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Unimig RAZOR 200 PULSE Operating Manual

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RAZOR 200 PULSE
11003K | Operating Manual

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  • Page 1 RAZOR 200 PULSE 11003K | Operating Manual...

  • Page 3: Table Of Contents

    CONTENTS GENERAL INFORMATION SAFETY TECHNICAL DATA MACHINE LAYOUT WHAT’S IN THE BOX DIGITAL SCREEN OPERATION DIGITAL SCREEN - BASIC OPERATION DIGITAL SCREEN - MACHINE SETTINGS MENU DIGITAL SCREEN - MIG DIGITAL SCREEN - TIG DIGITAL SCREEN - STICK DIGITAL SCREEN - JOB MEMORY MIG SETUP SETUP FOR MIG (GASLESS) SETUP FOR MIG (GAS-SHIELDED)

  • 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 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 workpiece, and hot equipment can cause fires and burns. Accidental contact of the electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding/cutting.
  • 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 a maximum of 80% humidity. ii. When using the machine outdoors, protect the machine from direct sunlight, rainwater and snow, etc.; the temperature of the working environment should be maintained within -10°C to +40°C.
  • Page 7 SAFETY ATTENTION! - CHECK FOR GAS LEAKAGE 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.

  • Page 8: Technical Data

    TECHNICAL DATA RAZOR™ 200 PULSE MIG/TIG/STICK Welder Key Features: • Single/Double Pulse MIG • 3-in-1 Multi-process • 5″ Touch Colour LCD • Synergic Programs • 4 Geared Wire Drive TECHNICAL DATA TIG SPECIFICATIONS SKU U11003K TIG FUNCTION TYPE High-Frequency PRIMARY INPUT VOLTAGE 240V Single Phase TIG WELDING CURRENT RANGE 5-200A SUPPLY PLUG 15 AMP TIG DUTY CYCLE @ 40°C 20% @ 200A, 60% @ 116A, 100% @ 90A...

  • Page 9: Machine Layout

    MACHINE LAYOUT Front Panel Layout 1. Digital Screen 2. "Back" Button 3. Amp / Wire Speed / Scroll Knob 4. Voltage / Arc Length Knob 5. ''Menu" Button 6. "+" Output Terminal 7. Euro Connection 8. "-" Output Terminal 9. 12 Pin Socket For Spool Gun 10.

  • Page 10: Interior Layout

    MACHINE LAYOUT Interior Layout 15. Wire Feeding Spool Holder 16. Polarity Selector 17. 4 Geared Wire Feeder Digital MIG Torch Top Button Synergic: +Increase Current Manual: +Increase Voltage 18. Bottom Button Synergic: -Decrease Current Manual: -Decrease Voltage 19. Left Button Synergic: -Decrease Arc Length Manual: -Decrease Wire Speed 20.

  • Page 11: What's In The Box

    WHAT’S IN THE BOX Includes: • DM26 Consumable Starter Kit RAZOR 200 PULSE 3m DM26 Digital MIG Torch & 3m Electrode Holder MIG/TIG/STICK Welder Consumables Includes: • 2 x 0.8-0.9mm "V GROOVE" 30/22 • 2 x 0.8-0.9mm "F GROOVE" 30/22 •...

  • Page 12: Digital Screen Operation

    DIGITAL SCREEN - BASIC OPERATION 1. Digital Screen The digital screen is a Touch Screen, you can hand-bac Tap menu items to select and adjust values. You can also hand-bac arrows-l Swipe on screen to navigate menu items. 2. Back Button hand-bac Press the undo BACK Button to return to the previous page.

  • Page 13: Digital Screen - Machine Settings Menu

    DIGITAL SCREEN - MACHINE SETTINGS MENU 1. Wifi Settings 2. QR Code 3. Select Language 4. Machine Information 5. Plug & Play 6. Check for software update 7. Factory Reset Press the bars MENU button to enter the main menu. The following options are available in the menu. 1.

  • Page 14: Digital Screen - Mig

    DIGITAL SCREEN - MIG 1. MIG Settings 2. Advanced MIG Settings 1. MIG Settings MIG Type Select the desired welding mode. MIG Type Description Manual Standard MIG controls, set your parameters by adjusting Wire Speed and Voltage. Synergic Machine will calculate optimal settings based on your selected Wire / Gas / Material Thickness. Pulse Single Pulse MIG alternates between the Peak Current and the Low Current.
  • Page 15 DIGITAL SCREEN - MIG 2. Advanced MIG Settings MIG - Manual Setting Values Description Inductance ±10 Set how fast the current rises to reach the amps that have been selected when welding. Burnback Adjustment ±10 Set how far the wire will burn back once the torch trigger has been released. Pregas Timer 0.1 - 3s Set how long you would like your gas to flow before the arc ignites.

  • Page 16: Digital Screen - Tig

    DIGITAL SCREEN - TIG 1. TIG Settings 2. Advanced TIG Settings 1. TIG Settings TIG Type Select the desired TIG type. TIG Type Description Standard Standard TIG welding. Pulse Pulse TIG alternates between the Peak Current and the Base Current. Weld Mode Select the desired mode.
  • Page 17 DIGITAL SCREEN - TIG 2. Advanced TIG Settings TIG - Manual Setting Values Description HF Switch Off - On Set whether to use High Frequency start. To use button controls on a torch, you'll need HF ON. Pregas Timer 0.1 - 10s Set how long you would like your gas to flow before the arc ignites.

  • Page 18: Digital Screen - Stick

    DIGITAL SCREEN - STICK 1. STICK Settings 2. Advanced STICK Settings 1. STICK Settings Weld Mode Select the desired mode. Torch Mode Description Manual Standard MMA controls, set your parameters by adjusting Current and Arc Force. Synergic Machine will calculate optimal settings based on your selected Electrode / Material Thickness. Electrode Select the desired electrode.

  • Page 19: Digital Screen - Job Memory

    3. Reset Job to original values 4. Return to Free Job Up to 100 saved jobs can be stored with the RAZOR 200 PULSE's Job feature. The Jobs menu can be accessed from the top settings menu in MIG and TIG modes.

  • Page 20: Setup For Mig (Gasless)

    SETUP FOR MIG (GASLESS) Connect the polarity connector to the negative (-) Connect the earth clamp to the positive (+) connection, unscrew the bolt and move the dinse connection, twist to lock in place. connector, then screw and tighten in place. Connect the MIG torch to the Euro connection Connect the plug into a 15 AMP socket, then and twist end to secure in place.
  • Page 21 SETUP FOR MIG (GASLESS) Pull down the roller tension knob to release the Unscrew both roller caps. wire drive. Ensure you have Knurled (F Groove) drive Unscrew spool retaining nut. rollers installed. If not, fit correct rollers and replace the roller covers. Burnback Adjustment...
  • Page 22 SETUP FOR MIG (GASLESS) Place 5kg wire spool onto the spool holder. For Tighten spool retaining nut. 1kg spool, see step 19. STANDARD STANDARD SPOOL GUN SPOOL GUN Burnback Adjustment Burnback Adjustment Burnback Adjustment Burnback Adjustment Feed wire through the inlet guide tube through Lift roller tension knob to lock wire in place.
  • Page 23 SETUP FOR MIG (GASLESS) Remove front end consumables from the MIG Hold the torch trigger for 5s until the "INCH torch. WIRE" message appears on the digital screen. Release the torch trigger then hold trigger again immediately to feed wire through to the torch.
  • Page 24 SETUP FOR MIG (GASLESS) Set weld paramaters on the digital screen. See Line up the torch with your workpiece, then "Digital Screen - MIG" on page 14. simply pull the trigger to initiate the weld. For gasless MIG, the drag method is recommended for optimum weld quality.
  • Page 25 SETUP FOR MIG (GASLESS) For 1kg spool: Place 1kg spool over 1kg spool housing, then tighten and secure with 1kg spool bolt and nut. Burnback Adjustment...

  • Page 26: Setup For Mig (Gas-Shielded)

    SETUP FOR MIG (GAS-SHIELDED) Connect the polarity connector to the positive (+) Connect the earth clamp to the negative (-) connection, unscrew the bolt and move the dinse connection, twist to lock in place. connector then screw and tighten in place. Connect the MIG torch to the Euro connection Connect the plug into a 15 AMP socket, then and twist end to secure in place.
  • Page 27 SETUP FOR MIG (GAS-SHIELDED) Pull down the roller tension knob to release the Unscrew both roller caps. wire drive. Ensure you have V Groove drive rollers Unscrew the roller cap. installed. If not, fit correct rollers and replace the roller covers. Burnback Adjustment...
  • Page 28 SETUP FOR MIG (GAS-SHIELDED) Place 5kg wire spool onto the spool holder. For Tighten spool retaining nut. 1kg spool, see step 24. STANDARD STANDARD SPOOL GUN SPOOL GUN Burnback Adjustment Burnback Adjustment Burnback Adjustment Burnback Adjustment Feed wire through the inlet guide tube through Lift roller tension knob to lock wire in place.
  • Page 29 SETUP FOR MIG (GAS-SHIELDED) Remove front end consumables from the MIG Hold the torch trigger for 5s until the "INCH torch. WIRE" message appears on the digital screen. Release the torch trigger then hold trigger again immediately to feed wire through to the torch.
  • Page 30 SETUP FOR MIG (GAS-SHIELDED) Tighten securely with wrench. Connect gas hose to the regulator outlet, and crimp in place. Adjust gas flow to 8-12L/min. Connect gas hose to the gas inlet on the rear of the machine.
  • Page 31 SETUP FOR MIG (GAS-SHIELDED) Connect earth clamp to your workpiece. Set weld paramaters on the digital screen. See "Digital Screen - MIG" on page 14. Line up the torch with your workpiece, then For 1kg spool: After removing spool holder simply pull the trigger to initiate the weld.
  • Page 32 SETUP FOR MIG (GAS-SHIELDED) For 1kg spool: Remove spool holder housing For 1kg spool: Place 1kg spool over 1kg spool and spring. Place 1kg spool housing inside housing, then tighten and secure with 1kg the square hole where the spool housing is spool bolt and nut.

  • Page 33: Mig (Metal Inert Gas) Welding

    MIG WELDING GUIDE MIG (Metal Inert Gas) Welding MIG (Metal Inert Gas) welding, also known as GMAW (Gas Metal Arc Welding) or MAG (Metal Active Gas Welding), is a semi-automatic arc welding process in which a consumable wire electrode and a shielding gas are fed through a welding gun.
  • Page 34 MIG WELDING GUIDE Basic MIG Welding Good weld quality and weld profile depend on gun angle, the direction of travel, electrode extension (stick out), travel speed, the thickness of base metal, wire feed speed (amperage) and arc voltage. To follow are some basic guides to assist with your setup.

  • Page 35: Stick Out

    MIG WELDING GUIDE Travel Angle The travel angle is the right to left, relative to the direction of welding. A travel angle of 5°- 15° is ideal and produces the right level of control over the weld pool. A travel angle higher than 20° will give an unstable arc condition with poor weld metal transfer, less penetration, high levels of spatter, weak gas shielding and a poor quality finished weld.

  • Page 36: Travel Speed

    MIG WELDING GUIDE Travel Speed Travel speed is the rate that the gun is moved along the weld joint and is usually measured in mm per minute. Travel speeds can vary depending on conditions and the welder's skill and is limited to the welder's ability to control the weld pool.

  • Page 37: Gas Selection

    Using poor quality milled wire can result in poor performance and appearance. To ensure optimal performance when welding, use standards approved wire such as UNIMIG HYPERMIG wire. Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger machine.

  • Page 38: Mig Drive Rollers

    MIG DRIVE ROLLERS Drive Roller Selection The importance of smooth, consistent wire feeding during MIG welding cannot be emphasised enough. The smoother the wire feed, 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.

  • Page 39: Changing The Mig Torch Liner

    CHANGING THE MIG TORCH LINER Remove MIG torch front end parts. Remove the liner retaining nut. Carefully pull out and completely remove the Carefully feed in the new liner down the torch existing liner. Ensure MIG torch is completely lead all the way to exit the torch neck. unravelled until setup is complete.
  • Page 40 CHANGING THE MIG TORCH LINER Fit the liner retaining nut and screw only 1/2 Snip the excess liner off, about the length of way down. the where tip holder sits past the end of the torch neck. Replace the front end parts Fully screw down the liner retaining nut and nip it up tight.

  • Page 41: Changing The Mig Torch Liner (Aluminium)

    CHANGING THE MIG TORCH LINER (ALUMINIUM) Remove MIG torch front end parts. Remove the liner retaining nut. Carefully pull out and completely remove the Fit the neck spring to the front end of the existing liner. Ensure MIG torch is completely aluminium liner.
  • Page 42 CHANGING THE MIG TORCH LINER (ALUMINIUM) Feed liner and neck spring through the torch, Push the liner firmly into the torch lead and then fit liner collet, liner O-ring and liner tighten the liner retaining nut. retaining nut. Loosen the inlet guide tube retaining screw. Remove the inlet guide tube using long nose pliers.
  • Page 43 CHANGING THE MIG TORCH LINER (ALUMINIUM) Install a U groove drive roller of the correct size Feed liner through Euro connection, and for the diameter wire being used. connect and tighten the torch. Take the extended aluminium liner all the way Cut the extended aluminium liner with a sharp up and over the drive roller.
  • Page 44 CHANGING THE MIG TORCH LINER (ALUMINIUM) Replace the front end parts.

  • Page 45: Setup For Mma (Stick) Welding

    SETUP FOR MMA (STICK) WELDING For DC+ electrodes, connect earth clamp to the For DC- electrodes, connect earth clamp to the negative (-) dinse connection, and electrode positive (+) dinse connection, and electrode holder to the positive (+) dinse connection. holder to the negative (-) dinse connection.
  • Page 46 SETUP FOR MMA (STICK) WELDING Twist electrode holder to loosen grip. Place electrode into electrode holder. Twist electrode holder to tighten and securely Connect earth clamp to your workpiece. grip electrode.
  • Page 47 SETUP FOR MMA (STICK) WELDING Strike electrode against workpiece to initiate Drag along workpiece to weld. Pull the arc. electrode away from the workpiece to finish weld.

  • Page 48: Mma (Stick) Welding Guide

    MMA (STICK) WELDING GUIDE Manual Metal Arc (STICK) Welding One of the most common types of arc welding is Manual Metal Arc welding, also known as MMA 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.

  • Page 49: Electrode Selection

    MMA (STICK) WELDING GUIDE 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 50: Setup For Tig

    SETUP FOR TIG Connect the TIG torch to the negative (-) dinse Connect the earth clamp to the positive (+) connection, twist to lock in place. Plug 2-pin dinse connection, twist to lock in place. torch connector in the 2-pin outlet. Connect the plug into a 15 AMP socket, then Connect gas hose to the gas inlet on the rear switch the machine ON.
  • Page 51 SETUP FOR TIG Place argon flowmeter regulator into your gas Tighten securely with wrench. outlet. Connect gas hose to the flowmeter outlet, and Adjust gas flow to 6-10L/min. crimp in place.
  • Page 52 SETUP FOR TIG Set weld paramaters on the digital screen. See Connect earth clamp to your workpiece. "Digital Screen - TIG" on page 16. Initiate arc by pressing the button on the TIG Torch. 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.

  • Page 53: Dc Tig Welding Guide

    DC TIG WELDING GUIDE DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical 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 54 DC TIG WELDING GUIDE Razor Razor 32OAC/DC TIG-MMA C Pulse TIG Welding DC Pulse TIG Welding 32OAC/DC TIG-MMA ulse TIG welding is when the current output (amperage) changes between high and low current. Pulse TIG welding is when the current output (amperage) changes between high and low current. Pulse DC TIG Welding lectronics within the welding machine create the pulse cycle.

  • Page 55: Tig Welding Fusion Technique

    DC TIG WELDING GUIDE 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 electrode and the workpiece.

  • Page 56: Tungsten Electrodes

    DC TIG WELDING GUIDE 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 57: Tungsten Preparation

    DC TIG WELDING GUIDE Tungsten Electrodes Rating for Welding Currents Tungsten Diameter (mm) Diameter at the Tip (mm) Constant Included Angle (°) Current Range (Amps) Current Range (Pulsed Amps) 1.0mm 0.25 5 - 30 5 - 60 1.6mm 8 - 50 5 - 100 1.6mm 10 - 70...

  • Page 58: Torch Breakdown & Spares

    TORCH BREAKDOWN & SPARES DM26 BINZEL Style Digital MIG Torch Part No. Length DM2600-JDM2-MT1-30ER DM2600-JDM2-MT1-40ER DM2600-JDM2-MT1-50ER TORCH SPARES TECHNICAL DATA UG1515 Ergo Handle Location Body COOLING METHOD Air Cooled UG8015 Handle Cable Support C/W Ball Joint DUTY CYCLE - CO2 60% @ 270A DM2514/KJ Digi-Mig Handle Kit DUTY CYCLE - MIXED GAS 60% @ 240A...
  • Page 59 TORCH BREAKDOWN & SPARES DM26 Digital MIG Torch Consumables Description PCTH26M8S TIP HOLDER Description PCGD26 Gas Diffuser Description PCT0005-08 CONTACT TIPS - Steel 0.8mm - M8 PCT0005-09 CONTACT TIPS - Steel 0.9mm - M8 PCT0005-10 CONTACT TIPS - Steel 1.0mm - M8 PCT0005-12 CONTACT TIPS - Steel 1.2mm - M8 PCTAL0005-08...

  • Page 60: Machine Parts Breakdown

    MACHINE PARTS BREAKDOWN MACHINE SPARES MACHINE SPARES 10045432 Quick Socket 10078964 Rear Panel 10078954 Front Panel 10064977 Gas Connector 10083962 12 Core Aviation Socket 10056467 Rocker Switch 10083981 12 Core Aviation Socket 10078773 Bracket For Rear Panel 10041795 Gas Connector 10041714 Insulation Cover 10083994...

  • Page 61: Faq & Troubleshooting

    FAQ & TROUBLESHOOTING WARNING: There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unit by removing external cover unless you are an authorised repair agent for UNIMIG. MIG TROUBLESHOOTING 1. Excessive Spatter •...
  • Page 62 FAQ & TROUBLESHOOTING 6. Lack of penetration - Shallow fusion between weld metal and base metal • Poor or incorrect joint preparation: Material too thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc characteristics. Keep the arc at the leading edge of the weld pool and maintain the gun angle at 5°...

  • Page 63: Tig Troubleshooting

    FAQ & TROUBLESHOOTING TIG TROUBLESHOOTING 1. Tungsten burning away quickly • Incorrect gas or no gas: Use pure argon. Check cylinder has gas is connected, turned on and torch valve is open. • Inadequate gas flow: Check the gas is connected, check hoses, gas valve and torch are not restricted. •...

  • Page 64: Mma (Stick) Troubleshooting

    FAQ & TROUBLESHOOTING MMA (STICK) TROUBLESHOOTING 1. No arc • Incomplete welding circuit: Check earth lead is connected. Check all cable connections. • Wrong mode selected: Check the MMA selector switch is selected. • No power supply: Check that the machine is switched on and has a power supply. 2.

  • Page 65: Error Code List

    FAQ & TROUBLESHOOTING ERROR CODE LIST Error Code Error Error Description Recommended action Possible Cause • Restart the machine. Critical supply voltage in the Exceeding internal voltage limits • If the problem still exists then • The main control board fault main control board.
  • Page 66 FAQ & TROUBLESHOOTING Error Code Error Error Description Recommended action Possible Cause • Fault in the Plug & Play • Restart the machine. temperature sensor. Error in the Plug & Play P&p connector temperature • If the problem still exists then •...
  • Page 67 FAQ & TROUBLESHOOTING Error Code Error Error Description Recommended action Possible Cause • Restart the machine. Hardware error in the power Hardware error • If the problem still exists then inverter. contact the service centre. • Restart the machine. Out of range of the calibration •...
  • Page 68 FAQ & TROUBLESHOOTING Error Code Error Error Description Recommended action Possible Cause • Restart the machine. • Overload in the power supply The power supply outside the Alarm 24v • If the problem still exists then or communication error with limits of 24V DC.
  • Page 69 FAQ & TROUBLESHOOTING Error Code Error Error Description Recommended action Possible Cause • Restart the machine. Recovery performed • If the problem still exists then contact the service centre. • Restart the machine. WiFi crashed WiFi crashed. • If the problem still exists then contact the service centre.
  • Page 70 NOTES...
  • Page 71 NOTES...
  • Page 72 PH: (02) 9780 4200 PH: (07) 3333 2855 PH: (03) 8682 9911 PH: (08) 6363 5111 FAX: (02) 9780 4210 FAX: (07) 3274 5829 FAX: (03) 9333 7867 FAX: (08) 9417 4781 EMAIL: sales@unimig.com.au EMAIL: qld@unimig.com.au EMAIL: vicsales@unimig.com.au EMAIL: wasales@unimig.com.au...

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