Razorweld Xcel-Arc ARC160 Manual Download Page 9 | Manualshive

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Razorweld Xcel-Arc ARC160 Manual Download Page 9

9

Amperage Control

Dial

MMA /TIG Selector

Switch

Negative Output

Terminal

Positive Output

Terminal

Thermal Alarm LED

Primary Input

Power Lead

VRD On/Off

VRD On LED

Power On LED

On/Off Switch

FRONT PANEL MACHINE LAYOUT:

Razor

Weld

ARC

16O-2OO

REAR PANEL MACHINE LAYOUT:

Razor

Weld

ARC

16O-2OO

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Summary of Contents for Xcel-Arc ARC160

Page 1: ...1 RazorWeld ARC16O ARC2OO 3YEARS Warranty Please read and understand this instruction manual carefully before the installation and operation of this equipment ...

Page 2: ...arketing 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 confidence that they will be well satisfied both now and in the future RAZORWELD welders are manufactured and compliant with CAN CSA E60974 1 ANSI IEC 60974 1 AS NZ60974 1 ...

Page 3: ...A stick Welding 11 MMA Stick Welding Information 12 13 Installation Operation for DC TIG Welding 14 15 Basic DC TIG Welding Guide 16 17 Tungsten Electrode information 18 19 XA17V Tig Torch Parts Guide Breakdown 20 21 MMA Welding Trouble Shooting Guide 22 DC TIG Welding Trouble Shooting Guide 23 24 Gas Leak Check Procedure 24 Gas Flow Regulators Sheilding Gases Gas Flow Rates 26 Warranty 27 ...

Page 4: ...protected from hot metal and sparks Frequently inspect input power cable for wear and tear replace the cable immediately if damaged bare wiring is dangerous and can kill Do not use damaged under sized or badly joined cables Do not drape cables over your body Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harmful to people s health Welding produces fumes and ...

Page 5: ...n explode Because gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damaged Protect gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Insure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding electrode or earth clamp to touch the gas cylinde...

Page 6: ...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 po...

Page 7: ...nd automatic Arc Force coupled with Selectable VRD and Power Factor Correction PFC this machine is perfectly suited to site work for use with most electrodes up to 4 0mm diameter Connection of the optional XA17V Tig Torch provides intermediate level DC TIG welding of steel stainless steel bronze and copper The Lift Arc TIG function delivers perfect arc ignition every time without any sticking or i...

Page 8: ...ding machine with a primary function of DC MMA Stick welding and additional DC TIG function incorporating Lift Arc Ignition Produced using the very latest generation 40KHz IGBT inverter technology this machine offers outstanding arc characteristics whilst also being highly reliable robust and incredibly portable The DC MMA welding function delivers a smooth and incredibly stable arc producing high...

Page 9: ...Switch Negative Output Terminal Positive Output Terminal Thermal Alarm LED Primary Input Power Lead VRD On Off VRD On LED Power On LED On Off Switch FRONT PANEL MACHINE LAYOUT RazorWeld ARC16O 2OO REAR PANEL MACHINE LAYOUT RazorWeld ARC16O 2OO ...

Page 10: ...rkpiece at the same time In damp wet and humid environments the chance of electric shock from the secondary welding to the operator is increased in particular if the operator is not wearing protective leather welding gloves VRD can make the arc iginiton of some electrodes more difficutl especially for the inexpeirenced operator Switchable VRD allows the VRD function to be switched off thereby incr...

Page 11: ... 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 finish 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 th...

Page 12: ...ransferred 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 flux coating ...

Page 13: ... 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 fillet 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 ...

Page 14: ...e of the Tig torch to regulator and connect the regulator to the gas cylinder 5 Assemble front end parts of the TIG torch fitting a sharpened tungsten suitable for DC welding 7 Set the welding current using the amperage control dial 4 Connect the gas line to the regulator and connect to the gas cylinder 2 Connect the TIG torch cable connector to 3 Connect earth lead to 1 Set Tig MMA selector switc...

Page 15: ...Gas Cup forward so that the Tungsten Electrode touches the work piece 9 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 5 Assemble front end parts of the TIG torch fitting a sharpened tungsten suitable for DC welding 6 Turn on the Gas Valve 7 Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1 2mm ...

Page 16: ...types DC TIG welding is also the cleanest weld with no sparks or spatter LIFT ARC IGNITION for TIG tungsten inert gas Welding Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts with a current limit of one or two amps well below the limit that causes metal to transfer and contamination of the weld or electrode When the machine detects that the...

Page 17: ... pool Travel direction Angle torch Add Tig filler wire Retract the filler 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 difficult of all the welding processes Because the welder must maintain a short arc length great care and skill are required to prevent contact between the elect...

Page 18: ...lifetime and over all cost effectivenes When E3 Tungsten Electrodes are compared with 2 thoriated tungsten E3 requires fewer re grinds and provides a longer overall lifetime Tests have shown that ignition delay with E3 Tungsten Electrodes actually improves over time while 2 thoriated tungsten starts to deteriorate after only 25 starts At equivalent energy output E3 Tungsten Electrodes run cooler t...

Page 19: ...n 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 flow steadily and easily to the end of the tungsten tip The arc starts straight and remains narrow concentrated and stable grind lon...

Page 20: ...Dinse Tig Power Cable Connector 10 25 Dinse Tig Power Cable Connector 35 50 15 WGCP 1V 58 Gas Hose Assembly x 2m Torch Model Description Part Number 4m 8m XA17V Tig Torch 16 25 Twistlok End 2m Gas Hose XA17V 12NBD25 XA17V 25NBD25 XA17V Tig Torch 35 50 Twistlok End 2m Gas Hose XA17V 12NBD50 XA17V 25NBD50 XA17VFX Flexi Tig Torch 16 25 Twistlok End 2m Gas Hose XA17VFX 12NBD25 XA17VFX 25NBD25 XA17VFX ...

Page 21: ...0N25 Collet 3 2mm 45V24 Gas Lens Collet Body 1 0mm 45V25 Gas Lens Collet Body 1 6mm 45V26 Gas Lens Collet Body 2 4mm 45V27 Gas Lens Collet Body 3 2mm 54N17L Long Gas Lens Nozzle Ø 8mm 5L 54N16L Long Gas Lens Nozzle Ø 10mm 6L 54N15L Long Gas Lens Nozzle Ø 11mm 7L Gas Lens Front End Parts 18CG Cup Gasket 54N01 Gas Lens Gasket USTB80300236 Gas Lens Gasket 10N22S Stubby Collet 1 0mm 10N23S Stubby Coll...

Page 22: ... larger electrode Poor welding technique Use the correct welding technique or seek assistance for the correct technique Poor joint preparation Check the joint design and fit up make sure the material is not too thick Seek assis tance for the correct joint design and fit up 5 Excessive penetration burn through Possible Reason Suggested Remedy Excessive heat input Reduce the amperage or use a smalle...

Page 23: ...metal Remove materials like paint grease oil and dirt including mill scale from base metal Contaminated filler wire Remove all grease oil or moisture from filler metal Incorrect filler wire Check the filler wire and change if necessary 4 Yellowish residue smoke on the alumina nozzle discoloured tungsten Possible Reason Suggested Remedy Incorrect Gas Use pure Argon gas Inadequate gas flow Set the g...

Page 24: ...he flow rate on the regulator to approximately 8 10 l min 4 Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the regulator if the needle drops away towards zero there is a gas leak Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator and line for an extended time period In this situation it is...

Page 25: ...ding process being used and type of material being welded The MIG process is typically a mixture of Argon and Co2 AR90 Co2 10 or pure Co2 for steel welding applications other specialised mixtures of Argon Co2 and Oxygen are available for stainless steel welding but with welding aluminium pure Argon is almost always used The TIG welding process almost always requires 100 Argon for welding of all ma...

Page 26: ...chased the goods of any alleged defect shortage in quantity damage or failure to comply with the description or quote You shall also afford Esseti NZ Ltd the opportunity to inspect the goods within a reasonable time following delivery if you believe the goods are defective in any way If you shall fail to comply with these provisions the goods shall be presumed to be free from any defect or damage ...

Page 27: ...ding Cable Electrode Holder Earth Clamps MMA TIG Welding Torch Consumables such as Tungsten Electrodes Collet Collet Body Alumina Nozzle Torch Head Torch Head water Cooled Torch Head Flexible Back Caps Gas Lens Torch Handle CupGasket TorchBodyGasValve O ring AllXCEL ARC TIGWeldingRods AllXCEL ARC MagmaweldElectrodes ArcLeads WeldingCable ElectrodeHolder Earth Clamps PLASMA Cutting Torches Consumab...

Page 28: ...28 New Zealand Limited RazorWeld RazorCut ...

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