RAZOR 145/180/210 Manual

RAZOR 145/180/210 Manual

Razorweld

Razor

weld

OPERATING MANUAL

KUMJRRW145

KUMJRRW180

®

KUMJRRW210

Please read and understand this instruction manual carefully before the installation and operation of this equipment.

3

YEARS Warranty

(Power Source)

©

JASIC Technologies America Inc

2013

Thank you for your purchase of your RAZORWELD Welding Machine.

We are proud of our range of welding equipment that has a proven track record of innovation, performance and reliability. Our product range represents the latest developments in Inverter technology put together by our professional team of highly skilled engineers. The expertise gained from our long involvement with inverter technology has proven to be invaluable towards the evolution and future development of our equipment range. This experience gives us the inside knowledge on what the arc characteristics, performance and interface between man and machine should be. Within our team are specialist welders that have a proven history of welding knowledge and expertise, giving vital input towards ensuring that our machines deliver control and performance to the utmost professional level. We employ an expert team of professional sales, marketing and technical personnel that provide us with market trends, market feedback and customer comments and requirements. Secondly they provide a customer support service that is second to none, thus ensuring our customers have confidence that they will be well satisfied both now and in the future.

RAZORWELD welders are manufactured and compliant with - CAN/CSA E60974-1 &

ANSI/IEC 60974-1, guaranteeing you electrical safety and performance.

2

Razorweld

California Proposition 65

®

WARNING: This product contains or produces a chemical known to the State of California to cause cancer and birth defects (or other reproductive harm) (California Health and Safety Code Section 25249.5 et seq.)

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer (California Health and Safety Code Section 25249.5 et seq.).

INFORMATION SOURCES

• California Health and Safety Code, Section 25249.4 through 25249.13.

• The California Office of Environmental Health Hazard Assessment, 301 Capitol Mall, Sacramento, CA

95814; telephone 916-445-6900.

Razor

weld

WARRANTY

• 3 Years from date of purchase.

• JASIC Technologies America Inc Ltd warranties all goods as specified by the manufacturer

of those goods.

• This Warranty does not cover freight or goods that have been interfered with.

• All goods in question must be repaired by an authorised repair agent as appointed by this

company.

• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.

• New product will not be supplied unless JASIC Technologies America Inc has inspected

product returned for warranty and agree to replace product.

• Product will only be replaced if repair is not possible

• Please view full Warranty term and conditions supplied with machine or at www.razorweld.com

or at the back of this manual.

CONTENTS PAGE

Warranty 2

Technical Data, Product Information

Safety - Cautions

Machine Layout

Installation & Operation for ARC(stick) Welding

ARC (Stick) Welding Information

Installation & Operation for MIG Welding with Gas

Wire Feed Drive Roller Selection

Wire Installation Set up Guide

Installation & Operation for MIG Welding with No Gas

Installation Guide for Mig Torch Liner Installation

MIG Torch and Wire Feeder Set Up Guide for Aluminum MIG Wire

Installation & Operation for MIG Welding with Spool Gun

MIG (Metal Inert Gas) Welding

Basic MIG Welding Guide

Installation & Operation for TIG Welding

TIG Fusion Technique

Tungsten Electrodes & Preparation

TWC2 MIG Torch Parts Breakdown

SPGRW200 Spool Gun Torch Parts Breakdown

SRE TIG Torch Parts Breakdown

MMA Welding Trouble Shooting Guide

18-19

20

21-22

23-24

25-26

27-30

31-32

33

4-6

7-9

10

11

12-13

14-15

16

17

34-35

36-37

33-39

40-41

42

MIG Welding Trouble Shooting Guide

TIG Welding Trouble Shooting Guide

43-44

45-46

Warranty 47-49

3

4

TIG

Razor weld

Razor

weld

MIG-TIG-ARC

• MIG, TIG AND ARC Welding machine

145

• Latest IGBT inverter technology

• MIG/MAG with Gas and Gasless wire function

• Excellent MIG welding with CO2 gas & mixed gas

• Euro style MIG and TIG torch connection

• Internal wire feeder with solid construction

• Adjustable Burn Back

• Spool Gun Connection

• Stepless voltage and wire feed control

• Wire Inch + Smart Set functionality

• Dual voltage 115/230V

• Hot Start - Anti Stick

• Digital Readout

• Solid case construction

• IP21S rating and CSA/CAN Approved

Input voltage

Ieff

Imax

Welding wire diameter

MIG

ARC

Input:115V

Output:30A/15.5V 80A/18V

Input:230V

Output:30A/15.5V 145A/21.2V

Input:115V

Output:10A/10.4V 80A/13.2V

Input:230V

Output:10A/10.4V 145A/15.8V

Input:115V

Output:10A/20.4V 80A/23.2V

Input:230V

Output:10A/20.4V 145A/25.8V

Dimensions (in)

Weight Machine (Ibs.)

JASIC Technologies America Inc

25503 74th Ave S Kent WA 98032 USA

Phone:

Fax : e-mail:

+1 253-859-6277 / +1 253-859-6278

+1 253-859-6286 [email protected]

3

YEARS

Warranty

(Power Source)

Complete with Torch, Regulator, return and ARC lead set and Adaptor!

Dual Voltage

Single phase AC230V/115V±15% 50/60Hz

14A

28A

0.025/0.03/0.035(in.)

I2

U2

X

I2

U2

X

X

I2

U2

X

I2

U2

25%

80A

18V

25%

145A

21.2V

25%

80A

13.2V

25%

145A

15.8V

60%

52A

16.6V

60%

93.6A

18.7V

60%

52A

12.1V

60%

93.6A

13.7V

100%

40A

16V

100%

72.5A

12.9V

72.5A

17.6V

100%

40A

11.6V

100%

X

I2

U2

X

I2

U2

25%

80A

60%

52A

23.2V

25%

145A

25.8V

22.1V

60%

93.6A

23.7V

19.1x7.3x14.6

28

100%

40A

21.6V

100%

72.5A

22.9V

This new RAZORWELD Welder will provide 145 amps of MIG, TIG and ARC output for you to complete your welding jobs! Ideal for the DIY enthusiast ,this beautifully designed and highly functional multi-system is a powerful, portable and dual voltage machine ensuring smooth and trouble free welding and backed up by a big 3 year warranty. Our Smart-set function allows you to dial in your preferred wire size and gas mixture and you are ready to start welding! The machine comes complete with

Torch, Regulator, Adaptor and Arc lead set .

Razor weld

Razor

weld

MIG-TIG-ARC

• Latest IGBT inverter technology

180

• MIG/MAG with Gas and Gasless wire function

• Excellent MIG welding with CO2 gas & mixed gas

• Euro style MIG and TIG torch connection

• Internal wire feeder with solid construction

• Adjustable Burn Back

• Spool Gun Connection

• Stepless voltage and wire feed control

• Wire Inch + Smart Set functionality

• MIG, TIG AND ARC Welding machine

• Dual voltage 115/230V

• Hot Start - Anti Stick

• Digital Readout

• Solid case construction

• IP21S rating and CSA/CAN Approved

JASIC Technologies America Inc

25503 74th Ave S Kent WA 98032 USA

Phone:

Fax : e-mail:

+1 253-859-6277 / +1 253-859-6278

+1 253-859-6286 [email protected]

3

YEARS

Warranty

(Power Source)

Input voltageV

Ieff

Imax

Welding wire diameter

Complete with Torch, Regulator, return and ARC lead set and Adaptor!

Dual Voltage

Single phase AC230V/115V±15%50/60Hz

15A

30A

0.025/0.03/0.035(in.)

X 25% 60% 100%

MIG

Input:115V-15A

Output:30A/15.5V80A/18V

Input:230V

Output:30A/15.5V180A/23V

U2

X

I2

I2

U2

X

I2

100A

19V

25%

180A

23V

25%

100A

64.5A

17.2V

60%

116A

19.8V

60%

64.5A

50A

16.5V

100%

90A

18.5V

100%

50A

TIG

Input:115V

Output:10A/10.4V100A/14V

Input:230V

Output:10A/10.4V180A/17.2V

U2

X

I2

U2

14V

25%

180A

17.2V

12.6V

60%

116A

14.6V

12V

100%

90A

13.6V

X

I2

25% 60% 100%

ARC

Input:115V-20A

Output:10A/20.4V100A/24V

U2

X

100A

24V

25%

64.5A

22.6V

60%

50A

22V

100%

Input:230V

Output:10A/20.4V160A/26.4V

I2 160A 103A 80A

Dimensions (in.)

U2 26.4V

24.1V

19.1×7.3×14.6

23.2V

Weight 28.4 Pounds (Machine)

This new RAZORWELD Welder will provide 180 amps of MIG, TIG and ARC output for you to complete your welding jobs! Ideal for the serious tradesman ,this beautifully designed and highly functional multi-system is a powerful, portable and dual voltage machine ensuring smooth and trouble free welding and backed up by a big 3 year warranty. Our Smart-set function allows you to dial in your preferred wire size and gas mixture and you are ready to start welding! The machine comes complete with Torch, Regulator, Adaptor and Arc lead set . A real workhorse with a hight duty Cycle.!

5

6

TIG

Razor weld

Razor

weld

MIG-TIG-ARC

210

• Latest IGBT inverter technology

• MIG/MAG with Gas and Gasless wire function

• Excellent MIG welding with CO2 gas & mixed gas

• Euro style MIG and TIG torch connection

• Internal wire feeder with solid construction

• Adjustable Burn Back

• Spool Gun Connection

• Stepless voltage and wire feed control

• Wire Inch + Smart Set functionality

• MIG, TIG AND ARC Welding machine

• Dual voltage 115/230V

• Hot Start - Anti Stick

• Digital Readout

• Solid case construction

• IP21S rating and CSA/CAN Approved

Input voltageV

Ieff

Imax

Welding wire diameter

MIG

ARC

Input:115V

Output:30A/15.5V120A/20V

Input:230V

Output:30A/15.5V150A/21.5V

Input:115V

Output:10A/10.4V120A/14.8V

Input:230V

Output:10A/10.4V210A/18.4V

Input:115V

Output:10A/20.4V120A/24.8V

Input:230V

Output:10A/20.4V210A/18.4V

Dimensions (in.)

Weight

JASIC Technologies America Inc

25503 74th Ave S Kent WA 98032 USA

Phone:

Fax : e-mail:

+1 253-859-6277 / +1 253-859-6278

+1 253-859-6286 [email protected]

3

YEARS

Warranty

(Power Source)

X

I2

U2

X

I2

U2

X

I2

U2

X

I2

I2

U2

X

U2

X

I2

U2

Complete with Torch, Regulator, return and ARC lead set and Adaptor!

Dual Voltage

Single phase AC230V/115V±15%50/60Hz

115V 21A / 230V 22A

115V 42A / 230V 44A

0.025/0.03/0.035(in.)

25%

120A

20V

25%

210A

24.5V

25%

120A

14.8V

25%

210A

18.4V

25%

120A 77.5A

24.8V

20%

210A

18.4V

23.1V

60%

136A

15.4V

19.1×7.3×14.6

28.4 Pounds (Machine)

60%

77.5A

17.9V

60%

136A

20.8V

60%

77.5A

13.1V

60%

136A

15.4V

60%

100%

60A

17V

100%

105A

19.3V

100%

60A

12.4V

100%

105A

14.2V

100%

60A

22.4V

100%

105A

14.2V

This new RAZORWELD Welder will provide 210 amps of MIG, TIG and ARC output for you to complete your welding jobs! Ideal for the serious tradesman ,this beautifully designed and highly functional multi-system is a powerful, portable and dual voltage machine ensuring smooth and trouble free welding and backed up by a big 3 year warranty. Our Smart-set function allows you to dial in your preferred wire size and gas mixture and you are ready to start welding! The machine comes complete with Torch, Regulator, Adaptor and Arc lead set . A real workhorse with a high duty Cycle.!

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 United States 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.

7

8

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.

CAUTION

1. Working Environment.

1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive

chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity.

1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;

the temperature of working environment should be maintained within 14°Fto .4 to +104°F.

1.3 Keep this equipment 12” 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 12”. Good ventilation is of critical importance for the normal performance and service life of this equipment.

2.2

Thermal Overload protection.

Should the machine be used to an excessive level, or in high temperature environment, poorly ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the machine will cease to operate. Under this circumstance, leave the machine switched on to keep the built-in fan working to bring down the temperature inside the equipment. The machine will be ready for use again when the internal temperature reaches safe level.

2.3

Over-Voltage Supply

Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.

This equipment 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

Note:

Minimum Motor Generator Power Suggested: 9.4KVA for MIG210

9

10

FRONT PANEL LAYOUT

1. Digital Volts Meter

2. Digital Amps Meter

3. 2T/4T Selector Button

4. Wire Speed / AmpsAdjustment Knob

5. Voltage / Downslope /ARC Force Adjustment Knob

6. MIG / TIG / MMA /Smartset Selector Knob

7. “-” Output terminal

8. Euro MIG / TIG Torch Connector (MIG/MAG)

9. “+” Output terminal

10. SpoolGun Power Supply Connection

8

9

7

1

4

2

BACK PANEL LAYOUT

11. Power switch

12. Gas Inlet

13. Fan

14. Input power cable

15. Data Plate

11

12

3 6

5

10

14

15

13

16

17

18

INTERNAL PANEL LAYOUT

16. Spoolgun/Standard selector switch

17. Inch wire feed button

18. Gas Check button

19. Spool holder assembly

20. Geared Wire feed assembly

19

20

Installation set up for ARC (Stick) Welding with RAZOR 210

1)

Connection of Output Cables

Two sockets are available on this welding machine. For ARC welding the electrode holder is shown be connected to the negative socket, while the earth lead (work piece) is connected to the positive socket, this is known as DC- polarity. However various electrodes require a different polarity for optimum results and careful attention should be paid to the polarity, refer to the electrode manufacturers information for the correct polarity.

DC+ Electrode connected to output socket.

DC- Electrode connected to output socket.

(2) Turn the power source on and select the ARC function with the MIG/TIG/ARC selector switch.

(3) Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer.

(2) Set MIG/TIG/ARC selector switch to MMA

(1) Connect the earth

lead to

(1) Connect the electrode lead

to

(3) Set the welding current using the amperage control dial. and adjust arcforce if required

(4) Place the electrode into the electrode holder and clamp tight.

(5) Strike the electrode against the workpiece to create an arc and hold the electrode steady to maintain the arc.

(6) Hold the electrode slightly above the work maintaining the arc while travelling at an even speed.

(7) To finish the weld, break the arc by quickly snapping the electrode away from the work piece.

(8) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal below.

11

12

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.

+

Power Source

Core wire

Flux coating

Gas shield from flux melt

Arc with core wire melt

Flux residue forms slag cover

Weld metal

Core wire

Flux coating

Base metal

Protective gas

Arc

Slag

Weld pool

• The arc is initiated by momentarily touching the electrode to the base metal.

• The heat of the arc melts the surface of the base metal to form a molten pool

at the end of the electrode.

• The melted electrode metal is transferred across the arc into the molten pool

and becomes the deposited weld metal.

• The deposit is covered and protected by a slag which comes from the

electrode coating.

• The arc and the immediate area are enveloped by an atmosphere of

protective gas

Manual metal arc ( stick) electrodes have a solid metal wire core and a flux coating. These electrodes are identified by the wire diameter and by a series of letters and numbers. The letters and numbers identify the metal alloy and the intended use of the electrode.

The Metal Wire Core works as conductor of the current that maintains the arc.

The core wire melts and is deposited into the welding pool.

The covering on a shielded metal arc welding electrode is called Flux.

The flux on the electrode performs many different functions.

These include:

● producing a protective gas around the weld area

● providing fluxing elements and deoxidizers

● creating a protective slag coating over the weld as it cools

● establishing arc characteristics

● adding alloying elements.

Covered electrodes serve many purposes in addition to adding filler metal to the molten pool. These additional functions are provided mainly by the covering on the electrode.

ARC 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.

Average Thickness Maximum Recommended of Material Electrode Diameter

0.03 - 0.07 inches

0.07 - 0.19 inches

0.19 - 0.31 inches

0.31 - > inches

0.09 inches

0.12 inches

0.15 inches

0.19 inches

The size of the electrode generally depends on the thickness of the section being welded, and the thicker the section the larger the electrode required. The table gives the maximum size of electrodes that maybe used for various thicknesses of section base on using a general purpose type 6013 electrode.

Welding Current (Amperage)

Electrode Size

ø mm

0.09 inches

0.12 inches

0.15 inches

0.19 inches

Current Range

(Amps)

60 - 100

100 - 130

130 - 165

165 - 260

Correct current selection for a particular job is an important factor in arc welding. With the current set too low, difficulty is experienced in striking and maintaining a stable arc. The electrode tends to stick to the work, penetration is poor and beads with a distinct rounded profile will be deposited. Too high current is accompanied by overheating of the electrode resulting undercut and burning through of the base metal and producing excessive spatter. Normal current for a particular job may be considered as the maximum, which can be used without burning through the work, over-heating the electrode or producing a rough spattered surface.

The table shows current ranges generally recommended for a general purpose type 6013 electrode.

Arc Length

To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld. An excessively short arc will cause sticking of the electrode and result in poor quality welds. General rule of thumb for down hand welding is to have an arc length no greater than the diameter of the core wire.

Electrode Angle

The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal.

When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should be between 80 and 90 degrees to the work piece.

Travel Speed

The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel will frequently lead to arc instability,slag inclusions and poor mechanical properties.

Material and Joint Preparation

The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases edges should be clean and free of any contaminates. The type of joint will be determined by the chosen application.

13

Installation set up for MIG with Gas for RAZOR 210

(1) Connect Mig Torch IMPORTANT : When connecting the torch be sure to tighten the connection.

(2) Connect the earth lead to Negative socket

(3) Connect the weld power lead to Positive socket

(4) Turn the power source on and select the MIG function with the MIG/TIG/MMA selector switch.

Or Select Smartset this is a predefined setting based on Gas and wire used. The machine will

preselect voltage and wire speed allowing the user to quickly find the best welding parameters

(5) Set torch operation 2T / 4T.

• When 2T operation is selected press trigger Arc starts, release trigger, Arc stops.

burnback operation is automatic and preset.

• When 4T operation is selected press and release trigger Arc starts, press and release trigger Arc stops.

burnback operation is automatic and preset.

SmartSet by RazorWeld ® makes welding easy by taking the guess work out of MIG machine settings.Simply select the correct wire diameter and gas type that you’re using then dial in your desired wire feed speed for the job. Use more wire speed for thicker material and less wire speed for thinner material.

The SmartSet system will auto-adjust the welding voltage to give you an ideal arc condition while welding. SmartSet also allows you to fine tune the auto-adjusted voltage to personalise your setting for optimal results.

(4) Set MIG/TIG/MMA selector switch to MIG

OR Select SMARTSET

(6) Connect the gas line to the regulator and connect to the gas cylinder

(2) Connect earth lead

to

(5) Set torch operation 2T / 4T

(1) Connect MIG torch

IMPORTANT :

When connecting the torch be sure to tighten the connection.

(3) Connect weld power lead to

14

(5) Select torch operation 2T or 4T

(7) Place wire onto spool holder - (spool retaining nut is left hand thread ) Feed the wire through the inlet guide tube on to the drive roller.

(8) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx 4-5in.

WARNING:

Ensure that an approved welding helmet, protective clothing and gloves are use for all welding operations

WARNING:

Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding voltage is present and can cause arcing or flash.

Continued set up for MIG with Gas for RAZOR 210

(7) Place wire onto spool holder - (spool retaining nut is left hand thread )

Feed the wire through the inlet guide tube on to the drive roller.

(8) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx 3-4in

(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller, lock the pressure arm into place.

(10) Apply a medium amount of pressure to the drive roller.

(11) Remove the gas nozzle and contact tip from the torch neck,

(12) Press and hold the inch button to feed the wire through to the torch neck, release the inch button when the wire exits the torch neck.

(13) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch head and nip it up tightly.

(14) Fit the gas nozzle to the torch head.

(15) Carefully open the gas cylinder valve and set the flow rate to between 11-21cfh.

(16) Set the welding parameters using the wire feed and voltage control knobs.

NOTE:

WIRE FEED SPEED TAKES EFFECT ONLY WHEN ARC IS STRUCK.

(17) Or use Smartset, Smartset is a predefined setting based on Gas and wire used.

The machine will preselect Voltage and wire speed allowing the user to quickly find the best welding parameters for a given metal.

(9) Close down the top roller bracket and clip the pressure arm into place.

(10) Apply a medium amount of pressure to the drive roller

(11) Remove the gas nozzle and contact tip from the front end of the mig torch.

(12) Press and hold the inch wire button to feed the wire down the torch cable through to the torch head.

(13) Fit the correct size contact tip over the wire and fasten tightly into the tip holder.

(14) Fit the gas nozzle to the torch head.

(15) Carefully open the valve of the gas cylinder, set the flow to 21cfh

NOTE:

GEAR DRIVE FEEDER ON 210 MODEL ONLY

(16) Set welding parameters using the voltage and wire feed controls.

NOTE:

WIRE FEED SPEED TAKES

EFFECT ONLY WHEN ARC IS STRUCK

(17) Smartset is a predefined setting based on Gas and wire used. The machine will preselect Voltage and wire speed allowing the user to quickly find the best welding parameters for a given metal.

15

Wire Feed Roller Selection

The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.

Simply put the smoother the wire feed then the better the welding will be.

Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.

Feed rollers are designed to be used for certain types of welding wire and they have different types of grooves machined in them to accommodate the different types of wire. The wire is held in the groove by the top roller of the wire drive unit and is referred to as the pressure roller, pressure is applied by a tension arm that can be adjusted to increase or decrease the pressure as required. The type of wire will determine how much pressure can be applied and what type of drive roller is best suited to obtain optimum wire feed.

Solid Hard Wire - like Steel, Stainless Steel require a drive roller with a V shape groove for optimum grip and drive capability. Solid wires can have more tension applied to the wire from the top pressure roller that holds the wire in the groove and the V shape groove is more suited for this. Solid wires are more forgiving to feed due to their higher cross sectional column strength, they are stiffer and don’t bend so easy.

Soft Wire - like Aluminium requires a U shape groove. Aluminium wire has a lot less column strength, can bend easily and is therefore more difficult to feed. Soft wires can easily buckle at the wire feeder where the wire is fed into inlet guide tube of the torch. The U-shaped roller offers more surface area grip and traction to help feed the softer wire. Softer wires also require less tension from the top pressure roller to avoid deforming the shape of the wire, too much tension will push the wire out of shape and cause it to catch in the contact tip.

Flux Core / Gasless Wire - these wires are made up of a thin metal sheath that has fluxing and metal compounds layered onto it and then rolled into a cylinder to form the finished wire. The wire cannot take too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied.

A knurled drive roller has been developed and it has small serrations in the groove, the serrations grip the wire and assist to drive it without too much pressure from the top roller. The down side to the knurled wire feed roller on flux cored wire is it will slowly over time bit by bit eat away at the surface of the welding wire, and these small pieces will eventually go down into the liner. This will cause clogging in the liner and added friction that will lead to welding wire feed problems. A U groove wire can also be used for flux core wire without the wire particles coming of the wire surface. However it is considered that the knurled roller will give a more positive feed of flux core wire without any deformation of the wire shape.

Top Pressure Roller Top Pressure Roller Top Pressure Roller

V Groove U Groove Knurled Groove

16

Wire

Drive Rollers

10mm

22mm

Wire

MIG145/180

Part Number

0.6-0.8V30/10

0.8-1.0V30/10

0.9-1.2V30/10

1.0-1.2V30/10

Part Number

0.6-0.8F30/10

0.8-0.9F30/10

0.9-1.2F30/10

Part Number

0.8-1.0U30/10

0.9-1.0U30/10

0.9-1.2U30/10

1.0-1.2U30/10

Wire

MIG210 Drive roller sizes

V Groove Drive Roller - Steel Wire

Part Number Description

0.6-0.8V30/22

0.8-1.0V30/22

0.9-1.2V30/22

1.0-1.2V30/22

1.2-1.6V30/22

Drive Roll V Groove 0.6-0.8mm / 0.023” - 0.030”

Drive Roll V Groove 0.8-1.0mm / 0.030” - 0.040”

Drive Roll V Groove 0.9-1.2mm / 0.035” - 0.045”

Drive Roll V Groove 1.0-1.2mm / 0.040” - 0.045”

Drive Roll V Groove 1.2-1.6mm / 0.045” - 0.062”

Knurled Drive Roller - Flux Core Wire

Part Number Description

0.6-0.8F30/22

0.8-0.9F30/22

0.9-1.2F30/22

1.2-1.6F30/22

Drive Roll Knurled 0.6-0.9mm / 0.023” - 0.035”

Drive Roll Knurled 0.8-0.9mm / 0.030” - 0.035”

Drive Roll Knurled 0.9-1.2mm / 0.035” - 0.045”

Drive Roll Knurled 1.2-1.6mm / 0.045” - 0.062”

U Groove Drive Roller - Soft Wire

Part Number Description

0.8-1.0U30/22

0.9-1.0U30/22

0.9-1.2U30/22

1.0-1.2U30/22

Drive Roll U Groove 1.0-1.2mm / 0.040” - 0.045

Drive Roll U Groove 0.9-1.0mm / 0.035” - 0.040”

Drive Roll U Groove 0.9-1.2mm / 0.035” - 0.045”

Drive Roll U Groove 1.0-1.2mm / 0.040” - 0.045”

Wire Installation and Set Up Guide

Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.

The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and consistent wire feed. A high percentage of faults with mig welders emanate from poor set up of the wire into the wire feeder. The guide below will assist in the correct setup of your wire feeder.

(1) Remove the spool retaining nut.

(2) Note the tension spring adjuster and spool locating pin.

(3) Fit the wire spool onto the spool holder fitting the locating pin into the location hole on the spool. Replace the spool retaining nut tightly

(4) Snip the wire carefully, be sure to hold the wire to prevent the spool uncoiling. Carefully feed the wire into the inlet guide tube of the wire feed unit.

(5) Feed the wire through the drive roller and into the outlet guide tube of the wire feeder.

NOTE: MIG 180-145 not geared

(6) Lock down the top pressure roller and apply a medium amount of pressure using the tension adjustment knob

NOTE: MIG 180-145not geared

(7) Check that the wire passes through the centre of the outlet guide tube without touching the sides. Loosen the locking screw and then loosen the outlet guide tube retaining nut too make adjustment if required. Carefully retighten the locking nut and screw to hold the new position.

NOTE: MIG 180-145 not geared

(8) A simple check for the correct drive tension is to bend the end of the wire over hold it about

4in

from your hand and let it run into your hand, it should coil round in your hand without stopping and slipping at the drive rollers, increase the tension if it slips.

(8) The weight and speed of the wire spool turning creates an inertia that can cause the spool to run on and the wire loop over the side of the spool and tangle. if this happens increase the pressure on the tension spring inside the spool holder assembly using the tension adjustment screw.

17

Installation set up for MIG with Gasless for RAZOR 210

(1) Connect Mig Torch

IMPORTANT : When connecting the torch be sure to tighten the connection. Additionally Digital MIG

torch must be connected prior to power being turned on otherwise remote control will not work

(2) Connect the earth lead to Positive socket

(3) Connect the weld power lead to Negative socket

(4) Turn the power source on and select the MIG function with the MIG/TIG/MMA selector switch.

(5) Set torch operation 2T / 4T.

• When 2T operation is selected press trigger Arc starts, release trigger, Arc stops.

burnback operation is automatic and preset.

• When 4T operation is selected press and release trigger Arc starts, press and release trigger Arc stops.

burnback operation is automatic and preset..

(6) Fit the correct size Knurled drive roller for Gas Less Flux Core wire.

(4) Set MIG/TIG/MMA selector switch to MIG

(1) Connect MIG torch

IMPORTANT :

When connecting the torch be sure to tighten the connection.

(3) Connect weld power lead to

(2) Connect earth lead

to

18

(5) Select torch operation 2T or 4T (6) Fit the correct sized Knurled Drive roller for Gas Less Flux Cored wire

(7) Place wire onto spool holder - (spool retaining nut is left hand thread ) Feed the wire through the inlet guide tube on to the drive roller.

WARNING:

Ensure that an approved welding helmet, protective clothing and gloves are use for all welding operations

WARNING:

Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding voltage is present and can cause arcing or flash.

Continued set up for MIG with Gasless wire for RAZOR 210

(7) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread.

Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling. Feed the wire into the wire feeder inlet guide tube through to the drive roller.

(8) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 8-9in into the torch receptacle. .

(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller, lock the pressure arm into place.

(10) Apply a light amount of pressure to the drive roller. Too much pressure will crush the cored wire.

(11) Remove the gas nozzle and contact tip from the torch neck,

(12) Press and hold the inch button to feed the wire through to the torch neck, release the inch button when the wire exits the torch neck.

(13) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch head and nip it up tightly.

(14) Fit the gas nozzle to the torch head.

(15) Set the welding parameters using the wire feed and voltage control knobs.

NOTE:

WIRE FEED SPEED TAKES EFFECT ONLY WHEN ARC IS STRUCK.

(8) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx 8-9in. Use a Knurled

Drive Roller of the correct size

(9) Close down the top roller bracket and clip the pressure arm into place.

(10) Apply a medium amount of pressure to the drive roller

(11) Remove the gas nozzle and contact tip from the front end of the mig torch.

(12) Press and hold the inch wire button to feed the wire down the torch cable through to the torch head.

(13) Fit the correct size contact tip over the wire and fasten tightly into the tip holder.

(14) Fit the gas nozzle to the torch head.

(15) Set welding parameters using the voltage and wire feed controls.

NOTE:

WIRE FEED SPEED TAKES

EFFECT ONLY WHEN ARC IS

STRUCK

NOTE:

GEAR DRIVE FEEDER ON 210 MODEL ONLY

19

Mig Torch Liner Installation

(1) Lay the torch out straight on the ground and remove the front end parts

(2) Remove the liner retaining nut.

(3) Carefully pull the liner out of the torch cable assembly

(4) Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will make it no good and will require replacement.

(5) Carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end. Avoid kinking the liner, kinking liner it will make it no good and require replacement.

(6) Fit the liner retaining nut and screw down only 1/2 way

(7) Leaving the torch straight snip the liner approximately 1/8in past the end of the torch neck

(8) Place the tip holder over the end of the liner and screw into the torch neck trimming it up tight.

(9) Screw down the liner nut the remaining 1/2 and trim it up tight. This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed.

(1) Remove mig torch front end parts

(2) Remove the liner retaining nut (3) Carefully pull out and completely remove the liner

(4) Carefully unravel the new liner

(5) Carefully feed in the new liner down the torch lead all the way to exit the torch neck.

(6) Fit the liner retaining nut and screw only 1/2 way down

20

(7) Snip the liner off 3mm past the end of the torch neck.

(8) Replace the front end parts (9) Fully screw down the liner retaining nut and nip it up tight.

Torch & Wire Feed Set Up for Aluminium Wire

(1) Lay the torch out straight on the ground and remove the front end parts

(2) Remove the liner retaining nut.

(3) Carefully pull the liner out of the torch cable assembly

(4) Select a PA or liner, carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end. Avoid kinking the liner, kinking the liner will ruin it and require replacement.

(5) Leave the liner extending out the end of the torch neck end by 1/8in

(5) Fit the liner retaining nut together with the liner o-ring.

8) Push the liner firmly into the torch lead and tighten the liner retaining nut.

(9) Install a U groove drive roller of the correct size to match the wire diameter being used.

(1) Remove mig torch front end parts

(2) Remove the liner retaining nut (3) Carefully pull out and completely remove the liner

(4) Carefully unravel the new liner

(5) Carefully feed in the new liner in short forward movements down the torch lead all the way to exit the torch neck. Be careful not to kink the liner

(6) Replace the front end parts

(7) Fit the liner collet, liner O-ring and liner retaining nut.

(8) Push the liner firmly into the torch lead and tighten the liner retaining nut

(9) Cut the liner flush with the end of liner retaining nut using a sharp box cutter knife.

21

Continued Torch & Wire Feed Set Up for Aluminum Wire

(10) Loosen off the inlet guide tube retaining screw

(11) Remove the inlet guide tube from the front end machine euro connector using long nose pliers.

(12) Carefully feed the extended PA liner section into the inlet guide tube hole of the machine euro

connector

(13) Feed the extended PA liner all the way up and over the drive roller

(14) Tighten the torch euro connection to the machine euro connector

(15) Cut the extended liner with a sharp razor knife just in front of the drive roller

(16) Fit an Aluminum contact tip of the correct size to match the diameter of the wire being used

(17) Fit the remaining front end parts to the torch neck ready for welding

(10)Connect the torch to the machine tighten and secure the torch euro connector to the machine euro connection.

(11) Install a U groove drive roller of the correct size for the diameter wire being used.

NOTE: MIG 180-145not geared

(7) Place aluminum wire onto spool holder. Feed the wire through the inlet guide tube on to the drive roller.

NOTE: MIG 180-145 not geared

(12) Press and hold the inch wire button to feed the wire down the torch cable through to the torch head.

(16) Fit an Aluminium contact tip of the correct size to match the wire diameter being used

(17) Fit the remaining front end parts to the torch neck ready for welding.

22

NOTE:

GEAR DRIVE FEEDER ON 210 MODEL ONLY

Installation set up of the Spool Gun for RAZOR 210

(1) Select Spool Gun using the Standard/Spool Gun selector switch.

(2) Connect the Spool Gun to the Euro MIG torch connection socket on the front panel, and tighten it.

Connect the Spool Gun control cable to the receptacle and tighten it.

IMPORTANT :

When connecting the torch be sure to tighten the connection. A loose connection can result in the connector arcing and damaging the machine and gun connector.

This damage is not covered under warranty.

(3) Insert the earth cable plug into the Negative socket on the front of the machine and tighten it.

(4) Connect weld power lead to Positive socket

(5) Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder.

(6) Turn the power source on and select the MIG function with the MIG/TIG/MMA selector switch.

(7) Take the Spool Gun and push the Cover Release Button to unlock the wire feed / spool cover.

(8) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread.

Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling.

(1) Set Standard/Spoolgun selector switch inside door to Spoolgun

(3) Connect earth lead

to

(5) Connect the gas line to the regulator and connect to the gas cylinder

(6) Set MIG/TIG/MMA selector switch to MIG

(2) Connect Spool Gun to Euro connection

Connect the Spool Gun control cable to the receptacle

IMPORTANT :

When connecting the torch be sure to tighten the connection.

(4) Connect weld power lead to

Remove wire from the drive unit

(1) Set Standard/Spoolgun selector switch inside door to Spoolgun

(7) Push the cover release button to unlock the wire feed /spool cover

(8) Place a spool of wire onto the Spool holder. Note: the spool retaining nut is Left

Hand thread, turn it clockwise to undo it

WARNING:

Ensure that an approved welding helmet, protective clothing and gloves are use for all welding operations

WARNING:

Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding voltage is present and can cause arcing or flash.

23

Continued set up of the Spool Gun with RAZOR 210

(9) Carefully feed the wire over the drive roller into the outlet guide tube, feed through into the torch neck.

Check that the drive roller being used complies with the wire diameter, replace the roller if necessary.

(10) Align the wire into the groove of the drive roller and release the tension arm making sure the wire is in the groove of the drive roller.

(11) Apply a adepuate amount of pressure to the drive roller by winding in the tension adjusting knob,

(12) Adjust spool hoder tension

(13) Remove the gas nozzle and contact tip from the torch neck, Pull the trigger to drive the wire through the neck until it exits the contact tip holder

(14) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch neck and nip it up tightly.

(15) Fit the gas nozzle to the torch head and close the wire spool cover.

(16) Carefully open the gas cylinder valve and set the flow rate to between 21-30cfh.

(17) Set the welding parameters using the wire feed and voltage control knobs.

(9) Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube. Squeezing the tension arm adjustment knob to release the pressure of the tension arm will allow the wire to be guided through the drive roller easily

(10) Check to make sure that the wire passes cleanly through the drive roller into the outlet guide tube.

(11) Apply a medium amount of pressure using the tension arm adjustment knob.

(12) Adjust spool hoder tension (13) Remove the gas nozzle and contact tip.

Pull the trigger to drive the wire through the neck until it exits the contact tip holder

(14) Fit the contact tip over the wire and screw it into the tip holder, nip it up tight.

24

(15) Fit the gas nozzle and close the wire feed spool cover

(16) Carefully open the valve of the gas cylinder, set the flow to 12-15 l/min

(17) Set welding parameters using the voltage and wire feed controls.

MIG (Metal Inert Gas) Welding

Definition of MIG Welding

-

MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. A constant voltage, direct current power source is most commonly used with MIG welding.

There are four primary methods of metal transfer in MIG welding, called short circuit (also known as dip transfer) globular transfer, spray transfer and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations. To perform MIG welding, the basic necessary equipment is a welding gun, a wire feed unit, a welding power supply, an electrode wire, and a shielding gas supply. Short circuit transfer is the most common used method whereby the wire electrode is fed continuously down the welding torch through to and exiting the contact tip. The wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool. This process is repeated about 100 times per second, making the arc appear constant to the human eye.

MIG Circuit Diagram

5 6

4

1

2

3

1.

Mig Torch -

2.

Work Piece -

3.

Power Source -

4. Wire Feeder - 5. Wire Spool - 6. Gas

25

MIG (Metal Inert Gas) Welding

Short Circuit Transfer - Short circuit transfer is the most common used method whereby the wire

electrode is fed continuously down the welding torch through to and exiting the contact tip. The wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool. This process is repeated about 100 times per second, making the arc appear constant to the human eye.

short circuit wire heating magnetic field pinches wire

The wire approaches the work piece and touches the work creating a short circuit between the wire and the base metal, because there is no space between the wire and the base metal there is no arc and current flows through the wire

.

The wire cannot support all the current flow, resistance builds up and the wire becomes hot and weak and begins to melt

The current flow creates a magnetic field that begins to pinch the melting wire forming it into droplet

26

droplet separates arc flattens the droplet cycle repeats

The pinch causes the forming droplet to separate and fall towards the now creating weld pool.

An arc is created at the separation of the droplet and the heat and force of the arc flattens out the droplet into the weld pool. The heat of the arc melts the end of the wire slightly as it feeds towards the base metal

The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short circuit and repeat the cycle.

Basic MIG Welding

.

Good weld quality and weld profile depends on gun angle, direction of travel, electrode extension

(stick out), travel speed, thickness of base metal, wire feed speed (amperage) and arc voltage.

To follow are some basic guides to assist with your setup.

Gun Position - Travel Direction, Work Angle

Gun position or technique usually refers to how the wire is directed at the base metal, the angle and travel direction chosen. Travel speed and work angle will determine the characteristic of the weld bead profile and degree of weld penetration.

Push Technique - The wire is located at the leading edge of the weld pool and pushed towards

the un-melted work surface. This technique offers a better view of the weld joint and direction of the wire into the weld joint. Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration - useful for welding thin materials. The welds are wider and flatter allowing for minimal clean up / grinding time.

Perpendicular Technique - The wire is fed directly into the weld, this technique is used prima-

rly for automated situations or when conditions make it necessary. The weld profile is generally higher and a deeper penetration is achieved.

Drag Technique - The gun and wire is dragged away from the weld bead. The arc and heat is

concentrated on the weld pool, the base metal receives more heat, deeper melting, more penetration and the weld profile is higher with more build up.

(A) Push Technique

10°

(B) Gun Perpendicular (C) Drag Technique

10° travel direction wire pointed ahead of bead travel direction travel direction wire pointed back into bead flat even weld profile light penetration narrower weld profile even penetration narrow higher weld profile more penetration

27

Travel Angle - Travel angle is the right to left angle relative to the direction of welding. A travel

angle of 5°- 15° is ideal and produces a good level of control over the weld pool. A travel angle greater that 20° will give an unstable arc condition with poor weld metal transfer, less penetration, high levels of spatter, poor gas shield and poor quality finished weld.

Angle 5°- 15°

Not enough angle

Angle more than 20° good level of control over the weld pool, even flat weld less control over the weld pool more spatter poor control, unstable arc, less penetration, lots of spatter

Angle to Work - The work angle is the forward back angle of the gun relative to the work piece.

The correct work angle provides good bead shape, prevents undercut, uneven penetration, poor gas shield and poor quality finished weld.

Correct angle

Not enough angle

Too much angle good level of control over the weld pool, even flat weld less control over the weld pool more spatter poor control, unstable arc, less penetration, lots of spatter

Stick Out- Stick out is the length of the unmelted wire protruding from the end of the contact tip.

A constant even stick out of 1/8-1/4” will produce a stable arc, and an even current flow providing good penetration and even fusion. Too short stick out will cause an unstable weld pool, produce spatter and over heat the contact tip. Too long stick out will cause an unstable arc, lack of penetration, lack of fusion and increase spatter.

Normal stick out

Too short

Too long

28

‘1/8-1/4”

Even arc, good penetration even fusion, good finish

Unstable arc, spatter, over heat contact tip

Unstable arc, spatter, poor penetration and fusion

Travel Speed - Travel speed is the rate that the gun is moved along the weld joint and is usually

measured in mm per minute. Travel speeds can vary depending on conditions and the welders skill and is limited to the welders ability to control the weld pool. Push technique allows faster travel speeds than Drag technique. Gas flow must also correspond with the travel speed, increasing with faster travel speed and decreasing with slower speed. Travel speed needs to match the amperage and will decrease as the material thickness and amperage increase.

Too Fast Travel Speed - A too fast travel speed produces too little heat per inch of travel resulting

in less penetration and reduced weld fusion, the weld bead solidifies very quickly trapping gases inside the weld metal causing porosity. Undercutting of the base metal can also occur and an unfilled groove in the base metal is created when the travel speed is too fast to allow molten metal to flow into the weld crater created by the arc heat.

high narrow bead

Too Fast Travel Speed

undercut porosity spatter lack of fusion lack of joint penetration

Too Slow Travel Speed - A too slow travel speed produces a large weld with lack of penetration

and fusion. The energy from the arc dwells on top of the weld pool rather than penetrating the base metal. This produces a wider weld bead with more deposited weld metal per mm than is required resulting in a weld deposit of poor quality.

large wide bead

Too Slow Travel Speed

lack of fusion porosity cold lap lack of joint penetration

Correct Travel Speed - The correct travel speed keeps the arc at the leading edge of the weld

pool allowing the base metal to melt sufficiently to create good penetration, fusion and wetting out of the weld pool producing a weld deposit of good quality.

even shaped bead

Correct Travel Speed

good toe fusion good side wall fusion good penetration

29

30

Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless

steel wire for stainless steel, aluminium wires for aluminium and steel wires for steel.

Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger machine, check the recommended welding capability of you machine.

As a guide refer to the “Welding Wire Thickness Chart” below.

WELDING WIRE DIAMETER CHART

RECOMMENDED WIRE DIAMETERS

MATERIAL

THICKNESS

24 Gauge (.60mm)

0.025”

MIG SOLID WIRE

0.030” 0.035” 0.040”

GASLESS FLUX CORED WIRE

0.030” 0.035” 0.045”

22 Gauge (.75mm)

20 Gauge (.90mm)

18 Gauge (1.0mm)

16 Gauge (1.2mm)

14 Gauge (1.9mm)

0.118” / 3.0mm

0.196” / 5.0mm

0.236” / 6.0mm

0.314” / 8.0mm

0.393” / 10.mm

0.472” / 12.0mm

For material thickness of 0.196” / 5.0mm and greater, multi-pass runs or a beveled joint design may be required depending on the amperage capability of your machine.

Gas selection - The purpose of the gas in the MIG process is to protect / shield the wire, the arc

and the molten weld metal from the atmosphere. Most metals when heated to a molten state will react with the air in the atmosphere, without the protection of the shielding gas the weld produced would contain defects like porosity, lack of fusion and slag inclusions. Additionally some of the gas becomes ionised (electrically charged) and helps the current flow smoothly.

The correct gas flow is also very important in protecting the welding zone from the atmosphere.

Too low flow will give inadequate coverage and result in weld defects and unstable arc conditions.

Too high flow can cause air to be drawn into the gas column and contaminate the weld zone.

Use the correct shielding gas. Co2 is good for steel and offers good penetration characteristics, the weld profile is narrower and slightly more raised than the weld profile obtained from Argon Co2 mixed gas. Argon Co2 mix gas offers better weld ability for thin metals and has a wider range of setting tolerance on the machine. Argon 75% Co2 25% is a good all round mix suitable for most applications.

Argon Co2 Co2

Penetration Pattern for Steel

Installation and set up for DC TIG welding for

RAZOR 210

(1) Connect TIG torch to Euro connection socket,

IMPORTANT : When connecting the torch be sure to tighten the connection.

(2) Connect earth lead to Positive

(3) Connect weld power lead to Negative

(4) Turn the power source on and select the TIG function with the MIG/TIG/MMA selector switch.

(5) Set torch operation 2T / 4T.

• When 2T operation is selected press trigger Gas starts, touch and lift arc start,

release trigger Gas and Arc stops.

• When 2T operation is selected with downslope time of either 1 to 10 seconds press trigger Gas starts,

touch and lift arc star, release trigger, after 1 to 10 seconds depending on the downslope time selected

Gas and Arc stops. Crater fill operation is automatic to factory preset level.

• When 4T operation is selected press and release trigger Gas starts, touch and lift arc start,

press and release trigger Gas and Arc stops.

• When 4T operation is selected with downslope time of either 1 to 10 seconds press and release

trigger Gas starts, touch and lift arc start Press and hold trigger, after 1 to 10 seconds depending on

the downslope time selected Arc crater fill downslopes, crater fill operation is automatic to factory

preset level., release trigger Gas and Arc stops

NOTE: This feature is recommend for welding above 70Amps only.

(6) Connect the gas line to regulator and connect the regulator to the gas cylinder.

(5) Set Torch operation 2T/4T

(6) Connect the gas line to the regulator and connect to the gas cylinder

(4) Set TIG/MMA/MIG/Spool Gun selector switch to TIG

(3) Connect weld power lead to

(1) Connect TIG torch to Euro Connection

IMPORTANT :

When connecting the torch be sure to tighten the connection.

(2) Connect earth lead to

WARNING:

Ensure that an approved welding helmet, protective clothing and gloves are use for all welding operations

WARNING:

Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding voltage is present and can cause arcing or flash.

31

LIFT ARC DC TIG Operation for RAZOR 210

Lift Arc ignition allows the arc to be started easily in DC TIG by simply touching the tungsten to the work piece and lifting it up to start the arc. This prevents the tungsten tip sticking to the work piece and breaking the tip from the tungsten electrode. There is a particular technique called “rocking the cup” used in the Lift Arc process that provides easy use of the Lift Arc function.

(7) Carefully open the valve of the gas cylinder, set the flow to 21-30cfh

(8)

Set the welding current using the amperage control dial

(9) Make sure the front end parts of the tig torch are correctly assembled, use the correct size and type of tungsten electrode for the job, the tungsten electrode requires a sharpened point for DC welding.

(10) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1/16 inm from the

work piece. Press the trigger button on TIG torch to start the gas flow.

(11) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work

piece.

(12) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc.

(7) Carefully open the valve of the gas cylinder, set the flow to 6-10 l/min

(8) Set the welding current using the amperage control dial

(9) Assemble front end parts of the TIG torch, fitting a sharpened tungsten suitable for DC welding.

(10) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode

1/16infrom the work piece. Press the trigger button on TIG torch to start the gas flow.

32

(11) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece.

(12) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc.

TIG Welding Fusion Technique

Manual TIG welding is often considered the most difficult of all the welding processes.

Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the workpiece. Similar to Oxygen Acetylene torch welding, Tig welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other. However, some welds combining thin materials can be accomplished without filler metal like edge, corner, and butt joints.

This is known as Fusion welding where the edges of the metal pieces are melted together using only the heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size. Once the weld pool is established tilt the torch at about a 75

° angle and move smoothly and evenly along the joint while fusing the materials together.

75°

Travel direction

Form a weld pool Angle torch Move the torch slowly and evenly forward

TIG Welding with Filler Wire Technique

It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size. Once the weld pool is established tilt the torch at about a 75

° angle and move smoothly and evenly along the joint. The filler metal is introduced to the leading edge of the weld pool. The filler wire is usually held at about a 15° angle and fed into the leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward. It is important during the welding to keep the molten end of the filler wire inside the gas shield as this protects the end of the wire from being oxidized and contaminating the weld pool.

Travel direction

Form a weld pool

Retract the filler wire

Angle torch

75° gas shield

Move the torch forward to the front of the weld pool

15°

Add Tig filler wire

Repeat the process

33

34

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

3/64” (0.040”)

1/16” (.062” & .060”)

3/32” (.93”)

1/8” (.125”)

5/32” (.156”)

15 - 80

70 -150

150- 250

250 - 400

400 - 500

15 - 80

70 - 150

140 - 235

225 - 325

300 - 400

20 - 60

60 - 120

100 - 180

160 - 250

200 - 320

Tungsten Preparation

Always use

DIAMOND

wheels when grinding and cutting. While tungsten is a very hard material, the surface of a diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects.

Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel. Tungsten electrodes are manufactured with the molecular structure of the grain running lengthwise and thus grinding crosswise is “grinding against the grain.” If electrodes are ground crosswise, the electrons have to jump across the grinding marks and the arc can start before the tip and wander. Grinding longitudinally with the grain, the electrons flow steadily and easily to the end of the tungsten tip. The arc starts straight and remains narrow, concentrated, and stable. grind longitudinal on the grinding wheel don’t grind across the grinding whee l

Electrode Tip/Flat

The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur and the more difficult it will be to arc start. However, increasing the flat to the maximum level that still allows arc start and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders still grind electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from melting at the tip and the possibility of the point falling off into the weld pool.

2.5 times tungsten diameter flat tip pointed tip

Electrode Included Angle/Taper - DC Welding

Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide the following benefits:

• Last Longer

• Have better weld penetration

• Have a narrower arc shape

• Can handle more amperage without eroding. flat spot diameter

Sharper electrodes with smaller included angle provide:

• Offer less arc weld

• Have a wider arc

• Have a more consistent arc included angle

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

Tungsten

Diameter

3/64” (0.040”)

1/16” (.062” & .060”)

1/16” (.062” & .060”)

3/32” (.93”)

3/32” (.93”)

1/8” (.125”)

1/8” (.125”)

Diameter at the Tip - mm

.250

.500

.800

.800

1.100

1.100

1.500

Constant Included

Angle - Degrees

20

25

30

35

45

60

90

Current Range

Amps

05 - 30

08 - 50

10 - 70

12 - 90

15 - 150

20 - 200

25 - 250

Current Range

Pulsed Amps

05 - 60

05 - 100

10 - 140

12 - 180

15 - 250

20 - 300

25 - 350

35

TWC2 STYLE MIG TORCH

TWC2 STYLE MIG TORCH

TWC2 Air Cooled Mig Welding Torch

Rating: 200A CO2 150A mixed gas, EN60974-7 @ 60% duty cycle. 0.6 to 1.2mm / 0.025” to 0.045

47/34” wires

6 5 3

2

4

1

8

11

9

7

12

10

14

15 16 17

19

21

13

20

18

36

7

7

7

5

5

6

3

3

4

8

8

1

1

2

2

Torch Model

Description

Welding Torch c/w Euro Fitting

Spare Parts

Part Number

15ft

TWC2-15FTE

Part Number Description

PWGA32 Adjustable Nozzle Insulator

U62J60 TW No.2 Metal Jacket Neck Assembly

WGA62A-45 45 Degreet Neck Assembly

WGA62A-60 60 DegreetNeck Assembly

U102 Block C/W Spacer & Screws

U244T

UB5044

Control Wire Terminals

Hose Clamp 18.5mm

U141-6S

U200-10E

U200-12E

U200-15E

U200-10

U200-12

U200-15

UP83

Spring Cable Support Small & Ball Joint

Hyperflex C/Assy X 10ft Euro

Hyperflex C/Assy X 12ft Euro

Hyperflex C/Assy X 15ft Euro

Hyperflex C/Assy X 10ft

Hyperflex C/Assy X 12ft

Hyperflex C/Assy X 15ft

Handle With Hook & Screw

9

9

Part Number

U92

U152

10 U152

Description

Grey Trigger Switch

Hanger Hook

Screw Kit 11

11

U122FMS

U122FMS

112 UB1522

13

13

UXL1542

UXL1542

14 UPA2041

15

15

UB1518

UB1518

16 UB1526

17

17

19

UB1519/S

UB1519/S

U174EX-1

19 U174EX-1

20

20

UB1524

UB1524

21 UXL1826

Cable Terminal Male

Cable End Lock Nut (M12 X 1.0)

Cable Support

Gun Plug Housing C/W Nut

Gun Plug Screw

Gun Plug Nut

Gun Plug Terminal Female

TWC Euro Gun Plug Body

Gun Plug ‘O’ Ring

Liner Retaining Nut

These parts are manufactured in China and are offered as

TWC2 STYLE MIG TORCH

47/34” wires

6 5 3

2

4

1

8

11

9

7

12

10

14

15 16 17

19

13

18

8

6

7

7

4

5

6

3

4

2

1

2

Welding Torch c/w Euro Fitting

Part Number Description

WGA62A-45 45 Degreet Neck Assembly

WGA62A-60 60 DegreetNeck Assembly

9

Part Number

10 U152

Description

10 U152

11 U122FMS

112 UB1522

112 UB1522

13 UXL1542

14 UPA2041

14 UPA2041

15 UB1518

16 UB1526

16 UB1526

17 UB1519/S

18 UB1523

18 UB1523

19 U174EX-1

20 UB1524

20 UB1524

21 UXL1826

20

21

Spare Parts

for Tweco 2

style torches

Torch Model

Description

15 FT Welding Torch Classic Style

10 FT Welding Torch Euro Style Handle

Part Number

TWC2-15FTE

TWC2-10FTE

TWC2 Contact Tips

Part Number

PRW14-30

PRW14-35

PRW14-40

PRW14-45

Description

Contact tip 0.8mm / 0.030”

Contact tip 0.9mm / 0.035”

Contact tip 1.0mm / 0.040”

Contact tip 1.2mm / 0.045”

TWC2 Contact Tips H/D

Part Number Description

PRW14H-30

PRW14H-35

PRW14H-40

PRW14H-45

Contact H/D tip 0.8mm / 0.030”

Contact H/D tip 0.9mm / 0.035”

Contact H/D tip 1.0mm / 0.040”

Contact H/D tip 1.2mm / 0.045”

TWC2 Gas Diffuser

Part Number

PRW52

TWC2 Gas Insulator

Part Number

PRW32

Description

Gas Diffuser

Description

Insulator

TWC2 Torch Nozzle

Part Number

PRW22-50

PRW22-62

Description

Nozzle Adjustable 13mm / (33/67)

Nozzle Adjustable 16mm / (5/8)

QTY

QTY x 2

QTY

QTY x 2

QTY

QTY x2

QTY x2

QTY

QTY x5

QTY x5

QTY x5

QTY x5

QTY

QTY x5

QTY x5

QTY x5

QTY x5

EAN CODE

0680474943777

0680474944095

EAN CODE

0680474943951

0680474943968

EAN CODE

0680474943920

0680474943937

0680474944033

0680474944040

EAN CODE

0680474944057

0680474944064

0680474944071

0680474944088

EAN CODE

0680474943975

EAN CODE

0680474943999

TWC2 Liners

Part Number

PRW42-3035-15

PRW42-4045-15

Description

Liner 15 ft 0.8 - 0.9mm / 0.030” - 0.035”

Liner 15ft 1.0 - 1.2mm / 0.040” - 0.0457”

QTY

QTY x1

QTY x1

PRW42N-3035-15 Liner 15ft 0.8- 0.9mm / 0.030” - 0.035” Alloy QTYx 1

EAN CODE

0680474944002

0680474944101

0680474944118

37

SPG200II AMP SPOOL GUN

Duty Cycle 35% @ 200Amp

Wear Parts Next Page

38

Torch Model

Description

Spool Gun x 19ft

Spare Parts

Part Number

5

6

7

8

1

2

3

4

LMZ2017

LMH2114

LMH2111

LMH2115

LMS2101

LMZ2001

LMZ2011

LMZ2012

9 LMZ2013

10 LMZ2016

11 LMT2101

12 LMH2112

13 LMH2113

14 LMJ2101

Description

Speed Adjusting Knob

Open/Close Button

Left-Gun Case

Hang Hook

Spring Support

Motor

Motor Plate

Suspension Screw

Drive Roll Assembly

Wire Nipple

Spool Shaft

Right-Gun Case

Upper-Gun Case

Switch

Part Number

SPGRWA200

Part Number

15 LMZ2014

16 LMZ2015

17 LMK2001

18 EF1101

19 LML2140

20 ES1201

21 EH2201

22 LMV2007

23 EP2001

24 LMV0004

Description

Potentiometer

Push Roll

Conducting Board

Conducting Tube

Welding Cable

Spring Support (Back)

Adaptor Support

Adaptor Support Nut

Adaptor

4 Pin Plug

SPG200II AMP SPOOL GUN

TWC2 Contact Tips

Part Number

PRW14-30

PRW14-35

PRW14-40

PRW14-45

Description

Contact tip 0.8mm / 0.030”

Contact tip 0.9mm / 0.035”

Contact tip 1.0mm / 0.040”

Contact tip 1.2mm / 0.045”

TWC2 Contact Tips H/D

Part Number Description

PRW14H-30 Contact H/D tip 0.8mm / 0.030”

PRW14H-35

PRW14H-40

PRW14H-45

Contact H/D tip 0.9mm / 0.035”

Contact H/D tip 1.0mm / 0.040”

Contact H/D tip 1.2mm / 0.045”

TWC2 Gas Diffuser

Part Number

PRW52

TWC2 Gas Insulator

Part Number

PRW32

Description

Gas Diffuser

Description

Insulator

TWC2 Torch Nozzle

Part Number

PRW22-50

PRW22-62

Description

Nozzle Adjustable 13mm / (33/67)

Nozzle Adjustable 16mm / (5/8)

QTY

QTY x 2

QTY

QTY x2

QTY x2

TWC2 Liners

Part Number

PRW42-3035-15

PRW42-4045-15

PRW42N-3035-15

Description QTY

Liner 15 ft 0.8 - 0.9mm / 0.030” - 0.035” QTY x1

Liner 15ft 1.0 - 1.2mm / 0.040” - 0.0457” QTY x1

Liner 15ft 0.8- 0.9mm / 0.030” - 0.035” Alloy QTYx 1

QTY

QTY x5

QTY x5

QTY x5

QTY x5

QTY

QTY x5

QTY x5

QTY x5

QTY x5

QTY

QTY x 2

EAN CODE

0680474943920

0680474943937

0680474944033

0680474944040

EAN CODE

0680474944057

0680474944064

0680474944071

0680474944088

EAN CODE

0680474943975

EAN CODE

0680474943999

EAN CODE

0680474943951

0680474943968

EAN CODE

0680474944002

0680474944101

0680474944118

39

7

8

5

6

9

Stubby

series

4

3

SR17 EURO TIG TORCH

2

150A AIR COOLED TIG WELDING TORCH

Rating: 150A DC, 105A AC @35% ducy cycle.

Standa rd

series

G as

L en s s eri es

La rge

Gas

Lens

series

Stubby

Gas

Lens

series

10

11

12

13

Torch Model

Description

SR17 Suregrip Tig Torch Package Euro Connection

Part Number

13ft

SRE17-13FTE

40

4

5

6

1

2

3

7

8

9

10

11

Spare Parts

Part Number

WP17

WP17F

57Y02

57Y03

57Y04

UER1MS

UERSWL4

UERSWL8

UERSP1

UERH100

UERKJ100

UERLC200-08

UERJK100

Description

Torch head

Torch head flexible

Back cap long

Medium back cap

Short back cap

Momentary Kit

Trigger Lead 12.5ft

Trigger Lead 25ft

Screw Pack

Small Ergo Tig Handle

Small Knuckle Joint

Leather Cover X 0.8mt

Jointing Repair Kit

12

13

Part Number

UERNCL-32

UERNCL-72

UERCO100-40

UERCO100-80

Description

Neoprene Cover X 3.2mt

Neoprene Cover X 7.2mt

Sheath X 12.5ft Inc Leather Cover

Sheath X 25ft Inc Leather Cover

©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.

SR17 EURO TIG TORCH

SR17 EURO TIG TORCH

Part # Description

18CG Cup Gasket

Part # Description

10N30 Collet Body 1.0mm / 0.040”

10N31 Collet Body 1.6mm / (1/16)

10N32 Collet Body 2.4mm / (3/32)

10N28 Collet Body 3.2mm / (1/8)

Standard Front End Parts

Part # Description

10N49L Long Alumina Nozzle Ø 8mm / (5/16) #5L

53N48L Long Alumina Nozzle Ø 10mm / (25/64) #6L

53N47L Long Alumina Nozzle Ø 11mm / (7/16) #7L

Part # Description

10N22 Collet 1.0mm / 0.040”

10N23 Collet 1.6mm / ((1/16)

10N24 Collet 2.4mm / (3/32)

10N25 Collet 3.2mm / (1/8)

Part # Description

10N50 Alumina Nozzle Ø 6mm / (15/64)

10N49 Alumina Nozzle Ø 8mm / (5/16)

10N48 Alumina Nozzle Ø 10mm / (25/64)

10N47 Alumina Nozzle Ø 11mm / (7/16)

10N46 Alumina Nozzle Ø 13mm / (33/64)

10N45 Alumina Nozzle Ø 16mm / (5/8)

10N44 Alumina Nozzle Ø 19mm / (3/4)

Compact Gas Lens Front End Parts

Part # Description

Part # Description

54N01 Gas Lens Gasket 45V25

45V26

Gas Lens Body 1.6mm / (1/16)

Gas Lens Body 2.4mm / (3/32)

45V27 Gas Lens Body 3.2mm /(1/8)

#4

#5

#6

#7

#8

#10

#12

Part # Description

54N14 Gas lens ceramic 8.0mm / (5/16)

54N15 Gas lens ceramic 7.0mm / (9/32)

54N17 Gas lens ceramic 5.0mm / (13/64)

TR0004-16

RED

ANSI/AWS A5.12-98

ISO 6848 WT20

2% Thoriated: Best stability at medium currents, good arc starts, medium tendency to spit, medium erosion rate.

Commonly used for steel and stainless steel applications

1/16 x 7” (1.6mm x 175mm)

3/32 x 7” (2.4mm x 175mm)

1/8 x 7” (3.2mm x 175mm)

TR0006-16

WHITE

ANSI/AWS A5.12 M-98

ISO 6848 WZ8

.8% Zirconiated: Balls well, handles higher current with less spitting, better arc starts and arc stability than pure tungsten

Commonly used for aluminium applications

1/16 x 7” (1.6mm x 175mm)

3/32 x 7” (2.4mm x 175mm)

1/8 x 7” (3.2mm x 175mm)

Part #

TR0004-10

TR0004-16

TR0004-24

TR0004-32

Description

1.0mm x 175mm / 0.040” x 6

57/64

” thoriated tungsten electrode 2%

1.6mm x 175mm / (1/16) x 6

57/64

” thoriated tungsten electrode 2%

2.4mm x 175mm / (3/32) x 6

57/64

” thoriated tungsten electrode 2%

3.2mm x 175mm / (1/8) x 6

57/64

” thoriated tungsten electrode 2%

Part #

TR0006-10

TR0006-16

TR0006-24

TR0006-32

Description

1.0mm x 175mm / 0.040” x 6

57/64

” zirconiated tungsten electrode 1%

1.6mm x 175mm / (1/16) x 6

57/64

” zirconiated tungsten electrode 1%

2.4mm x 175mm / (3/32) x 6

57/64

” zirconiated tungsten electrode 1%

3.2mm x 175mm / (1/8) x 6

57/64

” zirconiated tungsten electrode 1%

©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means, electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.

41

42

ARC(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

Wrong mode selected

No power supply

Check earth lead is connected. Check all cable connections.

Check the ARC selector switch is selected

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

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

Possible Reason Suggested Remedy

Arc length too long

Work piece dirty, contaminated or moisture

Damp electrodes

3: Excessive Spatter

Possible Reason

Shorten the arc length

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

Use only dry electrodes

Suggested Remedy

Amperage too high

Arc length too long

Decrease the amperage or choose a larger electrode

Shorten the arc length

3: Weld sits on top, lack of fusion

Possible Reason Suggested Remedy

Insufficient heat input

Work piece dirty, contaminated or moisture

Poor welding technique

4: Lack of penetration

Possible Reason

Increase the amperage or choose a larger electrode

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

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

Suggested Remedy

Insufficient heat input

Poor welding technique

Poor joint preparation

Increase the amperage or choose a larger electrode

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

Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit up

5: Excessive penetration - burn through

Possible Reason Suggested Remedy

Excessive heat input

Incorrect travel speed

6: Uneven weld appearance

Possible Reason

Reduce the amperage or use a smaller electrode

Try increasing the weld travel speed

Suggested Remedy

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

7: Distortion − movement of base metal during welding

Possible Reason Suggested Remedy

Excessive heat input

Poor welding technique

Poor joint preparation and or joint design

Reduce the amperage or use a smaller electrode

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

Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit up

7: Electrode welds with different or unusual arc characteristic

Possible Reason Suggested Remedy

Incorrect polarity Change the polarity, check the electrode manufacturer for correct polarity

MIG WELDING TROUBLE SHOOTING

The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.

1: Excessive Spatter

Possible Reason Suggested Remedy

Wire feed speed set too high

Voltage too high

Wrong polarity set

Stick out too long

Select lower wire feed speed

Select a lower voltage setting select the correct polarity for the wire being used - see machine setup guide

Bring the torch closer to the work

Contaminated base metal

Contaminated mig wire

Inadequate gas flow or too much gas flow

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

Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 21-30cfh flow rate. Check hoses and fittings for holes, leaks etc

Protect the welding zone from wind and drafts

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

Possible Reason Suggested Remedy

Wrong gas

Inadequate gas flow or too much gas flow

Moisture on the base metal

Contaminated base metal

Contaminated mig wire

Gas nozzle clogged with spatter, worn or out of shape

Missing or damaged gas diffuser

Mig torch euro connect o-ring missing or damaged

Check that the correct gas is being used

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 21-30cfh flow rate. Check hoses and fittings for holes, leaks etc.

Protect the welding zone from wind and drafts

Remove all moisture from base metal before welding

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

Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc

Clean or replace the gas nozzle

Replace the gas diffuser check and replace the o-ring

4: Wire stubbing during welding

Possible Reason Suggested Remedy

Holding the torch too far away

Welding voltage set too low

Bring the torch closer to the work and maintain stick out of 5-10mm

Increase the voltage

Wire Speed set too high Decrease the wire feed speed

5: Lack of Fusion − failure of weld metal to fuse completely with base metal or a proceeding weld bead.

Possible Reason Suggested Remedy

Contaminated base metal

Not enough heat input

Improper welding technique

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

Select a higher voltage range and /or adjust the wire speed to suit

Keep the arc at the leading edge of the weld pool.

Gun angle to work should be between 5 & 15°

Direct the arc at the weld joint

Adjust work angle or widen groove to access bottom during welding

Momentarily hold arc on side walls if using weaving technique

5: Excessive Penetration − weld metal melting through base metal

Possible Reason Suggested Remedy

Too much heat Select a lower voltage range and /or adjust the wire speed to suit

Increase travel speed

6: Lack of Penetration − shallow fusion between weld metal and base metal

Poor in incorrect joint preparation

Not enough heat input

Material too thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc characteristics

Keep the arc at the leading edge of the weld pool and maintain the gun angle at

5 & 15° keeping the stick out between 1/8-1/4in

Select a higher voltage range and /or adjust the wire speed to suit

Reduce travel speed

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

43

44

MIG WIRE FEED TROUBLE SHOOTING

The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.

1: No wire feed

Possible Reason Suggested Remedy

Wrong mode selected

Wrong torch selector switch

Check that the TIG/ARC/MIG selector switch set to MIG position

Check that the STANDARD/SPOOLGUN selector switch is set to STANDARD position for MIG welding and SPOOLGUN when using the Spoolgun

2: Inconsistent / interrupted wire feed

Possible Reason Suggested Remedy

Adjusting wrong dial

Wrong polarity selected

Incorrect wire speed setting

Voltage setting incorrect

Mig torch lead too long

Be sure to adjust the WIRE FEED and VOLTAGE dials for MIG welding.

The AMPERAGE dial is for STICK and TIG welding mode

Select the correct polarity for the wire being used - see machine setup guide

Adjust the wire feed speed

Adjust the voltage setting

Small diameter wires and soft wires like aluminium don’t feed well through long torch leads - replace the torch with a lesser length torch

Remove the kink, reduce the angle or bend Mig torch lead kinked or too sharp angle being held

Contact tip worn, wrong size, wrong type

Replace the tip with correct size and type

Liner worn or clogged (the most common causes of bad feeding)

Wrong size liner

Blocked or worn inlet guide tube

Try to clear the liner by blowing out with compressed air as a temporary cure, it is recommended to replace the liner

Install the correct size liner

Clear or replace the inlet guide tube

Wire misaligned in drive roller groove Locate the wire into the groove of the drive roller

Incorrect drive roller size

Wrong type of drive roller selected

Worn drive rollers

Drive roller pressure too high

Fit the correct size drive roller eg; .030in wire requires .030in drive roller

Fit the correct type roller (e.g. knurled rollers needed for flux cored wires)

Replace the drive rollers

Can flatten the wire electrode causing it to lodge in the contact tip - reduce the drive roller pressure

Too much tension on wire spool hub Reduce the spool hub brake tension

Wire crossed over on the spool or tangled

Remove the spool untangle the wire or replace the wire

Contaminated mig wire Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc

TIG WELDING TROUBLE SHOOTING

The following chart addresses some of the common problems of DC TIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.

1: Tungsten burning away quickly

Possible Reason Suggested Remedy

Incorrect Gas

No gas

Inadequate gas flow

Back cap not fitted correctly

Torch connected to DC +

Incorrect tungsten being used

Tungsten being oxidised after weld is finished

2: Contaminated tungsten

Possible Reason

Check that pure Argon is being used

Check the gas cylinder contains gas and is connected and the torch gas valve is open

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 21-30cfh flow rate

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

Connect the torch to the DC- output terminal

Check and change the tungsten type if necessary

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

Suggested Remedy

Touching tungsten into the weld pool

Touching the filler wire to the tungsten

Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work piece 1/8-1/4in

Keep the filler wire from touching the tungsten during welding, feed the filler wire into the leading edge of the weld pool in front of the tungsten

Tungsten melting into the weld pool Check that correct type of tungsten is being used. Too much current for the tungsten size so reduce the amps or change to a larger tungsten

3: Porosity - poor weld appearance and colour

Possible Reason Suggested Remedy

Incorrect Gas

Inadequate gas flow / gas leaks

Moisture on the base metal

Contaminated base metal

Contaminated filler wire

Incorrect filler wire

Check that pure Argon is being used

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 21-30cfh flow rate. Check hoses and fittings for holes, leaks etc.,

Remove all moisture from base metal before welding

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

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

Check the filler wire and change if necessary

4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten

Possible Reason Suggested Remedy

Incorrect Gas

Inadequate gas flow

Alumina gas nozzle too small for size of tungsten being used

5: Unstable Arc during DC welding

Use pure Argon gas

Set the gas flow between 21-30cfh flow rate

Increase the size of the alumina gas nozzle

Possible Reason Suggested Remedy

Torch connected to DC +

Contaminated base metal

Tungsten is contaminated

Arc length too long

7: Arc wanders during DC welding

Connect the torch to the DC- output terminal

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

Remove 10mm of contaminated tungsten and re grind the tungsten

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

Possible Reason Suggested Remedy

Poor gas flow

Incorrect arc length

Tungsten incorrect or in poor condition

Poorly prepared tungsten

Check and set the gas flow between 21-30cfh flow rate

Lower torch so that the tungsten is off of the work piece 1/8-1/4in

Check that correct type of tungsten is being used. Remove 1/2in from the weld end of the tungsten and re sharpen the tungsten

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

Contaminated base metal

Contaminated filler wire

Incorrect filler wire

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

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

Check the filler wire and change if necessary

45

46 continued- TIG WELDING TROUBLE SHOOTING

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

Possible Reason Suggested Remedy

Incorrect machine set up

No gas, incorrect gas flow

Tungsten is contaminated

Incorrect tungsten size and or tungsten being used

Loose connection

Earth clamp not connected to work

Check machine set up is correct

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

Remove 10mm of contaminated tungsten and re grind the tungsten

Check and change the size and or the tungsten if required

Check all connectors and tighten

Connect the earth clamp directly to the work piece wherever possible

ATTENTION! - CHECK FOR GAS LEAKS

At initial set up and at regular intervals we recommend to check for gas leakage.

Recommended procedure is as follows:

1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.

2. Slowly open the cylinder valve.

3. Set the flow rate on the regulator to approximately 21-30cfh.

4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure

gauge on the regulator, if the needle drops away towards zero there is a gas leak.

Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the

regulator and line for an extended time period. In this situation it is recommended to open the

cylinder valve, set the flow rate to 21-30cfh, close the cylinder valve and check after a

minimum of 15 minutes.

5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying

with soapy water, bubbles will appear at the leakage point.

6. Tighten clamps or fittings to eliminate gas leakage.

Important:

We strongly recommend that you check for gas leakage prior to operation of your machine. We recommend that you close the cylinder valve when the machine is not in use. Jasic Technologies America, authorized representatives or agents of

Jasic Technologies will not be liable or responsible for the loss of any gas.

Razorweld

25503 74th Ave S Kent WA 98032 USA

Phone:

FAX:

EMAIL:

+1 253-859-6277

+1 253-859-6278

+1 253-859-6286 [email protected]

[email protected]

Razor weld

JASIC Technologies America Inc

WARRANTY

JASIC Technologies America Inc (‘Us’, ‘We’) warrants that the following products under RAZORWELD supplied by Us and purchased by you from an Authorised RAZORWELD Dealer throughout the U.S.A & Canada are free of Material and Faulty Workmanship defects except for those products listed under ‘Warranty Exclusions’.

These terms and conditions supersede and exclude all former and other representations and arrangements relating to any warranties on these products.

WARRANTY PERIOD

We offer the following ‘Warranty Periods’ from ‘date of purchase’:

An Extended Warranty Period of 6 months total shall apply only to Machinery where offered and warranty is registered online.

RAZORWELD WELDING MACHINES

RAZORWELD DIY Series (Power Source Only)

RAZORWELD JASIC Inverter MIG (Power Source Only)

3 Years

3 Years

RAZORWELD JASIC Inverter MIG SWF (Power Source / Separate Wire Feeder Only) 3 Years

RAZORWELD JASIC Inverter TIG (Power Source Only)

RAZORWELD Water Cooler

RAZORWELD JASIC Series (Power Source Only)

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

UNI-FLAME Automatic Welding Helmet

RAZORWELD Automatic Welding Helmets

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

INTERCONNECTING CABLES, GAS HOSE

3 Years

1 Year

3 Years

1 Year

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3

(Clause 3)

2 Years

2 Years

3 Months (Clause 3)

(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB, and all other components.

(Clause 2) Gas Hose, Flashbacks are subject to and covered by the Manufacturer’s Individual Warranty, Contact the manufacturer for details

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

• SELLER MAKES NO WARRANTIES EXPRESSED OR IMPLIED, INCLUDING BUT NOT BY WAY OF LIMITATION,

ANY IMPLIED WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A

PARTICULAR PURPOSE, ON ANY ORDER EXCEPT THAT SELLER WARRANTS TITLE TO ALL GOODS FURNISHED

BY SELLER AND EXCEPT THAT SELLER WARRANTS FOR A PERIOD OF ONE YEAR FROM THE DATE MARK

LOCATED ON THE SELLER’S IDENTIFICATION TAG THAT ALL GOODS DESCRIBED ON SELLER’S

ACKNOWLEDGMENT OF PURCHASER’S PURCHASE ORDER WILL BE MANUFACTURED IN ACCORDANCE WITH

THE SPECIFICATIONS, IF ANY, SET FORTH IN SAID PURCHASE ORDER AND EXPRESSLY ACCEPTED IN

SELLER’S ACKNOWLEDGMENT SUBJECT TO SELLER’S STANDARD MANUFACTURING VARIATIONS AND

PRACTICES. IN THE CASE OF COMPONENTS OR ACCESSORIES FURNISHED BY SUPPLIERS TO SELLER,

PURCHASER’S WARRANTY FROM SELLER SHALL BE LIMITED TO THE WARRANTY OF THE COMPONENT OR

ACCESSORY SUPPLIER. THE FOREGOING WARRANTIES ARE THE SOLE AND EXCLUSIVE WARRANTIES

APPLICABLE TO THE GOODS DELIVERED, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING

WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY, ARE HEREBY EXPRESSLY DISCLAIMED AND

NEGATED. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, PURCHASER ACKNOWLEDGES THAT

SELLER’S PRODUCTS ARE NOT PACKAGED OR PROTECTED FOR LONG PERIODS OF STORAGE AND THUS

MAY CORRODE OR RUST OVER TIME..

47

48

WARRANTY / RETURNS / EXCHANGES

We understand that sometimes a product may need to be returned. If you have purchased from the RAZORWELD

Authorised Dealer Network, to assist you in following the correct procedure enclosed is the returns policy.

Our Returns Policy includes the rights you have under the American consumer Law and other relevant laws.

. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

• You shall inspect the Goods on delivery and shall within seven (7) days of delivery (time being of the essence) notify

JASIC Technologies America Inc of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.

• You shall also afford JASIC Technologies America Inc the opportunity to inspect the Goods within a reasonable time following delivery if you believe the Goods are defective in any way.

• If you shall fail to comply with these provisions the Goods shall be presumed to be free from any defect or damage.

For defective Goods, Which JASIC Technologies America Inc has agreed in writing that you are entitled to reject,

JASIC Technologies America Inc ‘s liability is limited to, at the discretion of JASIC Technologies America Inc either replacing the Goods or repairing the Goods except where you have acquired Goods as a consumer within the meaning of the relevant State legislation and trade act policies and is therefore also entitled to, at the consumer’s discretion either a refund of the purchase price of the Goods, or repair of the Goods, or replacement of the Goods.

Returns will only be accepted provided that:

(a) You have complied with the provisions outlined above, and

(b) where the Goods are unable to be repaired, the Goods are returned at your cost within thirty (30) days of the delivery date, and

(c) JASIC Technologies America inc will not be liable for Goods which have not been stored or used in a proper manner, and

(d) the Goods are returned in the condition in which they were delivered and with all packaging material, brochures and instruction material in as new condition as is reasonably possible in the circumstances.

• JASIC Technologies America Inc Accepts no responsibility for products lost, damaged or mislaid whilst in transit

• JASIC Technologies America Inc may (at their sole discretion) accept the return of Goods for credit but this may incur a handling fee of up to fifteen percent (15%) of the value of the returned Goods plus any freight costs.

• Where a failure does not amount to a major failure, JASIC Technologies America Inc is entitled to choose between providing you with a repair, replacement or other suitable remedy.

PURCHASER’S REMEDIES :

WITH RESPECT TO ANY CLAIM ARISING OUT OF ANY ORDER, ANY GOODS DELIVERED PURSUANT TO ANY

ORDER AND EXPRESSLY ACCEPTED IN SELLER’S ACKNOWLEDGMENT, OR SELLER’S PERFORMANCE IN

CONNECTION WITH ANY ORDER, INCLUDING, WITHOUT LIMITATION, ANY CLAIM ARISING OUT OF ANY

RECALL, DEFECT OR ALLEGED DEFECT IN ANY GOODS OR SERVICES FURNISHED BY SELLER, SHALL BE

LIMITED EXCLUSIVELY TO THE RIGHT OF REPAIR OR REPLACEMENT OF SUCH GOODS OR SERVICES, AT

SELLER’S OPTION. WITHOUT IN ANY WAY LIMITING THE GENERALITY OF THE FOREGOING, IN NO EVENT

SHALL SELLER BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING, WITHOUT

LIMITATION, ANY LOSS OF ANTICIPATED PROFITS INCURRED BY PURCHASER WITH RESPECT TO ANY GOODS

OR SERVICES FURNISHED BY SELLER, OR ANY DAMAGES ARISING FROM INJURIES TO PERSONS AS A

RESULT OF PURCHASER’S OR A THIRD PARTY’S NEGLIGENCE. SELLER’S WARRANTY DOES NOT COVER

FAILURES RESULTING FROM THE IMPROPER INSTALLATION, MOUNTING DESIGN OR APPLICATION OR FROM

CORROSION. THE PROVISIONS OF THIS PARAGRAPH ARE A MATERIAL TERM OF THIS TRANSACTION.

MAKING A CLAIM

If you wish to make a claim under this Warranty, you should:

• Return the product to the point of purchase either in person or on a prepaid courier; or

• Contact Us by Telephone on (+1) 253-859-6277, 253-859-6278 or e-mail [email protected]

• When returned, the product must be accompanied with the original invoice including the purchase price and disclosing the purchase date

• All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the Customer.

• To the extent permitted by law, our total liability for loss or damage of every kind related to the product in any way whatsoever is limited to the amount paid to the retailer by you for the product or the value of the product.

No responsibility will be taken for products lost, damaged or mislaid whilst in transit.

WARRANTY EXCLUSIONS

This Warranty covers Material and Faulty Workmanship defects only.

This Warranty does not cover damage caused by:

Dealers

Normal wear and tear due to usage

Misuse or abusive use of the RAZORWELD instructions supplied with the product.

Failure to clean or improper cleaning of the product

Failure to maintain the equipment such as regular services etc

Incorrect voltage or non-authorised electrical connections

Improper installation

Use of non-authorised/non-standard parts

Abnormal product performance caused by any ancillary equipment interference or other external factors

Failure or any breakage caused by overload, dropping or abusive treatment or use by the customer

Repair, modifications or other work carried out on the product other than by an Authorised RAZORWELD

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

MIG Welding Torches and Consumables to suit, such as:

Gas Nozzles, Gas Diffusers, Contact Tip holder, Contact tip, Swan Necks, Trigger, Handle, Liners,

Wire Guide, Drive Roller, Gas Nozzle Spring. Neck Spring, Connector Block, Insulator, Gas Nipple, Cap, Euro Block,

Head Assembly, Gas Block, Trigger Spring, Spring Cable Support, Neck Insulator, Shroud Spring,

Gun Plug Cover, Lock Nut, Snap On Head, Spring Cap, Ball, Motor 42 Volt, Pot 10K standard, Knob, Drive Roll Seat,

Washer, Bow, Ball Bearing, Wire Conduit Nipple, Central Plug, Printed Circuit Board, Gun Plug House, Cable Support, Gas Connector, Handle To Suit PP36 with Knobs, & Electrodes, Arc Leads, Welding Cable, Electrode Holder,

.

Earth Clamps

TIG Welding Torches and Consumables to suit, such as:

Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled,

Torch Head Flexible,Back Caps, Gas Lens, Torch Handle, Cup Gasket, Torch Body Gas Valve, O-ring,

Arc Leads, Welding Cable, Electrode Holder, Earth Clamps.

PLASMA Cutting Torches and Consumables to suit, such as:

All Cutting Tips, All Diffuser/Swirl Ring, All Electrode, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps,

All Air and Power Cables, All Switches, All O-rings, All Springs, All Circle Guides and Cutting Kits, Torch Bodies, Air

Filter Regulator, Arc Leads, Welding Cable, Electrode Holder, Eatch Clamps

STRAIGHT LINE CUTTING MACHINES and Consumables to suit, such as:

Hoses, Fittings, Track, Cutting Nozzles.

HIT-8SS Welding Carriage Consumables to suit, such as:

Input Cord, Inter-connecting Cord, Triggering Cable.

This Warranty does not cover products purchased:

From a non-authorized Dealer (such as purchases from unauthorized retailers and purchases over the

Internet from unauthorized local/international sellers or sites such as EBay)

At an auction;

From a private seller Unless it is a manufacturing fault, this Warranty does not apply to any products sold to Hire Companies.

These conditions may only be varied with the written approval of the Directors of JASIC Technologies America Inc

.

REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.

49

©

JASIC Technologies America Inc 2013

19

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JASIC Technologies America Inc

25503 74th Ave S Kent WA 98032 USA

Phone: +1 253-859-6277

+1 253-859-6278

FAX: +1 253-859-6286

EMAIL: [email protected]

[email protected]

Part of the JASIC group of companies

MADE IN CHINA

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