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CONTENTS

SAFETY

TECHNICAL DATA

WHAT’S IN THE BOX

MACHINE LAYOUT

CONTROL PANEL LAYOUT

SETUP FOR TIG

TIG CONTROL PANEL OPERATION

TIG WELDING GUIDE

SETUP FOR STICK (MMA) WELDING

MMA CONTROL PANEL OPERATION

MMA (STICK) ADDITIONAL NOTES

MMA (STICK) WELDING GUIDE

TORCH BREAKDOWN & SPARES

MACHINE PARTS BREAKDOWN

Содержание KUMJRRW320ACDC

Страница 1: ...RAZOR 320 AC DC KUMJRRW320ACDC Operating Manual ...

Страница 2: ...2 ...

Страница 3: ... 10 CONTROL PANEL LAYOUT 12 SETUP FOR TIG 13 TIG CONTROL PANEL OPERATION 16 TIG WELDING GUIDE 20 SETUP FOR STICK MMA WELDING 31 MMA CONTROL PANEL OPERATION 34 MMA STICK ADDITIONAL NOTES 35 MMA STICK WELDING GUIDE 36 TORCH BREAKDOWN SPARES 38 MACHINE PARTS BREAKDOWN 42 3 ...

Страница 4: ...ation to remove welding cutting fumes and gases In confined 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 degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to...

Страница 5: ...r can explode Because gas cylinders usually are 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 flames sparks and arcs Ensure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding cutting electrode or earth clamp to to...

Страница 6: ... to bring down the temperature inside the equipment The machine will be ready for use again when the internal temperature reaches a safe level iii Over Voltage Supply Regarding the power supply voltage range of the machine please refer to the Main parameter table This equipment is of automatic voltage compensation which enables the maintaining of the voltage range within the given range In case th...

Страница 7: ...as pressure in the regulator and line for an extended time period In this situation it is recommended to open the cylinder valve set the flow 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 o...

Страница 8: ...Arc Ignition TIG WELDING CURRENT RANGE 5 315A TIG DUTY CYCLE 40 C 30 320A TIG WELDING THICKNESS RANGE 1 16mm AC TIG SETTINGS AC WAVE FREQUENCY 50 200Hz 5 200A 50 100Hz 200 320A AC PULSE FREQUENCY 0 5 20Hz 5 200A 0 5 10Hz 200 320A PULSE WIDTH CONTROL 5 95 AC WAVE FORMS Square Trapezoidal Sine DC TIG SETTINGS DC PULSE FREQUENCY 0 5 200Hz 5 320A MIX ARC TIG SETTINGS AC DC MIX CYCLE 5 95 DC AC WAVE FR...

Страница 9: ...PULSE REMOTE WATER JOB SAVE JOB RECALL DELETE MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC Test ADJUSTMENT Ignition Time Ignition AMP AMP Set Arc Force AC Hz Hz Pulse Mix SPOT ON OFF AC Balance Start Amp Peak Amp Base Amp Spot Finish Amp JOB SELECT AC WAVE TORCH MODE LIFT ARC PULSE REMOTE WATER JOB SAVE JOB RECALL DELETE MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC RAZOR 320 AC DC TIG ...

Страница 10: ...B RECALL DELETE MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC ON OFF 1 2 3 4 5 6 9 10 11 8 7 Front Panel Layout 1 Digital control panel 2 Negative output terminal 3 Postive output terminal 4 Torch switch Remote connector 5 Quick lock gas connector 6 Adjustment Knob Rear Panel Layout 7 Power switch on off 8 Water Cooler Connector 9 Inlet gas connector 10 Water Cooler Fuse 11 Mains Power Cable ...

Страница 11: ...TMENT Ignition Time Ignition AMP AMP Set Arc Force AC Hz Hz Pulse Mix SPOT ON OFF AC Balance Start Amp Peak Amp Base Amp Spot Finish Amp JOB SELECT AC WAVE TORCH MODE LIFT ARC PULSE REMOTE WATER JOB SAVE JOB RECALL DELETE MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC 18 19 17 12 13 16 15 14 Water Cooler Layout 12 Fault Alarm 13 On Off Swicth 14 Coolant Filler 15 Water Connector Inlet Red 16 W...

Страница 12: ... 13 9 5 2 6 3 7 4 8 22 1 Voltage Value 2 Job Number 3 Program Status 4 Gas Flow Status 5 Amperage Value 6 Seconds Value 7 Frequency Value 8 Percentage Value 9 MMA STICK Controls 10 Job Select 11 Gas Test 12 Weld Sequence Control 13 Job Save 14 Job Recall Job Delete 15 TIG Mode Selector 16 TIG AC Waveform Selector 17 TIG Torch Mode Selector 18 TIG Ignition Selector 19 TIG Pulse Selector 20 MMA Mode...

Страница 13: ...me Ignition AMP AMP Set Arc Force AC Hz Hz Pulse Mix SPOT ON OFF AC Balance Start Amp Peak Amp Base Amp Spot Finish Amp JOB SELECT AC WAVE TORCH MODE LIFT ARC PULSE REMOTE WATER JOB SAVE JOB RECALL DELETE MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC 3 4 Connect the TIG torch to the negative dinse connection twist to lock in place Connect the earth clamp to the positive dinse connection twist...

Страница 14: ... JOB SELECT AC WAVE TORCH MODE LIFT ARC PULSE REMOTE WATER JOB SAVE JOB RECALL DELETE MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC 6 7 Connect gas hose to the flowmeter outlet and crimp in place 8 Adjust gas glow to 6 10L min Set parameters according to TIG Control Panel Operation Page 16 Connect earth clamp to your workpiece SETUP FOR TIG 14 ...

Страница 15: ... leakage prior to operation of your machine We recommend that you close the cylinder valve when the machine is not in use Welding Guns Of Australia PTY LTD authorised representatives or agents of Welding Guns Of Australia PTY LTD will not be liable or responsible for the loss of any gas SETUP FOR LIFT ARC TIG 15 ...

Страница 16: ... Mix SPOT ON OFF Peak Amp Base Amp Spot Finish Amp TORCH MODE LIFT ARC PULSE REMOTE WATER JOB SAVE JOB RECALL DELETE MMA MMA HF 2T 4T 4S SPOT ON ON DC AC TIG Mode Selector Enables selection of required welding mode DC AC Mix Arc AC Wave Form Selector Enables selection of AC Wave Form Square Trapezoidal Sine TIG Torch Mode Selector Controls the on off cycle of the machine using the torch switch whi...

Страница 17: ...mperage to Finish Amperage 0 15s 7 Finish Amp Provides selection for the amount of amperage required at the end of the weld 10 320A 8 Post Gas Timer Provides selection for continued gas flow time at the end of the welding after the arc is out 0 5 15s 9 AC Hertz Provides selection to adjust the frequency of the AC square wave in AC TIG mode Allows adjustment of frequency of the AC square wave cycle...

Страница 18: ...ix Provides selection and adjustment of the of DC output during the MIX ARC welding cycle Adjusts the amount of DC output during MIX ARC welding 5 95 SPOT MODE Selecting SPOT mode allows setting of an ON time and OFF time of the welding curent After pressing the torch switch and generating an established arc the welding current will stay on for the amount of ON TIME set in the SPOT weld program th...

Страница 19: ...cle through the JOB numbers 2 JOB SAVE Press the JOB SAVE button to save the current settings to the selected JOB number 3 JOB RECALL Select the desired JOB NUMBER then press the JOB RECALL button to load saved settings 4 JOB DELETE Select the desired JOB NUMBER then hold the JOB RECALL button for 2s to delete saved settings Water Cooler Mode Provides electronic link when water cooler unit is conn...

Страница 20: ... RAZOR320ACDC machine to adjust the frequency of the AC Square Wave output It means that the amount of time that it takes the AC square wave to complete a full cycle switch from postive to negative can be ad justed from 20Hz 20 times per second to 200Hz Increasing frequency Hz causes the current to change direction more often which means that it spends less time per cycle in both DC electrode nega...

Страница 21: ...ring and arc stop page These problems typically occur during the transition between and cycles The current is lesser 30 during the half of the cycle when the electrode is positive and there is a resistance of the electron flow during this half cycle rectification The lack of current flow during this half cycle makes the AC arc unstable To overcome this lack of flow during one half of the cycle a h...

Страница 22: ... dial on the welding machine More current flow from the polarity produces stronger arc energy and cur rent flow from the tungsten and is good for removing the oxidized surface of the work piece However too much current flow can drive too much energy to the tungsten causing it to overheat and melt the tungsten electrode BALANCED SQUARE WAVE FORM Balance Adjusted for More Oxide Cleansing Action Hott...

Страница 23: ...ters by turning the encoder to cycle through the front panel to select the pulse parameter icons and make settings as show in the following step by step procedure Turn the Encoder to set the Base Amperage The setting shows on the digital display Push the Encoder to lock the icon ready for adjustment Base Amp Turn the encoder to cycle through to illuminate the Base Amp icon 3 Select Base Amperage T...

Страница 24: ... DC waveform which can be varied from 5 95 It is good practice never to exceed the value of 50 DC waveform which would otherwise impair the oxide removal and flushing portion of the weld and effect the appearance of the weld bead MIX ARC WELDING MIX ARC can be used with the different AC wave forms of Square Wave Triangle Wave and Sinusiodal Wave AC MIX Square Wave AC MIX Trapeziodal triangle Wave ...

Страница 25: ...lled melting of most metals into a weld pool TIG welding offers the user the highest amount of flexibility 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 flows from the tungsten The welder regulates the welding current to adjust the power of the arc Typicall...

Страница 26: ... pool to about half its normal size while still keeping the weld pool fluid As a guide start by setting the background amperage at 20 to 30 ercent of peak amperage ulse Frequency is the control of the amount of times per second Hz that the welding current switches om Peak Current to Base Current DC Pulse TIG frequency generally ranges from 20 to 300 HZ depend ng on the job application Control of t...

Страница 27: ...he digital display Push the Encoder to lock the icon ready for adjustment Turn the Encoder to set Base Amperage The setting shows on the digital display Push the Encoder to lock the icon ready for adjustment Base Amp Turn the encoder to cycle through to illuminate the Base Amp icon 3 Select Base Amperage Turn the Encoder to set the Base Amperage Push the Encoder to lock the icon ready for adjustme...

Страница 28: ...ten will assist in 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 TIG Welding with Filler Wire Technique It is necessary for many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld On...

Страница 29: ...ve shown that ignition delay with T3 Tungsten Electrodes improve over time while 2 thoriated tungsten starts to deteriorate after only 25 starts At equivalent energy output T3 Tungsten Electrodes run cooler than 2 thoriated tungsten thereby extending overall tip lifetime T3 Tungsten Electrodes work well on AC or DC They can be used DC electrode positive or negative with a pointed end or balled for...

Страница 30: ...lead to jagged edges imperfections or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel Tungsten electrodes are manufactured with the molecular structure of the grain running lengthwise and thus grinding crosswise is grinding against the grain If electrodes a...

Страница 31: ...MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC Electrode Holder Earth Clamp DC Electrode 3 4 Test ADJUSTMENT Ignition Time Ignition AMP AMP Set Arc Force AC Hz Hz Pulse Mix SPOT ON OFF AC Balance Start Amp Peak Amp Base Amp Spot Finish Amp JOB SELECT AC WAVE TORCH MODE LIFT ARC PULSE REMOTE WATER JOB SAVE JOB RECALL DELETE MMA TIG MMA HF 2T 4T 4S SPOT DC AC Mix ON ON DC AC For DC electrodes co...

Страница 32: ... electrode into electrode holder Twist electrode holder to tighten and securely grip electrode Connect earth clamp to your workpiece Strike electrode against workpiece to initiate arc SETUP FOR STICK MMA WELDING 32 ...

Страница 33: ...9 Drag along workpiece to weld Pull the electrode away from the workpiece to finish weld SETUP FOR STICK MMA WELDING 33 ...

Страница 34: ...at the MMA Arc Ignition AMP time is on 0 01 1 50s 3 MMA Amp Set Provides selection and adjustment of welding current in MMA Mode 0 270A 4 MMA Arc Force Control Provides selection for adjustment of the ARC FORCE during MMA Stick welding Allows setting from a soft buttery arc characteristic to a more digging penetrating arc 0 40 MMA Mode Selector Enables selection of required welding mode DC AC Adju...

Страница 35: ...and bring things back in line But for most other applications AC is not needed There are some Aluminium MMA electrodes available that do require AC current ARC FORCE What is the Arc Force Control and what does it do During welding arc voltage drops as the arc gets tighter and can cause the electrode to stick to the work piece Arc force should be set according to the electrode diameter electrode ty...

Страница 36: ...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 Manual metal arc stick electrodes have a solid metal wire core and a flux coating These electrodes are identified by the wire diameter and by a serie...

Страница 37: ...0 4 0mm 130 165 5 0mm 165 260 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 finish to the weld An excessively short arc will cause sticking o...

Страница 38: ...ACK CAP 6 UMCTMS 1 BUTTON MOMENTARY 7 UMCTMK10KP 10K POTENTIOMETER 8 UMCTSPAN SPANNER 9 See following page Collet Body 10 See following page Gas Lens Collet Body TORCH SPARES 11 See following page Ceramic Cup TECHNICAL DATA COOLING METHOD Air Cooled DUTY CYCLE DC 35 190A DUTY CYCLE AC 35 135A LENGTHS m 4 8 DINSE SIZE 35 50 ELECTRODE SIZE 1 0 4 0 STANDARD EN60974 7 TORCH BREAKDOWN SPARES ARC TORCHO...

Страница 39: ...3 Ceramic Cup 6 10mm 1 UMCT3C07 T3 Ceramic Cup 7 11mm 1 UMCT3C08 T3 Ceramic Cup 8 12 5mm 1 UMCT3C10 T3 Ceramic Cup 10 16mm 1 A highly effective series of passages and wells force cool the collet maximising conductivity and extending consumable life Transferred heat from the ceramic cup is isolated by a unique external barrier resulting in cooler running torches with increased power to weight perfo...

Страница 40: ...BC T2 T3W SHORT BACK CAP 6 UMCTMS 1 BUTTON MOMENTARY 7 UMCTMK10KP 10K POTENTIOMETER 8 UMCTSPAN SPANNER 9 See following page Collet Body 10 See following page Gas Lens Collet Body TORCH SPARES 11 See following page Ceramic Cup TECHNICAL DATA COOLING METHOD Air Cooled DUTY CYCLE DC 35 190A DUTY CYCLE AC 35 135A LENGTHS m 4 8 DINSE SIZE 35 50 ELECTRODE SIZE 1 0 4 0 STANDARD EN60974 7 TORCH BREAKDOWN ...

Страница 41: ... a smaller body Part No Description Bore Size QTY UMCT2CB10 T2 T3W Collet Body 1 0mm 1 UMCT2CB16 T2 T3W Collet Body 1 6mm 1 UMCT2CB24 T2 T3W Collet Body 2 4mm 1 UMCT2CB32 T2 T3W Collet Body 3 2mm 1 Part No Description Bore Size QTY UMCT2GL10 T2 T3W Gas Lens Collet Body 1 0mm 1 UMCT2GL16 T2 T3W Gas Lens Collet Body 1 6mm 1 UMCT2GL24 T2 T3W Gas Lens Collet Body 2 4mm 1 UMCT2GL32 T2 T3W Gas Lens Coll...

Страница 42: ...85 Rear fixing plate 30 10060838 Plastic rear panel 31 10060835 Plastic handle seat 32 10058239 Handle seat bracket MACHINE SPARES 33 10066434 Cover bracket 34 10027249 EMC board 35 10066937 Switch power board 36 10058227 Handle bar 37 10064706 Power frequency transformer 38 10066731 Main control board 39 10064369 PCB bracket 40 10066446 PCB insulation board 41 10066623 Arc strike stabilization pl...

Страница 43: ...sten Incorrect Gas Use pure Argon gas Inadequate gas flow Set the gas flow between 10 15 L min flow rate Alumina gas nozzle too small Increase the size of the alumina gas nozzle 5 Unstable Arc during DC welding Torch connected to DC Connect the torch to the DC output terminal Contaminated base metal Remove materials like paint grease oil and dirt including mill scale from base metal Tungsten is co...

Страница 44: ...orrect technique 5 Lack of penetration Insufficient heat input Increase the amperage or choose a 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 assistance for the correct joint design and fit up 6 Excessive penetration Burn th...

Страница 45: ...NOTES 45 ...

Страница 46: ...NOTES 46 ...

Страница 47: ...NOTES 47 ...

Страница 48: ...CE 180 Kerry Rd Archerfield QLD 4108 PH 07 3333 2855 FAX 07 3274 5829 EMAIL qld unimig com au VIC OFFICE 91 Yellowbox Drive Craigieburn VIC 3064 PH 03 8682 9911 FAX 03 9333 7867 EMAIL vicsales unimig com au WA OFFICE Unit 2 29 Biscayne Way Jandakot WA 6164 PH 08 6363 5111 FAX 08 9417 4781 EMAIL wasales unimig com au ...

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