RAZOR 315 AC/DC MANUAL

RAZOR 315 AC/DC MANUAL
OPERATING MANUAL
KUMJRRW315AC/DC
3YEARS Warranty
(Power Source)
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
1
© Welding Guns Of Australia PTY LTD 2015
RazorWeld
Thank you for your purchase of your UNIMIG TIG 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.
UNIMIG welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1,
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.
2
CONTENTS
PAGE
Warranty2
Safety - Cautions4-6
Technical Data, Product Information7
Machine Layout Description8
Front Panel Operation - Weld Program Controller9
■ Mode Select
9
■ Adjustment Encoder Knob
10
■ Voltage Display Select
10
■ Torch Cycle Select
10
■ Job Recall Select
10
Weld Program Selection & Setting
11
■Pre-gas
11
■ Start Current
11
■Upslope
11
■ Base Current
12
■ Peak Current
12
■ Down Slope
12
■ Finish Current
12
■ Post Gas
13
Pulse Mode Selection & Setting13
■ Pulse Frequency Hz
13
■ Pulse % Width
13
AC Wave Selection & Setting
■ AC Wave Frequency Hz
13
■ AC Wave Balance
14
MMA (Stick Electrode) Selection & Setting
14
■ Ignition Current 14
■ Ignition Time
14
■ Weld Current 15
■ Arc Force
15
LED Display Functions & Alarm LED Codes
16-17
Weld Settings Storage - Job Recall
17
MMA (Stick) Welding - Setup & Operation
18-19
■ MMA (Stick) Welding Fundamentals
20-21
DC HF TIG Welding - Setup & Operation
23
■ DC TIG Welding Fundamentals
24
■ TIG Welding Fusion & Filler Wire Technique
25
■ Pulse TIG Welding Fundamentals
26
DC PULSE TIG Welding - Setup & Operation
27
AC TIG Welding - Setup & Operation
28-29
■ AC Wave Form Fundamentals
30-31
AC PULSE TIG Welding - Setup & Operation
32-33
■ AC Wave Balance Control
34
Remote Amperage Controls35
Tungsten Electrodes36-37
XA26 TIG Torch Parts List Breakdown
38-39
Trouble Shooting Guide - TIG Welding 40-41
Trouble Shooting Guide - MMA (Stick) Welding 42
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.
• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to earth.
Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can
be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health. •Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
•Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
•In confined or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
•Do not weld in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.
•Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic
fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding process produce
intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
•Always wear a welding helmet with correct shade of filter lens and suitable protective clothing including
welding gloves whilst the welding operation is performed.
•Measures should be taken to protect people in or near the surrounding working area. Use protective
screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
4
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 & spatter may cause fire, therefore remove any flammable materials well away from the working area. Cover flammable materials and containers with approved covers if unable to be moved from the welding area..
•Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared
according to the required Safety Standards to insure that flammable or toxic vapors and substances are
totally removed, these can cause an explosion even though the vessel has been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
•Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)
•Have a fire extinguisher nearby and know how to use it. Be alert that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding
on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders are normally part of the welding process, be sure to
treat them carefully. CYLINDERS can explode if damaged.
•Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames,
sparks, and arcs.
•Insure cylinders are held secure and upright to prevent tipping or falling over.
•Never allow the welding electrode or earth clamp to touch the gas cylinder, do not drape welding cables
over the cylinder.
•Never weld on a pressurised gas cylinder, it will explode and kill you.
•Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.
Gas build up. The build up of gas can causes a toxic environment, deplete the oxygen content
in the air resulting in death or injury. Many gases use in welding are invisible and odourless.
•Shut off shielding gas supply when not in use.
•Always ventilate confined spaces or use approved air-supplied respirator.
Electronic magnetic fields. MAGNETIC FIELDS can affect Implanted Medical Devices.
•Wearers of Pacemakers and other Implanted Medical Devices should keep away.
•Implanted Medical Device wearers should consult their doctor and the device manufacturer before going
near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
Hot parts. Items being welded generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the welding
gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns.
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 distant from the wall.
1.4 Ensure the working environment is well ventilated.
2. Safety Tips.
2.1 Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is
of critical importance for the normal performance and service life of this equipment.
2.2
Thermal Overload protection.
2.3
Over-Voltage Supply
Should the machine be used to an excessive level, or in high temperature environment, poorly
ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the
machine will cease to operate. Under this circumstance, leave the machine switched on to keep the
built-in fan working to bring down the temperature inside the equipment. The machine will be ready for
use again when the internal temperature reaches safe level.
Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.
This equipment is of automatic voltage compensation, which enables the maintaining of the voltage
range within the given range. In case that the voltage of input power supply amperage exceeds the
stipulated value, it is possible to cause damage to the components of this equipment. Please ensure
your primary power supply is correct.
2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock
may possibly occur.
MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to prevent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and
dry compressed air of required pressure.
Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of
this welding equipment will be void if the machine has been modified, attempt to take apart the machine or
open the factory-made sealing of the machine without the consent of an authorized representative of the
manufacturer.
TROUBLE SHOOTING
Caution: Only qualified technicians are authorized to undertake the repair of this welding equipment.
For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.
Note:
Minimum Motor Generator Power Suggested: 7KVA
• 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 amended 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.
6
RAZOR DIGITAL 315 AC/DC
TIG/MMA - Digital Inverter Welder
Welds: Aluminium, Magnesium, Zinc Alloys, Steels, Stainless,
Cast Iron, Bronze, Copper ™
Razorweld
™
• Latest IGBT Inverter Technology
• AC/DC HF TIG/MMA Function
• 2T/4T 2S/4S Trigger Select
• AC Square Wave • AC Balance Control
• Pulse Control
• Pulse Width Control • Base CurrentControl
• Up Slope / Down Slope Control
• Pre Gas / Post Gas Control
• Arc Ignition Current Control
• Arc Ignition Time Set Control
• Arc Force Select
• Remote Amperage Control
• Job Memory / Recall
Technical Data
Power Supply / Phases (V-Ph)
415V - 3 ±15%
Rated input capacity (KVA)
9
Rated Input Power (KW) 8.4
ieff (Amps)
13
imax (Amps)
19
Rated Output (A/V) 315/22.6 TIG
250/30 MMA
No-Load Voltage (V) 45
Duty Cycle @ 40ºC as per AS/NZ60974-1
20%@315Amps TIG
60%@230Amps MMA
Power Factor 0.93
Protection Class
IP21S
Insulation Class B
Cooling Mode
Forced air cooling
Parameters in MMA (DC, AC)
Welding current range (A)
DC: 10~250 / AC 20~250
Arc ingnition range (A)
DC: 10~300 / AC 20~300
Arc force current range (A) 0~100
AC frequency (Hz)
50
Parameters in TIG (DC, DC pulsed, AC, AC pulsed)
Start current range (A)
DC: 10~320 / AC: 20~250
Peak current range (A)
DC: 10~320 / AC: 20~320
Base current range (A)
DC: 10~320 / AC: 30~320
Finsih current range
DC: 10~320 / AC: 20~250
DC pulse frequency range (Hz)
0.5~200
DC pulse duty (%)
10~90
AC frequency range (Hz)
20~70
AC balance
10~60
AC pulse fequency range (Hz)
0.5~5.0
AC pulse duty (%)
10~90
Upslope time (s)
0~60
Downslope time (s)
0~60
Pre-flow time (s)
0~15.0
Post-flow time (s)
2.0~20.0
Arc ignition mode
Contact arc ignition, HF arc ignition
Size (mm) 590x375x380
Weight (kg) 33Kg
Warranty
3 years on power source
Certification Approval
AS/NZ60974-1
UTJRFC-3
Remote Foot Control Option
UTJRTROLLEY
Trolley Option
Overview
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Standard option includes: RAZOR315AC/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 PACKAGE: KUMJRRW315AC/DC
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The RAZOR315AC/DC is a Digital Controlled square wave AC/DC TIG inverter welder with full TIG functionality that offers simple step by step digital
setting of functions and parameters providing you with 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 controlling the start and finish of the weld process at a professional
level. Digital Pulse Frequency Control gives full parameter setting of Peak Current, Base Current, Pulse Frequency and Pulse Width, allowing control of
heat input into the work for penetration control and minimising distortion. AC Square Wave with Balance Control gives maximum control of the electron
flow at the tungsten allowing to set the AC TIG arc for maximised cleaning of the oxide layer on aluminium to adjustment for a deeper penetrating weld.
Combined functions of the RAZOR315AC/DC ensures comprehensive control of welding parameters when welding AC and DC weldable materials to
produce high quality Tig welds. Our unique Torch Remote Control Interface provides remote amperage control from the torch in both static and live
welding modes. The DC MMA welding function delivers a smooth and stable arc allowing easy welding with electrodes obtaining high quality welds
including cast Iron, stainless and low hydrogen. The added bonus of Arc Ignition and Arc Force control allows you to set the ideal arc condition no
matter what electrode you choose. The RAZOR315AC/DC has raised the benchmark for 415V three phase AC/DC welders making it ideal for multiple
applications; aluminium & stainless steel fabrication and repair and maintenance applications. Built to our specification and manufactured in compliance
to AS/NZ60974-1.
IG W R R A N
A
Machine Layout Description
™
Razorweld
™
Front Machine Layout Description
1. Control panel
2. Negative output socket
9
1
8
3. Torch gas connector outlet
4. Torch Switch Connector
5. Remote Foot Control Connector
6. Remote Torch Control Connector
7. Positive power connector
8. Mains switch
9. Adjustment control
2
7
3
4
5
6
Rear Machine Layout Description
10. Data Plate
10. Primary Input Power Lead
12.Gas Inlet Connector
10
13. Serial Number Plate
13
11
12
8
Front Panel Operation - Weld Program Sequence Control
™
Razorweld
™
Front Panel Selector Keys
AC
AC PULSE
1
DC
Volts
DC PULSE
Torch Cycle
AC
Job Recall
2
DC
8
ADJUSTMENT
3
ALARM
Peak
Current
Ignition Current
Start
Current
Finish
Current
Base
Current
AC Balance
AC Hz
% Pulse
Arc Force
Ignition
Time
Current
Remote
Pulse Hz
ON/OFF
7
6
5
4
Indicates Action
Selector Key
1. Mode Selector : Enables selection of required welding mode AC TIG - AC PULSE TIG - DC TIG - DC PULSE TIG.
AC MMA (Stick Electrode) - DC MMA (Stick Electrode)
AC
AC
AC
AC PULSE
AC PULSE
AC PULSE
DC
Volts
DC
DCVolts
DC PULSE
Torch
Cycle
DC
PULSE
DCTorch
PULSECycle
AC
AC
Job Recall
ACJob Recall
DC
DC
ADJUSTMENT
ALARM
AC TIG: Select by pushing the
selector key to cycle through to
illuminate the
AC icon.
Start
Current
ALARM
AC Pulse TIG: Select by pushing
the selector key to cycle through to
Ignition Current
illuminate
AC Pulse icon.
Peak
Current
DC
Finish
Current
Base
Current
Start
Current
Ignition
Time Base
Current
ALARM
DC TIG: Select by pushing the
selector key to cycle through to
Ignition Current
illuminate
DC Pulse icon.
Peak
Current
Finish
Start
Current Current
Arc Force
Ignition
Time
Base
Current
Current
AC
AC
AC
AC PULSE
AC PULSE
AC PULSE
DC
AC Balance
AC Hz
% Pulse
Volts
DC
AC Balance
Pulse Hz
AC Hz
% Pulse
Pulse Hz
Remote
ON/OFF
Volts
DC
AC Balance
Torch
Cycle
DC
PULSE
DCTorch
PULSECycle
AC
AC
Job Recall
ACJob Recall
DC
ADJUSTMENT
ALARM
DC Pulse TIG: Select by pushing
the selector key to cycle through to
illuminate
DC Pulse icon.
Start
Current
Finish
Current
Base
Current
AC Balance
AC Hz
% Pulse
Pulse Hz
Start
Current
9 AC Balance
Ignition
Time Base
Current
AC Hz
ALARM
DC MMA: Select by pushing the
selector key to cycle through to
illuminate
DC icon. Ignition Current
Peak
Current
Finish
Start
Current Current
Arc Force
Ignition
Time
Base
Current
Current
% Pulse
% Pulse
DC
ALARM
AC MMA: Select by pushing the
selector key to cycle through to
illuminate
AC icon.Ignition Current
Peak
Current
Current
AC Hz
DC PULSE
DC
Peak
Current
Pulse Hz
Remote
ON/OFF
AC Balance
AC Hz
Peak
Current
Current
% Puls
Front Panel Operation - Weld Program Sequence Control
h
ADJUSTMENT
The Adjustment Encoder Knob is used to set the value of the parameters required.
Turning the encoder will adjust the value shown in the digital display screen.
Arc Force
3.Voltage Display Selector: When selected shows the output voltage on the digital display.
Torch Cycle Selector: Controls the on/off cycle of the machine using the torch switch while
incorporatingthe weld program parameters selections.
Allows the setting and recall of welding parameters.
5 job settings and memory recalls for each welding mode
See page 17 for operational instruction
Remote
ON/OFF
Job Recall Selector:
AC
AC PULSE
Volts
Torch Cycle
Job Recall
Volts: Select the Volts icon using
the selector key.
DC
Volts
DC PULSE
Torch Cycle
AC
Job Recall
DC ADJUSTMENT
Peak
Current
Ignition Current
Ignition
Time
Volts
Ignition Current
Current
AC
Arc
Force
Start
Current
Base
Current
Volts
AC PULSE
Torch Cycle
Torch Cycle
Remote
Job Recall
Job Recall
AC Balance
ON/OFFAC Hz
Finish
Current
Ignition
Time
Arc Force
Current
DC
Volts
DC PULSE
Torch Cycle
Remote
Job RecallON/OFF
DC
Turn the encoder to select
the torch cycle desired.
The digital
ALARMdisplay will show the torch cycle mode selected
Peak
Current
Ignition Current
Ignition Current
Ignition
Time
Ignition
Time
Pulse Hz
AC
% Pulse
ADJUSTMENT
ADJUSTMENT
Torch Cycle: Select the Torch
Cycle icon using the selector key.
Finish
Current
ADJUSTMENT
The ALARM
digital display will show the output voltage present for the
welding mode selected
Ignition Current
Arc Force
Arc Force
Current
Start
Current
Current
AC
AC PULSE
Finish
Current
Base
Current
Ignition
Time
AC PULSE
Volts
DC
Remote
TorchON/OFF
Cycle
ON/OFF
AC
DC PULSE
AC Balance
AC
Job Recall
DC
Torch Cycle
AC Hz
AC Hz
% Pulse
Pulse Hz
Ignition
Time
Start
Current
Current
Pulse Hz
ADJUSTMENT
2T: Select
ALARMthe 2T cycle using the using the adjustment encoder knob
2T uses 2 actions of the torch switch while incorporating weld
Peak
program
parameter selections.
Current
(refer to page 23 for instruction of 2T function)Ignition Current
Finish
Current
% Pulse
Job Recall
DC
Base
Current
4T: Select
ALARMthe 4T cycle using the using the adjustment encoder knob
4T uses 4 actions of the torch switch while incorporating weld
Peak
program
parameter selections.
Current
(refer to page 23 for instruction of 4T function)Ignition Current
Finish
Current
Arc Force
AC Balance
Arc Force
Current
Volts
DC
Remote
Hz
DC
PULSE
ce
™
2. Adjustment Encoder Knob - provides digital adjustment of welding parameters and weld selection cycles
h
nt
nt
AC
Razorweld
™
Base
Current
10
AC Hz
Remote
% Pulse
Pulse Hz
Ignition
Time
Arc Force
Current
AC
AC PULSE
Front Panel Operation - Weld Program Sequence Control
DC
™
AC
4. Weld Program - Provides selection weld program parameters
Parameter selection: Select by pushing selector
pad to
cycle through to illuminate the icon
of the parameter
required. Each push of the selector pad will move the icon
illumination in a clockwise cycle.
Razorweld
™
DC PULSE
Volts
Job Rec
DC
ALARM
Peak
Current
Ignition Cur
Start
Current
Finish
Current
Base
Current
Indicates Action
AC
Selector
Key
AC PULSE
DC
Volts
DC PULSE
Torch Cycle
AC
Job Recall
AC Balance
DC
Pre Gas Timer - ProvidesALARM
selection for gas flow time prior to the arc starting.
AC Hz
% Pulse
Pulse Hz
ADJUSTMENT
Peak
Current
AC
Ignition Current
AC PULSE
Start
Current
Finish
Current
Base
Current
DC
Ignition
Time
Volts
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC Hz
AC
DC
ALARM
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
ADJUSTMENT
AC PULSE
Pre Gas Time: Select
by pushing selector key to cycle through to
DC
Peak
illuminate
the Pre Gas Timer
icon.
Current
DC PULSE
Ignition Current
AC
Base
Current
The value selected shows on the
digital display. It is the length of time
the gas will flow before the arc starts.
Turn the Encoder to set
the Pre-Gas Time
Torch Cycle
(Range is 0-15 Sec)
Volts
Job Recall
Finish
Current
DC
Arc Force
Ignition
Time
ADJUSTMENT
Current
Start Current - Provides ALARM
selection for the amount
of amps required at the start of the weld.
Peak
Current
AC
Ignition Current
AC
ce PULSE
AC Hz
% Pulse
Start
Remote
Pulse Hz
Current
Finish
Current
Base
Current
DC
Ignition
Time
Volts
ON/OFF
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC
DC
ALARM
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
ADJUSTMENT
AC PULSE
Pre Gas Time: Select
DC by pushing selector key to cycle through to
Peak
illuminate
the Start Amp icon.
Current
DC PULSE
Ignition Current
AC
Base
Current
Finish
Current
DC
Ignition
Time
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.
Turn the Encoder to set
the Start Current value
DC Range 10~320
AC Range 20~250
Job Recall
Volts
Torch Cycle
Arc Force
ADJUSTMENT
Up Slope Time - Sets theALARM
transition time from Start Amperage to Welding Amperage
Current
Peak
Current
AC
Ignition Current
AC
PULSE
ce
AC Hz
Start
% Pulse
Current
Pulse Hz
DC
Remote
Finish
Current
Base
Current
Ignition
Time
Volts
ON/OFF
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
DC
ADJUSTMENT
ALARM
Up Slope Time: Select by pushing selector key to cycle through
Peak
to Current
illuminate
the Up Slope icon.
Turn the Encoder to set
the Pre-Gas Time
(Range is 0-60 Sec)
Ignition Current
Base
Current
Finish
Current
Ignition
Time
Arc Force
Current
Torch C
11
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.
Ignition
Time
AC PULSE
DC
Volts
AC
Job Recall
Front PanelDCOperation
- Weld Program Sequence
Torch Cycle Control
PULSE
DC
™
Razorweld
™
ADJUSTMENT
Base Current - ProvidesALARM
selection for the Base Amperage during the Pulse Welding cycle.
Peak
Current
AC
Ignition Current
AC PULSE
Start
Current
Finish
Current
Base
Current
DC
Ignition
Time
Volts
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC Hz
AC
DC
ALARM
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
ADJUSTMENT
AC PULSE
Base Amp: SelectDC
by pushing selector key to cycle through to
Peak
illuminate
the Base Current icon.
Current
DC PULSE
Ignition Current
AC
Base
Current
Job Recall
Finish
Current
DC
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.
Turn the Encoder to set
the Base Current value
Torch Cycle
DC Range 10~320
AC Range 20~320
Volts
Arc Force
Ignition
Time
ADJUSTMENT
Current
Peak Current - Provides ALARM
selection for the Maximum
Welding Current (Amps) required during welding.
Peak
Current
AC
Ignition Current
AC
ce PULSE
AC Hz
% Pulse
Start
Remote
Pulse Hz
Current
Finish
Current
Base
Current
DC
ON/OFF
Ignition
Time
Volts
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC
DC
ALARM
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
ADJUSTMENT
AC PULSE
Peak Current: Select
DC by pushing selector key to cycle through to
Peak
illuminate
the Peak Current icon.
Current
DC PULSE
Ignition Current
AC
Base
Current
Finish
Current
DC
Torch Cycle
Arc Force
Ignition
Time
The value selected shows on the
digital display. It is the maximum set
value of amperage the machine will
deliver..
Turn the Encoder to set
the Peak Current value
DC Range 10~320
AC Range 20~320
Job Recall
Volts
ADJUSTMENT
Current Start Amperage to Welding Amperage
Down Slope Time - SetsALARM
the transition time from
Peak
Current
AC
Ignition Current
AC
PULSE
ce
AC Hz
Start
% Pulse
Current
Pulse Hz
DC
Remote
Finish
Current
Base
Current
Ignition
Time
Volts
ON/OFF
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC
DC
ALARM
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
ADJUSTMENT
AC PULSE
Down Slope Time:DCSelect by pushing selector key to cycle
Peak
through
Current to illuminate the Down Slope icon.
DC PULSE
Ignition Current
AC
Base
Current
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.
Turn the Encoder to set
the Down Slope Time
Torch Cycle
(Range is 0~60 Sec)
Volts
Job Recall
Finish
Current
DC
Arc Force
Ignition
Time
ADJUSTMENT
Current
ALARM
Finish Current - Provides
selection for the amount
of amps required at the end of the weld.
Peak
Current
AC
Ignition Current
AC
ce PULSE
AC Hz
% Pulse
Start
Current
Pulse Hz
Base
Current
DC
Remote
Finish
Current
Ignition
Time
Volts
ON/OFF
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
DC
ADJUSTMENT
ALARM
Finish Amp: Select by pushing selector key to cycle through to
Peak
illuminate
the Finish Amp icon.
Current
Turn the Encoder to set
the Finish Amp value
DC Range 10~320
AC Range 20~250
Ignition Current
Base
Current
Finish
Current
Ignition
Time
Arc Force
Current
12
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.
AC PULSE
DC
Volts
AC
Job Recall
Front PanelDCOperation
- Weld Program Sequence
Control
Torch Cycle
PULSE
DC
™
ADJUSTMENT
Peak
Current
Ignition Current
AC PULSE
Start
Current
Finish
Current
Base
Current
DC
Ignition
Time
Volts
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
DC
ADJUSTMENT
ALARM
Pre Gas Time: Select by pushing selector key to cycle through to
Peak
illuminate
the Post Gas Timer icon.
Current
Turn the Encoder to set
the Pre-Gas Time
(Range is 0-10 Sec)
Ignition Current
AC
Finish
Current
AC PULSE
Base
Current
Ignition
Time
The value selected shows on the
digital display. It is the length of
time the gas will flow after the arc is
finished.
Arc Force
Current
Volts
DC
Torch Cycle
5. Pulse
Mode Parameter Selection: Provides setting of the parameters for Pulse Frequency and Pulse Duty
AC
DC PULSE
% Pulse
Pulse Hz
ce
AC Hz
AC Wave Frequency
Selection:
ALARM
DC
AC Wave Peak
Balance Selection:
Recall
Remote
inJob
AC
Pulse TIG and DC
Pulse TIG Modes.
ON/OFF
ADJUSTMENT
Provides setting of the AC Wave Frequency (Hz) in AC TIG Mode
Provides setting of AC Wave + / - Balance in AC TIG Mode
Current
Ignition Current
AC
AC PULSEStart
Pulse Frequency - Provides setting of the amount of pulses per second of the Peak Current.
Current
Finish
Current
Base
Current
DC
AC
Current
Torch Cycle
AC PULSE
AC Balance
DC
Arc Force
Ignition
Time
Volts
AC
DC PULSE
AC Hz
% Pulse
Remote
Job Recall
Pulse Hz
ON/OFF
DC
Volts
ALARM
DC PULSE
Torch Cycle
Pulse Frequency: Select by pushing selector key
PeakAC
Current
to cycle through to illuminate the Pulse Hz icon.
DC
ADJUSTMENT
Turn the Encoder Knob to
set the Pulse Frequency
DC Range 0.5~200Hz
ADJUSTMENT
AC Range 0.5~5.0Hz
Job Recall
Ignition Current
ALARM
Base
Current
Finish
Current
Peak
Current
Ignition
Time
The value selected is shown in the
digital display. The value selected
is the amount of pulses per second
(Hz)
Arc Force
Current
Ignition Current
AC
AC PULSEStart
Pulse Duty - Provides setting of the % of time the peak current stays on within each pulse cycle.
Current
DC
ce
AC Hz
AC
Finish
Current
Base
Current
% Pulse
Pulse Hz
AC Balance
DC PULSE
DC
Current
Remote
ON/OFF
Torch Cycle
DC
AC
Arc Force
Ignition
Time
Volts
AC PULSE
DC PULSE
AC Hz
% Pulse
Job Recall
Pulse Hz
Volts
Remote
ON/OFF
Torch Cycle
AC
ALARM
PulseDCDuty: Select by pushing selector key to cycle
ADJUSTMENT
Job Recall
Turn the EncoderADJUSTMENT
Knob to
set the Pulse Width
(Range is 10 - 90%).
Peak
through
to illuminate the % Pulse icon.
Current
ALARM
Ignition Current
Peak
Current
Base
Current
AC PULSEStart
Finish
Current
Current
DC PULSE
Finish
Current
Base
Current
AC Hz
AC
Ignition
The value selected is shown in the
digital display. The value selected
is the % of ON time of the Peak
Current during each pulse cycle.
Ignition CurrentArc Force
Time
Current
AC Hz - Provides setting of the frequency
that
the direction of the AC wave (+ to -) completes a full cycle
DC
ce
Razorweld
Post Gas Timer - Provides
selection for continued gas flow time at the end of the welding after the arc is out.
ALARM
AC
AC
™
% Pulse
AC Balance
Volts
Arc Force
Current
Torch Cycle
Pulse Hz
AC Hz
Ignition
Time
Remote
ON/OFF
% Pulse
Pulse Hz
Remote
Job Recall
ON/OFF
DC
ADJUSTMENT
ALARM
AC Hz: Select by pushing selector pad to cycle
Turn the Encoder Knob to
set the Pulse Width
(Range is 20-70 Hz).
Peak
through
to illuminate the AC Hz icon.
Current
Ignition Current
Base
Current
Finish
Current
Ignition
Time
Arc Force
Current
13
The value selected is shown in the
digital display. The value selected
is how many times per second the
AC wave completes a full cycle.
DC PULSE
Torch Cycle
AC
Job Recall
DC
ADJUSTMENT
Front Panel Operation
- Weld Program Sequence Control
ALARM
™
Peak
Current
Razorweld
™
Ignition Current
AC
AC PULSEStart
AC Balance - Provides setting of the % of on time of the electrode negative portion of the AC Wave output current.
Current
Finish
Current
Base
Current
DC
Ignition
Time
Volts
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC Hz
% Pulse
Remote
Job Recall
Pulse Hz
ON/OFF
DC
ADJUSTMENT
ALARM
AC Balance: Select by pushing selector pad to
Turn the Encoder Knob to
set the AC Balance
(Range is 10-60 %).
Peak through to illuminate the AC Hz icon.
cycle
Current
Ignition Current
Finish
Current
Base
Current
ce
AC Hz
% Pulse
Arc Force
Ignition
Time
Current
The value selected is shown in the
digital display. The value selected
is the % of time that the current flow
remains at electrode negative during each AC cycle.
(See pages for 30-31-34 for more
AC Wave Balance information)
Remote
Pulse Hz
ON/OFF
6. MMA Mode Parameter Selection:
Provides setting of the parameters for MMA Ignition Current, Ignition Time
and Welding Current output.
Volts
Ignition Current - Provides setting of the amount of current (amps) delivered at the striking of the arc allowing
Torch Cyclestarting arc characteristic of the electrode. Setting a lower current value than the main welding current will
customised
place Job
theRecall
machine in a low current arc ignition mode providing a lift arc style soft start arc ignition.
Higher current setting provides ADJUSTMENT
contact arc ignition, touching the electrode to the work piece establishes a short circuit
whereby the higher ignition current is applied allowing welding without lifting the electrode.
Ignition Current
Finish
Current
Ignition
Time
Arc Force
Current
Volts
Torch Cycle
Job Recall Remote
ON/OFF
ADJUSTMENT
ALARM
eak
rrent
Ignition Current: Select by pushing
selectorVolts
key to cycle through to illuminate
the Ignition
Current icon.
Ignition Current
Torch Cycle
Job Recall
Finish
Ignition
Time
Current
Arc Force
Turn the Encoder Knob
to set the Ignition Current
level.
DC Range 10~300A
AC Range 20~300A
The value selected is shown in the
digital display. The value selected
is the amount amps delivered at the
striking of the arc in MMA Mode.
(Stick Electrode)
Current
ADJUSTMENT
Ignition Time - Provides setting of the amount Time that the Ignition Current is on.
Ignition Current
% Pulse
Finish
Current
Remote
Pulse Hz
ON/OFF
Ignition
Time
Arc Force
Current
Volts
Torch Cycle
Job Recall Remote
ON/OFF
ADJUSTMENT
ALARM
Ignition Time: Select by pushing
Turn the Encoder Knob
to set the Ignition Current
level.
(Range is 0.01- 1.0 sec)
selector key to cycle through to
illuminate the Ignition Current Ignition
icon.Current
eak
rrent
Finish
Current
% Pulse
Pulse Hz
Ignition
Time
Arc Force
Current
Remote
ON/OFF
14
The value selected is shown in the
digital display. The value selected is
the amount time that ignition current
is applied at the striking of the arc.
Volts
Cycle
FrontTorch
Panel
Operation - Weld Program Sequence Control
Job Recall
™
Razorweld
™
ADJUSTMENT
Current - Provides setting of the main welding current (amps) delivered in MMA Mode (stick electrode).
Ignition Current
Finish
Current
Ignition
Time
Arc Force
Current
Volts
Torch Cycle
Job Recall Remote
ON/OFF
ADJUSTMENT
ALARM
Current: Select by pushing selector key
to cycle through to illuminate the Current
icon.
Ignition Current
eak
rrent
Finish
Current
Ignition
Time
Volts
Arc Force
Turn the Encoder Knob
to set the Ignition Current
level.
DC Range 10~250A
AC Range 20~250A
The value selected is shown in the
digital display. The value selected is
the amount current (amps) delivered
during welding in MMA Mode.
(Stick Electrode)
Current
Arc Force
- Provides setting of extra current being applied to the electrode when the arc length becomes short
Torch Cycle
% Pulse
preventing the electrode from sticking during welding. The more Arc Force applied the more aggressive and digging
Job Recall
Remote to the work piece. The less Arc Force applied the smoother
becomes
the arc and less chance of the electrode sticking
Pulse Hz
ON/OFF
ADJUSTMENT
and softer is the arc characteristic.
The required Arc Force is dependant on the type of electrode, application and
operator preference.
Ignition Current
Finish
Current
Ignition
Time
Arc Force
Current
Volts
Torch Cycle
Job Recall Remote
ON/OFF
ADJUSTMENT
ALARM
eak
rrent
Arc Force: Select by pushing selector
key to cycle through to illuminate the Arc
Force
icon.
Ignition Current
ADJUSTMENT
Finish
Current
Force
% Pulse
7. Pulse
Remote ON/OFF :
Hz
Ignition
Time
Turn the Encoder Knob
to set the Arc Force level.
(Range is 0-100)
The value selected is shown in the
digital display. The value selected is
the amount of Arc Force applied to
the electrode during welding.
Arc Force
Current
Provides use of remote amperage
controls. Functional in TIG mode only.
Remote
ON/OFF
Remote
ON/OFF
Remote : Select by pushing the Remote ON/
OFF
key. The led will flash when the remote
ADJUSTMENT
function is on.
1. No LED Remote is OFF
The minimum welding current will be
30 amps - the maximum obtainable
welding current will be as is preset at
the machine.
2. Press button once
Force
LED Light is Solid and ready to activate
3. Press button twice and LED Light is Flashing
Remote control is activated
Remote
ON/OFF
15
The adjusting welding current will
be displayed at the digital meter in
real time while the remote control is
being used.
Remote control is functional in TIG
mode only.
Front Panel Operation - LED Display Functions - Alarms
Razorweld
™
7. LED Display Functions - Alarms :
™
Provides display of parameters and alarm codes.
Parameter Display - Provides display of parameter settings.
AC
AC
AC PULSE
AC PULSE
DC
Volts
DC PULSE
AC
Torch Cycle
DC
Volts
DC
Volts
Torch Cycle
DC PULSE
Torch Cycle
AC
Job Recall
Job Recall
ADJUSTMENT
Job Recall
ALARM
Parameter Settings: The display will
Base
Current
ALARM
ADJUSTMENT
Peak
Current
LARM
DC
illuminate and display the welding current
Finish Ignition Current
during welding.
Current
Finish
Current
Ignition
Time
Turn the Encoder Knob
to adjust parameters
Start
settings
Arc Force
Current
Ignition Current
Ignition
Time
Current
ON/OFF
AC
AC
Pulse Hz
AC PULSE
AC Hz
% Pulse
Volts
DC PULSE
TorchDC
Cycle
PULSE
Torch Cycle
AC
AC
Job Recall
DC
Job Recall
DC
ADJUSTMENT
ALARM
Peak
Current
ware version number will be show on the
Finishis powered
Start
display when the machine
up.
Current
Current
% Pulse
ADJUSTMENT
ALARM
Software Version Display: The soft-Ignition Current
AC Hz
Pulse Hz
ON/OFF
Volts DC
nce
Current
Remote
AC PULSE
DC
Base
Current
Ignition
Time
Current
AC Hz
% Pulse
Ignition Current
Arc Force
Remote Software
Software
Version
Display - Provides display of the Version
AC Balance
% Pulse
Pulse Hz
nce
Peak
Current
Other parameter settings will be
displayed as selected, such as
preset current time, pulseFinish
ratio, pulse
Current
Base frequency etc.
Current
Pulse Hz
Ignition
Time
Peak
Current
Software version will display for
2 seconds and then revert to the
Finishweldpreset
current of last used
Arc Force
Current
Base
Current ing current setting.
Current
AC Balance
AC Hz
% Pulse
Ignition Current
Ignition
Time
Arc Force
Current
Remote
Remote
Pulse
Hz
ON/OFF
ON/OFF
Alarm LEDs - Provides display of alarm condition and error code.
In normal condition, all alarm LEDs are off. In case of any error, the corresponding LED will illuminate
and the digital meter will display the corresponding error code
AC
AC
AC
AC PULSE
AC PULSE
AC PULSE
DC
Volts DC
Volts DC
Volts
DC PULSE
TorchDC
Cycle
PULSE
TorchDC
Cycle
PULSE
Torch C
AC
AC
Job Recall
AC
Job Recall
DC
nce
DC
ADJUSTMENT
ALARM
Peak
Current
situation. Re-start the machine and
Finish
Start
welding can continue. Current
Current
AC Hz
% Pulse
ADJUSTMENT
ALARM
Alarm E-0: Indicates over current
Base
Current
Job Re
DC
Pulse Hz
ALARM
Peak
Current
Alarm E-1: Indicates over current
Ignition Current
Ignition
Time
AC Balance
Base
Current
Current
situation. Re-start the machine and
Start
welding
Arc Forcecan continue. Finish
Current
Current
AC Hz
% Pulse
Remote
Pulse
Hz
ON/OFF
16
Peak
Current
Ignition Current
Ignition
Time
AC Balance
Alarm E-2: Indicates that mains
voltage supply is overly low or the
Finish
secondary
inverter driveCurrent
fails. In
Arc Force
Base
Currentthe first instance
Current
Supply the correct mains voltage.
For the inverter fail contact ask a
technician for checking.
AC Hz
% Pulse
Remote
Pulse
Hz
ON/OFF
Ignition Cu
Ignitio
Time
Front Panel Operation - LED Display Functions - Alarms
™
AC
AC PULSE
DC
Volts DC
Volts
DC PULSE
TorchDC
Cycle
PULSE
Torch Cycle
AC
AC
Job Recall
DC
h
nt
Hz
™
AC
AC PULSE
nce
Razorweld
Job Recall
DC
ADJUSTMENT
ALARM
Peak
Current
Peak
Current
Alarm E-3: Indicates the machine
Base
Current
has over heated and the thermal
Finish the
switch has activated. Leave
Current
machine on to allow the fan to cool
the machine and recover.
AC Hz
% Pulse
ADJUSTMENT
ALARM
Ignition Current
Start
Current
Pulse Hz
Ignition
Time
AC Balance
Alarm E-4: Indicates the main
circuit of the machine has overFinish on to
heated.
Arc Force Leave the machine
Current
Base
Current allow the fan to cool the machine
Current
and recover.
AC Hz
% Pulse
Ignition Current
Ignition
Time
Arc Force
Current
Remote
Remote
Pulse
Hz
ON/OFF
ON/OFF
Welding Parameter Storage Allows the setting and recall of welding parameters.
Job recall
5 job settings and memory recalls for each welding mode.
The parameters having been adjusted will be auto saved in the Job number currently in use. No auto saving will happen if welding is not carried out after the parameters have been changed. When the machine is turned on it will revert
to the last welding parameters used for that selected Job. There is no manual save function available.
Allows users to save welding parameters based on the welding application in use for a total of 5 Jobs in each welding
mode. 5 Jobs for each of the six welding modes available.
When the machine is turned on the last Job used welding parameters will be displayed. If a new Job number is not
selected the machine will continue to work under the current Job.
Note: (Parameters in all the five Job groups are the same as default when using the machine for the first time.)
Volts
Volts
Torch Cycle
Torch Cycle
Job Recall
Job Recall
ADJUSTMENT
ADJUSTMENT
Job Recall: Select the Job Recall
icon using the selector pad.
Turn the encoder to select
the Job number required.
The digital display will show the Job number recalled.
Ignition Current
Ignition Current
Finish
Current
Ignition
Time
Ignition
Time
Arc Force
Arc Force
Current
Current
Remote
Remote
ON/OFF
ON/OFF
17
Set Up Procedure for MMA (Stick) Welding:
Razorweld
™
™
MMA (Stick Electrode) Welding Set 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 front control panel.
(3) Select you preferred MMA mode using the MODE selector key.
(3) Select preferred MMA mode
using the MODE selector key
(2) Turn on the Power source
using the on/off switch at the
rear of the machine
(1) Connect theElectrode Lead
lead to
terminal
(1) Connect Earth Lead
the
terminal
MMA - Ignition Current Set
MMA - Current Set
AC
AC
AC PULSE
AC PULSE
DC
Volts
DC
Volts
DC PULSE
Torch Cycle
DC PULSE
Torch Cycle
Job Recall
AC
AC
DC
Job Recall
DC
ADJUSTMENT
ADJUSTMENT
ALARM
ALARM
Peak
Current
Peak
Current
Ignition Current
Start
Current
Finish
Current
Base
Current
AC Balance
AC Hz
% Pulse
Pulse Hz
Ignition
Time
Ignition Current
Start
Current
Arc Force
Remote
AC Balance
ON/OFF
(4) Select the Welding Current push the key until the Current
icon is illuminated. Set the weld amperage by rotating the
Adjustment Knob. Set the amperage according to the electrode
type and size as recommended by the electrode manufacturer. The
the set amperage will show in the Digital Display.
Finish
Current
Base
Current
Current
AC Hz
% Pulse
Pulse Hz
(5) Select Ignition Current. Push the
Ignition
Time
Arc Force
Current
Remote
ON/OFF
key until the Ignition
Current icon illuminates. Turn the Adjustment Knob to set the
Ignition Current, the set current will be shown on the Digital Display. Refer to Page 14 for instruction on Ignition Current.
18
Set Up Procedure for MMA (Stick) Welding:
Razorweld
™
MMA - Ignition Time Set
MMA - Arc Force Set.
AC
AC
AC PULSE
AC PULSE
DC
Volts
DC
Volts
DC PULSE
Torch Cycle
DC PULSE
Torch Cycle
AC
Job Recall
AC
DC
Job Recall
DC
ADJUSTMENT
ADJUSTMENT
ALARM
ALARM
Peak
Current
Peak
Current
Ignition Current
Start
Current
Finish
Current
Base
Current
AC Balance
™
AC Hz
% Pulse
Ignition
Time
Ignition Current
Start
Current
Arc Force
Pulse Hz
Remote
AC Balance
ON/OFF
(6) Select the Ignition Time. Push the key until the Ignition time
icon is illuminated. Set the Ignition time by rotating the Adjustment
Knob. The set Ignition time will show in the Digital Display.
Refer to Page 14 for instruction on Ignition Time.
Finish
Current
Base
Current
Current
AC Hz
% Pulse
Pulse Hz
Ignition
Time
Arc Force
Current
Remote
ON/OFF
(7) To set the Arc Force push the same
key until the Arc Force
icon illuminates. Turn the Adjustment Knob to set the Arc Force,
the set value will be shown on the Digital Display.
Refer to Page 15 for instruction on Arc Force.
MMA (Stick Electrode) Welding
6) Connect the Earth Clamp securely to
7) Place and clamp an electrode into the
the work piece or the work bench.
Electrode Hand Piece
9) Hold the electrode slightly above the
10) To finish the weld, break the arc by
quickly snapping the electrode away from
the work piece.
work maintaining the arc while travelling
at an even speed.
19
8) Strike the electrode against the work
piece to create an arc, lift slightly and
hold the electrode steady to maintain
the arc
11) Wait for the weld to cool and carefully
chip away the slag to reveal the weld
metal below.
MMA (Manual Metal Arc) Welding
One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod
is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from
atmospheric contamination. The electrode core itself acts as filler material the residue from the flux that forms a slag
covering over the weld metal must be chipped away after welding.
Core wire
+
Flux coating
Gas shield from flux melt
Power Source
Arc with core wire melt
Flux residue forms slag cover
Weld metal
▬
• The arc is initiated by momentarily touching the electrode to the base metal.
Core wire
Flux coating
Base metal
• The heat of the arc melts the surface of the base metal to form a molten pool
at the end of the electrode.
• The melted electrode metal is transferred across the arc into the molten pool
and becomes the deposited weld metal.
• The deposit is covered and protected by a slag which comes from the
electrode coating.
• The arc and the immediate area are enveloped by an atmosphere of
protective gas
Protective gas
Arc
Manual metal arc ( stick) electrodes have a solid metal wire core and a flux
coating. These electrodes are identified by the wire diameter and by
a series of letters and numbers. The letters and numbers identify the metal
alloy and the intended use of the electrode.
The Metal Wire Core works as conductor of the current that maintains the arc.
The core wire melts and is deposited into the welding pool.
Slag
Weld pool
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.
20
MMA (Stick) Welding Fundamentals
Electrode Selection
As a general rule, the selection of an electrode is straight forward,in that it is only a matter of selecting an
electrode of similar composition to the parent metal. However, for some metals there is a choice of several
electrodes, each of which has particular properties to suit specific classes of work. It is recommend to consult your welding supplier for the correct selection of electrode.
Electrode Size
Average Thickness
of Material
Maximum Recommended
Electrode Diameter
1.0 - 2.0mm
2.0 - 5.0mm
5.0 - 8.0mm
8.0 - > mm
2.5mm
3.2mm
4.0mm
5.0mm
Current Range
(Amps)
60 - 95
100 - 130
130 - 165
165 - 260
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)
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.
21
Set Up Procedure for DC TIG Welding:
™
Razorweld
™
TIG Welding Set and Operation
(1) Connect the TIG Torch connector to the negative terminal and tighten it
(2) Connect the torch switch remote lead into the torch remote socket
(3) Insert the torch gas connector into the quick lock gas receptacle
(4) Connect the Earth Cable connector into the positive terminal and tighten it
(5) (A) Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder
(B) Connect the gas line to the quick lock gas inlet connector at the rear of the machine
(C) Slowly open the cylinder valve.
(D) Set the flow rate on the regulator to approximately 8 -12 l/min.
(E) 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 -12 l/min, close the cylinder valve and check after a minimum of 15 minutes.
(F) 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.
(G) 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.
(6 Turn on the machine using the ON/OFF switch
(7) Select the preferred TIG function with the MODE selector switch
(5) Connect the regulator to the cylinder,
Connect the gas lead to the regulator.
Set the flow to 8-12 l/min
(7) Select preferred TIG mode using
the MODE selector switch
(6) Turn on the machine using the
ON/OFF switch on the back of machine
(2) Connect the torch switch lead
to the torch remote receptacle
(3) 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
22
DC HF TIG Welding Standard Operation:
™
Razorweld
™
HF (high frequency) ignition allows the arc to be started in TIG welding without touching the tungsten to the
work piece. By pressing the torch switch the machine will activate the gas flow and the HF ignition
resulting in the arc igniting across the gap between the tungsten electrode and the work piece.
The distance between the electrode and the work piece can be up to 5mm. This arc ignition method
prevents tungsten inclusion in the work piece, promotes longer tungsten life and offers better operator
control over the starting and stopping the arc.
(1) Assemble the front end torch parts use the correct size and type of tungsten electrode for the job,
the tungsten electrode requires a sharpened point for DC welding.
(2) Select DC TIG and choose 2T or 4T trigger function preferred as per the descriptions below
2T Selection provides 2 times function of the torch switch.
(1) Pressing the torch switch gives arc ignition and initializes the welding current and the welding
current is maintained by the torch remaining on.
(2) Releasing the torch switch stops the welding by introducing down slope and the current falls to
minimum level and then terminates the welding current and introduces the post flow gas.
4T Selection provides 4 times function of the torch switch
(1) Pressing the torch switch gives arc ignition and initializes the welding current
(2) Releasing the torch switch continues the welding operation.
(3) Pressing the torch switch and holding introduces down slope and current falls to minimum current.
(4) Releasing the torch switch terminates the welding operation and introduces the post flow gas.
(3) Choose the preferred welding current (amperage) to suit the tungsten size material type and
thickness to be welded.
(4) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 3mm from the
work piece this method will provide a clean positive arc ignition.
(5) Press the torch switch and the arc will ignite across the gap between the tungsten and work piece.
Hold even distance of about 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.
AC
AC
AC PULSE
AC PULSE
DC
DC
Volts
Volts
DC PULSE
DC PULSE
Torch Cycle
Torch Cycle
AC
AC
Job Recall
Job Recall
DC
DC
ADJUSTMENT
Peak
Current
(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
Electrode1- 3mm from the work piece
(2) Select DC TIG Function.
Push the
key until the
DC Tig icon illuminates
Start
Current
Base
Current
Start
Current
AC Balance
AC Hz AC Balance
% Pulse
Peak
Current
(3) Select 2 or 4 trigger function as required by the pushing
the
key until the Torch Cycle icon illuminates. Turn the
Adjustment knob to select the option shown on the digital
display. Press the torch switch to exit Torch Cycle mode. The
display will default to the set welding current, adjust the set
Remote
Remote
AC
Hz
Pulsethe
Hz
Pulse
Hz % Pulse using
current
Adjustment knob.
Ignition Current
Ignition Current
Base
Current
Finish
Current
(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 &
work piece to maintain the arc.
23
ADJUSTMENT
ALARM
ALARM
Finish
Ignition
Current
Time
Ignition
Arc
Force
Time
Current
Arc Force
Current
ON/OFF
ON/OFF
(6) Release the torch switch to bring in the end
of the welding sequence dependant of 2T
or 4T trigger function choice
DC TIG Welding
30%
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 ).
70%
argon gas
power source
low
current
nozzle
DC TIG welding is a process in which an arc is struck between a
TUNGSTEN electrode and the metal work piece. The weld area
is shielded by an inert gas flow to prevent contamination of the
tungsten, molten pool and weld area.
When the TIG arc is struck the inert gas is ionized and
superheated changing it’s molecular structure which converts it into
a plasma stream. This plasma stream flowing between the tungsten
and the work piece is the TIG arc and can be as hot as 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.
The intensity of the arc is proportional to the current that flows from the
tungsten. The welder regulates the welding current to adjust the power
of the arc. Typically thin material requires a less powerful arc with less
heat to melt the material so less current (amps) is required, thicker
material requires a more powerful arc with more heat so more current high
current
(amps) are necessary to melt the material.
HF ARC IGNITION for TIG (tungsten inert gas) Welding
HF (high frequency) ignition allows the arc to be started in TIG welding without touching the tungsten to the
work piece. By pressing the torch switch the machine will activate the gas flow and introduce the HF (high
frequency) (high voltage) spark, this “ionizes” the air gap making it conductive allowing an arc to be created
without touching the tungsten to the work piece. The gas molecules are superheated by the arc creating
a stream of super heated gas that changes the molecular structure into producing a plasma stream. This
plasma stream provides heat and energy that allows us to melt and fuse metals in an inert gas shielded
environment know as TIG (tungsten inert gas) welding.
gas flow
gas
molecules
. .
.... . ..
.. .. .
HF
plasma
stream
24
TIG Welding Fusion Technique
Manual TIG welding is often considered the most difficult of all the welding
processes. Because the welder must maintain a short arc length, great care and skill are
required to prevent contact between the electrode and the work piece. Similar to Oxygen
Acetylene torch welding, TIG welding normally requires two hands and in most
instances requires the welder to manually feed a filler wire into the weld pool with one
hand while manipulating the welding torch in the other. However, some welds combining
thin materials can be accomplished without filler metal like edge, corner, and butt joints.
This is known as Fusion welding where the edges of the metal pieces are melted together using only the
heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until
a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired
size. Once the weld pool is established tilt the torch at about a 75° angle and move smoothly and evenly
along the joint while fusing the materials together.
75°
Travel direction
Form a weld pool
Angle torch
Move the torch slowly
and evenly forward
TIG Welding with Filler Wire Technique
It is necessary in many situations with TIG welding to add a filler wire into the weld
pool to build up weld reinforcement and create a strong weld. Once the arc is started
the torch tungsten is held in place until a weld pool is created, a circular movement
of the tungsten will assist is creating a weld pool of the desired size. Once the weld
pool is established tilt the torch at about a 75° angle and move smoothly and
evenly along the joint. The filler metal is introduced to the leading edge of the weld pool. The filler wire is usually held at about a 15° angle and fed into the
leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is
moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the
wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly
and evenly forward. It is important during the welding to keep the molten end of the filler wire inside
the gas shield as this protects the end of the wire from being oxidised and contaminating the weld
pool.
75°
Travel direction
Form a weld pool
15°
Angle torch
Add Tig filler wire
gas
shield
Retract the filler wire
Move the torch forward to
the front of the weld pool
25
Repeat the process
DC Pulse TIG Welding
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. Background Amps is a percentage of peak amperage. As a rule, use enough background current to reduce the weld pool to about half its normal size while still keeping the weld pool fluid. As a guide
start by setting the background amperage at 20 to 30 percent of peak amperage.
Pulse Frequency is the control of the amount of times per second (Hz) that the welding current switches
from Peak Current to Base Current. DC Pulse TIG frequency ranges from 0.5 to 200 HZ depending on the
job application. Control of the pulse frequency also determines the appearance of the weld.
Pulse Width is the control of the percentage of time during one pulsing cycle the power source spends at
the peak current (main amperage). Example is with the Pulse Width set at 80 percent and a rate of 1 pulse
per second (PPS), the machine will spend 80% of the pulse at peak amperage and 20% at the base
current. Increasing the pulse width percentage adds more heat to the job, while decreasing pulse width
percentage reduces heat
Current
peak
background
ON
OFF
Time
DC Pulse TIG welding allows faster welding speeds with better control of the heat input to the job, reducing
the heat input minimising distortion and warping of the work and is of particular advantage in the welding
of thin stainless steel and carbon steel applications. The high pulse frequency capability of the advanced
inverter agitates the weld puddle and allows you to move quickly without transferring too much heat to the
surrounding metal. Pulsing also constricts and focuses the arc thus increasing arc stability, penetration and
travel speeds.
high frequency
pulsing
high frequency
pulsing
no pulse
26
no pulse
Set up and operation for DC PULSE TIG Welding
The Razorweld 315 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:
AC
Material = Stainless Steel x 2.0mm / Tungsten
Electrode = 1.6mm 2% Thoriated / Gas = Argon
AC PULSE
The following steps are a guide as a starting
point for you to set the machine upVolts
in Pulse mode to give an
DC
example of welding in Pulse mode function. You can experiment by changing any of the variables to see
Torch Cycle
DC PULSE
what effect it has over the welding and what the end result can be, but it is suggested to change only one
AC
Job Recall
variable at a time and then check the welding to see what the result is, in this way
you acquire a better
DC
ADJUSTMENT
understanding of how each variable affects the welding
current.
ALARM
Peak
Current
AC
Ignition Current
AC PULSE
Start
Current
DC
AC
Ignition
Time
Job Recall
DC
AC Balance
ALARM
DC PULSE
1. Select DC Pulse
AC by pushing
selector key to cycle through to
DC icon.
illuminate DC Pulse
Start
Current
AC Hz
Volts
% Pulse
2. Select Peak Current by pushing the selector button to
Job Recall
cycle through to illuminate the Peak Current Icon
Peak
Current
Ignition Current
ALARM
Finish
Current
Ignition
Time
AC Balance
Finish
Current
AC Hz
% Pulse
Ignition
Time
Pulse Hz
ON/OFF
3. Turn the Adjustment Knob to set the
Peak Current at 100A
ADJUSTMENT(Range is 10-200 Amps)
Arc Force
Current
Peak
Amp
Ignition Current
Base
Current
Remote
ADJUSTMENT
Pulse Hz
Torch Cycle
Base
Peak
Current
Current
Start
Current
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC PULSE
DC
Finish
Current
Volts
Base
Current
Arc Force
Remote
Current
100A
ON/OFF
AC
Base
Amp
AC PULSE
AC Balance
DC
AC Hz
% Pulse
DC PULSE
4. Select the BaseACCurrent by pushing the selector key to
cycle through to illuminate the Base Current Icon
DC
30A
Remote
Volts
Pulse Hz
ON/OFF
Torch Cycle
5. Turn the Adjustment Knob to set the Base
Current at 30A (Range is 10-200 Amps)
Job Recall
ADJUSTMENT
ALARM
Pulse Width
Peak
Current
Ignition Current
Start
Current
Finish
Current
Base
Current
Ignition
Time
Arc Force
Current
Peak
Amp
Peak Amp
On Time
100A
100A
60%
AC
Base
Amp
AC PULSE
AC Balance
DC
AC Hz
% Pulse
ON/OFF
Torch Cycle
DC PULSE
6. Select the Pulse
AC width ( % on time of the Peak Amp) by
pushing the selector key to cycle through to illuminate the %
DC
Pulse Icon
7. Turn the Adjustment Knob to set the
Pulse Width at 60%. (Range is 10 - 90%).
Job Recall
ADJUSTMENT
ALARM
Time = 1 Second (Hz)
Peak
Current
Peak
Amp
Ignition Current
Start
Current
30A
40%
30A
Remote
Volts
Pulse Hz
Finish
Current
Base
Current
Ignition
Time
100A
60%
Arc Force
Current
100A
60%
Base
Amp
AC Balance
AC Hz
% Pulse
Remote
Pulse Hz
8. Select the Pulse Frequency by pushing the selector key to
cycle through to illuminate the Pulse Hz Icon
ON/OFF
9. Turn the Adjustment Knob to set the
Pulse Hz to 2 Hz (Range is 0.5 - 200Hz)
27
30A
40%
30A
40%
Set Up Procedure for AC TIG Welding:
™
Razorweld
™
TIG Welding Set and Operation
(1) Connect the TIG Torch connector to the negative terminal and tighten it
(2) Connect the torch switch remote lead into the torch remote socket
(3) Insert the torch gas connector into the quick lock gas receptacle
(4) Connect the Earth Cable connector into the positive terminal and tighten it
(5) (A) Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder
(B) Connect the gas line to the quick lock gas inlet connector at the rear of the machine
(C) Slowly open the cylinder valve.
(D) Set the flow rate on the regulator to approximately 8 -12 l/min.
(E) 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 -12 l/min, close the cylinder valve and check after a minimum of 15 minutes.
(F) 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.
(G) 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.
(6 Turn on the machine using the ON/OFF switch
(7) Select the preferred TIG function with the MODE selector switch
(5) Connect the regulator to the cylinder,
Connect the gas lead to the regulator.
Set the flow to 8-12 l/min
(7) Select preferred TIG mode using
the MODE selector switch
(6) Turn on the machine using the
ON/OFF switch on the back or the machine
(2) Connect the torch switch lead
to the torch remote receptacle
(3) 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
28
AC HF TIG Welding Standard Operation:
™
Razorweld
™
AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminium, Aluminium Alloys and
Magnesium. These materials have an insulating surface oxide layer that melts at a higher temperature than
the base metal making it difficult to weld the base metal if the oxides are not removed. AC welding current
is ideal because the nature of the AC wave form assists in breaking the surface oxide layer. HF arc ignition provides easy and precise starting of the arc.
(8) Assemble the front end torch parts use the correct size and type of tungsten electrode for the job.
(9) Select AC tig function using the mode selection key (10) Choose 2T or 4T trigger function preferred as per the descriptions below
2T Selection provides 2 times function of the torch switch.
(1) Pressing the torch switch gives arc ignition and initializes the welding current and the welding
current is maintained by the torch remaining on.
(2) Releasing the torch switch stops the welding by introducing down slope and the current falls to
minimum level and then terminates the welding current and introduces the post flow gas.
4T Selection provides 4 times function of the torch switch
(1) Pressing the torch switch gives arc ignition and initializes the welding current
(2) Releasing the torch switch continues the welding operation.
(3) Pressing the torch switch and holding introduces down slope and current falls to minimum current.
(4) Releasing the torch switch terminates the welding operation and introduces the post flow gas.
(11) Choose the preferred welding current (amperage) to suit the tungsten size material type and
thickness to be welded.
(12) Set the AC Balance control to approximately 20%
(13) Set the AC Hz control to approximately 60Hz
(14) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 3mm from the
work piece this method will provide a clean positive arc ignition.
(15) 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.
(16) Release the torch switch to bring in the end of the welding sequence dependant of 2T or 4T trigger
function choice.
AC
AC
AC PULSE
AC PULSE
DC
DC
Volts
Volts
DC PULSE
DC PULSE
Torch Cycle
Torch Cycle
AC
AC
Job Recall
Job Recall
DC
DC
ADJUSTMENT
AC
Peak
Current
AC PULSE
(8) Assemble the front
end torch parts
use the correct size and type of tungsten
DC
electrode for the job, the tungsten electrode requires a sharpened
DC PULSE point for DC
welding
(9) Select AC TIG Function.
Push the
key until the
Volts
AC Tig icon illuminates
Start
Current
Base
Current
Start
Current
Torch Cycle
AC
AC Balance
AC Balance
AC Hz Recall
% Pulse
Job
DC
ADJUSTMENT
ALARM
ALARM
Peak
Current
(10) Select 2 or 4 trigger function as required by the pushing
the
key until the Torch Cycle icon illuminates. Turn the
Adjustment knob to select the option shown on the digital
display. Press the torch switch to exit Torch Cycle mode. The
display will default to the set welding current, adjust Remote
the set
Remote
AC
Hz Hz % Pulse
Pulse Hz
Pulse
current using
the Adjustment knob.
Ignition Current
Ignition Current
Base
Current
Finish
Current
Finish
Ignition
Current
Time
Ignition
Arc
Force
Time
Current
Arc Force
Current
ON/OFF
ON/OFF
ADJUSTMENT
ALARM
Peak
Current
AC
Ignition Current
AC PULSE
Start
Current
Finish
Current
Base
Current
DC
Ignition
Time
Volts
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC Balance
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
DC
ADJUSTMENT
ALARM
(11) Current Set. Select by pushing selector key to cycle through
Peak
to illuminate
the Peak Current icon. Set the Peak Current (amps)
Current
to suit the tungsten size material type and thickness
to be welded.
Ignition Current
Base
Current
Finish
Current
Ignition
Time
Turn the Adjustment Knob
to set the Peak Current
value. (Range is 20-320A)
Arc Force
Current
29
The value selected shows on the
digital display. It is the maximum set
value of amperage the machine will
deliver..
AC TIG Welding - AC Wave Balance Control
AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminium, Magnesium and Aluminium Alloys. These materials have an insulating surface oxide layer that melts at a higher temperature than
the base metal making it difficult to weld the base metal if the oxides are not removed. AC welding current
is ideal because the nature of the AC wave form assists in breaking the surface oxide layer.
AC (alternating current) has a current cycle that flows from + (direct) polarity to - (reverse) polarity. The reversing of the polarity breaks the surface oxide while the direct polarity melts the base material.
current
direct polarity
reverse polarity
There are inherent problems that come with AC TIG arc rectification, arc stutter, arc wandering and arc
stoppage. These problems typically occur during the transition between + and - cycles.
The current is less (30%) during the half of the cycle when the electrode is positive and there is a resistance of the electron flow during this half cycle (rectification). The lack of current flow during this half cycle
makes the AC arc unstable.
current
direct polarity
30%
30%
reverse polarity
To overcome this lack of flow during one half of the cycle, a high-frequency (HF) voltage is generated and
fed into the welding circuit. The HF maintains the arc stability during the half cycle when the electrode is
positive.
UNBALANCED WAVE FORM
+
_
HF
current
direct polarity
30%
30%
reverse polarity
High-frequency voltage flows continually in the welding circuit and keeps the shielding arc in the welding
area in an ionized state. When the arc is ionized the arc is maintained during the half of the cycle when the
electrode is positive. However while the arc is maintained less current flows during this half of the AC cycle,
producing an unbalanced wave.
30
e Arc
AC TIG Welding - AC Wave Balance Control
In older machines, a balanced current output wave was achieved using a large number of capacitors in
series or a battery in the welding circuit. Modern TIG power sources use electronics to create and maintain
a balanced wave and now most AC TIG power sources produce a square wave current output.
direct polarity
current
reverse polarity
A square wave power supply can change the current from electrode + positive to electrode - negative very
quickly. This produces high voltage as the current switches polarities allowing the arc to restart easily. The
arc can be maintained without the use of high-frequency or any other arc stabilising methods.
EVEN BALANCE
LESS POSITIVE
BALANCE
MORE POSITIVE
BALANCE
BALANCED
SQUARE WAVE FORM
direct polarity
current
Even Penetration - Stable Arc
reverse polarity
More Penetration - Faster Welding
More Electrode Capacity
Less Penetration - Oxide Cleaning
Less Electrode Capacity
The output current and voltage are controlled electronically so the amount of current electrode positive and
the amount of current electrode negative can be adjusted. This allows the welder to adjust the amount of
cleaning and the amount of penetration. This is achieved electronically by adjusting the balance control dial
on the welding machine. More current flow from the + direct polarity produces stronger arc energy and current flow from the tungsten and is good for removing the oxidized surface of the work piece. However too
much + current flow can drive too much energy to the tungsten causing it to overheat and melt the tungsten
electrode.
LESS POSITIVE
BALANCE
MORE POSITIVE
BALANCE
Balance Adjusted for More Penetration - Cooler Tungsten
25%
direct polarity
current
More Penetration - Faster Welding
More Electrode Capacity
MORE POSITIVE
BALANCE
reverse polarity
Less Penetration - Oxide Cleaning
Less Electrode Capacity
Balance Adjusted for More Oxide Cleansing Action - Hotter Tungsten
25%
direct polarity
current
reverse polarity
Less Penetration - Oxide Cleaning
Less Electrode Capacity
31
AC
AC PULSE
Volts
DC
Set up and operation for AC PULSE TIG
Welding
Torch Cycle
DC PULSE
AC
Job Recall
DC
ADJUSTMENT
ALARM
Peak
Current
C
Ignition Current
C PULSE
Start
Current
C
C PULSE
AC PULSE
ALARM
AC Hz
% Pulse
Job Recall
Remote
Pulse Hz
ON/OFF
DC
Volts
DC PULSE
Torch Cycle
(12) Select the AC Balance Controlby pushing selector key to
AC
Peakthrough to illuminate
cycle
the AC Balance icon.
Current
DC
Turn the Adjustment
to set the AC
Balance
(Range is 10-60 %).
Ignition Current
Finish
CurrentPeak
Base
Current
Ignition
Time
Current
ADJUSTMENT
Knob
Job Recall
ALARM
Arc Force
Set the value at 20. It is the % of
time that the current flow remains at
electrode negative during each AC
ADJUSTMENT
cycle. (See pages for 31-32-34 for
more AC Balance information)
Current
Ignition Current
C PULSE
Start
Current
e
AC Hz
% Pulse
Finish
Current
Base
Current
C
Pulse Hz
AC Hz
% Pulse
Arc Force
Current
Remote
ON/OFF
Torch Cycle
C
AC Balance
Ignition
Time
Volts
C PULSE
Job Recall
Remote
Pulse Hz
ON/OFF
C
e
Arc Force
Current
Torch Cycle
AC Balance
C
Ignition
Time
Volts
AC
C
C
Finish
Current
Base
Current
ADJUSTMENT
ALARM
(13) Select the AC Hz Controlby pushing selector key to cycle
Peak
through
to illuminate the AC Hz icon.
Current
Turn the Adjustment
Knob to set the AC Hz
(Range is 20-70).
Ignition Current
Finish
Current
Base
Current
AC Hz
% Pulse
Ignition
Time
Arc Force
Current
Remote
Pulse Hz
(14) Lay the outside edge of the Gas Cup on
the work piece with the Tungsten
Electrode 1- 3mm from the work piece
Set the value at 60. The value
selected is how many times per
second the AC wave completes a
full cycle.
ON/OFF
(15) 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.
32
(16) Release the torch switch to bring in the
end of the welding sequence dependant of 2T
or 4T trigger function choice
Set up and operation for AC PULSE TIG Welding
The Razorweld 315ACDC machine has digital pulse frequency control. All the parameters for AC & 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 AC TIG WELDING - SETUP PARAMETERS:
Material = Aluminium x 3.0mm / Tungsten Electrode = 2.4mm Zirconiated / Gas = Argon
(1) Prepare the machine for AC TIG welding AC
as per the AC TIG operating guide on page
(2) Set the Peak Current at 150 Amps
AC PULSE
(3) Set the Base Current around 40% (Base Current is % of the Peak Current eg 40% of 150 = 60 Amps)
Volts
DC
(4) Set the Pulse Frequency around 2Hz (pulses per second)
Torch Cycle
DC PULSEwill spend 60% at Peak Current & 40%
(5) Set the Pulse Width around 60% (the current
at Base Current)
AC
You can experiment by changing any of the variables
to see what effect it has over the Job
welding
and what the end
Recall
result can be, but it is suggested to change only
one
variable
at
a
time
and
then
check
the
welding
result.
DC
ADJUSTMENT
ALARM
Peak
Current
AC
Ignition Current
AC PULSE
Start
Current
DC
AC
Ignition
Time
Job Recall
DC
AC Balance
ALARM
DC PULSE
1. Select AC Pulse
ACby pushing
selector key to cycle through to
DCicon.
illuminate AC Pulse
Start
Current
AC Hz
Volts
% Pulse
Torch Cycle
2. Select Peak Current by pushing the selector button to
Job Recall
cycle through to illuminate the Peak Current Icon
Ignition Current
ALARM
Finish
Current
Ignition
Time
AC Balance
Finish
Current
AC Hz
% Pulse
Ignition
Time
Pulse Hz
ON/OFF
3. Turn the Adjustment Knob to set the
Peak Current at 150A
ADJUSTMENT(Range is 20-3200 Amps)
Arc Force
Current
Peak
Amp
Ignition Current
Base
Current
Remote
ADJUSTMENT
Pulse Hz
Peak
Current
Base
Peak
Current
Current
Start
Current
Arc Force
Current
Torch Cycle
DC PULSE
AC
AC PULSE
DC
Finish
Current
Volts
Base
Current
Arc Force
Remote
Current
150A
ON/OFF
AC
60A
AC PULSE
AC Balance
DC
Base
Amp
AC Hz
% Pulse
Remote
Volts
Pulse Hz
DC PULSE
4. Select the BaseACCurrent by pushing the selector key to
cycle through to illuminate the Base Current Icon
DC
ON/OFF
Torch Cycle
5. Turn the Adjustment Knob to set the Base
Current at 60A (Range is 30-320 Amps)
Job Recall
ADJUSTMENT
ALARM
Pulse Width
Peak
Current
Peak
Amp
Ignition Current
Start
Current
Finish
Current
Base
Current
Ignition
Time
150A
Arc Force
Current
Base
Amp
AC
AC Hz
% Pulse
Remote
Volts
Pulse Hz
7. Turn the Adjustment Knob to set the
Pulse Width at 60%. (Range is 10 - 90%).
Job Recall
ADJUSTMENT
ALARM
Time = 1 Second (Hz)
Peak
Current
Peak
Amp
Ignition Current
Finish
Current
Base
Current
AC Balance
30A
40%
ON/OFF
Torch Cycle
DC PULSE
6. Select the Pulse
AC width ( % on time of the Peak Amp) by
pushing the selector key to cycle through to illuminate the %
DC
Pulse Icon
Start
Current
150A
60%
60A
AC PULSE
AC Balance
DC
Peak Amp
On Time
AC Hz
% Pulse
Ignition
Time
Remote
Pulse Hz
8. Select the Pulse Frequency by pushing the selector key to
cycle through to illuminate the Pulse Hz Icon
150A
60%
Arc Force
Current
ON/OFF
9. Turn the Adjustment Knob to set the
Pulse Hz to 2 Hz (Range is 0.5 - 5.0Hz)
33
Base
Amp
30A
40%
150A
60%
30A
40%
AC TIG Welding - AC Wave Balance 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 20 Hz (20 times per second) to 70 Hz
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
Current
20Hz
70Hz
Frequency Adjustment
Low AC Square Wave Hz
Wider Cleaning
Action
Wider Weld Bead
Wider Arc
Broader Weld Pool
High AC Square Wave Hz
Narrower Cleaning
Action
Narrower Weld Bead
Faster Weld Speed
Narrow Arc
Narrower Weld Pool
34
DC PULSE
Torch Cycle
AC
Job Recall
Remote
Amperage Controls
DC
ADJUSTMENT
ALARM
Current controls allow for the welding current to adjusted remotely from the welding machine
Remote amperage
Ignition Current
during welding.
Peak
Start
Current
AC
Finish
Current
Base
Remote Current
Foot
Amp Control Connection
Ignition
Time
AC PULSE
Arc Force
Current
Volts
DC
Torch Cycle
DC PULSE
AC Balance
AC Hz
AC
% Pulse
Remote
Pulse Hz
ON/OFF
Job Recall
DC
ADJUSTMENT
(3) Activate the remote control.
ALARM
Peak
Current
AC
Connect the remote control 2 pin and 5 pin plugs
Ignition
Currentleads to the correfrom the Remote Foot
Control
sponding remote receptacles on the front panel of
the machine.
Finish
Arc Force
Ignition
Current
Volts
Time
AC PULSE
Start
Current
DC
Base
Current
Current
DC PULSE
Torch Cycle
AC
Job Recall
DC
AC Balance
AC Hz
% Pulse
ALARM
1. No LED Remote is OFF
2. Press button once
LED Light is Solid and ready to activate
3. Press button twice and LED Light is Flashing
Remote control is activated
Remote
ADJUSTMENT
Pulse Hz
ON/OFF
Peak
Current
Ignition Current
Start
Current
AC
Current
Remote Hand
Amp Control Connection
Base
Finish
Ignition
Time
Current
AC PULSE
Type: ER1MS-H
Volts
DC
Torch Cycle
DC PULSE
AC Balance
AC Hz
AC
Arc Force
Current
% Pulse
Remote
Pulse Hz
ON/OFF
Job Recall
DC
ADJUSTMENT
(3) Activate the remote control.
ALARM
1. No LED Remote is OFF
Peak
Current
Start
Current
on/off
switch
amperage
adjustment
Base
Current
AC Balance
AC Hz
% Pulse
Ignition Current
Connect the remote
control 7 pin plug from the TIG
Torch switch lead to the 7 pin remote receptacle on
Finish
the front panel of theIgnition
machine.
Arc Force
Current
Time
Current
2. Press button once
LED Light is Solid and ready to activate
3. Press button twice and LED Light is Flashing
Remote control is activated
Remote
Pulse Hz
ON/OFF
NOTE:
DO NOT connect both remote controls at the same time, this will cause settings to be inconsistent when both remote’s
are connected.
35
Tungsten Electrodes
Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest
melting point of any metal, 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
36
Tungsten Preparation
Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a
diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium
oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects.
Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel. Tungsten electrodes are manufactured with the molecular structure of the grain running lengthwise and thus grinding crosswise is “grinding against
the grain.” If electrodes are ground crosswise, the electrons have to jump across the grinding marks and the arc can
start before the tip and wander. Grinding longitudinally with the grain, the electrons flow steadily and easily to the end
of the tungsten tip. The arc starts straight and remains narrow, concentrated, and stable.
grind longitudinal on the
grinding wheel
don’t grind across
the grinding wheel
Electrode Tip/Flat
The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection
of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur
and the more difficult it will be to arc start. However, increasing the flat to the maximum level that still allows arc start
and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders still grind
electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from
melting at the tip and the possibility of the point falling off into the weld pool.
2.5 times tungsten diameter
pointed tip
flat tip
Electrode Included Angle/Taper - DC Welding
Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a
specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and
offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide
the following benefits:
• Last Longer
flat spot diameter
• Have better weld penetration
• Have a narrower arc shape
• Can handle more amperage without eroding.
included angle
Sharper electrodes with smaller included angle provide:
• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration
increases and bead width decreases.
Tungsten
Diameter
Diameter at
the Tip - mm
Constant Included
Angle - Degrees
Current Range
Amps
Current Range
Pulsed Amps
1.0mm
1.6mm
1.6mm
2.4mm
2.4mm
3.2mm
3.2mm
.250
.500
.800
.800
1.100
1.100
1.500
20
25
30
35
45
60
90
05 - 30
08 - 50
10 - 70
12 - 90
15 - 150
20 - 200
25 - 250
05 - 60
05 - 100
10 - 140
12 - 180
15 - 250
20 - 300
25 - 350
37
Suregrip Series
SR26 ERGO TIG TORCH
180A AIR COOLED TIG WELDING TORCH
5
8
3
Rating:180Amp DC, 125Amp AC @35% duty cycle.
2
4
6
7
ens
as L
s
s
erie
serie
ns s
e
as L
s
serie
s
erie
ries
s se
Len
G
bby
eG
Larg
Gas
by s
dard
Stan
Stub
Stu
9
10
11
13
12
20
*
Wear Parts Identification Next Page
16
17
14
15
7
18
19
Torch Model
Description
Part Number
4m
8m
SR26 Suregrip Tig Torch Package c/w QF Gas Connect
SR-26-4MCP50
SR-26-8MCP50
Spare Parts
Part Number
Description
Part Number
Description
1
2
3
4
5
6
7
8
9
10
11
WP26
WP26F
57Y02
57Y03
57Y04
UER1MS
UERSWL4
UERSWL8
UERSP1
UERH200
UERKJ200
UERLC200-08
UERJK200
Torch head
Torch head flexible
Back cap long
Medium back cap
Short back cap
Momentary Kit
Trigger Lead 12.5ft
Trigger Lead 25ft
Screw Pack
Large Ergo Tig Handle
Large Knuckle Joint
Leather Cover X 0.8mt
Jointing Repair Kit
12
13
14
15
16
17
18
19
20
UERNCL-32
UERNCL-72
UERCO200-40
UERCO200-80
USLH26-S USLH26-H
USLH26-C
USL46V28AR
USL46V30AR
USL3550
USL-1-GS4
10004667
Neoprene Cover X 3.2mt
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
38
Suregrip Series
SR26 ERGO TIG TORCH
Standard Front End Parts
Part #
18CG
Description
Cup Gasket
Part #
10N30
10N31
10N32
10N28
Part #
10N22
10N23
10N24
10N25
Description
Collet Body 1.0mm
Collet Body 1.6mm
Collet Body 2.4mm
Collet Body 3.2mm
Description
Collet 1.0mm
Collet 1.6mm
Collet 2.4mm
Collet 3.2mm
Part #
10N49L
53N48L
53N47L
Part #
10N50
10N49
10N48
10N47
10N46
10N45
10N44
Description
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Description
Long Alumina Nozzle Ø8mm #5L
Long Alumina Nozzle Ø 10mm #6L
Long Alumina Nozzle Ø 11mm #7L
Ø 6mm #4
Ø 8mm #5
Ø 10mm #6
Ø 11mm #7
Ø 13mm #8
Ø 16mm #10
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 #
54N14
54N15
54N17
Description
Gas lens ceramic 8.0mm
Gas lens ceramic 7.0mm
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
Part #
TR0004-10
TR0004-16
TR0004-24
TR0004-32
Description
1.0mm x 175mm
1.6mm x 175mm
2.4mm x 175mm
3.2mm x 175mm
thoriated
thoriated
thoriated
thoriated
tungsten
tungsten
tungsten
tungsten
electrode
electrode
electrode
electrode
2%
2%
2%
2%
1/16 x 7” (1.6mm x 175mm)
3/32 x 7” (2.4mm x 175mm)
1/8 x 7” (3.2mm x 175mm)
TR0006-16
WHITE
ANSI/AWS A5.12 M-98
ISO 6848 WZ8
.8% Zirconiated: Balls well, handles
higher current with less spitting,
better arc starts and arc stability than
pure tungsten
Commonly used for
aluminium applications
Part #
TR0006-10
TR0006-16
TR0006-24
TR0006-32
Description
1.0mm x 175mm
1.6mm x 175mm
2.4mm x 175mm
3.2mm x 175mm
zirconiated
zirconiated
zirconiated
zirconiated
tungsten
tungsten
tungsten
tungsten
electrode
electrode
electrode
electrode
1/16 x 7” (1.6mm x 175mm)
3/32 x 7” (2.4mm x 175mm)
1/8 x 7” (3.2mm x 175mm)
©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means,
electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.
39
1%
1%
1%
1%
TIG WELDING TROUBLE SHOOTING
The following chart addresses some of the common problems of TIG welding. In all cases of equipment malfunction,
the manufacturer’s recommendations should be strictly adhered to and followed.
1: Tungsten burning away quickly
Possible Reason
Suggested Remedy
Incorrect Gas
Check that pure Argon is being used
No gas
Check the gas cylinder contains gas and is connected
Inadequate gas flow
Check the gas is connected, check hoses, gas valve and torch are not restricted. Set
the gas flow between 10 - 15 l/min flow rate
Back cap not fitted correctly
Make sure the torch back cap is fitted so that the o-ring is inside the torch body
Torch connected to DC +
Connect the torch to the DC- output terminal
Incorrect tungsten being used
Check and change the tungsten type if necessary
Tungsten being oxidised after weld
is finished
Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10
amps of weld current.
Tungsten melting back into the
nozzle on AC welding
Check that correct type of tungsten is being used. Check the balance control is not set
too high on the balance - reduce to a lower setting
2: Contaminated tungsten
Possible Reason
Suggested Remedy
Touching tungsten into the weld
pool
Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of
the work piece 2 - 5mm
Touching the filler wire to the tungsten
Keep the filler wire from touching the tungsten during welding, feed the filler wire into the
leading edge of the weld pool in front of the tungsten
Tungsten melting into the weld pool
Check that correct type of tungsten is being used. Too much current for the tungsten
size so reduce the amps or change to a larger tungsten
3: Porosity - poor weld appearance and colour
Possible Reason
Suggested Remedy
Incorrect Gas
Check that pure Argon is being used
Inadequate gas flow / gas leaks
Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the
gas flow between 10 - 15 l/min flow rate. Check hoses and fittings for holes, leaks etc.,
Moisture on the base metal
Remove all moisture from base metal before welding
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Contaminated filler wire
Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire
Check the filler wire and change if necessary
4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten
Possible Reason
Suggested Remedy
Incorrect Gas
Use pure Argon gas
Inadequate gas flow
Set the gas flow between 10 - 15 l/min flow rate
Inadequate post flow gas
Increase the post flow gas time
Alumina gas nozzle too small for size Increase the size of the alumina gas nozzle
of tungsten being used
5: Unstable Arc during DC welding
Possible Reason
Suggested Remedy
Torch connected to DC +
Connect the torch to the DC- output terminal
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long
Lower torch so that the tungsten is off of the work piece 2 - 5mm
6: HF present but no welding power
Possible Reason
Suggested Remedy
Incomplete welding circuit
Check earth lead is connected. Check all cable connections. If using a water cooled
torch check that the power cable is not separated.
No gas
Check the gas is connected and cylinder valve open, check hoses, gas valve and torch
are not restricted. Set the gas flow between 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
40
continued- TIG WELDING TROUBLE SHOOTING
7: Arc wanders during DC welding
Possible Reason
Suggested Remedy
Poor gas flow
Check and set the gas flow between 10 - 15 l/min flow rate
Incorrect arc length
Lower torch so that the tungsten is off of the work piece 2 - 5mm
Tungsten incorrect or in poor condition
Check that correct type of tungsten is being used. Remove 10mm from the weld end of
the tungsten and re sharpen the tungsten
Poorly prepared tungsten
Grind marks should run lengthwise with tungsten, not circular. Use proper grinding
method and wheel.
Contaminated base metal
Remove contaminating materials like paint, grease, oil, and dirt, including mill scale from
base metal.
Contaminated filler wire
Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire
Check the filler wire and change if necessary
8: Arc difficult to start or will not start DC welding
Possible Reason
Suggested Remedy
Incorrect machine set up
Check machine set up is correct
No gas, incorrect gas flow
Check the gas is connected and cylinder valve open, check hoses, gas valve and torch
are not restricted. Set the gas flow between 10 - 15 l/min flow rate
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Incorrect tungsten size and or tungsten being used
Check and change the size and or the tungsten if required
Loose connection
Check all connectors and tighten
Earth clamp not connected to work
Connect the earth clamp directly to the work piece wherever possible
Loss of high frequency
Check torch and cables for cracked insulation or bad connections. Check spark gaps
and adjust if necessary
41
MMA (Stick) WELDING TROUBLE SHOOTING
The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction,
the manufacturer’s recommendations should be strictly adhered to and followed.
1: No arc
Possible Reason
Suggested Remedy
Incomplete welding circuit
Check earth lead is connected. Check all cable connections.
Wrong mode selected
Check the MMA selector switch is selected
No power supply
Check that the machine is switched on and has a power supply
Possible Reason
Suggested Remedy
Arc length too long
Shorten the arc length
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Damp electrodes
Use only dry electrodes
2: Porosity − small cavities or holes resulting from gas pockets in weld metal.
3: Excessive Spatter
Possible Reason
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
Increase the amperage or choose a larger electrode
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Possible Reason
Suggested Remedy
Insufficient heat input
Increase the amperage or choose a larger electrode
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation
Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit up
4: Lack of penetration
5: Excessive penetration - burn through
Possible Reason
Suggested Remedy
Excessive heat input
Reduce the amperage or use a smaller electrode
Incorrect travel speed
Try increasing the weld travl speed
6: Uneven weld appearance
Possible Reason
Suggested Remedy
Unsteady hand, wavering hand
Use two hands where possible to steady up, practise your technique
Possible Reason
Suggested Remedy
Excessive heat input
Reduce the amperage or use a smaller electrode
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation and or joint
design
Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit up
7: Distortion − movement of base metal during welding
7: Electrode welds with different or unusual arc characteristic
Possible Reason
Suggested Remedy
Incorrect polarity
Change the polarity, check the electrode manufacturer for correct polarity
42
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
3 Months 1 Year 1 Year
2 Years
2 Years
1 Year 1 Year
1 Year
1 Year
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)
(Clause 2&3)
(Clause 3)
3 Months (Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB, and all other
components, .
(Clause 2) Gas Hose, Flashbacks are subject to and covered by the 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.
43
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.
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:
Queensland:
Victoria:
Western Australia:
02 9780 4200 or Mail PO Box 3033 Lansvale NSW 2166.
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.
44
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, 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, Earth Clamps
.
TIG Welding Torches and Consumables to suit, such as:
Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled,
Torch Head Flexible,Back Caps, Gas Lens, Torch Handle, Cup Gasket, Torch Body Gas Valve, O-ring,
All UNI-MIG TIG Welding Rods, All Xcel-Arc/ Magmaweld Electrodes, Arc Leads, Welding Cable, Electrode Holder,
Earth Clamps.
PLASMA Cutting Torches and Consumables to suit, such as:
All Cutting Tips, All Diffuser/Swirl Ring, All Electrode, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps,
All Air and Power Cables, All Switches, All O-rings, All Springs, All Circle Guides and Cutting Kits, Torch Bodies, Air
Filter Regulator, Arc Leads, Welding Cable, Electrode Holder, Earth 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.
45
46
47
© 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
48
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