australia PTY LTD of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.

• You shall also afford Welding Guns Of Australia PTY LTD 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 Welding Guns Of Australia PTY LTD has agreed in writing that you are entitled to reject,

Welding Guns Of Australia PTY LTD liability is limited to either (at the Welding Guns Of Australia PTY LTD discretion) replacing the Goods or repairing the Goods except where you have acquired Goods as a consumer within the meaning of the Trade Practices Act 1974 or the Fair Trading Acts of the relevant state or territories of Australia, 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) Welding Guns Of Australia PTY LTD 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.

• Welding Guns Of Australia PTY LTD Accepts no responsibility for products lost, damaged or mislaid whilst in transit

• Welding Guns Of Australia PTY LTD 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, Welding Guns Of Australia PTY LTD is entitled to choose between providing you with a repair, replacement or other suitable remedy.

• Your rights under the Australian Consumer Law are not limited by a defined time. However, the Australian

Consumer Law does recognise that the relevant time period can vary from product to product, depending on factors such as the nature of the product and the price. Welding Guns Of Australia PTY LTD adopts the same approach. As you can appreciate, the type of remedy we can offer you may also vary depending on how long it takes you to return the product to us.

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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

Sydney Head Office: 02 9780 4200 or Mail PO Box 3033 Lansvale NSW 2166.

Queensland:

Victoria:

Western Australia:

07 3333 2855

03 8682 9911

08 6363 5111

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.

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 UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA,

Failure to read and follow 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 UNI-MIG, UNI-TIG,

UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA Service Dealer

Unless it is a manufacturing fault, this Warranty does not cover the following parts:

MIG Welding Torches and Consumables to suit, such as:

Gas Nozzels, 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 Condue Nipple, Central Plug, Printed Circuit Board, Gun Plug House, Cable

Support, Gas Connector, Handle To Suit PP36 with Knobs, All Xcel-Arc/ Magmaweld Mig Welding Wires &

.

Electrodes, Arc Leads, Welding Cable, Electrode Holder, Eatch 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,

All UNI-MIG TIG Welding Rods, All Xcel-Arc/ Magmaweld Electrodes, Arc Leads, Welding Cable, Electrode Holder,

Eatch Clamps.

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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-authorised UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA,T&R, HIT-8SS & ROTA Dealer

(such as purchases from unauthorised retailers and purchases over the Internet from unauthorised 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 Welding Guns Of Australia PTY LTD

REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE

.

Notes

42

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©

Welding Guns Of Australia PTY LTD 2013

Welding Guns Of Australia Pty Ltd

ABN: 14 001 804 422

PO Box 3033, Lansvale NSW 2166, AUSTRALIA

112 Christina Rd, Villawood, NSW 2163

Phone: (02) 9780 4200

Fax: (02) 9780 4244

Email: [email protected] / Web: www.unimig.com.au

44

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