Xcel-Arc RAZORWELD ARC 630 Operating Manual
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Xcel-Arc RAZORWELD ARC 630 Operating Manual

630a mma/cag/tig inverter
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RAZORWELD
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
© Xcel-Arc 2023
XA-ARC630RZ | Operating Manual
3
3
YEAR
M AC H I N E
WARRANTY
CAG
MMA
YEAR
P RO DU CT
WARRANTY
TIG

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Summary of Contents for Xcel-Arc RAZORWELD ARC 630

  • Page 1 RAZORWELD XA-ARC630RZ | Operating Manual YEAR YEAR M AC H I N E P RO DU CT WARRANTY WARRANTY Please read and understand this instruction manual carefully before the installation and operation of this equipment. © Xcel-Arc 2023...

  • Page 2: Table Of Contents

    CONTENTS WARRANTY SAFETY RAZORWELD ARC 630 FEATURES INSTALLATION SET UP FOR MMA (STICK) WELDING MMA(STICK) WELDING GUIDE INSTALLATION SET UP FOR DC TIG WELDING TIG WELDING GUIDE ARC-AIR GOUGING SET UP ARC-AIR GOUGING GUIDE XA26V TIG TORCH & SPARES (OPTIONAL)

  • Page 3: Warranty

    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. Xcel-Arc welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1, guaranteeing you electrical safety and performance. WARRANTY •...

  • Page 4: Safety

    SAFETY 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.
  • Page 5 SAFETY ARC63O 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 fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
  • Page 6 SAFETY CAUTION 1. Working Environment. The environment in which this welding/cutting equipment is installed must be free of grinding dust, corrosive chemicals, flammable 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.

  • Page 7: Razorweld Arc 630 Features

    RAZORWELD ARC 630 FEATURES ARC63O Welds: Steels, Stainless, Cast Iron, Bronze, Copper RAZORWELD ARC630 RAZORWELD ARC630 230V 3-Phase 630 Amp DC Welder MMA/CAG/TIG Selectable VRD - Stick Electrode, Lift Arc DC TIG Features New MCU control system ■ (stick electrode) ■...
  • Page 8 MACHINE PARTS LAYOUT FRONT PANEL MACHINE LAYOUT: 8 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual...
  • Page 9 MACHINE PARTS LAYOUT ARC63O FRONT AND REAR PANEL LAYOUT: (1)“-” Output terminal. (11)Parameter select/adjust knob. (2)“+” Output terminal. (12)MMA Function (3)Arc force adjust (13)TIG Function (4)Hot start adjust (14)Switch the MMA and TIG function (5)Current Display (15)Power Access client: access to cable. (6)Alarm indicator (16)Power switch: control power through and (7)Power Indicator:Lights when...
  • Page 10 10 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual...

  • Page 11: Installation Set Up For Mma (Stick) Welding

    INSTALLATION SET UP FOR MMA (STICK) WELDING ARC63O (1) Turn the power source on and select the MMA function with the Tig/MMA selector switch. (2) Connection of Output Cables: Various electrodes require a different polarity for optimum results refer to the electrode manufacturers information for the correct polarity. Most GP electrodes are Electrode connected to output socket, Earth Connected to the output socket (3) Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer.

  • Page 12: Mma(Stick) Welding Guide

    MMA(STICK) WELDING GUIDE 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 current 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 flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
  • Page 13 MMA(STICK) WELDING GUIDE ARC63O MMA (Stick) Welding Fundamentals 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 specific classes of work.
  • Page 14 14 | RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual...

  • Page 15: Installation Set Up For Dc Tig Welding

    INSTALLATION SET UP FOR DC TIG WELDING ARC63O (1) Switch on the machine, select the TIG function with the Tig/MMA selector switch. (2) Insert the power cable plug of the Tig torch into the Negative socket on the front of the machine and tighten it. (3 Insert the earth cable plug into the Positive socket on the front of the machine and tighten it. (4) Connect the gas line of the Tig torch to regulator and connect the regulator to the gas cylinder.
  • Page 16 LIFT ARC DC TIG OPERATION Lift Arc ignition allows the arc to be started easily in DC Tig by simply touching the tungsten to the work piece and lifting it up to start the arc. This prevents the tungsten tip sticking to the work piece and breaking the tip from the tungsten electrode. There is a particular technique called “rocking the cup” used in the Lift Arc process that provides easy use of the Lift Arc function.

  • Page 17: Tig Welding Guide

    TIG WELDING GUIDE ARC63O DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main elec- trical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical principle at work which should always be taken into account when using any DC circuit.
  • Page 18 TIG WELDING GUIDE TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding process- es. Because the welder must maintain a short arc length, great care and skill are re- quired to prevent contact between the electrode and the workpiece. Similar to Oxy- gen Acetylene torch welding, Tig welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other.
  • Page 19 DC TIG WELDING GUIDE ARC63O Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.
  • Page 20 DC TIG WELDING GUIDE Tungsten Preparation Always use wheels when grinding and cutting. While tungsten is a very hard material, the surface of a DIAMOND diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contrib- ute to weld inconsistency and weld defects.
  • Page 21 ARC63O | 21 RAZORWELD™ ARC 630 - MMA/CAG/TIG Welder Manual...

  • Page 22: Arc-Air Gouging Set Up

    ARC-AIR GOUGING SET UP Select the CAG function with the MODE selector button. Connect the Arc Air Gouging torch lead to the Negative output terminal at the front of the machine and tighten it. Connect the air line to the air supply such as a compressor. Connect the earth lead to the Positive output terminal at the front of the machine and tighten it.
  • Page 23 ARC-AIR GOUGING SET UP An Arc Air Goging Torch is a good tool for heavy duty metal removal on a wide variety of jobs such as pressure ves- ARC63O sel shops, earth moving equipment, heavy machinery repairs and shipyards. (5) Slide back the insulating cover of the power block and connect a power lead cable to it, use minimum 50mm2 cable up to 10m in length, heavy cable is recommended for a longer power lead. Connect an air line to the air connection at the power block adapter. (6) Slide back the insulating cover. Rotate the jaw clamp so that the air holes are pointing in the direction you want to gouge. (8) Insert a DC gouging carbon into the jaw clamp. the carbon should not extend too far out otherwise the air flow will not meet with the arc gouging area at the end of the carbon to disperse the molten material. (6) Slide back the insulating cover (5) Slide back the insulating cover of the power block and connect a power lead cable to it.

  • Page 24: Arc-Air Gouging Guide

    ARC-AIR GOUGING GUIDE ARC-AIR GOUGING PROCESS Air Carbon-Arc Gouging (commonly referred to as Arc-Air Gouging) has been used since the early 1940’s when it was initially developed from the Carbon Arc Cutting process that was used to remove welds, rivet heads and cut metal while relying on gravity for removal of the molten material. The gouging process was further developed with the introduction of a jet of compressed air from behind and on the underside of the gouging carbon to remove the molten material. This compressed air was initially applied by a second operator directing an air gun towards the molten pool and was not very successful. With great ingenuity and further development, the Air Carbon-Arc Torch was designed whereby compressed air...
  • Page 25 ARC-AIR GOUGING GUIDE ARC63O Torch Head DC AIR CARBON ARC GOUGING Copper Coating Carbon Carbon Electrode DC (+) Clamp Air Flow @ 80psi Always underneath the Carbon Travel Direction Work Piece DC (-) The air jet orifice of the torch head clamp needs to be located underneath the electrode and facing towards the work end of the electrode with the air jet between the electrode and work piece. To avoid damage to the torch head a minimum ex- tension of the electrode should be no less than 45mm. Air pressure should range between 80 psi and 100 psi at the torch and the air supply hose requires and internal diameter of no less than 6.5mm. Single-phase machines with low open-circuit voltage are not suitable for air carbon arc gouging. Most three-phase weld- ing power sources of sufficient amperage output may be used for air arc gouging. The arc voltage required for air carbon arc gouging and cutting ranges from 35 to 56 volts, therefore the open-circuit voltage needs to be at least 60 volts. For...

  • Page 26: Xa26V Tig Torch & Spares (Optional)

    XA26V TIG TORCH & SPARES (OPTIONAL) XA26V TIG TORCH XA26V TIG TORCH Suregrip Suregrip™ ™ Series Series 180AMP AIR COOLED Gas Valve Torch Head Rating: 180A DC, 125A AC @35% duty cycle. Wear Parts Identification Next Page Torch Model Description Part Number XA26V Suregrip Tig Torch 4m, Surelok Connector QF Gas XA26V-S112GS4...
  • Page 27 XA26V TIG TORCH SPARES ARC63O Alumina Nozzle Ø 6mm 10N49L Long Alumina Nozzle Ø 8mm 18CG 10N22 Collet 1.0mm 10N30 Collet Body 1.0mm 10N50 Alumina Nozzle Ø 8mm 10N48L Long Alumina Nozzle Ø 10mm #6L Cup Gasket 10N23 Collet 1.6mm 10N31 Collet Body 1.6mm 10N49 10N48 Alumina Nozzle Ø 10mm 10N47L Long Alumina Nozzle Ø...

  • Page 28: Arc Air Gouging Torch, Dc Carbons (Optional)

    ARC AIR GOUGING TORCH, DC CARBONS (OPTIONAL) ARC AIR GOUGING TORCH Part-No Description K4000 K4000 Arc Air Gouging Torch Applications: Heavy Duty - highly efficient metal removal tool for fabrication jobs in steel fabrication plants, truck shops, railroads, general engineering shops,farms . . . anywhere people want to save time and money. Supplied with a 2m power cable complete with power block and air connector. To extend reach extra welding cable is available separately. Electrode Size: Round - 4.0mm - 12.7mm Flat - 15.9mm Air Requirement: 80 PSI - 5.6 kg/cm²...

  • Page 29: Gas Flow Regulators - Sheilding Gases

    GAS FLOW REGULATORS - SHEILDING GASES ARC63O GAS FLOW REGULATORS The job of the gas flow regulator is to reduce the bottle pressure gas down to a lower pressure and deliver it at a constant flow. This constant flow of gas is usually fed through the welding machine where it is controlled by a solenoid valve, operated when the torch trigger is pulled.

  • Page 30: Mma (Stick) Welding Trouble Shooting

    MMA (STICK) WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: No arc Possible Reason Suggested Remedy Incomplete welding circuit Check earth lead is connected.
  • Page 31 TIG WELDING TROUBLE SHOOTING ARC63O The following chart addresses some of the common problems of TIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: Tungsten burning away quickly Possible Reason Suggested Remedy Incorrect Gas or No Gas Use pure Argon.

  • Page 32: List Of Error Codes

    LIST OF ERROR CODES Error Type Error code Description Lamp status Thermal relay Over-heating(1st thermal relay) Yellow lamp(thermal protection) always on Over-heating(2nd thermal relay) Yellow lamp(thermal protection) always on Over-heating(3rd thermal relay) Yellow lamp(thermal protection) always on Over-heating(4th thermal relay) Yellow lamp(thermal protection) always on Over-heating(Program in default) Yellow lamp(thermal protection) always on...

  • Page 33: Warranty Terms

    WARRANTY TERMS ARC63O ESSETI New Zealand Limited (‘us’, ‘we’) warrants that the products bearing the brand names ESSETI, XCEL-ARC, RAZORWELD, RAZORCUT, JASIC, VIPER, T&R, XCEL-GAS, Otos, Servore, TECNA & HIT-8SS supplied by us and purchased by you from an Authorised ESSETI (NZ) Ltd.
  • Page 34 WARRANTY TERMS WARRANTY / RETURNS / EXCHANGES Our Warranty Returns Policy recognises all and any rights you have under New Zealand Consumer Law and other relevant laws. You shall inspect the goods on delivery and shall within seven (7) days of delivery (time being of the essence) notify the Esseti NZ Ltd. Authorised Distributor from whom you purchased the goods of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.
  • Page 35 Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled, Torch Head Flexible, Back Caps, Gas Lens, Torch Handle, Cup Gasket, Torch Body Gas Valve, O-ring, All XCEL-ARC TIG Welding Rods, All XCEL-ARC / Magmaweld Electrodes, Arc Leads, Welding Cable, Electrode Holder, Earth Clamps •...
  • Page 36 New Zealand Limited 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 - 2023...

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