Xcel-Arc RAZORWELD MIG200 Operating Manual Download Page 3

Page: 3 / 40

CONTENTS PAGE

Warranty 2

Safety - Cautions

4-6

Technical Data, Product Information

Machine Layout Pictogram

Installation & Operation for MMA (stick) Welding

MMA (Stick) Welding Information

10-11

Installation & Operation for MIG Welding with Gas

12-13

Wire Feed Drive Roller Selection

Wire Installation Set up Guide

Installation & Operation for MIG Welding with No Gas

16-17

Installation Guide for Mig Torch Liner Installation

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

Warranty terms and Conditions

37-39

Razor

Weld

REGISTER YOUR MACHINE ONLINE TO RECEIVE AN

ADDITIONAL 6 MONTHS ON YOUR WARRANTY

Visit

XcelArc.nz/warranty-registration/

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Summary of Contents for RAZORWELD MIG200

Page 1: ...erstand this instruction manual carefully before the installation and operation of this equipment YEAR MACHINE WARRANTY 1 1 R NE NTY YEAR PRODUCT WARRANTY 3 3 RAZORWELD MIG200 Operating Manual XA MIG2...

Page 2: ...d 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 ou...

Page 3: ...n 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...

Page 4: ...tly 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...

Page 5: ...der 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 mechan...

Page 6: ...e 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 vol...

Page 7: ...enance work The Razor MIG200 gives you great portability with plenty of power to get the job done Designed and built to our specification and manufactured in compliance to AS NZ60974 1 Overview Techni...

Page 8: ...inal 9 Euro Mig Torch Connector MIG MAG 10 Output terminal 11 SpoolGun Power Supply Connection 1 2 3 4 5 BACK PANEL LAYOUT 12 Power switch 13 Gas Inlet 14 Fan 15 Input power cable 16 Data Plate 15 13...

Page 9: ...nnected 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 resu...

Page 10: ...ross 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 envelope...

Page 11: ...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...

Page 12: ...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 ou...

Page 13: ...ate 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 tri...

Page 14: ...ause it to catch in the contact tip Flux Core Gasless Wire these wires are made up of a thin metal sheath that has fluxing and metal compounds layered onto it and then rolled into a cylinder to form t...

Page 15: ...t 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 spoo...

Page 16: ...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 th...

Page 17: ...s 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...

Page 18: ...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...

Page 19: ...eter 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...

Page 20: ...er 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 Rem...

Page 21: ...oller 14 Tighten the torch euro connection to the machine euro connector 15 Cut the extended liner with a sharp Stanley knife just in front of the drive roller 16 Fit an Aluminium contact tip of the c...

Page 22: ...Line to Gas Regulator and connect the gas regulator to the Gas Cylinder 6 Take the Spool Gun and remove the spool cover 7 Place the Wire Spool onto the Spool Holder Hold and snip the wire from the spo...

Page 23: ...h the neck until it exits the contact tip holder 11 Fit the correct sized contact tip by feeding the wire through it screw the contact tip into the tip holder of the torch neck and nip it up tightly 1...

Page 24: ...operties and corresponding advantages and limitations To perform MIG welding the basic necessary equip ment is a welding gun a wire feed unit a welding power supply an electrode wire and a shielding g...

Page 25: ...at and force of the arc flattens out the droplet into the weld pool The heat of the arc melts the end of the wire slightly as it feeds towards the base metal The wire feed speed overcomes the heat of...

Page 26: ...bead profile and degree of weld penetration Push Technique The wire is located at the leading edge of the weld pool and pushed towards the un melted work surface This technique offers a better view of...

Page 27: ...ape prevents undercut uneven penetration poor gas shield and poor quality finished weld Correct angle Not enough angle Too much angle good level of control over the weld pool even flat weld less contr...

Page 28: ...resulting in a weld deposit of poor quality cold lap lack of fusion lack of joint penetration porosity large wide bead Too Slow Travel Speed Correct Travel Speed The correct travel speed keeps the ar...

Page 29: ...ect shield the wire the arc and the molten weld metal from the atmosphere Most metals when heated to a molten state will react with the air in the atmosphere without the protection of the shielding ga...

Page 30: ...able Assembly x 4m XA2503 05 Duraflex Cable Assembly x 5m 8 XA2514 Ergo Handle Kit c w Lock Nut 9 XA2516 Medium Large Trigger 10 XA2517 Hanger Hook optional extra 11 XA2841 Cable Support 12 XA1522 Cab...

Page 31: ...30B Teflon Liner 1 0 1 2mm x 3 4m for Soft wire Red XA2513 40B Teflon Liner 1 0 1 2mm x 4 4m for Soft wire Red XA2513 50B Teflon Liner 1 0 1 2mm x 5 4m for Soft wire Red XA2564 30 PA Liner 1 0 1 2mm...

Page 32: ...APMS1 Motor Screw Pack Spare Parts Part Number Description 22 P7020 24 4 Screw 23 XAP7020W 08U Driver Roll For Aluminium Wire 0 8 XAP7020W 09U Driver Roll For Aluminium Wire 0 9 XAP7020W 10U Driver Ro...

Page 33: ...Amm D8 M6 x 28mm for Aluminium XA2504 12A Contact Tip ECu 1 2Amm D8 M6 x 28mm for Aluminium XA2504 16A Contact Tip ECu 1 6Amm D8 M6 x 28mm for Aluminium 26 0 M6 x 1 0 M6 x 1 0 19 5 13 1 14 5 XA24 Diff...

Page 34: ...Wire stubbing during welding Possible Reason Suggested Remedy Holding the torch too far away Bring the torch closer to the work and maintain stick out of 5 10mm Welding voltage set too low Increase th...

Page 35: ...atten the wire electrode causing it to lodge in the contact tip reduce the drive roller pressure Too much tension on wire spool hub Reduce the spool hub brake tension Wire crossed over on the spool or...

Page 36: ...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 i...

Page 37: ...nline We offer the following Warranty Periods effective from the date of purchase XCEL ARC Inverter MIG SWF MTS MMA TIG TIG ACDC Plasma Power Source Only 2 Years RAZORWELD Inverter MIG SWF MTS MMA TIG...

Page 38: ...ctual Remedies Act and therefore also entitled to at the consumer s discretion either a refund of the purchase price of the goods or repair of the goods or replacement of the goods Returns will only b...

Page 39: ...der 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...

Page 40: ...40 RazorWeld Esseti New Zealand Limited PO Box 4189 Palmerston North 4442 Phone 06 355 1103 Fax 06 354 2437 Email sales esseti co nz www esseti co nz Xcel Arc Esseti NZ LTD 2020 New Zealand Limited...

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