Razorweld JRW145D User manual

Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
YEARS Warranty
(Power Source)
3
OPERATING MANUAL
JRW145D
JRW180D
JRW210D
©JASIC Technologies America Inc
Razorweld
Razor
weld
™™
™™
®

2
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.
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 equip-
ment 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 profes-
sional sales, marketing and technical personnel that provide us with market trends, market feedback and
customer comments and requirements. Secondly they provide a customer support service that is second
to none, thus ensuring our customers have condence that they will be well satised both now and in the
future.
RAZORWELD welders are manufactured and compliant with - CAN/CSA E60974-1 &
ANSI/IEC 60974-1, guaranteeing you electrical safety and performance.
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 chemi-
cals 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 Oce of Environmental Health Hazard Assessment, 301 Capitol Mall, Sacramento, CA
95814; telephone [phone].
• California Proposition 65 website: www.oehha.ca.gov/prop65.html.
• American National Standards Institute (ANSI). Product Safety Signs And Labels (ANSI Z535.4), available
from ANSI, 25 West 43rd Street, New York, NY 10036; telephone: [phone]; web site: www.ansi.org.
Razorweld
Razorweld
™™
™™
®

3
CONTENTS PAGE
Warranty 2
Technical Data, Product Information 4-6
Safety - Cautions 7-9
Machine Layout 10
Installation & Operation for ARC(stick) Welding 11
ARC (Stick) Welding Information 12-13
Installation & Operation for MIG Welding with Gas 14-15
Wire Feed Drive Roller Selection 16
Wire Installation Set up Guide 17
Installation & Operation for MIG Welding with No Gas 18-19
Installation Guide for Mig Torch Liner Installation 20
MIG Torch and Wire Feeder Set Up Guide for Aluminum MIG Wire 21-22
Installation & Operation for MIG Welding with Spool Gun 23-24
MIG (Metal Inert Gas) Welding 25-26
Basic MIG Welding Guide 27-30
Installation & Operation for TIG Welding 31-32
TIG Fusion Technique 33
Tungsten Electrodes & Preparation 34-35
TWC2 MIG Torch Parts Breakdown 36-37
SPGRW200 Spool Gun Torch Parts Breakdown 33-39
SRE TIG Torch Parts Breakdown 40-41
MMA Welding Trouble Shooting Guide 42
MIG Welding Trouble Shooting Guide 43-44
TIG Welding Trouble Shooting Guide 45-46
Warranty 47-49
DO NOT OPERATE YOUR RAZORWELD EQUIPMENT ON AN EXTENSION LEAD UNLESS ABSOLUTELY
NECESSARY. IF YOU NEED TO OPERATE WITH AN EXTENSION LEAD YOU MUST PROCURE ONE THAT IS
THICK ENOUGH TO MEET THE DESIGN SPECIFICATIONS OF THE MACHINE. EXTENSION LEADS REDUCE THE
POWER TO YOUR MACHINE AND MAY DAMAGE CRITICAL COMPONENTS OF YOUR PCB BOARDS DUE TO
UNDER POWER.

4
JASIC Technologies America Inc
25503 74th Ave S Kent WA 98032 USA
Phone: [phone]
Fax : [phone]
e-mail: [e-mail]
Razorweld
Input voltage Single phase AC230V/115V±15% 50/60Hz
Welding wire diameter 0.025/0.03/0.035(in.)
ARC
Input:115V Rated input current: 21.4A
Output:10A/20.4V 80A/23.2V
X25% 60% 100%
I2 80A 52A 40A
U2 23.2V 22.1V 21.6V
Input:230V Rated input current: 27A
Output:10A/20.4V 145A/25.8V
X25% 60% 100%
I2 145A 93.6A 72.5A
U2 25.8V 23.7V 22.9V
MIG
Input:115V Rated input current: 21.4A
Output:30A/15.5V 80A/18V
X25% 60% 100%
I2 80A 52A 40A
U2 18V 16.6V 16V
Input:230V Rated input current: 22.4A
Output:30A/15.5V 145A/21.2V
X25% 60% 100%
I2 145A 93.6A 72.5A
U2 21.2V 18.7V 17.6V
TIG
Input:115V Rated input current: 16.5A
Output:10A/10.4V 80A/13.2V
X 25% 60% 100%
I2 80A 52A 40A
U2 13.2V 12.1V 11.6V
Input:230V Rated input current: 16.5A
Output:10A/10.4V 145A/15.8V
X25% 60% 100%
I2 145A 93.6A 72.5A
U2 15.8V 13.7V 12.9V
Dimensions (in) 19.1x7.3x14.6
Weight Machine (Ibs.) 28
•MIG, TIG AND ARC Welding machine
• 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
YEARS
3
Warranty
(Power Source)
Complete with Torch, Regulator, return and ARC lead set and an Adaptor!
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 .
Razorweld
MIG-TIG-ARC 145

5
JASIC Technologies America Inc
25503 74th Ave S Kent WA 98032 USA
Phone: [phone]
Fax : [phone]
e-mail: [e-mail]
Razorweld
• 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
YEARS
3
Warranty
(Power Source)
Complete with Torch, Regulator, return and ARC lead set and Adaptor!
Dual Voltage
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.!
Razorweld
MIG-TIG-ARC 180
Input voltage（V）Single phase AC230V/115V±15%（50/60Hz）
Welding wire diameter 0.025/0.03/0.035(in.)
ARC
Input:115V-20A Rated input current: 27.5A
Output:10A/20.4V～100A/24V
X25% 60% 100%
I2 100A 65A 50A
U2 24V 22.6V 22V
Input:230V Rated input current: 30A
Output:10A/20.4V～160A/26.4V
X 25% 60% 100%
I2 160A 103A 80A
U2 26.4V 24.1V 23.6V
MIG
Input:115V-15A Rated input current: 21.4A
Output:30A/15.5V～100A/19V
X 25% 60% 100%
I2 100A 65A 50A
U2 19V 17.3V 16.5V
Input:230V Rated input current: 30.2A
Output:30A/15.5V～180A/21.5V
X 25% 60% 100%
I2 180A 116A 90A
U2 23V 19.8V 18.5V
TIG
Input:115V Rated input current: 21.4A
Output:10A/10.4V～100A/14V
X 25% 60% 100%
I2 100A 65A 50A
U2 14V 12.6V 12V
Input:230V Rated input current: 22.6A
Output:10A/10.4V～180A/17.2V
X 25% 60% 100%
I2 180A 116A 90A
U2 17.2V 14.6V 13.6V
Dimensions (in.) 19.1×7.3×14.6
Weight 28.4 Pounds (Machine)

6
JASIC Technologies America Inc
25503 74th Ave S Kent WA 98032 USA
Phone: [phone]
Fax : [phone]
e-mail: [e-mail]
Razorweld
• 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
YEARS
3
Warranty
(Power Source)
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.!
Razorweld
MIG-TIG-ARC 210
Input voltage（V）Single phase AC230V/115V±15%（50/60Hz）
Welding wire diameter 0.025/0.03/0.035(in.)
ARC
Input:115V-20A Rated input current: 27.5A
Output:10A/21.6V～110A/24.4V
X25% 60% 100%
I2 110A 71A 55A
U2 24.4V 22.8V 22.2V
Input:230V Rated input current: 42A
Output:40A/21.6V～150A/26V
X 25% 60% 100%
I2 210A 136A 105A
U2 28.4V 25.4V 24.2V
MIG
Input:115V-20A Rated input current: 28.6A
Output:30A/15.5V～120A/20V
X 25% 60% 100%
I2 120A 77.5A 60A
U2 19V 17.9V 17V
Input:230V Rated input current: 37.5A
Output:30A/15.5V～150A/21.5V
X 35% 60% 100%
I2 210A 136A 105A
U2 24.5V 20.8V 19.3V
TIG
Input:115V Rated input current: 21.4A
Output:10A/10.4V～120A/14V
X 25% 60% 100%
I2 120A 77.5A 60A
U2 14.8V 13.1V 12.4V
Input:230V Rated input current: 28.2A
Output:10A/10.4V～210A/18.4V
X 25% 60% 100%
I2 210A 136A 105A
U2 18.4V 15.4V 14.2V
Dimensions (in.) 19.1×7.3×14.6
Weight 28.4 Pounds (Machine)
Complete with Torch, Regulator, return and ARC lead set and Adaptor!
Dual Voltage

7
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.
• Do not switch the function modes while the machine is operating. Switching of the function modes during
welding can damage the machine. Damage caused in this manner will not be covered under warranty.
• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing
should the electrode be in contact with the work piece.
• Operators should be trained and or qualied.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe
burns. The electrode and work circuit is electrically live whenever the output is on. The input
power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding,
the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment is dangerous.
• Connect the primary input cable according to 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 conned or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
• Do not weld in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give o toxic
fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding process produce
intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
• Always wear a welding helmet with correct shade of lter lens and suitable protective clothing including
welding gloves whilst the welding operation is performed.
• Measures should be taken to protect people in or near the surrounding working area. Use protective
screens or barriers to protect others from ash,glare and sparks; warn others not to watch the arc.
Machine Operating Safety

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
res and burns. Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or re. Check and be sure the area is safe before doing any welding.
• The welding sparks & spatter may cause re, therefore remove any ammable materials well away from
the working area. Cover ammable materials and containers with approved covers if unable to be moved
from the welding area.
• Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared
according to the required Safety Standards to insure that ammable or toxic vapors and substances are
totally removed, these can cause an explosion even though the vessel has been“cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
• Do not weld where the atmosphere may contain ammable dust, gas, or liquid vapours (such as petrol)
• Have a re extinguisher nearby and know how to use it. Be alert that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding
on a ceiling, oor, bulkhead, or partition can cause re on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylin-
der can explode. Because gas cylinders are normally part of the welding process, be sure to
treat them carefully. CYLINDERS can explode if damaged.
• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open ames,
sparks, and arcs.
• 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 o shielding gas supply when not in use.
• Always ventilate conned spaces or use approved air-supplied respirator.
Electronic magnetic elds. MAGNETIC FIELDS can aect Implanted Medical Devices.
•Wearers of Pacemakers and other Implanted Medical Devices should keep away.
•Implanted Medical Device wearers should consult their doctor and the device manufacturer before going
near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
Hot parts. Items being welded generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the welding
gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

9
CAUTION
1. Working Environment.
1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive
chemicals, ammable gas or materials etc, and at no more than maximum of 80% humidity.
1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;
the temperature of working environment should be maintained within 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 pre-
vent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and
dry compressed air of required pressure.
Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of
this welding equipment will be void if the machine has been modied, attempt to take apart the machine or
open the factory-made sealing of the machine without the consent of an authorized representative of the
manufacturer.
TROUBLE SHOOTING
Caution: Only qualied technicians are authorized to undertake the repair of this welding equipment.
For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.
Note:
Minimum Motor Generator Power Suggested: 9.4KVA for MIG210

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
1
23 6
5
BACK PANEL LAYOUT
11. Power switch
12. Gas Inlet
13. Fan
14. Input power cable
15. Data Plate
14
12
15
11
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
17
20
19
4
7
8
910
13
18
16

Included angle
1. Turn the power source on and select the MMA function
with the MIG/MMA selector switch. (MMA IS ARC/STICK)
2. Polarity
Two sockets are available on this welding machine.
For MMA welding the electrode holder is shown to
be connected to the positive socket, while the
earth lead (work piece) is connected to the negative
socket, this is known as DC+ polarity. However
various electrodes require a different polarity for
optimum results and careful attention should be paid
to the polarity, refer to the electrode manufacturers
information for the correct polarity.
DC+ Electrode connected to output socket.
DC- Electrode connected to output socket.
(3) Set the welding current using the amperage control
dial.
(6)Hold the electrode slightly above the work
maintaining the arc while travelling at an even speed.
(4) Place the electrode into the electrode holder and
clamp tight.
(7) To nish the weld, break the arc by quickly snapping
the electrode away from the work piece.
(5) Strike the electrode against the work-piece to
create an arc and hold the electrode steady to maintain
the arc.
(8) Wait for the weld to cool and carefully chip away
the slag to reveal the weld metal below.
1
2(+)
2(-)
11
SET UP FOR STICK (MMA)
WELDING

12
ARC Welding
One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric cur-
rent is used to strike an arc between the base material and a consumable electrode rod or‘stick’. The electrode rod
is made of a material that is compatible with the base material being welded and is covered with a ux that gives o
gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from
atmospheric contamination. The electrode core itself acts as ller material the residue from the ux that forms a slag
covering over the weld metal must be chipped away after welding.
Core wire
Flux coating
Gas shield from ux melt
Arc with core wire melt
Flux residue forms slag cover
Weld metal
Power Source
+
▬
• The arc is initiated by momentarily touching the electrode to the base metal.
• The heat of the arc melts the surface of the base metal to form a molten pool
at the end of the electrode.
• The melted electrode metal is transferred across the arc into the molten pool
and becomes the deposited weld metal.
• The deposit is covered and protected by a slag which comes from the
electrode coating.
• The arc and the immediate area are enveloped by an atmosphere of
protective gas
Core wire
Flux coating
Base metal
Protective gas
Arc
Slag
Weld pool
Manual metal arc ( stick) electrodes have a solid metal wire core and a ux
coating. These electrodes are identied by the wire diameter and by
a series of letters and numbers. The letters and numbers identify the metal
alloy and the intended use of the electrode.
The Metal Wire Core works as conductor of the current that maintains the arc.
The core wire melts and is deposited into the welding pool.
The covering on a shielded metal arc welding electrode is called Flux.
The ux on the electrode performs many dierent functions.
These include:
●producing a protective gas around the weld area
●providing uxing elements and deoxidizers
●creating a protective slag coating over the weld as it cools
●establishing arc characteristics
●adding alloying elements.
Covered electrodes serve many purposes in addition to adding ller metal to
the molten pool. These additional functions are provided mainly by the cover-
ing on the electrode.

13
Electrode Size
The size of the electrode generally depends on the thickness
of the section being welded, and the thicker the section the
larger the electrode required. The table gives the maximum
size of electrodes that maybe used for various thicknesses of
section base on using a general purpose type 6013 elec-
trode.
Correct current selection for a particular job is an important
factor in arc welding. With the current set too low, diculty
is experienced in striking and maintaining a stable arc. The
electrode tends to stick to the work, penetration is poor and
beads with a distinct rounded prole will be deposited. Too
high current is accompanied by overheating of the elec-
trode resulting undercut and burning through of the base
metal and producing excessive spatter. Normal current for a
particular job may be considered as the maximum, which can be used without burning through the work, over-
heating the electrode or producing a rough spattered surface.
The table shows current ranges generally recommended for a general purpose type 6013 electrode.
Arc Length
To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple
rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An arc too long
reduces penetration, produces spatter and gives a rough surface nish to the weld. An 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, llet, horizontal or overhead the angle of the electrode is generally between 5 and
15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should be be-
tween 80 and 90 degrees to the work piece.
Travel Speed
The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of
run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive
travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel will frequently lead to arc
instability,slag inclusions and poor mechanical properties.
Material and Joint Preparation
The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or any other
material that will hinder the arc and contaminate the weld material. Joint preparation will depend on the method
used include sawing, punching, shearing, machining, ame cutting and others. In all cases edges should be clean
and free of any contaminates. The type of joint will be determined by the chosen application.
Welding Current (Amperage)
Electrode SizeCurrent Range
ø mm/Inch (Amps)
2.5mm (7/64) (0.09) 60 - 95
3.2mm ( 1/8 (0.12) 100 - 130
4.0mm (11/64)(0.15) 130 - 165
5.0mm (13/64)(0.19) 165 - 260
Electrode Selection
As a general rule, the selection of an electrode is straight forward,in that it is only a matter of selecting an elec-
trode of similar composition to the parent metal. However, for some metals there is a choice of several electrodes,
each of which has particular properties to suit specic classes of work. It is recommend to consult your welding
supplier for the correct selection of electrode.
ARC (Stick) Welding Fundamentals
Average Thickness Maximum Recommended
of Material Electrode Diameter
0.03 - 0.07 inches
0.07 - 0.19 inches
0.19 - 0.31 inches
0.31 - > inches
0.09 inches
0.12 inches
0.15 inches
0.19 inches

14
(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.
(3) Connect weld power lead to
(8) Feed wire over the drive roller into
the outlet guide tube, Push the wire
through approx 4-5in.
(2) Connect earth lead to (5) Set torch operation 2T / 4T
IMPORTANT : When connecting the torch
be sure to tighten the connection.
(1) Connect MIG torch
(5) Select torch operation 2T or 4T
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 ne tune the auto-adjusted voltage
to personalise your setting for optimal results.
(6) Connect the gas line to the regulator
and connect to the gas cylinder
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 ash.
WARNING:
Ensure that an approved welding helmet, protective clothing and gloves are use for all welding operations
(4) Set MIG/TIG/MMA selector
switch to MIG
OR Select SMARTSET

15
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 ow rate to between 11-21cfh.
(16) Set the welding parameters using the wire feed and voltage control knobs.
(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 pa-
rameters for a given metal.
(12) Press and hold the inch wire button to
feed the wire down the torch cable through
to the torch head.
(11) Remove the gas nozzle and contact tip
from the front end of the mig torch.
(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.
(16) Set welding parameters using the
voltage and wire feed controls.
(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.
(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
(15) Carefully open the valve of the gas
cylinder, set the ow to 21cfh
NOTE:
GEAR DRIVE FEEDER ON 210 MODEL ONLY

16
Drive Rollers
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 dierent types of
grooves machined in them to accommodate the dierent 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 stier 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 dicult 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 oers 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 uxing and metal
compounds layered onto it and then rolled into a cylinder to form the nished 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 ux 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 ux 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 ux core wire without any deformation of the wire shape.
V Groove U Groove Knurled Groove
Wire Wire Wire
Top Pressure Roller Top Pressure Roller Top Pressure Roller
22mm
30mm
10mm
V Groove Drive Roller - Steel Wire
Part Number Description
0.6-0.8V30/22 Drive Roll V Groove 0.6-0.8mm / 0.023”- 0.030”
0.8-1.0V30/22 Drive Roll V Groove 0.8-1.0mm / 0.030”- 0.040”
0.9-1.2V30/22 Drive Roll V Groove 0.9-1.2mm / 0.035”- 0.045”
1.0-1.2V30/22 Drive Roll V Groove 1.0-1.2mm / 0.040”- 0.045”
1.2-1.6V30/22 Drive Roll V Groove 1.2-1.6mm / 0.045”- 0.062”
Part Number
0.6-0.8V30/10
0.8-1.0V30/10
0.9-1.2V30/10
1.0-1.2V30/10
Knurled Drive Roller - Flux Core Wire
Part Number Description
0.6-0.8F30/22 Drive Roll Knurled 0.6-0.9mm / 0.023” - 0.035”
0.8-0.9F30/22 Drive Roll Knurled 0.8-0.9mm / 0.030” - 0.035”
0.9-1.2F30/22 Drive Roll Knurled 0.9-1.2mm / 0.035” - 0.045”
1.2-1.6F30/22 Drive Roll Knurled 1.2-1.6mm / 0.045” - 0.062”
Part Number
0.6-0.8F30/10
0.8-0.9F30/10
0.9-1.2F30/10
U Groove Drive Roller - Soft Wire
Part Number Description
0.8-1.0U30/22 Drive Roll U Groove 1.0-1.2mm / 0.040”- 0.045
0.9-1.0U30/22 Drive Roll U Groove 0.9-1.0mm / 0.035”- 0.040”
0.9-1.2U30/22 Drive Roll U Groove 0.9-1.2mm / 0.035”- 0.045”
1.0-1.2U30/22 Drive Roll U Groove 1.0-1.2mm / 0.040”- 0.045”
Part Number
0.8-1.0U30/10
0.9-1.0U30/10
0.9-1.2U30/10
1.0-1.2U30/10
MIG210 Drive roller sizes
MIG145/180

17
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. (3) Fit the wire spool onto the spool holder
tting the locating pin into the location hole
on the spool. Replace the spool retaining
nut tightly
(2) Note the tension spring adjuster
and spool locating pin.
(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
(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 us-
ing the tension adjustment knob
NOTE: MIG 180-145not 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.

18
(3) Connect weld power lead to
(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.
(6) Fit the correct sized Knurled Drive
roller for Gas Less Flux Cored wire
(2) Connect earth lead to
(4) Set MIG/TIG/MMA selector
switch to MIG
IMPORTANT : When connecting the torch
be sure to tighten the connection.
(1) Connect MIG torch
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.
(5) Select torch operation 2T or 4T
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 ash.
WARNING:
Ensure that an approved welding helmet, protective clothing and gloves are use for all welding operations

19
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.
(15) Set welding parameters using the
voltage and wire feed controls.
(10) Apply a medium amount of
pressure to the drive roller
(14) Fit the gas nozzle to the torch head.
(9) Close down the top roller bracket and clip
the pressure arm into place.
(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.
(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
NOTE:
GEAR DRIVE FEEDER ON 210 MODEL ONLY

20
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.
(2) Remove the liner retaining nut (3) Carefully pull out and completely
remove the liner
(4) Carefully unravel the new liner
(8) Replace the front end parts
(5) Carefully feed in the new liner down
the torch lead all the way to exit the torch
neck.
(9) Fully screw down the liner retaining
nut and nip it up tight.
(6) Fit the liner retaining nut and screw
only 1/2 way down
(1) Remove mig torch front end parts
(7) Snip the liner o 3mm past the end
of the torch neck.