Uni-Mig RAZOR COMPACT 250 User manual

COMP AC T 250
U11010K |Operating Manual
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RAZOR COMPACT 250
OPERATING MANUAL
1. Safety 3
2. Machine Features 7
3. Package Contents 8
4. Machine Specifications 9
5. Machine Layout 10
5.1Front Panel Layout 10
5.2Rear Panel Layout 10
5.3Interior Layout 11
5.4Geared Wire Drive System 12
6. Control Panel Layout 13
7. Control Panel Details 14
8. Advanced Settings Menu 16
9. MIG Manual Mode 17
10. Synergic Mode 17
11. MIG: Machine Setup 18
12. MIG Welding Further Explained 25
13. TIG: Machine Setup 32
14. TIG Welding Guide 36
15. MMA: Machine Setup 40
16. MMA: Welding Guide 43
17. MIG Troubleshooting 45
18. TIG Troubleshooting 47
19. MMA (STICK) Troubleshooting 48
20. Factory Reset 50
21. Indicator Lights 50
22. Error Codes 50
23. Wiring Diagrams 51
24. Machine Breakdown and Parts List 52
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RAZOR COMPACT 250
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1. Safety
Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working
area if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive
observance of all relevant safety regulations.
Read and understand this instruction manual carefully before the installation and operation of this equipment.
Machine operating safety
• Do not switch the function modes while the machine is operating. Switching of the function modes during welding can
damage the machine. Damage caused in this manner will not be covered under warranty.
• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing should the
electrode be in contact with the workpiece.
• Operators should be trained and or qualified.
Electric shock: it can kill
• Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live
whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. In MIG/
MAG welding, the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equipment is dangerous.
• Connect the primary input cable, according to Australian and New Zealand standards and regulations.
• Avoid all contact with live electrical parts of the welding/cutting circuit, electrodes and wires with bare hands.
• The operator must wear dry welding gloves while he/she performs the welding/cutting task.
• The operator should keep the workpiece 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, undersized, 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 while 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 while welding or cutting, keep your head out of the fumes.
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding/cutting fumes and gases.
• In confined or heavy fume environments always wear an approved air-supplied respirator.
• Welding/cutting 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/cut in locations near degreasing, 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 galvanised, lead, or cadmium plated steel, containing elements that can give o toxic fumes when welded/
cut. Do not weld/cut 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/cutting process produce intense visible and invisible ultraviolet and infrared rays that can burn
eyes and skin.
• Always wear a welding helmet with the correct shade of filter lens and suitable protective clothing, including welding gloves
while the welding/cutting operation is performed.
• Measures should be taken to protect people in or near the surrounding working area. Use protective screens or barriers to
protect others from flash, glare and sparks; warn others not to watch the arc.
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RAZOR COMPACT 250
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Fire hazard
• Welding/cutting on closed containers, such as tanks, drums, or pipes, can cause them to explode. Flying sparks from the
welding/cutting arc, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of the electrode
to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any
welding/cutting.
• The welding/cutting sparks & spatter may cause fire, therefore remove any flammable materials well away from the working
area. Cover flammable materials and containers with approved covers if unable to be moved from the welding/cutting area.
• Do not weld/cut on closed containers such as tanks, drums, or pipes, unless they are correctly prepared according to the
required Safety Standards to ensure that flammable or toxic vapours 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/cut where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)
• Have a fire extinguisher nearby and know how to use it. Be alert that welding/cutting sparks and hot materials from welding/
cutting can easily go through small cracks and openings to adjacent areas. Be aware that welding/cutting on a ceiling, floor,
bulkhead, or partition can cause a fire on the hidden side.
Gas cylinders
• Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders usually
are part of the welding/cutting process, be sure to treat them carefully. CYLINDERS can explode if damaged.
• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
• Ensure cylinders are held secure and upright to prevent tipping or falling over.
• Never allow the welding/cutting electrode or earth clamp to touch the gas cylinder, do not drape welding cables over the cylinder.
• Never weld/cut 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 cause a toxic environment, deplete the oxygen content in the air resulting in death or injury. Many
gases use in welding/cutting are invisible and odourless.
• Shut o shielding gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.
Electronic magnetic fields
• 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/cut 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/cutting gun. Use insulated
welding gloves and clothing to handle hot parts and prevent burns.
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Caution
Working environment
• The environment in which this welding/cutting equipment is installed must be free of grinding dust, corrosive chemicals,
flammable gas or materials etc., and at no more than a maximum of 80% humidity.
• When using the machine outdoors, protect the machine from direct sunlight, rainwater and snow, etc.; the temperature
of the working environment should be maintained within -10°C to +40°C.
• Keep this equipment 30cm distant from the wall.
• Ensure the working environment is well ventilated.
Safety tips
• 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/cutting operation. Important: Maintain
good ventilation of the louvres 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.
• Thermal Overload Protection: Should the machine be used to an excessive level, or in a 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 a safe level.
• Over-Voltage Supply: Regarding the power supply voltage range of the machine, please refer to the “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.
• Do not come into contact with the output terminals while the machine is in operation. An electric shock may occur.
Maintenance
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding/cutting machine. To prevent any possible
failure or fault of this welding/cutting 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/
cutting equipment will be void if the machine has been modified, attempt to take apart the machine or open the factory-
made sealing of the machine without the consent of an authorized representative of the manufacturer.
Troubleshooting
Caution: Only qualified technicians are authorized to undertake the repair of this welding/cutting equipment. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed in this manual.
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RAZOR COMPACT 250
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Attention! - Check For Gas Leakage
At initial set up and at regular intervals we recommend to check for gas leakage
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 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 flow 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 fittings to eliminate gas leakage.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your machine. We
recommend that you close the cylinder valve when the machine is not in use.
Welding Guns Of Australia PTY LTD, authorised representatives or agents of Welding Guns Of Australia PTY LTD
will not be liable or responsible for the loss of any gas.
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2. Machine Features
HD Backlit Interface
Experience a new level of convenience with our next-
generation interface panel. With its vibrant and easy-to-read
display, you'll be able to eortlessly navigate and customise
your welding settings in any lighting condition.
Synergic MIG Control
Say goodbye to complicated and time-consuming setup
with our innovative Synergic MIG control. This cutting-edge
technology automatically adjusts your welding settings based
on your wire type, gas, wire size, and material thickness,
ensuring precise and ecient results every time.
Digital Control MIG Torch
The ultimate solution for welders seeking unprecedented
control and precision in their work. No more hassle of
constantly adjusting your settings on a separate control panel.
With our leading technology, you can easily fine-tune your
amps, wire speed, and voltage right on the MIG torch itself.
Push-Pull Gun Ready
Achieve smooth and steady wire feeding, especially when
using softer wires such as aluminium. With a 'Pull' motor built
into the torch, the wire can be fed over a greater distance,
granting you the freedom to move and manoeuvre with ease
while MIG welding.
Spool Gun Ready
Attach a Spool Gun to run softer core wires such as aluminium
MIG wire. You don’t even need to change the setup of your
existing torch or drive rollers.
Gas & Gasless MIG
Our welding machine supports both gas-shielded and gasless
MIG wire, allowing you to tackle a wide variety of welding
projects with ease. Whether you're working with mild steel,
stainless steel, aluminium, or flux-cored wire, our machine has
got you covered.
4 Geared Wire Drive
Experience smooth and consistent wire feeding with our
advanced 4 geared roller drive unit. This feature ensures that
your wire is fed consistently and accurately, even when using
longer MIG torches.
Multi-Process Welding
Get the job done quickly and eciently with our versatile
three-in-one welding machine. With the ability to perform MIG,
TIG, and STICK welding all in one unit, you can save valuable
time and eort without sacrificing quality.
Foot Control Ready
Enjoy greater control and precision with our optional foot
control accessory. This handy feature allows you to easily
adjust your TIG amperage on the fly, without interrupting your
torch movement.
Trigger Controlled DC Lift Arc TIG
With Trigger Controlled DC Lift Arc ignition, starting your
welding projects has never been easier. Our Lift Arc TIG
technology ensures that your tungsten tip won't stick to the
workpiece, preventing costly tip breakages.
Smart Fan
Our advanced Smart Fan technology reduces noise, saves
power, and minimises contaminants, making it the perfect
choice for any welding environment.
Advanced MMA Features
The RAZOR COMPACT 250 features adjustable Arc Force
and Hot Start functionality. These features are designed for
improving weld quality and ease of use.
Optional Remote Control
Upgrade your machine with a handy remote control. Both a
wired and wireless controller are available.
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RAZOR COMPACT 250
OPERATING MANUAL
Includes:
• 0.8-0.9mm "V GROOVE" 30/22
• 0.8-0.9mm "F GROOVE" 30/22
• 1.0-1.2mm "U GROOVE" 30/22
3. Package Contents
RAZOR COMPACT 250 4m Electrode Holder
4m 300 AMP Earth Clamp
Twin Gauge Argon Regulator
Drive Roller
15A Plug Fitted
4m M24 Digital MIG Torch
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RAZOR COMPACT 250
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4. Machine Specifications
Technical Data
Parameter Values
SKU v
Primary Input Voltage 240V Single Phase
Supply Plug 15 AMP
Ie (A) 15
Rated Output 30A/15.5V - 250A/26.5V
No Load Voltage (V) 65
Protection Class IP23S
Insulation Class H
Minimum Generator (kVA) 11.0
Dinse Connector 35/50
Standard AS/NZ60974-1
Warranty (Years) 5
MIG Specifications
MIG Welding Current Range 30-250A
MIG Duty Cycle @ 40°C 20% @ 250A
60% @ 144A
100% @ 112A
MIG Welding Thickness Range 1-12mm
TIG Specifications
TIG Function Type DC Lift Arc
TIG Welding Current Range 5-250A
TIG Duty Cycle @ 40°C 20% @ 250A
60% @ 144A
100% @ 112A
TIG Welding Thickness Range 1-10mm
STICK Specifications
STICK Welding Current Range 20-220A
STICK Duty Cycle @ 40°C 20% @ 220A
60% @ 127A
100% @ 98A
STICK Welding Thickness Range 2-12mm
Size & Weight
Dimensions (mm) 900×480×760
Weight (kg) 41.3
Capable Welding Material Types By Welding Process
Mild Steel, Stainless Steel, Cast IronMild Steel, Stainless Steel, Copper,
Silicon Bronze
Mild Steel, Stainless Steel, Aluminium,
Silicon Bronze
MIG: TIG: MMA:
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5. Machine Layout
5.1 Front Panel Layout
1. Interface Panel
2. “+” Output Terminal
3. “-” Output Terminal
4. Euro Connect Torch Port
5. Wired Remote Connection Port
6. Polarity Cable
7. Wireless Remote Indicator
5.2 Rear Panel Layout
8. On/O Switch
9. Gas Input
10. Input Power Cord
11. Gas Bottle Mounting Base
12. Gas Bottle Chain Mounts
1
56
4
2
3
9
10
11
1212
8
7
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5.3 Interior Layout
1. 4 Geared Wire Drive System
2. Wire Spool Holder
3. Drive Roller Storage
4. Lift Handle
5. Cabinet Light
6. Settings Guide
1
2
5
6
4
3
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5.4 Geared Wire Drive System
1. Drive Roller Assemblies
2. Upper Roller Assembly
3. Tensioner Knob
4. Guide Tube
5. Wire Inlet Guide Tube
1 1
2
3
54
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6. Control Panel Layout
1. Numerical Display A
(Amperage, M/Min, Material Thickness)
2. Adjustment Knob A
3. Numerical Display B
(Volts, Inductance, Arc Force, Burnback)
4. Adjustment Knob B
5. Weld Mode Selection Button
6. Material/Gas Selection Buttons
7. Wire Diameter Size Selection Button
8. Torch Mode Selection Button
9. MIG Mode Button
10. Remote Mode Button
11. Synergic Mode Button
12. Wire Feed Button
13. Gas Test Button
14. Warning Indicators
(Overcurrent & Thermal Overload)
15. VRD Indicator Light
1
2
3
4
5 6 7
14
9
10
11
12
13
15
8
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RAZOR COMPACT 250
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7. Control Panel Details
TIG Mode
This indicates that the machine is in Lift Arc TIG mode (DC only).
Press the Wire Diameter Size Selection Button to cycle through the wire diameter sizes available for synergic
programming. Note: Not all sizes are available for all material/gas types.
MIG Mode
This indicates that the machine is in MIG mode.
The machine's default is MIG manual mode. For Synergic mode press the Synergic Mode
Button located on the front panel.
MMA 'Stick' Mode
This indicates that the machine is in Manual Metal Arc mode.
For MIG Synergic Mode, these options indicate
which programming the machine has available.
Simply press the Material/Gas Selection Buttons to
choose the material type and gas type you are using.
WELDING MODE SELECTION
WIRE DIAMETER SIZE SELECTION
MATERIAL/GAS SELECTION
TIG
MIG
MMA
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MIG MODE
TORCH MODE
ADDITIONAL BUTTONS
2T Torch Mode
While in 2T mode, press and hold the torch trigger button to initiate the weld, and continue
holding the trigger down during the duration of the desired weld.
Standard MIG Mode
Select this mode while using a regular MIG torch.
Remote Mode
Press this button to activate Remote Mode. Use this mode to pair with a wired or
wireless remote, or a torch with parameter controls.
Synergic Mode
Press this button to activate Synergic Mode. This will give you single knob quick settings
based on desired amperage, plate thickness, or wire speed. You can also fine-tune the
recommended settings.
Wire Feed
Press this button to activate the drive rollers. This allows for easy and safe wire feeding
when changing out rolls of wire.
Gas Test
Press this button to activate the gas solenoid. This allows you to ensure the gas system
is functioning correctly without wasting wire.
Spool Gun Mode
Select this mode while using a Spool Gun.
Push-Pull Gun Mode
Select this mode while using a Push-Pull Gun.
4T Torch Mode
While in 4T mode, press and release the torch trigger button to initiate the weld. To end
the weld cycle, press and release the torch button again.
2T
STANDARD
MIG
SPOOL
GUN
PUSH
PULL
GUN
4T
SYN
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RAZOR COMPACT 250
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F02
F03
F04
F05
F06
F07
F08
F09
8. Advanced Settings Menu
PRESS AND HOLD THE ADJUSTMENT KNOB A FOR 5
SECONDS TO ENTER THE ADVANCED SETTINGS MENU
NOTE: SETTINGS MENU IS DEPENDENT ON WHICH WELDING MODE YOU ARE IN.
(CHANGE WELDING MODE TO PARAMETERS YOU WISH TO EDIT)
F01
A
While in this menu you can scroll through the available
settings with the adjustment knob. Each of the dierent
settings is indicated by a code.
Standby Timer
Input Over-Voltage Protection
Pre-Flow Air Timer (MIG)
Post-Flow Air Timer (MIG)
Pre-Flow Air Timer (TIG)
Post-Flow Air Timer (TIG)
Downslope Time (TIG)
Burnback Voltage
Hot Start Current (MMA)
Slow Wire Feed Speed
Remote Mode Type
0 / 5 / 10 / 15
0 - 2
0 - 5
0 - 5
0 - 10
0 - 5
10-20
0-60
0
0
1
1
2 3
0 1
(minutes) 0 indicates standby mode is o.
(seconds)
(seconds)
(seconds)
(Volts)
(Amps)
(Disabled)
(Wireless)
(1/3 speed)
(Wired)
(1/2 speed) (2/3 speed)
OFF ON
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9. MIG Manual Mode
10. Synergic Mode
A
A
B
B
By default, the machine will be in Manual Mode when you are have selected MIG using the WELD
MODE BUTTON. In Manual MIG Mode the machine can be primarily adjusted using the Aand B
Adjustment Knobs.
Adjustment Knob A will adjust your wire speed.
(Adjusted in meters per minute)
Adjustment Knob A will adjust your amperage by default. Press the knob
to cycle through amperage, wire speed, and material thickness adjustment
modes based on your preference.
Adjustment Knob B is for fine-tuning your synergic setup. You can adjust
voltage by default, as well as Inductance and Burnback by pressing the
knob in.
Note: Available adjustment voltage with Knob B is based on your settings with Knob A.
Adjustment Knob B will adjust your voltage. Press the knob to cycle
through your Inductance and Burnback Settings.
Inductance: (-10 through 10)
Burnback: (0-800 milliseconds)
To activate Synergic mode, press the Synergic Mode Button while in MIG.
You will see the Synergic Mode indicator light to the right of the button light
up while Synergic Mode is active.
Using the Material/Gas Selection Buttons choose the metal you are welding and gas type you have
installed. Then choose the wire diameter using the Wire Size Button.
SYN
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11. MIG: Machine Setup
1. Begin by first choosing your desired MIG wire based
on what you're welding. Then ensure that you have
paired the selected wire to the correct torch tip, torch
liner, and drive roller.
2. To change the drive rollers, start by loosening the
tensioner knob by twisting it anti-clockwise. Then pull
it towards you so that the knob clears the upper roller
assembly.
4. You now have access to the drive rollers. When re-
installing your desired drive rollers, ensure you line up
the key slot on each assembly.
3. Lift the upper drive roller assembly up and out of the
way. Then, loosen and remove the drive roller retaining
nuts by spinning them anti-clockwise. Do this for both
assemblies.
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5. Based on what type of wire you wish to run, you need
to set the machine up in either DC Electrode (+) or DC
Electrode (-). Most MIG welding is done with DCEP
(+), so plug the polarity cable into the (+) dinse port.
Connect the earth clamp into the (-) dinse port.
6. For DCEN (-), plug the polarity cable into the (-) dinse
port, and the earth clamp into the (+) dinse port. DCEN
is used primarily for gasless flux-cored welding.
7. With the polarity cable and the earth clamp installed
into the correct dinse ports, now install the MIG torch
into the Euro Connect Port. Ensure you line up the
internal ports correctly.
8. With the torch correctly lined up and pressed inwards,
twist the locking nut to finish the torch installation.
(GAS-SHIELDED) (GASLESS)
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WARNING! Maintain positive control of the loose end of the wire or leave it tensioned into the catch hole on the side of
the spool at all times. If the wire becomes too unravelled, the spool of wire can become unusable.
9. After ensuring the required setup has been completed
for the wire you wish to run it is now time to install the
wire. You can begin to install the spool by loosening
and removing the spool holder retainer nut (clockwise
to loosen).
10. With the spool holder retainer nut removed, slide the
spool onto the spool holder. Ensure you line up the key
hole on the spool with the key on the base of the spool
holder.
11. You can now lock the spool of wire in place by
reinstalling the spool holder retainer nut (anti-clockwise
to tighten).
12. With the wire spool installed, begin feeding the wire
into the inlet wire guide. Maintain positive control of the
wire at all times as it is coiled under tension. Ensure the
upper roller assembly is in the upright position.
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