Xcel-Arc RAZORWELD ARC 630, Operating Manual

Page 1: ...RC630RZ Operating Manual Please read and understand this instruction manual carefully before the installation and operation of this equipment Xcel Arc 2023 YEAR MACHINE WARRANTY YEAR PRODUCT WARRANTY 3 3 TIG MMA CAG ...

Page 2: ...FOR MMA STICK WELDING 11 MMA STICK WELDING GUIDE 12 INSTALLATION SET UP FOR DC TIG WELDING 15 TIG WELDING GUIDE 17 ARC AIR GOUGING SET UP 22 ARC AIR GOUGING GUIDE 24 XA26V TIG TORCH SPARES OPTIONAL 26 ARC AIR GOUGING TORCH DC CARBONS OPTIONAL 28 GAS FLOW REGULATORS SHEILDING GASES 29 MMA STICK WELDING TROUBLE SHOOTING 30 LIST OF ERROR CODES 32 WARRANTY TERMS 33 2 RAZORWELD ARC630 MMA CAG TIGWelder...

Page 3: ...gent as appointed by this company Warranty does not cover abuse misuse accident theft general wear and tear New product will not be supplied unless ESSETI New Zealand Limited has inspected product returned for warranty and agrees to replace product Product will only be replaced if repair is not possible Please view full Warranty term and conditions supplied with machine or at www XcelArc nz warran...

Page 4: ...ble 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 over your body We recommend RCD safety switch is used with this equipment to detect any leakage of current to earth Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harmful to people s he...

Page 5: ...linders 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 mechanical shocks physical damage slag open flames sparks and arcs Insure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding cutting electrode or earth clamp to touch the gas cylinder do not...

Page 6: ...ge range within the given range In case that the voltage of input power supply amperage exceeds the stipulated value it is possible to cause damage to the components of this equipment Please ensure your primary power supply is correct iv Do not come into contact with the output terminals while the machine is in operation An electric shock may possibly occur MAINTENANCE Exposure to extremely dusty ...

Page 7: ...table The DC MMA welding function produces a smooth and stable arc enabling high quality welds for a variety of materials including cast iron stainless steel and low hydrogen Additionally the inclusion of Hot Start and Arc Force combined with Selectable VRD makes it perfect for on site work making it an excellent choice for professionals and contractors alike The Carbon Arc Gouging feature is a ne...

Page 8: ...8 RAZORWELD ARC630 MMA CAG TIGWelderManual MACHINE PARTS LAYOUT FRONT PANEL MACHINE LAYOUT ...

Page 9: ...tart adjust 5 Current Display 6 Alarm indicator 7 Power Indicator Lights when input power connected and machine switched on 8 CAG CEL function 9 VRD Function 10 Voltage Display 11 Parameter select adjust knob 12 MMA Function 13 TIG Function 14 Switch the MMA and TIG function 15 Power Access client access to cable 16 Power switch control power through and break ...

Page 10: ...10 RAZORWELD ARC630 MMA CAG TIGWelderManual ...

Page 11: ...ectrode steady to maintain the arc 6 Hold the electrode slightly above the work piece to maintain the arc while travelling at an even speed to create and even weld deposition 7 To finish the weld break the arc by quickly snapping the electrode away from the work piece 8 Wait for the weld to cool and carefully chip away the slag to reveal the weld metal underneath 4 Place the electrode into the ele...

Page 12: ...electrode metal is 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 Core wire Flux coating Base metal Protective gas Arc Slag Weld pool Manual metal arc stick electrodes have a solid metal wire core...

Page 13: ...welds General rule of thumb for down hand welding is to have an arc 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 fillet horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel When v...

Page 14: ...14 RAZORWELD ARC630 MMA CAG TIGWelderManual ...

Page 15: ...he 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 5 Assemble front end parts of the TIG torch fitting a sharpened tungsten suitable for DC welding 7 Set the welding current using the amperage control dial 4 Connect the gas line to the regulator and connect to the gas cylinder 1 Set Tig MMA selector switch to TI...

Page 16: ... from the work piece 11 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 12 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 8 Assemble front end parts of the TIG torch fitting a sharpened tungsten suitable for DC welding 9 Turn on the Gas Valve 10 Lay the outside edge of the G...

Page 17: ...the tungsten molten pool and weld area When the TIG arc is struck the inert gas is ionized and superheated changing it s molecular structure which converts it into a plasma stream This plasma stream flowing between the tungsten and the work piece is the TIG arc and can be as hot as 19 000 C It is a very pure and con centrated arc which provides the controlled melting of most metals into a weld poo...

Page 18: ... weld pool 75 15 Form a weld pool Travel direction Angle torch Add Tig filler wire Retract the filler wire Move the torch forward to the front of the weld pool Repeat the process gas shield 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 pre...

Page 19: ...er superior arc starting electrode lifetime and overall cost effectivenes When E3 Tungsten Electrodes are compared with 2 thoriated tungsten E3 requires fewer re grinds and provides a longer overall lifetime Tests have shown that ignition delay with E3 Tungsten Electrodes actually improves over time while 2 thoriated tungsten starts to deteriorate after only 25 starts At equivalent energy output E...

Page 20: ...f the grain running lengthwise and thus grinding crosswise is grinding against the grain If electrodes are ground crosswise the electrons have to jump across the grinding marks and the arc can start before the tip and wander Grinding longitudinally with the grain the electrons flow steadily and easily to the end of the tungsten tip The arc starts straight and remains narrow concentrated and stable...

Page 21: ...RAZORWELD ARC630 MMA CAG TIGWelderManual 21 ARC63O ...

Page 22: ...ire feeder power cable is connected to the postive terminal at the rear of the machine it means the wire feeder is live The same applys when the machine is in MMA mode Be careful not to place the MIG torch with out its gas nozzle fitted to the work piece as it will short out against the work piece and damage the MIG torch head Esseti NZ Ltd authorised representatives or agents of Esseti NZ Ltd wil...

Page 23: ...power block adapter 6 Slide back the insulating cover 7 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 8 Insert t...

Page 24: ...ator 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 is fed through the torch head and exited behind and beneath the carbon electrode The localised air blast provided much faster and more efficient removal of material from the molten pool Air Carbon Arc Gouging now pro...

Page 25: ...r 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 most applications the carbon electrode is connected DC and the electrode should not extend more than 170mm from the gouging torch otherwise the air jet becomes ineffectual in removing the molten material The air carbon arc...

Page 26: ...Surelok OB Rubber SL46V30AOB Power Cable x 8m Surelok OB Rubber 14 UD1025 38 Dinse Tig Power Cable Connector 10 25 UD3550 38 Dinse Tig Power Cable Connector 35 50 15 WGCP 1V 58 Gas Hose Assembly x 2m Wear Parts Identification Next Page S t u b b y s e r ie s S t a n d a r d s e r ie s G a s L e n s s e r ie s L a r g e G a s L e n s s e r ie s S t u b b y G a s L e n s s e r ie s 2 3 5 7 6 8 9 10 ...

Page 27: ...Gas Lens Collet Body 2 4mm 45V27 Gas Lens Collet Body 3 2mm Gas Lens Front End Parts 18CG Cup Gasket 54N01 Gas Lens Gasket USTB80300236 Gas Lens Gasket 10N22S Stubby Collet 1 0mm 10N23S Stubby Collet 1 6mm 10N24S Stubby Collet 2 4mm 10N25S Stubby Collet 3 2mm USTB45V43 Stubby Gas Lens Body 1 6mm USTB45V44 Stubby Gas Lens Body 2 4mm USTB45V45 Stubby Gas Lens Body 3 2mm 53N58 Gas Lens Nozzle Ø 6mm 4...

Page 28: ...d DC Gouging Carbon 5 0 x 305mm 50 DGC65305 Copper Clad DC Gouging Carbon 6 5 x 305mm 50 DGC80305 Copper Clad DC Gouging Carbon 8 0 x 305mm 50 DGC95305 Copper Clad DC Gouging Carbon 9 5 x 305mm 50 DGCF15948 Copper Clad Flat DC Gouging Carbon 15 9 x 4 8mm 50 DC GOUGING CARBONS Item Part No Description Part No Description 1 94 433 183 K4000 Insulator 2 94 378 368 K4000 Head 3 94 048 088 K4000 Upper ...

Page 29: ...ine The amount of gas flow needed to do the job will depend on the welding gas and the job being done but a common setting to start with is 10 L min SHIELDING GASES Shielding gases are almost always necessary for MIG and TIG welding processes to protect the weld zone from gases that are contained in the surrounding atmosphere particularly nitrogen and oxygen If allowed into the weld zone these gas...

Page 30: ...e 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 through Possible Reason Suggested Remedy Excessive heat input Reduce the amp...

Page 31: ...s 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 Possible Reason Suggested Remedy 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 conta...

Page 32: ...ellow lamp thermal protection always on E14 Over voltage Yellow lamp thermal protection always on E15 Over current Yellow lamp thermal protection always on E16 Wire feeder over load Switch E20 Button fault on operating panel when switch on the machine Yellow lamp thermal protection always on E21 Other faults on operating panel when switch on the machine Yellow lamp thermal protection always on E22...

Page 33: ...G SWF MTS MMA TIG TIG ACDC Plasma Power Source Only 2 Years RAZORWELD Inverter MIG SWF MTS MMA TIG TIG ACDC Power Source Only 3 Years RAZORCUT Inverter Plasma Power Source Only 3 Years VIPER MIG185 165 Viper TIG180ACDC Power Source Only 2 Years VIPER ARC140 VIPER ARC160 VIPER CUT30 Power Source Only 1 Year VIPER TIG200P VIPER SYNERGIC MIG 120 135 Power Source Only 1 Year JASIC Inverter MIG SWF MTS...

Page 34: ... 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 be accepted provided that a You have complied with the provisions outlined above and b where the goods are unable to be repaired the goods are returned at your cost within thirty 30 days of the delivery date and c Esseti NZ...

Page 35: ...elding 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 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 PLASMA Cutting Torches Consumables such as All Cutting Tips All Diffu...

Page 36: ...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 New Zealand Limited ...