Xcel-Arc Razor Weld ARC180 User manual

1
RazorWeld
ARC18O ARC2OO
3YEAR 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:- 10KVA

7
Features
■New 40KHz inverter frequency technology
■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 8.5 kVA minimum)
■Tolerant to variable power supply
230V Single Phase 180 Amp DC Welder MMA/TIG
Selectable VRD - Increased Workplace Safety
Industrial Rated 40KHz Inverter
RAZORWELD ARC180
RAZORWELD ARC180
MMA/TIG - 180 Amp DC Inverter Welder
Welds: Steels, Stainless, Cast Iron, Bronze, Copper
Razor
W eld
XA-ARC180RZ-K
Standard Package
Technical Data
Power Supply 240V 1-Phase ±15%
Rated Input Power 8.2 kVA
I i e as per AS/NZ60974-1 15.3 Amps
Rated Output MMA 180 Amps / 27.2V
Rated Output TIG 180 Amps / 17.2V
Welding Current Range 10 ~ 180 Amps
No Load Voltage (OCV) VRD On 9V - VRD O󰀨 77V
Duty Cycle @ 40ºC as per AS/NZ60974-1 20% @ 180 Amps MMA
50% @ 180 Amps TIG
Duty Cycle @ 25ºC (approximate) 50% @ 180 Amps MMA
80% @ 180 Amps TIG
E󰀩ciency 85%
Power Factor 0.70
Protection Class IP21S
Insulation Class F
Dimensions (LxWxH) 313 x 130 x 250mm
Weight 4.7 Kg
Certication Approval AS/NZ60974-1
Product Code: XA-ARC180RZ-K
Standard Package includes: XA-ARC180RZ Machine, Earth Lead & Arc Lead 25mm x 4m, Heavy Duty Safe Carry Case
Overview
The RazorWeld ARC180 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 both Hot-Start and automatic Arc Force coupled with Selectable VRD for increased workplace safety, this machine is suited to site
work and a popular choice for the general engineer or contractor. With connection of the optional XA17V Tig Torch, this machine also 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 ARC180RZ is an exceptional machine suitable for a wide range of applications including medium-level industrial use,
site welding, farming and general repair and maintenance work. The ARC180RZ 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.
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 ARC18O ARC2OO
REAR PANEL MACHINE LAYOUT: RazorWeld ARC18O ARC2OO
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

10 11
VRD - MMA (STICK) Operation:
SWITCHABLE VRD OPERATION:
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
RazorWeld ARC18O ARC2OO
RazorWeld ARC18O ARC2OO

11
(1) Set Tig/MMA selector
switch to MMA
(2) Connect earth
lead to (2) Connect the electrode
lead to
Installation set up for MMA (Stick) Welding with Razor ARC180/ARC200
(1) Turn the power source on and select the MMA function with the Tig/MMA selector switch.
(2) Connection of Output Cables: Various electrodes require a di󰀨erent 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
(3) Set the welding current relevant to the electrode type and size being used as recommended by the
electrode manufacturer.
(4) Place the electrode into the electrode holder and clamp tight
(5) Strike the electrode on the work to create the arc and hold the electrode steady to maintain the arc
(6) Hold the electrode slightly above the work piece to maintain the arc while travelling at an even speed
to create and even weld deposition
(7) To nish the weld, break the arc by quickly snapping the electrode away from the work piece.
(8) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal underneath
4) Place the electrode into the electrode
holder and clamp tight.
5) Strike the electrode against the work
piece to create and arc and hold the elec-
trode steady to maintain the arc
6) Hold the electrode slightly above the
work maintaining the arc while travelling
at an even speed.
7) To nish the weld, break the arc by
quickly snapping the electrode away from
the work piece.
8) Wait for the weld to cool and carefully
chip away the slag to reveal the weld
metal below.
(3) Set the welding current using
the amperage control dial
MMA (Stick) Operation: RazorWeld ARC18O ARC2OO

12 13
RazorWeld ARC18O ARC2OO
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 cur-
rent is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod
is made of a material that is compatible with the base material being welded and is covered with a ux that gives o󰀨
gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from
atmospheric contamination. The electrode core itself acts as ller material the residue from the ux that forms a slag
covering over the weld metal must be chipped away after welding.
Core wire
Flux coating
Gas shield from ux melt
Arc with core wire melt
Flux residue forms slag cover
Weld metal
Power Source
+
▬
• The arc is initiated by momentarily touching the electrode to the base metal.
• The heat of the arc melts the surface of the base metal to form a molten pool
at the end of the electrode.
• The melted electrode metal is transferred across the arc into the molten pool
and becomes the deposited weld metal.
• The deposit is covered and protected by a slag which comes from the
electrode coating.
• The arc and the immediate area are enveloped by an atmosphere of
protective gas
Core wire
Flux coating
Base metal
Protective gas
Arc
Slag
Weld pool
Manual metal arc ( stick) electrodes have a solid metal wire core and a ux
coating. These electrodes are identied by the wire diameter and by
a series of letters and numbers. The letters and numbers identify the metal
alloy and the intended use of the electrode.
The Metal Wire Core works as conductor of the current that maintains the arc.
The core wire melts and is deposited into the welding pool.
The covering on a shielded metal arc welding electrode is called Flux.
The ux on the electrode performs many di󰀨erent functions.
These include:
● producing a protective gas around the weld area
● providing uxing elements and deoxidizers
●creating a protective slag coating over the weld as it cools
●establishing arc characteristics
●adding alloying elements.
Covered electrodes serve many purposes in addition to adding ller metal to
the molten pool. These additional functions are provided mainly by the cover-
ing on the electrode.

13
RazorWeld ARC18O ARC2OO
Electrode Size
Average Thickness Maximum Recommended
of Material Electrode Diameter
1.0 - 2.0mm 2.5mm
2.0 - 5.0mm 3.2mm
5.0 - 8.0mm 4.0mm
8.0 - > mm 5.0mm
The size of the electrode generally depends on the
thickness of the section being welded, and the thicker
the section the larger the electrode required. The table
gives the maximum size of electrodes that maybe used
for various thicknesses of section base on using a gen-
eral purpose type 6013 electrode.
Correct current selection for a particular job is an im-
portant factor in arc welding. With the current set too
low, di󰀩culty is experienced in striking and maintaining
a stable arc. The electrode tends to stick to the work,
penetration is poor and beads with a distinct rounded
prole will be deposited. Too high current is accompa-
nied 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 exces-
sively 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)
2.5mm 60 - 95
3.2mm 100 - 130
4.0mm 130 - 165
5.0mm 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 specic classes of work. It is recommend to con-
sult your welding supplier for the correct selection of electrode.
MMA (Stick) Welding Fundamentals

14 15
(1) Switch on the machine, select the TIG function with the Tig/MMA selector switch.
(2) Insert the power cable plug of the Tig torch into the Negative socket on the front of the machine and
tighten it.
(3 Insert the earth cable plug into the Positive socket on the front of the machine and tighten it.
(4) Connect the gas line of the Tig torch to regulator and connect the regulator to the gas cylinder.
(5) Assemble front end parts of the TIG torch,
tting a sharpened tungsten suitable for DC
welding.
(7) Set the welding current using
the amperage control dial
(4) Connect the gas line to the regulator
and connect to the gas cylinder
(2) Connect the TIG torch cable
connector to
(3) Connect earth
lead to
(1) Set Tig/MMA selector
switch to TIG
(6) Carefully open the valve of the gas
cylinder, set the l/min to 6-12
Installation and Setup for DC TIG Welding:

15
Lift Arc ignition allows the arc to be started easily in DC Tig by simply touching the tungsten to the
work piece and lifting it up to start the arc. This prevents the tungsten tip sticking to the work piece and
breaking the tip from the tungsten electrode. There is a particular technique called “rocking the cup” used in
the Lift Arc process that provides easy use of the Lift Arc function.
(5) Make sure the front end parts of the tig torch are correctly assembled, use the correct size and type of
tungsten electrode for the job, the tungsten electrode requires a sharpened point for DC welding.
(6) Turn on the Gas Valve located on the tig torch handle.
(7) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from the
work piece.
(8) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work
piece.
(9) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to
create the arc.
(5) Assemble front end parts of the TIG torch,
tting a sharpened tungsten suitable for DC
welding.
(6) Turn on the Gas Valve (7) Lay the outside edge of the Gas Cup on
the work piece with the Tungsten Electrode
1- 2mm from the work piece.
(8) With a small movement rotate the Gas
Cup forward so that the Tungsten Elec-
trode touches the work piece.
(9) Now rotate the Gas Cup in the reverse
direction to lift the Tungsten electrode from
the work piece to create the arc.
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.
LIFT ARC DC TIG Operation: RazorWeld ARC18O ARC2OO

16 17
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 19,000°C. It is a very
pure and concentrated arc which provides the controlled melting of
most metals into a weld pool. TIG welding o󰀨ers 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.
LIFT ARC IGNITION for TIG (tungsten inert gas) Welding
Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts, with
a current limit of one or two amps (well below the limit that causes metal to transfer and contamination of the
weld or electrode). When the machine detects that the tungsten has left the surface and a spark is present,
it immediately (within microseconds) increases power, converting the spark to a full arc. It is a simple, safe
lower cost alternative arc ignition process to HF (high frequency) and a superior arc start process to scratch
start.
arc ignition
established
TIG arc
gas ow
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
Lay the nozzle on the job
without the tungsten touch-
ing the work
Rock the torch sideways so
that the tungsten touches
the work & hold momentarily
Rock the torch back in the
opposite direction, the arc
will ignite as the tungsten
lifts o󰀨 the work
Lift the torch to maintain
the arc
tungsten touches
the work
tungsten o󰀨 the
work

17
TIG Welding with Filler Wire Technique
It is necessary in many situations with TIG welding to add a ller wire into the weld
pool to build up weld reinforcement and create a strong weld. Once the arc is started
the torch tungsten is held in place until a weld pool is created, a circular movement of
the tungsten will assist is creating a weld pool of the desired size. Once the weld pool
is established tilt the torch at about a 75° angle and move smoothly and evenly
along the joint. The ller metal is introduced to the leading edge of the weld
pool. The ller wire is usually held at about a 15° angle and fed into the lead-
ing edge of the molten pool, the arc will melt the ller wire into the weld pool as the torch is moved
forward. Also a dabbing technique can be used to control the amount of ller wire added, the wire
is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and
evenly forward. It is important during the welding to keep the molten end of the ller wire inside the
gas shield as this protects the end of the wire from being oxidised and contaminating the weld pool.
75°
15°
Form a weld pool
Travel direction
Angle torch Add Tig ller wire
Retract the ller wire Move the torch forward to
the front of the weld pool
Repeat the process
gas
shield
TIG Welding Fusion Technique
Manual TIG welding is often considered the most di󰀩cult of all the welding processes.
Because the welder must maintain a short arc length, great care and skill are required
to prevent contact between the electrode and the workpiece. Similar to Oxygen Acety-
lene torch welding, Tig welding normally requires two hands and in most instances
requires the welder to manually feed a ller wire into the weld pool with one hand
while manipulating the welding torch in the other. However, some welds combining thin
materials can be accomplished without ller metal like edge, corner, and butt joints.
This is known as Fusion welding where the edges of the metal pieces are melted to-
gether using only the heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten
is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld
pool of the desired size. Once the weld pool is established tilt the torch at about a 75° angle and move
smoothly and evenly along the joint while fusing the materials together.
75°
Form a weld pool Angle torch Move the torch slowly
and evenly forward
Travel direction

18 19
Tungsten DC Current Amps AC Current Amps AC Current Amps
Diameter Torch Negative Un-Balanced Wave Balanced Wave
mm 2% Thoriated 0.8% Zirconiated 0.8% Zirconiated
1.0mm 15 - 80 15 - 80 20 - 60
1.6mm 70 -150 70 - 150 60 - 120
2.4mm 150- 250 140 - 235 100 - 180
3.2mm 250 - 400 225 - 325 160 - 250
4.0mm 400 - 500 300 - 400 200 - 320
Tungsten Electrodes Rating for Welding Currents
Tungsten Electrodes
Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s
hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of
any metal, 3,410 degrees Celsius. Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made
from pure tungsten or an alloy of tungsten and other rare earth elements. Choosing the correct tungsten depends on the
material being welded, amps required and whether you are using AC or DC welding current.Tungsten electrodes are colour-
coded at the end for easy identication. Below are the most commonly used tungsten electrodes found in the New Zealand
and Australian market.
Thoriated
Thoriated tungsten electrodes (AWS classication EWTh-2) contain a minimum of 97.30 percent tungsten and 1.70 to 2.20
percent thorium and are called 2 percent thoriated. They are the most commonly used electrodes today and are preferred for
their longevity and ease of use. Thorium however is a low-level radioactive hazard and many users have switched to other
alternatives. Regarding the radioactivity, thorium is an alpha emitter but when it is enclosed in a tungsten matrix the risks are
negligible. Thoriated tungsten should not get in contact with open cuts or wounds. The more signicant danger to welders
can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours during welding or from
ingestion of material/dust in the grinding of the tungsten. Follow the manufacturer’s warnings, instructions, and the Material
Safety Data Sheet (MSDS) for its use.
E3 (Color Code: Turquoise)
E3 tungsten electrodes (AWS classication EWG) contain a minimum of 98% percent tungsten and up to 1.5 percent Lantha-
num and small percentages of Zirconium and Yttrium they are called E3 Tungsten. E3 Tungsten Electrodes provide conductiv-
ity similar to that of thoriated electrodes. Typically, this means that E3 Tungsten Electrodes are exchangeable with thoriated
electrodes without requiring signicant welding process changes. E3 deliver superior arc starting, electrode lifetime, and over-
all cost-effectivenes. When E3 Tungsten Electrodes are compared with 2% thoriated tungsten, E3 requires fewer re-grinds and
provides a longer overall lifetime. Tests have shown that ignition delay with E3 Tungsten Electrodes actually improves over
time, while 2% thoriated tungsten starts to deteriorate after only 25 starts. At equivalent energy output, E3 Tungsten Electrodes
run cooler than 2% thoriated tungsten, thereby extending overall tip lifetime. E3 Tungsten Electrodes work well on AC or DC.
They can be used DC electrode positive or negative with a pointed end, or balled for use with AC power sources.
Ceriated (Color Code: Grey)
Ceriated tungsten electrodes (AWS classication EWCe-2) contain a minimum of 97.30 percent tungsten and 1.80 to 2.20
percent cerium and are referred to as 2 percent ceriated. Ceriated tungstens perform best in DC welding at low current set-
tings. They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding, thin
sheet metal work. They are best used to weld carbon steel, stainless steel, nickel alloys, and titanium, and in some cases
it can replace 2 percent thoriated electrodes. Ceriated tungsten is best suited for lower amperages it should last longer than
Thoriated tungsten higher amperage applications are best left to Thoriated or Lanthanated tungsten.
Lanthanated (Color Code: Gold)
Lanthanated tungsten electrodes (AWS classication EWLa-1.5) contain a minimum of 97.80 percent tungsten and 1.30
percent to 1.70 percent lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent arc starting,
a low burn off rate, good arc stability, and excellent re-ignition characteristics. Lanthanated tungstens also share the conduc-
tivity characteristics of 2 percent thoriated tungsten. Lanthanated tungsten electrodes are ideal if you want to optimise your
welding capabilities. They work well on AC or DC electrode negative with a pointed end, or they can be balled for use with
AC sine wave power sources. Lanthanated tungsten maintains a sharpened point well, which is an advantage for welding
steel and stainless steel on DC or AC from square wave power sources.
Zirconiated (Color Code: White)
Zirconiated tungsten electrodes (AWS classication EWZr-1) contain a minimum of 99.10 percent tungsten and 0.15 to 0.40
percent zirconium. Most commonly used for AC welding Zirconiated tungsten produces a very stable arc and is resistant
to tungsten spitting. It is ideal for AC welding because it retains a balled tip and has a high resistance to contamination. Its
current-carrying capacity is equal to or greater than that of thoriated tungsten. Zirconiated tungsten is not recommended for
DC welding.

19
Electrode Included Angle/Taper - DC Welding
Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a
specic included angle in conjunction with the tip/at preparation. Different angles produce different arc shapes and
offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide
the following benets:
• Last Longer
• Have better weld penetration
• Have a narrower arc shape
• Can handle more amperage without eroding.
Sharper electrodes with smaller included angle provide:
• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration
increases and bead width decreases.
Tungsten Preparation
Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a
diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium
oxide wheels, can lead to jagged edges, imperfections, or poor surface nishes not visible to the eye that will contrib-
ute to weld inconsistency and weld defects.
Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel. Tungsten electrodes are manu-
factured with the molecular structure of the grain running lengthwise and thus grinding crosswise is “grinding against
the grain.” If electrodes are ground crosswise, the electrons have to jump across the grinding marks and the arc can
start before the tip and wander. Grinding longitudinally with the grain, the electrons ow steadily and easily to the end
of the tungsten tip. The arc starts straight and remains narrow, concentrated, and stable.
grind longitudinal on the
grinding wheel
don’t grind across
the grinding wheel
at tip
2.5 times tungsten diameter
pointed tip
Electrode Tip/Flat
The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection
of tip/at size will balance the need for several advantages. The bigger the at, the more likely arc wander will occur
and the more difcult it will be to arc start. However, increasing the at to the maximum level that still allows arc start
and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders still grind
electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from
melting at the tip and the possibility of the point falling off into the weld pool.
at spot diameter
included angle
Tungsten Diameter at Constant Included Current Range Current Range
Diameter the Tip - mm Angle - Degrees Amps Pulsed Amps
1.0mm .250 20 05 - 30 05 - 60
1.6mm .500 25 08 - 50 05 - 100
1.6mm .800 30 10 - 70 10 - 140
2.4mm .800 35 12 - 90 12 - 180
2.4mm 1.100 45 15 - 150 15 - 250
3.2mm 1.100 60 20 - 200 20 - 300
3.2mm 1.500 90 25 - 250 25 - 350

20 21
Spare Parts
Part Number Description
1 XA17V Torch Body with Valve
XA17VFX Torch Body Flexible with Valve
1a VS-2 Valve Stem
2 57Y02 Back Cap Long
2a 98W18 Back Cap O Ring
3 P300M Back Cap Medium
4 57Y05 Back Cap Short
5 ERBS Blank Switch Cover
6 ERSP1 Screw Pack
7 ERH100 Small Ergo Tig Handle
8 ERKJ100 Small Knuckle Joint & Lock Nut
9 ERLC100-08 Leather Cover x 0.8m
XA17V Suregrip TIG Torch 150 Amp - Valved Head
TIG WELDING TORCHES
Air Cooled 150 Amp - Available in 4m, 8m Lengths
Spare Parts
Part Number Description
10 ERJK100 Jointing Repair Kit
12 ERCO100-40 Sheath x 4m c/w Leather Cover
ERCO100-80 Sheath x 8m c/w Leather Cover
13 SLHD57Y01AOB Power Cable x 4m Surelok OB Rubber
SLHD57Y03AOB Power Cable x 8m Surelok OB Rubber
15 Dinse Tig Power Cable Connector 10-25
Dinse Tig Power Cable Connector 35-50
15 WGCP-1V-58 Gas Hose Assembly x 2m
Torch Model Description Part Number
4m 8m
XA17V Tig Torch 16-25 Twistlok End, 2m Gas Hose XA17V-12NBD25 XA17V-25NBD25
XA17V Tig Torch 35-50 Twistlok End, 2m Gas Hose XA17V-12NBD50 XA17V-25NBD50
XA17VFX Flexi Tig Torch 16-25 Twistlok End, 2m Gas Hose XA17VFX-12NBD25 XA17VFX-25NBD25
XA17VFX Flexi Tig Torch 35-50 Twistlok End, 2m Gas Hose XA17VFX-12NBD50 XA17VFX-25NBD50
15
*
Stubby series
Standard series
Gas lens series
Large gas lens series
Stubby gas lens series
Wear Parts Identification Next Page
2
3
5
7
6
8
12
9
10
11
13 14 15
16
17
6
4
1a
2a
150AMP AIR COOLED
Gas Valve Torch Head
Rating: 150A DC, 105A AC @35% duty cycle.
XA17V TIG TORCHXA17V TIG TORCH
SuregripSuregrip™™ Series Series
RedNeck Gas Lens series
13
14
Wear Parts Identication Next Page