Download
Share
Print this page
  1. Manuals
  2. Brands
  3. Xcel-Arc Manuals
  4. Welding System
  5. RazorWeld MIG500RZSWF
  6. Operator's manual

Xcel-Arc RazorWeld MIG500RZSWF Operator's Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
OPERATOR
MANUAL
3
3
YEAR
N E
PROD UCT
NTY
WARRANTY
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
Xcel-Arc © Esseti NZ LTD - 2022
1
1
YEAR
M ACHIN E
WARRANTY
OPERATING MANUAL
OPERATING MANUAL
Razor
MIG5OOSWF
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
Weld
1

Advertisement

loading
Need help?

Need help?

Do you have a question about the RazorWeld MIG500RZSWF and is the answer not in the manual?

Questions and answers

Related Manuals for Xcel-Arc RazorWeld MIG500RZSWF

Summary of Contents for Xcel-Arc RazorWeld MIG500RZSWF

  • Page 1 OPERATING MANUAL Please read and understand this instruction manual carefully Please read and understand this instruction manual carefully before the installation and operation of this equipment. before the installation and operation of this equipment. Xcel-Arc © Esseti NZ LTD - 2022...
  • Page 2 Razor Weld Thank you for choosing to purchase this RAZORWELD Welding Machine. We are proud of our range of welding equipment that has a proven track record of innovation, performance and reliability. Our product range represents the latest developments in inverter technology put together by our professional team of highly skilled engineers.
  • Page 3 Razor Weld CONTENTS PAGE Warranty Safety Caution, Maintenance and Trouble Shooting Technical Data, Product Information Machine Layout 8-10 Set Up for MMA (Stick) Welding) MMA (Stick) Welding) Information 12-13 Installation & Operation for MIG Welding 14-16 Wire Feed Drive Rollers Wire Installation and Wire Feeder Set Up Mig Torch Liner Installation Torch and Wire Feeder Setup for Aluminium Wire...
  • Page 4 Razor Weld 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.
  • Page 5 Razor Weld 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. Check and be sure the area is safe before doing any welding/cutting.
  • Page 6 Razor Weld CAUTION 1. Working Environment. 1.1 The environment in which this welding 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. 1.2 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 Razor Weld RAZORWELD MIG500RZSWF MIG/TIG/STICK - 500 Amp DC Inverter Welder Welds: Steels, Stainless, Cast Iron, Bronze, Aluminium, Copper RAZORWELD MIG500RZSWF RAZORWELD MIG500RZSWF 500 Amp MIG/TIG/MMA DC Inverter Welder Features ■ Proven IGBT inverter technology ■ MIG/MAG with Gas and Gasless capability...
  • Page 8 Razor Weld MIG5OOSWF MACHINE LAYOUT Front Panel Breakdown Rear Panel Breakdown - Polarity Weld Power Socket Wire Feeder Control Cable Socket + Polarity Weld Power Socket Rear Panel Breakdown Front Control Panel Breakdown Thermal VRD On Primary Power Control Cable Indicator Check Alarm...
  • Page 9 Razor Weld MIG5OOSWF WIRE FEEDER LAYOUT Digital Amperage Digital Voltage Wire Speed Display Display Standard Spool Gun - Push Pull Front Panel Wire Speed Wire Inch Voltage Control Button Control Euro Torch Spool Gun Water Cooling Connection Push Pull Gun Connections Connection Wire Spool...
  • Page 10 Razor Machine Trolley Layout Weld MIG5OOSWF Trolley- Standard Option with Storage Drawer Wire Feeder Post Gas Cylinder Rack Torch Spares Storage Box Cable Suspension Hooks Solid Heavy Duty Rubber Wheels Removable Storage Drawer Heavy Duty Locking Castors Trolley with Water Cooler Unit Option Torch Water Water Filling Inlet Outlet Connections...
  • Page 11 Razor Weld Set up installation for MMA (Stick) Welding MIG5OOSWF (1) Select the MMA function with the Tig/MMA/Mig selector switch. (2) Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DC+ polarity.
  • Page 12 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 cur- rent 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 Razor Weld MIG5OOSWF 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 Razor Weld Installation set up for MIG Welding MIG5OOSWF Select the MIG function with the MMA/Mig selector switch. Insert the earth cable plug into the twist loock socket of required polarity and tighten - negative for gas shielded wires positive for gas less wires. The weld power cable from the wire feeder goes into the opposing negative or positive socket.
  • Page 15 Razor Weld MIG5OOSWF Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive rollers, lock the pressure arm into place. Apply a medium amount of pressure to the drive roller. Remove the gas nozzle and contact tip from the torch neck, (10) (11)
  • Page 16 Razor Weld Continued set up for MIG Welding MIG5OOSWF Crater Current Control Setting: The purpose of the crater control setting is to be able to reduce or eliminate the crater that is left behind when finishing the weld. The following steps explain how to set the and use the Crater Current Control.
  • Page 17 Razor Weld Wire Feed Roller Selection MIG5OOSWF The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. Simply put the smoother the wire feed then the better the welding will be. Feed rollers or drive rollers are used to feed the wire mechani- cally along the length of the welding gun.
  • Page 18 Razor Weld Wire Installation and Set Up Guide MIG5OOSWF Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and consistent wire feed.
  • Page 19 Mig Torch Liner Installation Lay the torch out straight on the ground and remove the front end parts Remove the liner retaining nut. Carefully pull the liner out of the torch cable assembly Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will make it no good and will require replacement.
  • Page 20 Razor Weld Torch & Wire Feed Set Up for Aluminium Wire MIG5OOSWF Lay the torch out straight on the ground and remove the front end parts Remove the liner retaining nut. Carefully pull the liner out of the torch cable assembly Select a PA or liner, carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end.
  • Page 21 Razor Continued Torch & Wire Feed Set Up for Aluminium Wire Weld MIG5OOSWF (10) Loosen off the inlet guide tube retaining screw (11) Remove the inlet guide tube from the front end machine euro connector using long nose pliers. (12) Carefully feed the extended PA liner section into the inlet guide tube hole of the machine euro connector (13) Feed the extended PA liner all the way up and over the drive roller (14) Tighten the torch euro connection to the machine euro connector...
  • Page 22 Razor Weld MIG5OOSWF Set up installation for Push Pull Gun Select the MIG function with the MMA/MIG/TIG selector switch. Insert the earth cable plug into the twist lock socket of required polarity and tighten - negative for gas shielded wires positive for gas less wires. The weld power cable from the wire feeder goes into the opposing negative or positive socket.
  • Page 23 Razor Weld continued: Set up installation for Push Pull Gun MIG5OOSWF (09) Unclip and swing open the wire feed housing cover to expose the wire feed mechanism. (10) Unclip and open out the wire tension swing arm. Check the that the correct drive roller is installed. (11) Remove the gas nozzle and contact tip from the torch neck.
  • Page 24 Gas Flow Regulators - Sheilding Gases Gas Flow Rates Razor Weld MIG5OOSWF 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 25 Razor Weld Mig Torch Liner Types MIG5OOSWF Mig Torch Liner Types Mig Torch Liners The liner is both one of the simplest and most important components of a MIG gun. Its sole purpose is to guide the welding wire from the wire feeder, through the gun cable and up to the contact tip. Steel Liners Most MIG gun liners are made from coiled steel wire also known as piano wire, which provides the liner with good during operational use.
  • Page 26 Basic MIG Welding Good weld quality and weld profile depends on gun angle, direction of travel, electrode extension (stick out), travel speed, thickness of base metal, wire feed speed (amperage) and arc voltage. To follow are some basic guides to assist with your setup. Gun Position - Travel Direction, Work Angle Gun position or technique usually refers to how the wire is directed at the base metal, the angle and travel direction chosen.
  • Page 27 Basic MIG Welding Travel Angle - Travel angle is the right to left angle relative to the direction of welding. A travel angle of 5°- 15° is ideal and produces a good level of control over the weld pool. A travel angle greater that 20°...
  • Page 28 Basic MIG Welding 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 welders skill and is limited to the welders ability to control the weld pool. Push technique allows faster travel speeds than Drag technique.
  • Page 29 Basic MIG Welding Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel, aluminium wires for aluminium and steel wires for steel. Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger machine, check the recommended welding capability of you machine.
  • Page 30 MIG (Metal Inert Gas) Welding Definition of MIG Welding MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a weld- ing gun.
  • Page 31 MIG (Metal Inert Gas) Welding Short Circuit Transfer - Short circuit transfer is the most common used method whereby the wire electrode is fed continuously down the welding torch through to and exiting the contact tip. The wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool.
  • Page 32 Razor Weld Set up for DC TIG Welding with Lift Arc MIG5OOSWF Select the TIG function with the MMA/MIG/TIG selector switch. Connect the Tig torch lead to the Negative output terminal at the front of the machine and tighten it. Connect the gas lead from the TIG torch to the regulator.
  • Page 33 Razor Weld DC TIG Welding with Lift Arc MIG5OOSWF 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.
  • Page 34 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 35 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 Oxygen Acetylene torch welding, Tig welding normally requires two hands and in most instanc- es 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 36 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. Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare earth elements.
  • Page 37 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 38 Razor Weld Set up for ARC AIR GOUGING MIG5OOSWF Select the GOUGING function with the MODE selector switch. Connect the Arc Air Gouging torch lead to the Positive 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 Negative output terminal at the front of the machine and tighten it.
  • Page 39 Razor Weld Set up ARC AIR GOUGING Torch MIG5OOSWF An Arc Air Goging Torch is a good tool for heavy duty metal removal on a wide variety of jobs such as pressure vessel shops, earth moving equipment, heavy machinery repairs and shipyards. 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.
  • Page 40 ARC-AIR GOUGING 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.
  • Page 41 ARC-AIR GOUGING 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.
  • Page 42 MIG WELDING TORCHES XA38 MIG TORCH XA38 MIG TORCH XA38 MIG TORCH Suregrip Suregrip™ ™ Series Series 340A AIR COOLED MIG WELDING TORCH Rating:340A CO 300A mixed gas EN60974-7 @ 60% duty cycle. 1.0 to 1.6mm wires ² Front end parts shown on opposite page Liners shown on opposite page...
  • Page 43 MIG WELDING TORCHES XA38 MIG TORCH XA38 MIG TORCH CONSUMABLES XA38 MIG TORCH CONSUMABLES Suregrip Suregrip™ ™ Series Series Front end consumables XA38 Contact Tips M8 Part Number Description XA4014-08 Contact Tip ECu 0.8mm D10 M8 x 30mm XA4014-09 Contact Tip ECu 0.9mm D10 M8 x 30mm XA4014-10 Contact Tip ECu 1.0mm D10 M8 x 30mm 30.0...
  • Page 44 MIG WELDING TORCHES XA501W MIG TORCH XA501W MIG TORCH XA501W MIG TORCH Suregrip Suregrip™ ™ Series Series 500A WATER COOLED MIG WELDING TORCH Rating:500A CO 450A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.6mm wires ² Cable parts shown below Front end parts shown on opposite page Liners shown...
  • Page 45 MIG WELDING TORCHES XA501W MIG TORCH Suregrip Suregrip™ ™ Series Series XA501W MIG TORCH CONSUMABLES XA501W MIG TORCH CONSUMABLES Front end consumables XA501W Contact Tips M8 Part Number Description XA4014-08 Contact Tip ECu 0.8mm D10 M8 x 30mm XA4014-09 Contact Tip ECu 0.9mm D10 M8 x 30mm XA4014-10 Contact Tip ECu 1.0mm D10 M8 x 30mm XA4014-12...
  • Page 46 MIG WELDING TORCHES XASP36 SPOOL GUN Suregrip Suregrip™ ™ Series Series 270A AIR COOLED SPOOL ON GUN MIG WELDING TORCH Rating:270A CO 250A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires ² Wear parts next page Torch Model Part Number Description XASP36-24-P1-60ER...
  • Page 47 MIG WELDING TORCHES XASP36 SPOOL GUN Suregrip Suregrip™ ™ Series Series XASP36 MIG TORCH CONSUMABLES XASP36 MIG TORCH CONSUMABLES Front end consumables XA36 Contact Tips M6 Part Number Description XA2504-06 Contact Tip ECu 0.6mm D6 M6 x 28mm XA2504-08 Contact Tip ECu 0.8mm D8 M6 x 28mm XA2504-09 Contact Tip ECu 0.9mm D8 M6 x 28mm XA2504-10...
  • Page 48 MIG WELDING TORCHES XAP360 PUSH-PULL TORCH Suregrip Suregrip™ ™ Series Series 300A AIR COOLED MIG WELDING TORCH Rating:300A CO 270A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires Cable parts below Front end parts shown on opposite page All torch packages are supplied with a speed control board Wear parts on opposite page...
  • Page 49 MIG WELDING TORCHES XAP360 PUSH-PULL TORCH Suregrip Suregrip™ ™ Series Series XAP360 MIG TORCH CONSUMABLES XAP360 MIG TORCH CONSUMABLES Front end consumables XA36 Contact Tips M6 Part Number Description XA2504-06 Contact Tip ECu 0.6mm D6 M6 x 28mm XA2504-08 Contact Tip ECu 0.8mm D8 M6 x 28mm XA2504-09 Contact Tip ECu 0.9mm D8 M6 x 28mm XA2504-10...
  • Page 50 MIG WELDING TORCHES XAP401W PUSH-PULL TORCH Suregrip Suregrip™ ™ Series Series 400A WATER COOLED MIG WELDING TORCH Rating:400A CO 350A mixed gas EN60974-7 @ 100% duty cycle. 1.0 to 1.6mm wires ² Cable Parts Below Front end parts shown on opposite page All torch packages are supplied with a speed control board Wear parts on opposite page...
  • Page 51 MIG WELDING TORCHES XAP401W PUSH-PULL TORCH Suregrip Suregrip™ ™ Series Series XAP410W MIG TORCH CONSUMABLES XAP410W MIG TORCH CONSUMABLES Front end consumables XA401W Contact Tips M8 Part Number Description XA4014-08 Contact Tip ECu 0.8mm D10 M8 x 30mm XA4014-09 Contact Tip ECu 0.9mm D10 M8 x 30mm XA4014-10 Contact Tip ECu 1.0mm D10 M8 x 30mm XA4014-12...
  • Page 52 TIG WELDING TORCHES XA26V TIG TORCH 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 53 TIG WELDING TORCHES XA26V TIG TORCH Standard Front End Parts 18CG 10N50 Alumina Nozzle Ø 6mm 10N49L Long Alumina Nozzle Ø 8mm 10N22 Collet 1.0mm 10N30 Collet Body 1.0mm Alumina Nozzle Ø 8mm 10N48L Long Alumina Nozzle Ø 10mm #6L Cup Gasket 10N23 Collet 1.6mm...
  • Page 54 ARC AIR GOUGING TORCH, DC CARBONS 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.
  • Page 55 MIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manu- facturer’s recommendations should be strictly adhered to and followed. 1: Excessive Spatter Possible Reason Suggested Remedy Wire feed speed set too high Select lower wire feed speed Voltage too high...
  • Page 56 MIG WIRE FEED TROUBLE SHOOTING The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: No wire feed Possible Reason Suggested Remedy Wrong mode selected Check that the TIG/MMA/MIG selector switch set to MIG position...
  • Page 57 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 58 DC TIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of DC 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 59 WARRANTY TERMS 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. Distributor are free of Material and Faulty Workmanship Defects except for those products listed under ‘Warranty Exclusions’...
  • Page 60 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 61 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 62 NOTES...
  • Page 63 NOTES...
  • Page 64 New Zealand Limited RazorWeld RazorCut 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 - 2022...