Xcel-Arc RAZORWELD ARC 630 User manual

RAZORWELD
XA-ARC630RZ | Operating Manual
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
© Xcel-Arc 2023
YEA
R
MACHINE
WARRANTY
1
1
YEAR
MACHINE
WARRANTY
YEAR
PRODUCT
WARRANTY
3
3
TIG
MMA CAG

REGISTER YOUR MACHINE ONLINE TO RECEIVE AN
ADDITIONAL 6 MONTHS ON YOUR WARRANTY
Visit XcelArc.nz/warranty-registration/ to register your machine.
WARRANTY 3
SAFETY 4
RAZORWELD ARC 630 FEATURES 7
INSTALLATION SET UP FOR MMA (STICK) WELDING 11
MMA(STICK) WELDING GUIDE 12
INSTALLATION SET UP FOR DC TIG WELDING 15
TIG WELDING GUIDE 17
ARC-AIR GOUGING SET UP 22
ARC-AIR GOUGING GUIDE 24
XA26V TIG TORCH & SPARES (OPTIONAL) 26
ARC AIR GOUGING TORCH, DC CARBONS (OPTIONAL) 28
GAS FLOW REGULATORS - SHEILDING GASES 29
MMA (STICK) WELDING TROUBLE SHOOTING 30
LIST OF ERROR CODES 32
WARRANTY TERMS 33
2 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
CONTENTS

Thank you for your purchase of your RAZORWELD ARC 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
equipment 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.
Xcel-Arc welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1, guaranteeing you electrical safety and performance.
WARRANTY
• 3 Years from date of purchase.
• ESSETI New Zealand Limited warranties all goods as specied 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, misuse, accident, theft, general wear and tear.
• New product will not be supplied unless ESSETI New Zealand Limited has inspected product returned for warranty and agrees to replace product.
• Product will only be replaced if repair is not possible
• Please view full Warranty term and conditions supplied with machine or at www.XcelArc.nz/warranty-terms/ or at the back of this manual.
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 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 leaks 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.
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WARRANTY

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 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/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 work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged, bare wiring is dangerous and can
kill.
• Do not use damaged, under sized, or badly joined cables.
• Do not drape cables over your body.
• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to earth.
Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding
produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding/cutting fumes and gases.
• In conned 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 de-greasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapours to
form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic fumes when welded/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 correct shade of lter lens and suitable protective clothing including welding gloves whilst 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 ash,glare and sparks; warn others not to watch the arc.
4 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
SAFETY

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 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/cutting.
• The welding/cutting sparks & spatter may cause re, therefore remove any ammable materials well away from the working area.
Cover ammable materials and containers with approved covers if unable to be moved from the welding/cutting area.
• Do not weld/cut 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 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 ammable dust, gas, or liquid vapours (such as petrol)
• Have a re 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, oor, bulkhead, or
partition can cause re on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders are
normally 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 ames, sparks, and arcs.
• Insure 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 causes 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 off shielding gas supply when not in use.
• Always ventilate conned spaces or use approved air-supplied respirator.
Electronic magnetic elds. MAGNETIC FIELDS can affect Implanted Medical Devices.
• Wearers of Pacemakers and other Implanted Medical Devices should keep away.
• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near any electric welding,
cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.
• Wear approved ear protection if noise level is high.
Hot parts. Items being welded/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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SAFETY

CAUTION
1. Working Environment.
i. The environment in which this welding/cutting 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.
ii. 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.
iii. Keep this equipment 30cm distant from the wall.
iv. Ensure the working environment is well ventilated.
2. Safety Tips.
i. 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.
ii. 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.
iii. 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.
iv. 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/cutting machine. In order 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 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/cutting equipment. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed in this manual.
INSTALLATION & OPERATION
Please install the machine strictly according to the steps. The protection class of this machine is IP21S, so avoid using it in rain.
CONNECTION OF INPUT CABLES
Primary input cable is supplied with this welding equipment. Connect the primary input cable with power supply of required input voltage. Refer to data
plate on machine for Input voltage, IMAX and IEFF.
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)
6 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
SAFETY

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RAZORWELD ARC 630 FEATURES
Technical Data
Power Supply 415V 3-Phase ±10%
I i e MMA 31.0 Amps
TIG 31.6 Amps
IMax MMA 62.0 Amps
TIG 50.0 Amps
Welding Current Range 20 ~ 630 Amps
No Load Voltage (OCV) 90V
Duty Cycle @ 40ºC as per AS/NZ60974-1 25% @ 630A MMA
100% @ 315A MMA
40% @ 630A TIG
100% @ 400A TIG
Power Factor 0.7
E󰀩ciency ≥80
ElectrodeDiameter φ1.6~φ6.0
Protection Class IP21S
Insulation Class H
Cooling AF
Dimensions (LxWxH) 550 x 240 x 445mm
Weight 33.5kg
CerticationApproval AS/NZ60974-1
Features
■New MCU control system
■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
■ Arc Air Gouging Mode with High OCV
■ Thermaloverloadprotection
■Generator compatible
■ Toleranttovariablepowersupply
Product Code: XA-ARC630RZ-K
Standard Package includes: ARC630RZ Machine and Manual
Earth Lead & Arc Lead are optional
Overview
The RazorWeld ARC630isasuperiorqualityinverterweldingmachinefromXcel-Arc.ItsprimaryfunctionisDC-MMA(Stick)welding,
and it also o󰀨ers DC-TIG capabilities with Lift-Arc Ignition. This advanced welding machine utilizes the latest generation MCU control
system,resultinginexceptionalarccharacteristicsandhighreliability.Moreover,itissturdyandportable.TheDC-MMAweldingfunction
produces a smooth and stable arc, enabling high-quality welds for a variety of materials, including cast iron, stainless steel, and low
hydrogen.Additionally,theinclusionofHot-StartandArcForce,combinedwithSelectableVRD,makesitperfectforon-sitework,making
it an excellent choice for professionals and contractors alike. The Carbon Arc Gougingfeatureisanewadditiontothemachine,making
itperfectforweldremoval,crackremoval,backgouging,andwelddefectrepairsforcarbonsteels,alloysteels,stainlesssteels,andnon-
ferrousmaterials.Themachine’soptionalXA26VTigTorchprovideshighlevelDC-TIGweldingofsteel,stainlesssteel,bronze,andcopper.
TheLift-ArcTIGfunctionisexceptionalanddeliversperfectarcignitioneverytimewithoutanystickingorinclusionofthetungstenelectrode
to the workpiece. It produces high-quality TIG welds with remarkable smoothness and stability.
TheARC630RZisahighlyversatilemachinesuitableforawiderangeofapplications,includingmediumtoheavyindustrialuse,sitewelding,
farming,andgeneralrepairandmaintenancework.Itscompactdesigno󰀨ersgreatportabilitywithoutsacricingpower.Furthermore,it
isbuilttospecicationsandcomplieswithAS/NZ60974-1manufacturingstandards.Overall,theRazorWeldARC630RZisaremarkable
machinethato󰀨erssuperiorperformance,reliability,andportabilityforallweldingneeds.
230V 3-Phase 630 Amp DC Welder MMA/CAG/TIG
Selectable VRD - Stick Electrode, Lift Arc DC TIG
RAZORWELD ARC630RAZORWELD ARC630
Optional machine accessories available - www.xcelarc.nz
Welds: Steels, Stainless, Cast Iron, Bronze, Copper
XA-ARC630RZ-K
Standard Package

8 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
MACHINE PARTS LAYOUT
FRONT PANEL MACHINE LAYOUT:
/

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FRONT AND REAR PANEL LAYOUT:
MACHINE PARTS LAYOUT
(1)“-” Output terminal.
(2)“+” Output terminal.
(3)Arc force adjust
(4)Hot start adjust
(5)Current Display
(6)Alarm indicator
(7)Power Indicator:Lights when
input power connected and
machine switched on.
(8)CAG/CELfunction
(9)VRD Function
(10)Voltage Display
(11)Parameter select/adjust knob.
(12)MMA Function
(13)TIG Function
(14)Switch the MMA and TIG function
(15)Power Access client: access to cable.
(16)Power switch: control power through and
break.

10 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual

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INSTALLATION SET UP FOR MMA
(STICK) WELDING
(1) Set Tig/MMA selector
switch to MMA
(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
/
(2) Connect the electrode
lead to
(2) Connect earth
lead to

12 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
MMA(STICK) WELDING GUIDE
MMA (Manual Metal Arc) Welding
One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current
is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is
made of a material that is compatible with the base material being welded and is covered with a ux that gives off
gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from
atmospheric contamination. The electrode core itself acts as ller material the residue from the ux that forms a slag
covering over the weld metal must be chipped away after welding.
Core wire
Flux coating
Gas shield from ux melt
Arc with core wire melt
Flux residue forms slag cover
Weld metal
Power Source
+
▬
• The arc is initiated by momentarily touching the electrode to the base metal.
• The heat of the arc melts the surface of the base metal to form a molten pool
at the end of the electrode.
• The melted electrode metal is transferred across the arc into the molten pool
and becomes the deposited weld metal.
• The deposit is covered and protected by a slag which comes from the
electrode coating.
• The arc and the immediate area are enveloped by an atmosphere of
protective gas
Core wire
Flux coating
Base metal
Protective gas
Arc
Slag
Weld pool
Manual metal arc ( stick) electrodes have a solid metal wire core and a ux
coating. These electrodes are 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 different functions.
These include:
● producing a protective gas around the weld area
● providing uxing elements and deoxidizers
●creating a protective slag coating over the weld as it cools
●establishing arc characteristics
●adding alloying elements.
Covered electrodes serve many purposes in addition to adding ller metal to
the molten pool. These additional functions are provided mainly by the cover-
ing on the electrode.

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MMA(STICK) WELDING GUIDE
MMA (Stick) Welding Fundamentals
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, dif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.

14 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual

RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual | 15
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INSTALLATION SET UP FOR
DC TIG WELDING
(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
(1) Set Tig/MMA selector
switch to TIG
(6) Carefullyopenthevalveofthegas
cylinder,setthel/minto6-12
XCEL-GAS
/
(2) Connect the TIG torch cable
connector to
(3) Connect earth
lead to

16 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
LIFT ARC DC TIG OPERATION
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.
(8) 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.
(9) TurnontheGasValvelocatedonthetigtorchhandle.
(10) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from the
work piece.
(11)WithasmallmovementrotatetheGasCupforwardsothattheTungstenElectrodetouchesthework
piece.
(12) NowrotatetheGasCupinthereversedirectiontolifttheTungstenelectrodefromtheworkpieceto
create the arc.
(8) AssemblefrontendpartsoftheTIGtorch,
ttingasharpenedtungstensuitableforDC
welding.
(9) TurnontheGasValve (10) Lay the outside edge of the Gas Cup
on the work piece with the Tungsten Elec-
trode 1- 2mm from the work piece.
(11) WithasmallmovementrotatetheGas
Cup forward so that the Tungsten Elec-
trode touches the work piece.
(12) 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.

RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual | 17
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TIG WELDING GUIDE
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 TUNG-
STEN electrode and the metal work piece. The weld area is shielded by
an inert gas ow to prevent contamination of the tungsten, molten pool
and weld area.
When the TIG arc is struck the inert gas is ionized and superheated
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 con-
centrated arc which provides the controlled melting of most metals into
a weld pool. TIG welding offers the user the greatest amount of exibility
to weld the widest range of material and thickness and types. DC TIG
welding is also the cleanest weld with no sparks or spatter.
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

18 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
TIG WELDING GUIDE
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 leading 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 difcult of all the welding process-
es. Because the welder must maintain a short arc length, great care and skill are re-
quired to prevent contact between the electrode and the workpiece. Similar to Oxy-
gen Acetylene 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 together 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

RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual | 19
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DC TIG WELDING GUIDE
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ca-
tion. 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 Lanthanum
and small percentages of Zirconium and Yttrium they are called E3 Tungsten. E3 Tungsten Electrodes provide conductivity 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 overall 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 settings. 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 conductivity 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. Lan-
thanated 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 per-
cent 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.

20 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual
DC TIG WELDING GUIDE
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.
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
Tungsten Preparation