Razorweld KUMJRRW160 User manual

1
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
OPERATING MANUAL
KUMJRRW160
KUMJRRW200
©
JASIC Technologies America Inc 2013
YEARS Warranty
(Power Source)
3
Razorweld
Razorweld
™™
™
™

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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 condence that they will be well satised 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 Ofce of Environmental Health Hazard Assessment, 301 Capitol Mall, Sacramento, CA
95814; telephone 916-445-6900.
• 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: 212-642-4900; web site: www.ansi.org.
Razorweld
Razorweld
™
™
™™

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CONTENTS PAGE
Warranty 2
Safety - Cautions 4-6
Technical Data, Product Information 7-8
weld Program Sequence Control 9-12
Installation & Operation for MMA (Stick) Welding 13-14
MMA (Stick) Welding 15-16
Installation & Operation for DC TIG Welding 17-18
DC TIG Welding, DC Pulse TIG Welding 19-20
Set & Operation for Pulse DC TIG with TIG160/200 21
TIG Welding Fusion and Filler Wire Technique 22
Remote Controls - Installation and Operation 23
Tungsten Electrode Selection & Preparation 24-25
TIG Torch Parts Breakdown 26-27
Trouble Shooting Guide - TIG Welding 28-29
Trouble Shooting Guide - MMA (Stick) Welding 30
Machine Spare Parts Identication 31
Full Warranty Terms 32-34

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SAFETY
Welding and cutting equipment can be dangerous to both the operator and people in or near the
surrounding working area, if the equipment is not correctly operated. Equipment must only be
used under the strict and comprehensive observance of all relevant safety regulations.
Read and 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 qualied.
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 American standards and regulations. ANSI Z49.1.
• Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.
The operator must wear dry welding gloves while he/she performs the welding task.
• The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.
• Do not use damaged, under sized, or badly joined cables.
• Do not drape cables over your body.
Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can
be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health.
•Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
• In conned 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 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

5
Fire hazard. Welding on closed containers, such as tanks,drums, or pipes, can cause them
to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause
res and burns. Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or re. Check and be sure the area is safe before doing any welding.
•The welding sparks may cause re, therefore remove any ammable materials away from the working
area, at least 39ft from the welding arc. Cover ammable materials and containers with approved covers
if unable to be moved from the welding area.
• Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared
according to the required Safety Standards to insure that ammable or toxic vapors and substances are
totally removed, these can cause an explosion even though the vessel has been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
• Do not weld where the atmosphere may contain ammable dust, gas, or liquid vapours (such as petrol)
•Have a re extinguisher nearby and know how to use it. Be alert that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding
on a ceiling, oor, bulkhead, or partition can cause re on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylin-
der can explode. Because gas cylinders are normally part of the welding process, be sure to
treat them carefully. CYLINDERS can explode if damaged.
• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open ames,
sparks, and arcs.
• 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 conned spaces or use approved air-supplied respirator.
Electronic magnetic elds. 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.

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CAUTION
1. Working Environment.
1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive
chemicals, ammable gas or materials etc, and at no more than maximum of 80% humidity.
1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;
the temperature of working environment should be maintained within -14°F to +104°F.
1.3 Keep this equipment 1ft 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 1ft. 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 modied, 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 qualied 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:- 9KVA
• Our equipment as described in this manual conforms to all applicable rules and regulations of the
‘LowVoltage Directive’ (European Council Directive 73/23/EEC) as set out and amended by Council
Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
• Our equipment as described in this manual conforms to all applicable rules and regulations of the
European Council Directive 89/336/EEC, (EMC Directive) and to the National legislation for he
enforcement of this Directive.

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Technical Data
Power Supply / Phases (V-Ph) 115V/230V - 1 ±15%
Rated Input Power (KVA) 7
ieff (Amps) 14.2A 115V - 13.2A 230V
Imax (Amps) 23A 115V - 23A 230V
Rated Output 140A/25.6V MMA - 160A/16.4V TIG
Welding Current Range 10 ~ 160A
No-Load Voltage (V) 65
Duty Cycle @ 104ºF 35%@140Amps TIG-230V
35%@100Amps TIG-115V
Duty Cycle @ 104ºF 35%@140Amps MMA-230V
35%@80Amps MMA-115V
Protection Class IP21S
Size (inches) 14.4” x 5.3” x 10.9”
Weight (pounds) 13.0
Warranty 3 years on power source
Features
• Latest IGBT Inverter Technology
• Digital Weld Program Sequence Control
• DC TIG (DC tungsten inert gas welding)
- HF Arc Ignition (prevents tungsten inclusion & tungsten damage)
- Adjustable Pulse Frequency 0.5 - 200Hz
- Peak Current, Base Current and Pulse Width Adjustment
- 2/4T Trigger + Spot Time Adjustment
- Start & Final Current Adjustment
- Pre and Post Gas Flow Adjustment
- Up and Down Slope Adjustment
- Remote Torch Amp Control
• MMA (stick electrode)
- Arc Ignition
- Arc Force
• Digital Display
• Thermal Overload Protection
• Generator compatible (recommend 7.0KVA minimum)
Overview
The RAZOR160 is an inverter-based Digital Controlled DC Tig welding machine with HF arc ignition and pulse capability. Produced
using the latest in IGBT technology this machine offers simple easy step by step digital setting of functions and parameters providing
you with professional and complete control. The HF arc ignition provides pre gas and instant arc ignition with the press of the torch
switch leaving no tungsten inclusion and no contamination of the tungsten electrode. Digital set of Pre Gas Time, Start Current Level,
Up Slope Time, Down Slope Time, Finish Current Level and Post Gas Time combined with the choice of 2 or 4T trigger function allows
you to control the start and finish of the weld process at the highest professional level. The Digital Control Pulse Frequency allows full
parameter setting of Peak Current, Base Current, Pulse Frequency and Pulse Width, allowing to manipulate the heat input to the work,
control penetration and minimise distortion. Combining the functions of the RAZOR160 ensures comprehensive control of the welding
parameters when welding all DC weldable materials to produce high quality Tig welds. Our unique Torch Remote Control Interface pro-
vides remote amperage control from the torch in both static and live welding modes. The DC MMA welding function delivers a smooth
and stable arc allowing easy welding with electrodes obtaining high quality welds including cast Iron, stainless and low hydrogen. The
added bonus of Arc Ignition and Arc Force control allows you to set the ideal arc condition no matter what electrode you choose.
The RAZOR160 is a professional machine that is suitable for multiple applications; stainless steel fabrication, dairy & food industry, site
welding, repair and maintenance applications.
Built to our specification and manufactured in compliance to CAN/CSA E60974-1 & ANSI/IEC 60974-1
Product Code: KUMJRRW160
Standard Package includes: RAZOR TIG160, SR17 13ft Pro-Grip Lite TIG torch, 13ft Arc Lead Set, Argon regulator, Carry Bag,
Power Adaptor.
DIGITAL DC INVERTER WELDER
TIG/MMA - 160 Amp DC Inverter Welder
Welds: Steels, Stainless, Cast Iron, Bronze, Copper
KUMJRRW160

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Technical Data
Power Supply / Phases (V-Ph) 240V - 1 ±15%
Rated Input Power (KVA) 9KVA -230V / 5KVA -115V
ieff (Amps) 14.6
Rated Input Current (A) 20.0
Rated Output 10-160A/26.4V MMA
05-200A/18.0V TIG
No-Load Voltage (V) 43
Duty Cycle @ 104ºC TIG 35%@200 Amps 230V
35%@140 Amps 115V
Duty Cycle @ 104ºC MMA 35%@180 Amps 230V
35%@120 Amps 115V
Efficiency (%) 85
Power Factor 0.70
Protection Class IP21S
Insulation Class F
Size (mm) 14.4 x 5.3 x 10.9”
Weight (pounds) 13.5
Warranty 3 years on power source
Features
• Latest IGBT Inverter Technology
• Digital Weld Program Sequence Control
• DC TIG (DC tungsten inert gas welding)
- HF Arc Ignition (prevents tungsten inclusion & tungsten damage)
- Adjustable Pulse Frequency 0.5 - 200Hz
- Peak Current, Base Current and Pulse Width Adjustment
- 2/4T Trigger + Spot Time Adjustment
- Start & Final Current Adjustment
- Pre and Post Gas Flow Adjustment
- Up and Down Slope Adjustment
- Remote Torch Amp Control
• MMA (stick electrode)
- Arc Ignition
- Arc Force
• Digital Display
• Thermal Overload Protection
• Generator compatible (recommend 9.0KVA 230V)
Overview
The RAZOR200 is an inverter-based Digital Controlled DC Tig welding machine with HF arc ignition and pulse capability. Produced
using the latest in IGBT technology this machine offers simple easy step by step digital setting of functions and parameters providing
you with professional and complete control. The HF arc ignition provides pre gas and instant arc ignition with the press of the torch
switch leaving no tungsten inclusion and no contamination of the tungsten electrode. Digital set of Pre Gas Time, Start Current Level,
Up Slope Time, Down Slope Time, Finish Current Level and Post Gas Time combined with the choice of 2 or 4T trigger function allows
you to control the start and finish of the weld process at the highest professional level. The Digital Control Pulse Frequency allows full
parameter setting of Peak Current, Base Current, Pulse Frequency and Pulse Width, allowing to manipulate the heat input to the work,
control penetration and minimise distortion. Combining the functions of the RAZOR200 ensures comprehensive control of the welding
parameters when welding all DC weldable materials to produce high quality Tig welds. Our unique Torch Remote Control Interface pro-
vides remote amperage control from the torch in both static and live welding modes. The DC MMA welding function delivers a smooth
and stable arc allowing easy welding with electrodes obtaining high quality welds including cast Iron, stainless and low hydrogen. The
added bonus of Arc Ignition and Arc Force control allows you to set the ideal arc condition no matter what electrode you choose.
The RAZOR200 is a professional machine that is suitable for multiple applications; stainless steel fabrication, dairy & food industry, site
welding, repair and maintenance applications.
Built to our specification and manufactured in compliance to CAN/CSA E60974-1 & ANSI/IEC 60974-1
Product Code: KUMJRRW200
Standard Package includes: RAZOR200 Machine, SR26 x 13Ft Tig Torch, 13Ft Arc Lead set, Argon Regulator
DIGITAL DC INVERTER WELDER
TIG/MMA - 200 Amp DC Inverter Welder
Welds: Steels, Stainless, Cast Iron, Bronze, Copper
KUMJRRW200

9
43
1
Indicates Action
Selector Pad
2
2. Encoder Knob - provides digital adjustment of welding parameters.
The Encoder Knob is used to set the value of
the parameters required. Turning the encoder
will adjust the value shown in the digital display
screen.
3. Torch Switch Mode Selector - Controls the on/off cycle of the machine using the torch switch while
incorporating the weld program parameters selections.
2T: Select the 2T icon using the selector pad.
2T uses 2 actions of the torch switch while
incorporating weld program parameter
selections.
(refer to page 11 for instruction of 2T function)
4T: Select the 4T icon using the selector pad.
4T uses 4 actions of the torch switch while
incorporating weld program parameter
selections. 4T provides operator control of the
Start and Finish periods of the weld sequence
(refer to page 12 for instruction of 4T function)
SPOT: Select the SPOT icon using the
selector pad.
Spot uses a single action of the torch switch
1) Pressing the torch switch gives arc igni-
tion and initializes the welding sequence for a
period of time set using the spot timer.
(refer to page 12 for instruction of SPOT
function)
DC Pulse Tig: Select by pushing
selector pad to cycle through to
illuminate the DC Pulse icon.
DC Tig: Select by pushing the
selector button to cycle through to
illuminate the DC icon.
MMA: Select by pushing the
selector button to cycle through to
illuminate the DC icon.
1. Mode Selector - Enables selection of required welding mode - MMA - DC TIG - DC PULSE TIG.
Front Panel Functions
Front Panel Operation - Weld Program Sequence Control

10
Base Amp - Provides selection for the Base Amperage during the Pulse Welding cycle.
Peak Amp - Provides selection for the Maximum Welding Amperage required during welding.
Up Slope Time - Sets the transition time from Start Amperage to Welding Amperage
Start Amp - Provides selection for the amount of amps required at the start of the weld.
Continued - Front Panel Operation - Weld Program Sequence Control
Parameter selection: Select by pushing selector pad to
cycle through to illuminate the icon of the parameter
required. Each push of the selector pad will move the icon
illumination in a clockwise cycle.
Pre Gas Timer - Provides selection for gas ow time prior to the arc starting.
Turn the Encoder to set
the Pre-Gas Time
(Range is 0-10 Sec)
Pre Gas Time: Select by pushing selector
pad to cycle through to illuminate the Pre
Gas Timer icon.
The value selected shows on the digital
display. It is the length of time the gas
will ow before the arc starts.
Indicates Action
Selector Pad
Turn the Encoder to set
the Start Amp value
(Range is 10-200A)
Pre Gas Time: Select by pushing selector
pad to cycle through to illuminate the Start
Amp icon.
The value selected shows on the digital
display. It is the amount of amps the
machine will deliver at the start of the
welding sequence.
Turn the Encoder to set
the Up Slope value
(Range is 0-60 Sec)
Up Slope Time: Select by pushing selector
pad to cycle through to illuminate the
Up Slope icon.
The value selected shows on the digital
display. It is the amount of time the
welding current takes to climb from
start amperage to welding amperage.
Turn the Encoder to set
the Peak Amp value
(Range is 10-200A)
Peak Amp: Select by pushing selector
pad to cycle through to illuminate the Peak
Amp icon.
The value selected shows on the digital
display. It is the maximum set value of
amperage the machine will deliver.
Turn the Encoder to set
the Peak Amp value
(Range is 10-200A)
Base Amp: Select by pushing selector
pad to cycle through to illuminate the Peak
Amp icon.
The value selected shows on the digital
display. It is the set value of amperage
the machine will deliver during the Base
Amp period of the pulse cycle.
4. Weld Program - Provides selection weld program parameters

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Pulse Mode Selection - Provides parameters for Pulse Width and Pulse Frequency in DC Pulse Tig Mode.
Pulse Frequency: Select by push-
ing selector pad to cycle through to
illuminate the Hz Pulse icon.
Rotate the Adjustment Encoder
Knob to set the Pulse Frequency
(Range is 0.5 - 200 Hz).
The value selected is shown in the digital
display. The value selected is the amount
of pulses per second (Hz)
Pulse Width: Select by pushing
selector pad to cycle through to
illuminate the % Pulse icon.
Rotate the Adjustment Encoder
Knob to set the Pulse Width
(Range is 10 - 90%).
The value selected is shown in the digital
display. The value selected is the % of on
time of the Peak Amp during each pulse.
Turn the Encoder to set
the Peak Amp value
(Range is 10-200A)
Base Amp: Select by pushing selector
pad to cycle through to illuminate the Peak
Amp icon.
The value selected shows on the digital
display. It is the amount of amps the
machine will deliver at the nish of the
welding sequence.
Finish Amp - Provides selection for the amount of amps required at the end of the weld.
Down Slope Time - Sets the transition time from Welding Amperage to Finish Amperage
Turn the Encoder to set
the Up Slope value
(Range is 0-60 Sec)
The value selected shows on the digital
display. It is the amount of time it takes
for the welding amperage to drop down
to the set Finish Amperage.
Continued - Front Panel Operation - Weld Program Sequence Control
Up Slope Time: Select by pushing selector
pad to cycle through to illuminate the
Up Slope icon.
Post Gas Timer - Provides selection for continued gas ow time at the end of the welding after the arc is out.
Turn the Encoder to set
the Post Gas Time
(Range is 0-10 Sec)
Pre Gas Time: Select by pushing selector
pad to cycle through to illuminate the
Post Gas Timer icon.
The value selected shows on the digital
display. It is the length of time the gas
will ow after the arc is nished.
Torch Switch Mode Selection - Provides a choice of Torch Switch control sequence.
2T: Select by pushing
selector pad to cycle through to
illuminate the 2T icon.
2T Selection provides 2 times function of the torch switch.
(1) Pressing the torch switch gives arc ignition and initializes the welding sequence,
the welding current is maintained by the torch switch being held on.
(2) Releasing the torch switch stops the welding sequence by introducing down slope,
the current falls to minimum level and then terminates the welding current and
introduces the post ow gas.
2T - Selection provides 2 times function of the torch switch.

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Continued - Front Panel Operation - Weld Program Sequence Control
4T: Select by pushing
selector pad to cycle through to
illuminate the 4T icon.
(1) Pressing and holding on the torch switch activates Pre Gas then arc ignition initializing the set
Start Amp level. Holding the torch switch on keeps the amperage output at the set Start Amp level.
(2) Releasing the torch switch activates Up Slope allowing the amperage to increase during the set
Up Slope time to reach the set Peak Amp level. Machine output remains at Peak Amp level.
(3) Pressing and holding on the torch switch activates Down Slope allowing the amperage to
decrease during the set Down Slope time to reach the set Finish Amp level. Holding the torch
switch on keeps the amperage output at the set Final Amp level.
(4) Releasing the torch switch ends the welding sequence bringing in the Post Flow gas time.
SPOT: Select by pushing
selector pad to cycle through to
illuminate the SPOT icon.
Provides a set weld sequence
time.
Turn the Encoder to set
the SPOT TIME value
(Range is 0.1-10 Sec)
The value selected shows on the
digital display. It is the set amount
of time the machine will deliver
amperage output.
SPOT TIME: Select by pushing
selector pad to cycle through to
illuminate the SPOT icon.
Allows to set the weld sequence
time.
SPOT TIME
IGNITION: Select MMA by pushing
selector pad to cycle through to
illuminate the icon.
Only for MMA (Stick Electrode)
welding. Provides short time period
of high amperage at the start of the
welding.
Turn the Encoder to
set the IGNITION TIME
value.
(Range is 0.1-1.0 Sec)
The value selected shows on the
digital display. It is the set amount
of time the machine will deliver
higher amperage at the start of the
welding. Only for MMA function
Select by pushing selector pad
to cycle through to illuminate the
IGNITION icon. Allows to set
the time period of the arc ignition.
4T - Selection provides 4 times function of the torch switch.
SPOT Selection provides a set weld sequence time
IGNITION TIME For MMA ( Stick) welding only. Selection allows for high amperage start for a selected time period.
ARC FORCE: Select MMA by
pushing selector pad to cycle
through to illuminate the icon.
Only for MMA (Stick Electrode)
welding. Provides soft or digging
type of arc.
Turn the Encoder to set
the ARC FORCE value.
(Range is 0-180)
The value selected shows on the
digital display. Low setting pro-
vides soft buttery arc. High setting
provides aggressive digging arc.
Only for MMA function
Select by pushing selector pad
to cycle through to illuminate the
ARC FORCE icon. Allows to set
the force of the arc from soft to
digging type.
ARC FORCE For MMA ( Stick) welding only. Selection allows for adjustment of the ARC FORCE
ARC FORCE - What is the Arc Force Control and what does it do?
The arc force control lets you adjust the force of the arc from a soft buttery arc to a more penetrating, digging type of arc.
Arc voltage drops as the arc gets tighter and can cause the electrode to stick/short circuit to the work piece.
When you set the arc force high the machine senses the drop in voltage. As the rod is about to stick the machine compensates by
increasing the arc voltage. This boost in arc voltage/current blasts away base metal and electrode to prevent the electrode from
welding itself to the work piece. Higher Arc Force is more suited to Cellulose and Low Hydrogen type electrodes where a forceful
arc characteristic is preferred to maintain the arc and better control penetration. Lower Arc Force is better suited to Hardfacing and
Cast Iron electrodes where a soft buttery arc is preferred to prevent the electrode material diluting too much with the base metal.

13
Continued - Front Panel Operation - Weld Program Sequence Control
(1) Connecting the Welding Lead Set: Various electrodes require a different polarity for optimum results
refer to the electrode manufacturers information for the correct polarity. Most GP electrodes are
Electrode connected to output socket, Earth Connected to the output socket
(2) Turn the power source on using the on/off switch located on the rear machine panel.
Set Up Procedure for MMA (Stick) Welding: Razor16O/2OO TIG-MMA
(2) Turn on the Power source
using the on/off switch at the
rear of the machine
(1) Connect the Earth Lead
lead to terminal
(1) Connect Electrode Lead
the terminal
(3) Select DC MMA Function. Push the
button until the DC icon illuminates
green.
(4) Set the weld amperage by rotating the
Adjustment Encoder Knob. Set the amper-
age according to the electrode type and size
being used as recommended by the electrode
manufacturer. The Peak Amp icon will be
illuminated and the set amperage will show in
the Digital Display.
(5) Select Ignition and Arc Force Push the
button until the Ignition icon illuminates
green. Rotate the Adjustment Encoder Knob
to set the Arc Ignition Time the set time will
be shown on the Digital Display.
Push the button until the Arc Force icon
illuminates green. Rotate the Adjustment
Encoder Knob to set the Arc Force the set
value will be shown on the Digital Display
Refer to Page 12 for instruction on Arc
Ignition Time and Arc Force Control

14
9) Hold the electrode slightly above the
work maintaining the arc while travelling
at an even speed.
10) To nish the weld, break the arc by
quickly snapping the electrode away from
the work piece.
11) Wait for the weld to cool and carefully
chip away the slag to reveal the weld
metal below.
Continued - Set Up Procedure for MMA (Stick) Welding: Razor16O/2OO TIG-MMA
6) Connect the Earth Clamp securely to
the work piece or the work bench.
7) Place and clamp an electrode into the
Electrode Hand Piece
8) Strike the electrode against the work
piece to create an arc, lift slightly and
hold the electrode steady to maintain
the arc

15
MMA (Manual Metal Arc) Welding
One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric
current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode
rod is made of a material that is compatible with the base material being welded and is covered with a ux 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 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 identied 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 different 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
covering on the electrode.

16
Electrode Size
Average Thickness Maximum Recommended
of Material Electrode Diameter
0.03 - 0.07 inches 0.09 inches
0.07 - 0.19 inches 0.12 inches
0.19 - 0.31 inches 0.15 inches
0.31 - > 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 based on using a
general purpose type 6013 electrode.
Correct current selection for a particular job is an
important factor in arc welding. With the current set too
low, difculty 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
prole 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 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 between 80 and 90 degrees to the work piece.
Travel Speed
The electrode should be moved along in the direction of the joint being welded at a speed that will give the
size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all
times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel
will frequently lead to arc instability,slag inclusions and poor mechanical properties.
Material and Joint Preparation
The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or
any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend
on the method used include sawing, punching, shearing, machining, ame cutting and others. In all cases
edges should be clean and free of any contaminates. The type of joint will be determined by the chosen
application.
Welding Current (Amperage)
Electrode Size Current Range
ø mm (Amps)
0.09 inches 60 - 100
0.12 inches 100 - 130
0.15 inches 130 - 165
0.19 inches 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
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 specic classes of work. It is recommend to
consult your welding supplier for the correct selection of electrode.
MMA (Stick) Welding Fundamentals

17
(1) Turn on the machine using the ON/OFF switch
(2) Select the TIG function with the TIG/MMA selector switch
(3) Connect the Tig Torch connector to the negative terminal and tighten it
(4) Connect the Earth Cable connector into the positive terminal and tighten it
(5) Connect the torch switch remote lead into the torch remote socket
(6) Insert the torch gas connector into the quick lock gas receptacle
(7) Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder
Connect the gas line to the quick lock gas inlet connector at the rear of the machine
(7) Connect the regulator to the cylinder,
Connect the gas lead to the regulator.
Set the ow to 17-25 CFH
(4) Connect the Earth cable
connector to the terminal
(5) Connect the torch switch lead
to the torch remote receptacle
(1) Turn on the machine using the
ON/OFF switch at the rear of machine
(2) Select TIG using the TIG/MMA
selector switch
(3) Connect the TIG torch connector
to the terminal.
(6) Insert the torch gas connector into
the quick lock gas receptacle.
Installation Set Up for DC TIG Welding: Razor16O/2OO TIG-MMA

18
HF (high frequency) ignition allows the arc to be started in Tig welding without touching the tungsten to the
work piece. By pressing the torch switch the machine will activate the gas ow and the HF ignition result-
ing in the arc igniting across the gap between the tungsten electrode and the work piece. The distance
between the electrode and the work piece can be up to 13/64”. This arc ignition method prevents tungsten
inclusion in the work piece, promotes longer tungsten life and offers better operator control over the starting
and stopping the arc.
(1) Assemble the front end torch parts use the correct size and type of tungsten electrode for the job,
the tungsten electrode requires a sharpened point for DC welding.
(2) Select DC Tig and choose 2T or 4T trigger function preferred as per the descriptions below
2T Selection provides 2 times function of the torch switch.
(1) Pressing the torch switch gives arc ignition and initializes the welding current and the welding
current is maintained by the torch remaining on.
(2) Releasing the torch switch stops the welding by introducing down slope and the current falls to
minimum level and then terminates the welding current and introduces the post ow gas.
4T Selection provides 4 times function of the torch switch
(1) Pressing the torch switch gives arc ignition and initializes the welding current
(2) Releasing the torch switch continues the welding operation.
(3) Pressing the torch switch and holding introduces down slope and current falls to minimum current.
(4) Releasing the torch switch terminates the welding operation and introduces the post ow gas.
(3) Choose the preferred welding current (amperage) to suit the tungsten size material type and
thickness to be welded.
(4) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 0.040” - 1/8” from
the work piece this method will provide a clean positive arc ignition.
(5) Press the torch switch and the arc will ignite across the gap between the tungsten and work piece.
Hold even distance of about 5/64” gap between the tungsten and work piece to maintain the arc.
(6) Release the torch switch to bring in the end of the welding sequence dependant of 2T or 4T trigger
function choice.
(1) Assemble the front end torch parts use the
correct size and type of tungsten electrode
for the job, the tungsten electrode requires
a sharpened point for DC welding
(2) Select DC Tig Function. Push the button
until the DC icon illuminates green. Select 2T
or 4T trigger function as required by the push-
ing the button to cycle through the trigger
options. The icon will illuminate green for the
selected trigger option.
(4) Lay the outside edge of the Gas Cup on
the work piece with the Tungsten Electrode
0.040” - 1/8 from the work piece
(5) Press the torch switch and the arc will ignite
across the gap between the tungsten and
work piece. Hold even distance of about
5/64” gap between the tungsten and work
piece to maintain the arc.
(6) Release the torch switch to bring in the end
of the welding sequence dependant of 2T
or 4T trigger function choice
(3) Set the amps required by pushing the
button, cycle through to illuminate the Peak Amp
icon. Set the amperage with the encoder adjust-
ment knob.
DC HF TIG Welding Standard Operation: Razor16O/2OO TIG-MMA

19
DC TIG Welding
The DC power source uses what is known as DC (direct current) in which the main elec-
trical component known as electrons ow in only one direction from the negative pole
(terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical
principle at work which should always be taken into account when using any DC circuit.
With a DC circuit 70% of the energy (heat) is always on the positive side. This needs to
be understood because it determines what terminal the TIG torch will be connected to
(this rule applies to all the other forms of DC welding as well ).
DC TIG welding is a process in which an arc is struck between a
TUNGSTEN electrode and the metal work piece. The weld area is
shielded by an inert gas ow to prevent contamination of the tung-
sten, molten pool and weld area.
When the TIG arc is struck the inert gas is ionized and superheat-
ed changing it’s molecular structure which converts it into a plasma
stream. This plasma stream owing between the tungsten and the
work piece is the TIG arc and can be as hot as 34232°F. It is a very
pure and concentrated arc which provides the controlled melting of
most metals into a weld pool. TIG welding offers the user the greatest
amount of exibility to weld the widest range of material and thickness
and types. DC TIG welding is also the cleanest weld with no sparks
or spatter.
HF ARC IGNITION for TIG (tungsten inert gas) Welding
HF (high frequency) ignition allows the arc to be started in Tig welding without touching the tungsten to the
work piece. By pressing the torch switch the machine will activate the gas ow and introduce the HF (high
frequency) (high voltage) spark, this “ionizes” the air gap making it conductive allowing an arc to be created
without touching the tungsten to the work piece. The gas molecules are superheated by the arc creating
a stream of super heated gas that changes the molecular structure into producing a plasma stream. This
plasma stream provides heat and energy that allows us to melt and fuse metals in an inert gas shielded
environment know as TIG (tungsten inert gas) welding.
.
.
.
.
.
.
.
.
.
.
. .
.
.
gas
molecules
gas ow HF plasma
stream
The intensity of the arc is proportional to the current that ows from the
tungsten. The welder regulates the welding current to adjust the power
of the arc. Typically thin material requires a less powerful arc with less
heat to melt the material so less current (amps) is required, thicker
material requires a more powerful arc with more heat so more current
(amps) are necessary to melt the material.
30%
70%
high
current
low
current
power source
argon gas
nozzle

20
no pulse
high frequency
pulsing
no pulse
high frequency
pulsing
DC Pulse TIG Welding
Pulse TIG welding is when the current output (amperage) changes between high and low current.
Electronics within the welding machine create the pulse cycle. Welding is done during the high-amperage
interval (this high amperage is referred to as peak current). During the low amperage period, the arc is
maintained but the current output of the arc is reduced (this low amperage is referred to as base current).
During pulse welding the weld pool cools during the low amperage period. This allows a lower overall heat
input into the base metal. It allows for controlled heating and cooling periods during welding providing better
control of heat input, weld penetration, operator control and weld appearance.
There are 4 variables within the pulse cycle:
Peak Current - Base Current - Pulse Frequency - Pulse Width
Setting and manipulation of these variables will determine the nature of the weld current output and is at the
discretion of the operator.
Peak Current is the main welding current (amps) set to melt the material being welded and works much
the same as setting maximum amperage values for regular DC TIG: as a guide use 30-40 amps for every
0.040”of material thickness.
Base Current is the set level of background current (amps) which cools the weld puddle and affects overall
heat input. Background Amps is a percentage of peak amperage. As a rule, use enough background
current to reduce the weld pool to about half its normal size while still keeping the weld pool uid. As a
guide start by setting the background amperage at 20 to 30 percent of peak amperage.
Pulse Frequency is the control of the amount of times per second (Hz) that the welding current switches
from Peak Current to Base Current. DC Pulse TIG frequency generally ranges from 20 to 300 HZ depend-
ing on the job application. Control of the pulse frequency also determines the appearance of the weld.
Pulse Width is the control of the percentage of time during one pulsing cycle the power source spends at
the peak current (main amperage). Example is with the Pulse Width set at 80 percent and a rate of 1 pulse
per second (PPS), the machine will spend 80% of the pulse at peak amperage and 20% at the base cur-
rent. Increasing the pulse width percentage adds more heat to the job, while decreasing pulse width per-
centage reduces heat
peak
background
ON OFF
Current
Time
DC Pulse Tig welding allows faster welding speeds with better control of the heat input to the job, reducing
the heat input minimising distortion and warping of the work and is of particular advantage in the welding
of thin stainless steel and carbon steel applications. The high pulse frequency capability of the advanced
inverter agitates the weld puddle and allows you to move quickly without transferring too much heat to the
surrounding metal. Pulsing also constricts and focuses the arc thus increasing arc stability, penetration and
travel speeds.
This manual suits for next models
1
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