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.
RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual | 3
ARC63O
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.
RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual | 5
ARC63O
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

RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual | 7
ARC63O
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:
/

RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual | 9
ARC63O
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