Xcel-Arc RAZORWELD MIG200 User manual

Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
YEA
R
MACHINE
WARRANTY
1
1
YEAR
MACHINE
WARRANTY
YEAR
PRODUCT
WARRANTY
3
3
RAZORWELD MIG200
Operating Manual | XA-MIG200RZ
© Xcel-Arc 2020

2
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/CSAE60974-1 &
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
RazorWeld

3
CONTENTS PAGE
Warranty 2
Safety - Cautions 4-6
Technical Data, Product Information 7
Machine Layout Pictogram 8
Installation & Operation for MMA (stick) Welding 9
MMA (Stick) Welding Information 10-11
Installation & Operation for MIG Welding with Gas 12-13
Wire Feed Drive Roller Selection 14
Wire Installation Set up Guide 15
Installation & Operation for MIG Welding with No Gas 16-17
Installation Guide for Mig Torch Liner Installation 18
Mig Torch and Wire Feeder Set Up Guide for Aluminium Mig Wire 20-21
Installation & Operation for MIG Welding with Spool Gun 22-23
MIG (Metal Inert Gas) Welding 24-25
Basic MIG Welding Guide 26-29
XA25 MIG Torch Parts Breakdown 30-31
XASP24 Spool Gun Torch Parts Breakdown 32-33
Mig Welding Trouble Shooting Guide 34-35
MMA Welding Trouble Shooting Guide 36
Warranty terms and Conditions 37-39
RazorWeld
REGISTER YOUR MACHINE ONLINE TO RECEIVE AN
ADDITIONAL 6 MONTHS ON YOUR WARRANTY
Visit XcelArc.nz/warranty-registration/ to register your machine.

4
RazorWeld
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 o󰀨 toxic fumes when
welded/cut. Do not weld/cut these materials unless the area is very well ventilated, and or wearing an air supplied
respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding/cutting process produce intense visible and
invisible ultraviolet and infrared rays that can burn eyes and skin.
Always wear a welding helmet with 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.
SAFETY

5
RazorWeld
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 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/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.
SAFETY

6
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.
RazorWeld
SAFETY

7
RazorWeld
RAZORWELD MIG200
Product Code: XA-MIG200RZ-K
Standard Package: XA-MIG200RZ Welding Machine, XA25 Mig Torch x 3m, Earth Lead & Arc Lead 25mm x 4m, Argon Regulator
TheRazor-MIG200 from Xcel-Arc is a high quality inverter MIG welding machine with added MMA(stickelectrode)function.At itsheart is the
very latest in IGBT inverter technology with a 40KHz inverter frequency providing simply outstanding arc characteristics and performance.
The MIG function allows you to weld with both Gas Shielded and Gasless wires and easy step-less adjustment of voltage and wire feed
make for easy setting of welding parameters giving excellent, professional welding results. Wire Inch gives easy feeding of the wire during
set up without gas wastage and the Burn Back adjustment leaves the wire stick out ready for the next weld. The Razor-MIG200 is also
Spoolgun-Ready and allows simple connection of the XASP24 Spoolgun for use with soft or very thin wires that often don’t have the column
strength to successfully feed through standard Mig Torches, such as aluminium wire. The MMAwelding capability delivers easy welding with
electrodes producing high quality welds including cast Iron, stainless steel and low hydrogen. The Razor-MIG200 is an exceptional machine
and is well suited to a wide range of applications including medium-level industrial use, site welding, panel repair, farming and general repair
and maintenance work. The Razor-MIG200 gives you great portability with plenty of power to get the job done.
Designed and built to our specication and manufactured in compliance to AS/NZ60974-1.
Overview
Technical Data
Power Supply 240V 1-Phase ±15%
Rated Input Power 9.4 kVA
I
i e as per AS/NZ60974-1 15.0 Amps
IMax 39.0 Amps
Output Current Range MIG 30A/15.5V - 200A/24.0V
Output Current Range MMA 10A/20.4V - 200A/28.0V
Duty Cycle @ 40°C as per AS/NZ60974-1 20% @ 200 Amps MIG
15% @ 200 Amps MMA
Duty Cycle @ 25°C (approximate) 45% @ 200 Amps MIG
40% @ 200Amps MMA
Power factor 0.70
Protection Class IP21S
Insulation Class F
Wire Spool Capacity 5 kg (Ø200mm)
Wire Diameter Range (mm) 0.6, 0.8, 0.9, 1.0, 1.2
Dimensions (LxWxH) 470 x 190 x 380mm
Weight 18.0 kg
Certication Approval AS/NZ60974-1
Features
■Latest 40KHz IGBT inverter frequency technology
■MIG/MAG with Gas and Gasless capabilty
- Soft Start
- Adjustable Burn Back
- Wire Inch
- Stepless volatge and wire feed control
- Excellent welding with CO2gas
- Spool Gun connection
- Euro style Mig Torch connection
■MMA (stick electrode)
- VRD (Voltage Reduction Device)
- Hot start (improves electrode starting)
- Arc Force (boosts arc energy to prevent electrode extinguishing)
- Excellent arc stability with all electrodes
■Thermal overload protection
■IP21S rating for environmental/safety protection
■Generator compatible (recommend 9.5 kVA minimum)
■Tolerant to variable power supply
200Amp MIG/MMA DC Inverter Welder
XA-MIG200RZ
Standard Package
Optional machine accessories, Spool Guns
refer www.xcelarc.nz
RAZORWELD MIG200
MIG/MMA - 200 Amp DC Inverter Welder
Welds: Steels, Stainless, Cast Iron, Bronze,Aluminium, Copper

8
8
FRONT PANEL LAYOUT
1. Mains Power LED
2. VRD LED
3. Thermal Overload LED
4. Wire Feed Adjustment Knob (MIG/MAG)
5. Voltage Adjustment Knob (MIG/MAG)
6. MIG/MMA Selector Switch
7. Amperage Adjustment Knob (MMA)
8. “-” Output terminal
9. Euro Mig Torch Connector (MIG/MAG)
10. “+” Output terminal
11. SpoolGun Power Supply Connection
12 34
5
BACK PANEL LAYOUT
12. Power switch
13. Gas Inlet
14. Fan
15. Input power cable
16. Data Plate
15
13
16
12
INTERNAL PANEL LAYOUT
17. Burn back control
18. Spoolgun/Standard selector switch
19. Inch wire feed button
20. Spool holder assembly
21. Wire feed assembly
18
21
20
6
7
8
9
10 11
14
19
17
RazorWeld
MACHINE LAYOUT

9
9
(2) Connect the
electrode lead to
(1) Set MIG/MMA selector
switch to MMA
(2) Connect the earth
lead to
Installation set up for MMA (Stick) Welding with XA-MIG200 RAZORWELD
(1) Turn the power source on and select the MMA function with the Tig/MMA/Mig selector switch.
(2) Connection of Output Cables
Two sockets are available on this welding machine. For MMA welding the electrode holder is shown
be connected to the negative socket, while the earth lead (work piece) is connected to the positive
socket, this is known as DC- polarity. However various electrodes require a different polarity for
optimum results and careful attention should be paid to the polarity, refer to the electrode
manufacturers information for the correct polarity.
DC+ Electrode connected to output socket.
DC- Electrode connected to 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 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
9
(2) Connect the
electrode lead to
(1) Set MIG/MMA selector
switch to MMA
(2) Connect the earth
lead to
Installation set up for MMA (Stick) Welding with XA-MIG200 RAZORWELD
(1) Turn the power source on and select the MMA function with the Tig/MMA/Mig selector switch.
(2) Connection of Output Cables
Two sockets are available on this welding machine. For MMA welding the electrode holder is shown
be connected to the negative socket, while the earth lead (work piece) is connected to the positive
socket, this is known as DC- polarity. However various electrodes require a different polarity for
optimum results and careful attention should be paid to the polarity, refer to the electrode
manufacturers information for the correct polarity.
DC+ Electrode connected to output socket.
DC- Electrode connected to 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 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
RazorWeld
INSTALLATION SET UP FOR MMA
(STICK) WELDING WITH XA-MIG200
RAZORWELD

10
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.

11
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

12
12
Installation set up for MIG with Gas for XA-MIG200RZ
(1) Select the MIG function with the Tig/MMA/Mig selector switch.
(2) Select Standard using the Standard/Spool Gun selector switch.
(3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.
IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can
result in the connector arcing and damaging the machine and gun connector.
This damage is not covered under warranty.
(4) Insert the earth cable plug into the negative socket on the front of the machine and tighten it.
(5) Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder.
(6) Connect the weld power cable plug inside the wire feeder to the output socket GAS, and tighten it.
(7) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread.
Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling. Feed the wire into
the wire feeder inlet guide tube through to the drive roller.
(8) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into
the torch receptacle. Check that the drive roller being used complies with the wire diameter, replace the
roller if necessary.
Caution:
Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding
voltage is present and can cause arcing or ash.
(7) Place wire onto spool holder - (spool retaining
nut is left hand thread ) Feed the wire through the
inlet guide tube on to the drive roller.
(6) Connect weld power lead to (8) Feed wire over the drive roller into
the outlet guide tube, Push the wire
through approx 150mm.
(4) Connect earth
lead to
(2) Set Standard/Spoolgun
selector switch inside door
to Standard
(5) Connect the gas line to the regulator
and connect to the gas cylinder
(1) Set Tig/MMA/Mig selector
switch to Mig
IMPORTANT : When connecting the torch
be sure to tighten the connection.
(3) Connect Mig torch

13
13
Continued set up for MIG with Gas for XA-MIG200RZ
(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in
the groove of the bottom drive roller, lock the pressure arm into place.
(10) Apply a medium amount of pressure to the drive roller.
(11) Remove the gas nozzle and contact tip from the torch neck,
(12) Press and hold the inch button to feed the wire through to the torch neck, release the inch button when
the wire exits the torch neck.
(13) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of
the torch head and nip it up tightly.
(14) Fit the gas nozzle to the torch head.
(15) Carefully open the gas cylinder valve and set the ow rate to between 5-10 l/min.
(16) Set the welding parameters using the wire feed and voltage control knobs.
(17) Using the Burn Back control set the amount of wire to ‘burn back’ after you release the torch
trigger. This prevents the wire becoming stuck in the weld pool when nishing the weld.
(12) Press and hold the inch wire button to
feed the wire down the torch cable through
to the torch head.
(11) Remove the gas nozzle and contact tip
from the front end of the mig torch.
(13) Fit the correct size contact tip over
the wire and fasten tightly into the tip
holder.
(14) Fit the gas nozzle to the torch head.
(16) Set welding parameters using the
voltage and wire feed controls. (17) Adjust the burn back control to prevent the wire sticking in the weld pool.
(9) Close down the top roller bracket and clip
the pressure arm into place. (10) Apply a medium amount of pressure to the drive roller
(15) Carefully open the valve of the gas
cylinder, set the ow to 10 l/min

14
Wire Feed Roller Selection
The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.
Simply put the smoother the wire feed then the better the welding will be.
Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.
Feed rollers are designed to be used for certain types of welding wire and they have di󰀨erent types of
grooves machined in them to accommodate the di󰀨erent types of wire. The wire is held in the groove by
the top roller of the wire drive unit and is referred to as the pressure roller, pressure is applied by a tension
arm that can be adjusted to increase or decrease the pressure as required. The type of wire will determine
how much pressure can be applied and what type of drive roller is best suited to obtain optimum wire feed.
Solid Hard Wire - like Steel, Stainless Steel require a drive roller with a V shape groove for optimum grip
and drive capability. Solid wires can have more tension applied to the wire from the top pressure roller that
holds the wire in the groove and the V shape groove is more suited for this. Solid wires are more forgiving
to feed due to their higher cross sectional column strength, they are sti󰀨er and don’t bend so easy.
Soft Wire - likeAluminium requires a U shape groove. Aluminium wire has a lot less column strength, can
bend easily and is therefore more di󰀩cult to feed. Soft wires can easily buckle at the wire feeder where the
wire is fed into inlet guide tube of the torch. The U-shaped roller o󰀨ers more surface area grip and traction
to help feed the softer wire. Softer wires also require less tension from the top pressure roller to avoid de-
forming the shape of the wire, too much tension will push the wire out of shape and cause it to catch in the
contact tip.
Flux Core / Gasless Wire - these wires are made up of a thin metal sheath that has uxing and metal
compounds layered onto it and then rolled into a cylinder to form the nished wire. The wire cannot take
too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied.
A knurled drive roller has been developed and it has small serrations in the groove, the serrations grip the
wire and assist to drive it without too much pressure from the top roller. The down side to the knurled wire
feed roller on ux cored wire is it will slowly over time bit by bit eat away at the surface of the welding wire,
and these small pieces will eventually go down into the liner. This will cause clogging in the liner and added
friction that will lead to welding wire feed problems. A U groove wire can also be used for ux core wire
without the wire particles coming of the wire surface. However it is considered that the knurled roller will
give a more positive feed of ux core wire without any deformation of the wire shape.
V Groove U Groove Knurled Groove
Wire Wire Wire
Top Pressure Roller Top Pressure Roller Top Pressure Roller
MACHINE TYPE: MIG185V - MIG200RZ - MIG205SS - MIG250CRZ
MIG250DRZ - MIG350WRZ - MIG350SWF - MIG500SWF (older model)
V Groove Drive Roller - Steel Wire
Part Number Description
XA-DRV0608 XA Drive Roll V Groove 0.6-0.8mm - 30/22/10
XA-DRV0810 XA Drive Roll V Groove 0.8-1.0mm - 30/22/10
XA-DRV1012 XA Drive Roll V Groove 1.0-1.2mm - 30/22/10
XA-DRV1216 XA Drive Roll V Groove 1.2-1.6mm - 30/22/10
Knurled Drive Roller - Flux Core Wire
Part Number Description
XA-DRK0809 XA Drive Roll Knurled 0.8-0.9mm - 30/22/10
XA-DRK0912 XA Drive Roll Knurled 0.9-1.2mm - 30/22/10
XA-DRK1216 XA Drive Roll Knurled 1.2-1.6mm - 30/22/10
U Groove Roller - Soft Wire
Part Number Description
XA-DRU1012 XA Drive Roll U Groove 1.0-1.2mm - 30/22/10
XA-DRU1216 XA Drive Roll U Groove 1.2-1.6mm - 30/22/10
22mm
30mm
10mm
ROLLER DIAMETER: 30/22/10

15
15
Wire Installation and Set Up Guide
Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.
The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even
and consistent wire feed. A high percentage of faults with mig welders emanate from poor set up of the
wire into the wire feeder. The guide below will assist in the correct setup of your wire feeder.
(1) Remove the spool retaining nut. (3) Fit the wire spool onto the spool holder
tting the locating pin into the location hole
on the spool. Replace the spool retaining
nut tightly
(2) Note the tension spring adjuster
and spool locating pin.
(7) Check that the wire passes through
the centre of the outlet guide tube without
touching the sides. Loosen the locking
screw and then loosen the outlet guide
tube retaining nut too make adjustment if
required. Carefully retighten the locking nut
and screw to hold the new position.
(4) Snip the wire carefully, be sure to hold the
wire to prevent the spool uncoiling. Carefully
feed the wire into the inlet guide tube of the
wire feed unit.
(5) Feed the wire through the drive roller and
into the outlet guide tube of the wire feeder. (6) Lock down the top pressure roller and apply a medium amount of pressure us-
ing the tension adjustment knob
(8) A simple check for the correct drive tension
is to bend the end of the wire over hold it about
100mm from your hand and let it run into your
hand, it should coil round in your hand without
stopping and slipping at the drive rollers,
increase the tension if it slips.
(8) The weight and speed of the wire spool
turning creates an inertia that can cause the
spool to run on and the wire loop over the
side of the spool and tangle. if this happens
increase the pressure on the tension spring
inside the spool holder assembly using the
tension adjustment screw.

16
16
Installation set up for MIG with Gasless wire for XA-MIG200RZ
(1) Switch on the machine, select the MIG function with the Tig/MMA/Mig selector switch.
(2) Select Standard using the Standard/Spool Gun selector switch.
(3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.
IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can
result in the connector arcing and damaging the machine and gun connector.
This damage is not covered under warranty.
(4) Insert the earth cable plug into the Positive socket on the front of the machine and tighten it.
(5) Connect the weld power cable plug inside the wire feeder to the output socket NO GAS, and tighten it.
(6) Fit the correct size Knurled drive roller for Gas Less Flux Core wire.
(7) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread.
Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling. Feed the wire into
the wire feeder inlet guide tube through to the drive roller.
Caution:
Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding
voltage is present and can cause arcing or ash.
(5) Connect weld power lead to
NO GAS (7) Place wire onto spool holder - (spool retaining
nut is left hand thread ) Feed the wire through the
inlet guide tube on to the drive roller.
(6) Fit the correct sized Knurled Drive roller for
Gas Less Flux Cored wire
(4) Connect earth
lead to
(2) Set Standard/Spoolgun
selector switch inside door
to Standard
(5) Connect the gas line to the regulator
and connect to the gas cylinder
(1) Set Tig/MMA/Mig selector
switch to Mig
IMPORTANT : When connecting the torch
be sure to tighten the connection.
(3) Connect Mig torch

17
17
(8) Feed wire over the drive roller into
the outlet guide tube, Push the wire
through approx 150mm. Use a Knurled
Drive Roller of the correct size
Continued set up for MIG with Gasless wire for XA-MIG200RZ
(8) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into
the torch receptacle. Check that the correct drive roller is being used.
(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in
the groove of the bottom drive roller, lock the pressure arm into place.
(10) Apply a light amount of pressure to the drive roller. Too much pressure will crush the cored wire.
(11) Remove the gas nozzle and contact tip from the torch neck,
(12) Press and hold the inch button to feed the wire through to the torch neck, release the inch button when
the wire exits the torch neck.
(13) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of
the torch head and nip it up tightly.
(14) Fit the gas nozzle to the torch head.
(16) Set the welding parameters using the wire feed and voltage control knobs.
(17) Using the Burn Back control set the amount of wire to ‘burn back’ after you release the torch
trigger. This prevents the wire becoming stuck in the weld pool when nishing the weld.
(16) Set welding parameters using the
voltage and wire feed controls. (17) Adjust the burn back control to prevent the wire sticking in the weld pool.
(9) Close down the top roller bracket and clip
the pressure arm into place. (10) Apply a medium amount of pressure to the drive roller
(11) Remove the gas nozzle and contact tip
from the front end of the mig torch.
(14) Fit the gas nozzle to the torch head.
(12) Press and hold the inch wire button to
feed the wire down the torch cable through
to the torch head.
(13) Fit the correct size contact tip over
the wire and fasten tightly into the tip
holder.

18
18
Mig Torch Liner Installation
(1) Lay the torch out straight on the ground and remove the front end parts
(2) Remove the liner retaining nut.
(3) Carefully pull the liner out of the torch cable assembly
(4) Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the
liner it will make it no good and will require replacement.
(5) Carefully and slowly feed the liner in short forward movements down the cable assembly all the way
through and out the torch neck end. Avoid kinking the liner, kinking liner it will make it no good and
require replacement.
(6) Fit the liner retaining nut and screw down only 1/2 way
(7) Leaving the torch straight snip the liner approximately 3mm past the end of the torch neck
(8) Place the tip holder over the end of the liner and screw into the torch neck nipping it up tight.
(9) Screw down the liner nut the remaining 1/2 and nip it up tight. This method compresses the liner
inside the torch cable assembly preventing it moving during use and ensures good wire feed.
(2) Remove the liner retaining nut (3) Carefully pull out and completely
remove the liner
(4) Carefully unravel the new liner
(8) Replace the front end parts
(5) Carefully feed in the new liner down
the torch lead all the way to exit the torch
neck.
(9) Fully screw down the liner retaining
nut and nip it up tight.
(6) Fit the liner retaining nut and screw
only 1/2 way down
(1) Remove mig torch front end parts
(7) Snip the liner off 3mm past the end of the
torch neck.

19
Mig Torch Liners
The liner is both one of the simplest and most important components of a MIG gun. Its sole purpose is to guide the
welding wire from the wire feeder, through the gun cable and up to the contact tip.
Steel Liners
Most MIG gun liners are made from coiled steel wire also known as piano wire, which provides the liner with good
ULJLGLW\DQGÀH[LELOLW\DQGDOORZVLWWRJXLGHWKHZHOGLQJZLUHVPRRWKO\WKURXJKWKHZHOGLQJFDEOHDVLWEHQGVDQGÀH[V
during operational use. Steel liners are primarily used for feeding of solid steel wires, other wires such as Aluminium,
6LOLFRQ%URQ]HHWFZLOOSHUIRUPEHWWHUXVLQJDWHÀRQRU3RO\DPLGHOLQHU7KHLQWHUQDOGLDPHWHURIWKHOLQHULVLPSRUWDQW
and releative to the wire diameter being used and will assit in smooth feeding and prevention of the wire kinking and
birdnesting at the drive rollers. Also bending the cable too tightly during welding increases the friction between the liner
DQGWKHZHOGLQJZLUHPDNLQJLWPRUHGLI¿FXOWWRSXVKWKHZLUHWKURXJKWKHOLQHUUHVXOWLQJLQSRRUZLUHIHHGLQJSUHPDWXUH
liner wear and birdnesting. Dust, grime and metal particles can accumalate inside the liner over time and cause friction
and blockages, it is recommended to periodically blow out the liner with compressed air.
6PDOOGLDPHWHUZHOGLQJZLUHVPPWKURXJKPPKDYHUHODWLYHO\ORZFROXPQDUVWUHQJWKDQGLIPDWFKHGZLWK
an oversized liner, can cause the wire to wander or drift within the liner. This in turn leads to poor wire feeding and
premature liner failure due to excessive wear. By contrast, larger diameter welding wires, 1.2mm through 2.4mm have
much higher columnar strength but it is important to make sure the liner has enough internal diameter clearance. Most
manufacturers will produce liners sized to match wire diameters and length of welding torch cable and most are colour
coded to suit
Blue - 0.6mm - 0.8mm
Red - 0.9mm - 1.2mm
Yellow - 1.6mm
Green - 2.0mm - 2.4mm
7HÀRQDQG3RO\DPLGH3$/LQHUV
7HÀRQOLQHUVDUHZHOOVXLWHGIRUIHHGLQJVRIWZLUHVZLWKSRRUFROXPQVWUHQJWKOLNHDOXPLQLXPZLUHV7KHLQWHULRUVRIWKHVH
OLQHUVDUHVPRRWKDQGSURYLGHVWDEOHIHHGDELOLW\HVSHFLDOO\RQVPDOOGLDPHWHUZHOGLQJZLUH7HÀRQFDQEHJRRGIRU
KLJKHUKHDWDSSOLFDWLRQVWKDWXWLOL]HZDWHUFRROHGWRUFKHVDQGEUDVVQHFNOLQHUV7HÀRQKDVJRRGDEUDVLRQUHVLVWDQFH
characteristics and can be used with a variety of wire types such as silicon bronze, stainless steel as well as alumi-
nium. A note of caution to careful inspect the end of the welding wire prior to feeding it down the liner. Sharp edges
and burrs can score the inside of the liner and lead to blockages and accelerated wear.
Polyamide Liners (PA) are made of carbon infused nylon and are ideal for softer aluminum, copper alloy welding wires
DQGSXVKSXOOWRUFKDSSOLFDWLRQV7KHVHOLQHUVDUHJHQHUDOO\¿WWHGZLWKDÀRDWLQJFROOHWWRDOORZWKHOLQHUWREHLQVHUWHG
all the way to the feed rollers.
&RSSHU%UDVV1HFN/LQHUV
)RUKLJKKHDWDSSOLFDWLRQV¿WWLQJEUDVVRUFRSSHUZRXQGMXPSHURUQHFNOLQHURQWKHHQGRIWKHOLQHUDWWKH
neck end will increase the working temperature of the liner as well as improve the electrical conductivity of
the welding power transfer to the wire.
Blue - 0.6mm - 0.8mm
Red - 0.9mm - 1.2mm
Yellow - 1.6mm
Black - 1.0mm - 1.6mm
Steel Liners
7HÁRQ/LQHUV
PA Liner
Neck Liner
Mig Torch Liner Types
Mig Torch Liner Types

20
20
Torch & Wire Feed Set Up for Aluminium Wire
(1) Lay the torch out straight on the ground and remove the front end parts
(2) Remove the liner retaining nut.
(3) Carefully pull the liner out of the torch cable assembly
(4) Select a PA or liner, carefully and slowly feed the liner in short forward movements down the cable
assembly all the way through and out the torch neck end. Avoid kinking the liner, kinking the liner will
ruin it and require replacement.
(5) Leave the liner extending out the end of the torch neck end by 3mm.
(5) Fit the liner retaining nut together with the liner o-ring.
(8) Push the liner rmly into the torch lead and tighten the liner retaining nut.
(9) Install a U groove drive roller of the correct size to match the wire diameter being used.
(2) Remove the liner retaining nut (3) Carefully pull out and completely
remove the liner
(4) Carefully unravel the new liner (5) Carefully feed in the new liner in short
forward movements down the torch lead
all the way to exit the torch neck. Be care-
ful not to kink the liner
(7) Fit the liner collet, liner O-ring and
liner retaining nut. (8) Push the liner rmly into the torch lead and tighten the liner retaining nut
(1) Remove mig torch front end parts
(6) Replace the front end parts
(9) Cut the liner ush with the end of
liner retaining nut using a sharp box cut-
ter knife.