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Razorweld Xcel-Arc ARC160 User manual

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1

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1
RazorWeld
ARC16O ARC2OO
3YEARS Warranty
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
2 3
RazorWeld
WARRANTY
• 3 Years from date of purchase.
• Esseti NZ 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 Esseti NZ Ltd 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 the back of this manual.
Thank you for choosing to purchase this 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 professional
sales, marketing and technical personnel that provide us with market trends, market feedback and customer
comments and requirements. Secondly they provide a customer support service that is second to none,
thus ensuring our customers have 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, AS/NZ60974-1 guaranteeing you electrical safety and performance.
At initial set up and at regular intervals we recommend to check for gas leakage.
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the ow rate on the regulator to approximately 8-10 l/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the
regulator, if the needle drops away towards zero there is a gas leak.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator
and line for an extended time period. In this situation it is recommended to open the cylinder valve, set
the ow rate to 8-10 l/min, close the cylinder valve and check after a minimum of 15 minutes.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying
with soapy water, bubbles will appear at the leakage point.
6. Tighten clamps or ttings to eliminate gas leakage.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to
operation of your machine. We recommend that you close the cylinder valve when the
machine is not in use.
Esseti NZ Ltd, authorised representatives or agents of Esseti NZ Ltd will not be liable
or responsible for the loss of any gas.
ATTENTION! - CHECK FOR GAS LEAKS
3
CONTENTS PAGE
Introduction - Warranty 2
Safety - Cautions 4-6
Technical Data, Product Information 7-8
Machine Layout Description 9
VRD Operation for MMA (stick) Welding 10
Set Up & Operation for MMA (stick) Welding 11
MMA (Stick) Welding Information 12-13
Installation & Operation for DC TIG Welding 14-15
Basic DC TIG Welding Guide 16-17
Tungsten Electrode information 18-19
XA17V Tig Torch Parts Guide / Breakdown 20-21
MMA Welding Trouble Shooting Guide 22
DC TIG Welding Trouble Shooting Guide 23-24
Gas Leak Check - Procedure 24
Gas Flow Regulators - Sheilding Gases - Gas Flow Rates 26
Warranty 27
4 5
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 Australian and New Zealand standards and regulations.
• Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.
The operator must wear dry welding gloves while he/she performs the welding task.
• The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.
• Do not use damaged, under sized, or badly joined cables.
• Do not drape cables over your body.
Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can
be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health.
• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
• 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
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 12m 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 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.
6 7
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 -10°C to +40°C.
1.3 Keep this equipment 30cm distant from the wall.
1.4 Ensure the working environment is well ventilated.
2. Safety Tips.
2.1 Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is
of critical importance for the normal performance and service life of this equipment.
2.2 Thermal Overload protection.
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
ARC160PFC :- 7.0KVA
ARC160PFC :- 10.0KVA
EMC DECLARATION
IEC 60974-10:2007
Arc Welding equipment - Part 10: Electromagnetic compatibility (EMC) requirements (Classication of ISM
Equipment - According to IEC 60974-10:2007 and CISPR 11: 2033+A1:2004 Clause 4.1 and 4.2. The EUT
Belongs to Apparatus Group2 Class A)
7
RAZORWELD ARC160
MMA/TIG - 160 Amp DC Inverter Welder
Welds: Steels, Stainless, Cast Iron, Bronze, Copper
Razor
W
eld
Product Code: XA-ARC160RZ-K
Standard Package includes: ARC160PFC Machine, Earth Lead & Arc Lead 25mm x 4m
Technical Data
Power Supply 240V 1-Phase ±15%
Rated Input Power 7.1 kVA
I
i
e as per AS/NZ60974-1 10.0 Amps
Rated Output MMA 160 Amps / 26.4V
Rated Output TIG 160 Amps / 16.4V
Welding Current Range 10 ~ 160 Amps
No Load Voltage (OCV) VRD On 9V - VRD O󰀨 77V
Duty Cycle @ 40ºC as per AS/NZ60974-1 20% @ 160 Amps MMA
45% @ 160 Amps TIG
Duty Cycle @ 25ºC (approximate) 40% @ 160 Amps MMA
80% @ 160 Amps TIG
E󰀩ciency 85%
Power Factor 0.99
Protection Class IP21S
Insulation Class F
Dimensions (LxWxH) 365 x 135 x 227mm
Weight 6.5 Kg
Certication Approval AS/NZ60974-1
Overview
The RazorWeld ARC160PFC from Xcel-Arc is a high quality inverter welding machine with a primary function of DC-MMA (Stick)
welding and additional DC-TIG function incorporating Lift-Arc Ignition. Produced using the very latest generation 40KHz IGBT inverter
technology; this machine o󰀨ers outstanding arc characteristics whilst also being highly reliable, robust and with the added benet of
being factory-tted with a domestic 10 Amp plug with NZ Standards approval. The DC-MMA welding function delivers a smooth and
incredibly stable arc, producing high quality welds including cast Iron, stainless and low hydrogen. With the inclusion of both Hot-Start
and automatic Arc Force coupled with Selectable VRD and Power Factor Correction (PFC), this machine is perfectly suited to site
work for use with most electrodes up to 4.0mm diameter. Connection of the optional XA17V Tig Torch provides intermediate level DC-
TIG welding of steel, stainless steel, bronze and copper. The Lift-Arc TIG function delivers perfect arc ignition every time without any
sticking or inclusion of the tungsten electrode to the work and a remarkably smooth stable arc produces high quality TIG welds. The
ARC160RZ is an exceptional machine suitable for a wide range of applications including light to medium industrial use, site welding,
farming and general repair and maintenance work. The ARC160PFC gives you great portability with the power to get the job done.
Built to our specication and manufactured in compliance to AS/NZ60974-1.
Features
■New 40KHz inverter frequency technology
■PFC Power Factor Correction (for maximum electrical e󰀩ciency)
■MMA (stick electrode)
- Selectable On/O󰀨 VRD (Voltage Reduction Device)
- Hot start (improves electrode starting)
- Arc Force (boosts current to prevent electrode extinguishing)
- Excellent arc stability with all electrodes
■DC-TIG
- Lift Arc ignition (prevents tungsten sticking during arc ignition)
- Ultra smooth DC-TIG welding current
■Thermal overload protection
■Generator compatible (recommend 7.5 kVA minimum)
■Tolerant to variable power supply
230V Single Phase 160 Amp DC Welder MMA/TIG
Latest 40KHz Inverter, PFC & Selectable VRD
Approved Domestic 10 Amp Plug
RAZORWELD ARC160
XA-ARC160RZ-K
Standard Package
10 AMP
Optional machine accessories available - refer page 16
8 9
Technical Data
Power Supply 240V 1-Phase ±15%
Rated Input Power 9.0 kVA
I
i
e as per AS/NZ60974-1 15 Amps
Rated Output 200 Amps / 28V MMA
200 Amps / 18V TIG
Welding Current Range 10 ~ 200 Amps
No Load Voltage (OCV) VRD On 9V - O󰀨 77V
Duty Cycle @ 40ºC as per AS/NZ60974-1 25% @ 200 Amps MMA
25% @ 200 Amps TIG
Duty Cycle @ 25ºC (approximate) 40% @ 200 Amps MMA
40% @ 200Amps TIG
Power Factor 0.99
Protection Class IP21S
Insulation Class F
Dimensions (LxWxH) 365 x 135 x 227mm
Weight 6.5 Kg
Certication Approval AS/NZ60974-1
Features
■New 40KHz inverter frequency technology
■PFC (Power Factor Correction) for maximum electrical e󰀩ciency
■MMA function (Stick electrode)
- Selectable On/O󰀨 VRD (Voltage Reduction Device)
- Hot start (improves electrode starting)
- Arc Force (boosts current to prevent electrode extinguishing)
- Excellent arc stability with all electrodes
■DC-TIG
- Lift Arc ignition (prevents tungsten sticking during arc ignition)
- Ultra smooth DC-TIG welding current
■Thermal overload protection
■IP21S rating for environmental/safety protection
■Generator compatible (recommend 9.0 kVA minimum)
■ Auto-compensation for voltage uctuation
■Minimal harmonic feedback to power grid
RAZORWELD ARC200
MMA/TIG - 200 Amp DC Inverter Welder
Welds: Steels, Stainless, Cast Iron, Bronze, Copper
Razor
W
eld
Product Code: XA-ARC200RZ-K
Standard Package includes: ARC200RZ Machine, Earth Lead & Arc Lead 25mm x 4m
Overview
The RazorWeld ARC200 from Xcel-Arc is a high quality inverter welding machine with a primary function of DC-MMA (Stick) welding and
additional DC-TIG function incorporating Lift-Arc Ignition. Produced using the very latest generation 40KHz IGBT inverter technology;
this machine o󰀨ers outstanding arc characteristics whilst also being highly reliable, robust and incredibly portable. The DC-MMA welding
function delivers a smooth and incredibly stable arc, producing high quality welds including cast Iron, stainless and low hydrogen. With the
inclusion of Hot-Start and Arc Force coupled with Selectable VRD and Power Factor Correction (PFC), this machine is perfectly suited to
site work and is an ideal choice for the welding professional or contractor. Connection of the optional XA17V Tig Torch provides intermediate
level DC-TIG welding of steel, stainless steel, bronze and copper. The Lift-Arc TIG function is superb and delivers perfect arc ignition every
time without any sticking or inclusion of the tungsten electrode to the work piece and a remarkably smooth stable arc produces high quality
TIG welds. The ARC200RZ is an exceptional machine suitable for a wide range of applications including medium to heavy industrial use, site
welding, farming and general repair and maintenance work. The ARC200RZ gives you great portability with the power to get the job done.
Built to our specication and manufactured in compliance to AS/NZ60974-1.
230V Single Phase 200 Amp DC Welder MMA/TIG
Selectable VRD - Stick Electrode, Lift Arc DC TIG
Industrial Rated with PFC (Power Factor Correction)
RAZORWELD ARC200RAZORWELD ARC200
XA-ARC200RZ-K
Standard Package
Optional machine accessories available - refer page 16
9
Amperage Control
Dial
MMA /TIG Selector
Switch
Negative Output
Terminal
Positive Output
Terminal
Thermal Alarm LED
Primary Input
Power Lead
VRD On/O󰀨
VRD On LED
Power On LED
On/O󰀨 Switch
FRONT PANEL MACHINE LAYOUT: RazorWeld ARC16O-2OO
REAR PANEL MACHINE LAYOUT: RazorWeld ARC16O-2OO
10 11
VRD - MMA (STICK) Operation: RazorWeld ARC16O-2OO
SWITCHABLE VRD OPERATION: RazorWeld ARC16O-2OO
VRD - What is it and what does it do?
VRD is short for Voltage Reduction Device and it is a Safety Feature of the welding machine.
VRD reduces the welding power source’s open circuit voltage (OCV). OCV is the voltage measured
between the terminals when not welding. The VRD function will activate welding power when the
electrode is in contact with the work piece and the resistance between the electrode and work is
less than 200 Ohms. This means that the chance of being electrocuted from the secondary welding
circuit has virtually been eliminated in situations where the operator is in contact with the electrode
and the workpiece at the same time. In damp, wet and humid environments the chance of electric
shock from the secondary welding to the operator is increased, in particular if the operator is not
wearing protective leather welding gloves.
VRD can make the arc iginiton of some electrodes more di󰀩cutl especially for the inexpeirenced
operator. Switchable VRD allows the VRD function to be switched o󰀨 thereby increasing the OCV
and providing extra energy to establish the arc at the electrode.
Switchable VRD is controlled by a key switch at the rear of the machine and is in accordance with
AS/NZS 1674.2 2003. It allows the VRD function to be locked ON by the work place supervisor in
those workplace environments where VRD operation is required.
Select VRD On/O󰀨 by inserting
the Key and swiching to the On/
O󰀨 position required
VRD Led will
illuminate when
VRD is ON
VRD Led will not
illuminate when
VRD is OFF
VRD - ON VRD - OFF