OPERATING MANUAL 3 YEAR - UNIMIG

SAFETYCAUTION1. Working Environment.i.The environment in which this welding/cutting equipment is installed must be free of grinding dust, corrosive chemicals, flammable gas ormaterials 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 environmentshould be maintained within -10 C to 40 C.iii. Keep this equipment 30cm distant from the wall.iv. Ensure the working environment is well ventilated.2. Safety Tips.i.Ventilation This equipment is small-sized, compact in structure, and of excellent performance in amperage output. The fan is used to dissipate heatgenerated by this equipment during the welding/cutting operation. Important: Maintain good ventilation of the louvres of this equipment. Theminimum distance between this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is of criticalimportance for the normal performance and service life of this equipment.ii. Thermal Overload protection. Should the machine be used to an excessive level, or in high temperature environment, poorly ventilated area or if the fan malfunctions theThermal Overload Switch will be activated and the machine will cease to operate. Under this circumstance, leave the machine switched on tokeep the built-in fan working to bring down the temperature inside the equipment. The machine will be ready for use again when the internaltemperature reaches safe level.iii. Over-Voltage Supply Regarding the power supply voltage range of the machine, please refer to “Main parameter” table. This equipment is of automatic voltagecompensation, which enables the maintaining of the voltage range within the given range. In case that the voltage of input power supplyamperage exceeds the stipulated value, it is possible to cause damage to the components of this equipment. Please ensure your primarypower 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.MAINTENANCEExposure to extremely dusty, damp, or corrosive air is damaging to the welding/cutting machine. In order to prevent any possible failure or fault of thiswelding/cutting equipment, clean the dust at regular intervals with clean and dry compressed air of required pressure.Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of this welding/cutting equipment will be void if themachine has been modified, attempt to take apart the machine or open the factory-made sealing of the machine without the consent of an authorizedrepresentative of the manufacturer.TROUBLE SHOOTINGCaution: Only qualified technicians are authorized to undertake the repair of this welding/cutting equipment. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed in this manual.6 RAZOR TIG 200 AC/DC Manual

SAFETYATTENTION! - CHECK FOR GAS LEAKAGEAt initial set up and at regular intervals we recommend to check for gas leakageRecommended procedure is as follows:1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.2. Slowly open the cylinder valve.3. Set the flow rate on the regulator to approximately 8-10 L/min.4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the regulator, if the needle drops away towardszero there is a gas leak. Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator and line for anextended 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 checkafter 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 leakagepoint.6. Tighten clamps or fittings to eliminate gas leakage.IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your machine. We recommend that you close thecylinder 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 forthe loss of any gas.RAZOR TIG 200 AC/DC Manual 7

RAZOR TIG 200 AC/DC FEATURES3 YEARWARRANTY(POWER SOURCE)FEATURESOVERVIEW 15 AMP PlugThe RAZOR TIG 200 AC/DC is the perfect AC/DC TIG & STICK Welder for professionalwelder wanting both AC and DC TIG welding capabilities. Fitted with a 15 AMP Plug,this machine is suited to light to medium industrial work. AC/DC H/F TIG & PULSE TIG-- Pre Gas 0.1 - 3.0 sec-- Start Amperage 10 - 200A-- Up Slope 0 - 10 sec-- Peak Amp 10 - 200A-- AC Square Wave 20 - 250Hz-- AC Balance Control 10-- Down Slope 0 - 15 sec-- Adjustable Finish Amperage 10 - 200A-- Post Gas 0.5 - 15.0 sec STICK (MMA) with ARC FORCEThe RAZOR TIG 200 AC/DC allows for full control over the TIG welding process toensure you can maximise your results from start to finish. Controllable parametersinclude Pre Gas Time, Start Current, Up Slope and Down Slope Time, Finish CurrentLevel and Post Gas Time, among many others.The all-new ARC TORCHOLOGY T2 TIG Torch comes standard with the RAZOR TIG200 AC/DC, offering up to 30% more power and longer consumable life-cycles. ARemote Foot Control (UTJRFC-4) can also be plugged into the machine for even moreversatility.With all of these features packed into an compact package, the RAZOR TIG 200 AC/DC is a must-have for any professional welder or TIG enthusiast. Thermal overload protectionMACHINE PACKAGE: KUM-M-RTIG200ACDC IP21S rating for environmental/safety protection RAZOR TIG 200 AC/DC Power Source Generator compatible (recommend KVA minimum) 4m High Performance T2 TIG Torch (including consumables) VRD (Voltage Reduction Device) 4m Twist Lock Electrode Holder Foot Control Ready 300 Amp Earth Clamp & Lead Argon Flowmeter Regulator 2m Gas Hose Complete with fittings Operating Manual8 RAZOR TIG 200 AC/DC Manual

RAZOR TIG 200 AC/DC TECHNICAL DATATECHNICAL DATASTICK SPECIFICATIONSMACHINERAZOR TIG 200 AC/DCSTICK WELDING CURRENT RANGE10-160ASKUKUM-M-RTIG200ACDCSTICK DUTY CYCLE @ 40 C30% @ 160APRIMARY INPUT VOLTAGE240V Single PhaseSTICK ELECTRODE RANGE2.5-4.0mmSUPPLY PLUG15 AMP2mm - 12mmRATED INPUT POWER (kVA)6.0STICK WELDING THICKNESSRANGEARC FORCE0-40Ieff (A)15.0Imax (A)29.0RATED OUTPUT10-200A/18.0VNO LOAD VOLTAGE (V)9-68PROTECTION CLASSIP21SINSULATION CLASSFVRDYesPOWER FACTOR0.7FOOT CONTROL READYYes (UTJCFC-4)MINIMUM GENERATOR (kVA)9.0CRATER CURRENT CONTROLYesDINSE CONNECTOR35/50THERMAL OVERLOADPROTECTIONYesSTANDARDAS/NZ60974-1WELDSMild Steel, Stainless Steel, Cast Iron,Silicon Bronze, Copper, Aluminium, ZincAlloysWARRANTY (Years)3SIZE & WEIGHTDIMENSIONS (mm)426x162x326mmWEIGHT (kg)10kgMACHINE FEATURESTIG SPECIFICATIONSTIG FUNCTION TYPEAC/DC HF TIG & AC/DC PulseTIG WELDING CURRENT RANGE10-200ATIG DUTY CYCLE @ 40 C25% @ 200ATIG WELDING THICKNESS RANGE1mm - 8mmAC/DC TIG PARAMETERSPRE GAS0.1-3.0sSTART AMP10-200AUP SLOPE0-10sPEAK AMP10-200AAC SQUARE WAVE20-250HzAC BALANCE CONTROL 10DOWN SLOPE0-15sFINISH AMP10-200APOST GAS0.5-15.0sPULSE FREQUENCY0.2-200HzPULSE WIDTH10-90%SPOT0.5-10sRAZOR TIG 200 AC/DC Manual 9

MACHINE PARTS LAYOUTFRONT PANEL LAYOUT1. Weld Function Selector81272. 2T / 4T / Spot Selector3. Positive Output Terminal4. Negative Output Terminal5. Quick Lock Gas Connector36. Torch Switch - Remote Connector7. Encoder Knob8. Weld Cycle Display4659BACK PANEL LAYOUT9. Power Switch10. Mains Power Input Cable10111210 RAZOR TIG 200 AC/DC Manual11. Fan12. Inlet Gas Connector

FRONT PANEL OPERATIONMode SelectorEnables selection of required welding mode: AC TIG AC PULSE TIG DC TIG DC PULSE TIG DC MMA (Stick)Torch Switch Mode SelectorControls the on/off cycle of the machine using the torch switch while incorporating the weld program parameters selections: 2T uses 2 actions of the torch switch while incorporating the weld program parameter selections. 4T uses 4 actions of the torch switch while incorporating the weld program parameter selections. 4T provides operator controlof the start and finish portions of the weld sequence. Spot uses a single action of the torch switch. Pressing the torch switch gives arc ignition and initialises the welding sequencefor the period of time set using the spot timer.Encoder KnobProvides digital adjustment of welding parameters and provides step by step motion through the weld cycle parameters. Turn the knob to increase or decrease the desired value displayed on the LED display. Press the knob to cycle between each step of the weld cycle.RAZOR TIG 200 AC/DC Manual 11

WELD PROGRAM OPERATIONArc ForceSpot12321AC HzPeakAmpStartAmpPulse Hz104BaseAmp59% Pulse1167FinishAmp8AC Balance1. Pre Gas Timer10. AC Hz Provides selection for gas flow time prior to the arc starting. (0.1 - 3.0s) 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 (transistion from to-) during AC TIG welding. (20-250 Hz)2. Start Amp Provides selection for the amount of amps required at the start of the weld.(5 - 160 AMP)11. Pulse Hz / % Pulse3. Up Slope Time The Pulse Hz / % Pulse combines two functions under the same section. Uponfirst illuminating, the display will refer to he Pulse Hz value. Push the Encoder Knobonce more to display the % Pulse value. Sets the transition time from Start Amperage to Welding Amperage. (0-10s)4. Peak Amp Provides selection for the Maximum Welding Amperage required during welding.(5 - 180 AMP)5. Base AmpPULSE HZ Provides selection of the pulse frequency of the welding output current. Allowsadjustment of frequency that the output current transistions from Peak Amp toBase Amp. (0.02-200 Hz)% PULSE Provides selection for the Base Amperage during the Pulse Welding cycle.(5-180 AMP) Provides selection of the on time ratio of the Peak Amp during the pulse weldingcycle (Pulse Width). Allows adjustment of the % of time that the Peak Amp is onduring each pulse cycle. (10-90%)6. Down Slope Time12. Spot / Arc Force Sets the transition time from Welding Amperage to Finish Amperage. (0 - 15s) The Spot / Arc Force combines two functions under the same section. When in TIGMode, and SPOT is selected from the Torch Switch Mode Slector, the section willrefer to Spot. When in MMA Mode, the section will refer to Arc Force.7. Finish Amp Provides selection for the amount of amperage required at the end of the weld.(5-180 AMP)8. Post Gas Timer Provides selection for continued gas flow time at the end of the welding after thearc is out. (0.5-15s)9. AC Balance Provides selection to adjust the balance of the AC wave form in AC TIG mode.Allows adjustment of the arc to be balanced, penetrating or oxide cleaning duringAC TIG welding. (-5 to 5)12 RAZOR TIG 200 AC/DC ManualSPOT Provides selection of a pre-set time period for welding current output. Allowsadjustment of the time that machine will deliver amperage output from triggeractivation. (0.5-10s)ARC FORCE Provides selection for adjustment of the ARC FORCE during MMA (Stick) welding.Low value allows a soft arc, a higher value allows stronger digging arc. (0-40)

ADDITIONAL FRONT PANEL OPERATIONRemoteThe remote icon illuminates when the remote function is active. Remote Hand Control: Press the torch switch and hold for 5 seconds the icon willilluminate when remote function is activated. Remote Foot Control: Remote function will become active when the foot controlis connected.Tungsten electrode Ømm For selection of Tungsten electrode and MMA electrode diameter. (Value is mm)Parameter WarningThe warning parameter icon illuminates when the the weld parameter settings do notmatch the electrode size selection.The machine will still function but it is a warning to the operator that the weldparameters chosen are outside the generally accepted capabilities of the electrodesize selected. For example excessive amperage selected may overheat and destroythe tungsten electrode.RAZOR TIG 200 AC/DC Manual 13

H/F DC TIG SETUPDC TIG PARAMETERSSELECTION:i.5Select DC TIGii. Set Tungsten Diameter6iii. Set Pre-Gas Timeiv. Set Start Ampsv.Set Up Slope Timevi. Set Peak Ampvii. Set Down Slope412viii. Set Finish Ampix. Set Post Gas31. Connect the TIG Torch connector to the negative terminal and tighten it.2. Insert the torch gas connector into the quick lock gas receptacle.3. Connect the torch switch remote lead into the torch remote socket.4. Connect the Earth Cable connector into the positive terminal andtighten it.6. Connect the gas line to the quick lock gas inlet connector at the rear ofthe machine. Check for gas leaks - Welding Guns of Australia PTY LTDnor it’s representatives will be responsible for any gas loss.7. Switch on the machine using the On/Off switch at the rear of themachine.8. Set the weld parameters using the front panel5. Connect gas line to Gas Regulator and connect the gas regulator tothe Gas Cylinder. Slowly open the valve on the gas cylinder and set gasflow to the required rate.Weld start procedure for HF DC TIG welding(1) Lay the outside edge of the Gas Cup on the workpiece with the Tungsten Electrode 1- 3mm from thework piece.14 RAZOR TIG 200 AC/DC Manual(2) Press the torch switch and the arc will igniteacross the gap between the tungsten and work piece.Hold even distance of about 2mm gap between thetungsten and work piece to maintain the arc.(3) Release the torch switch to bring in the end ofthe welding sequence dependant of 2T or 4T triggerfunction choice

DC TIG WELDING GUIDEDC TIG WELDING30%The DC power source uses what is known as DC (direct current) in which the main electricalcomponent known as electrons flow in only one direction from the negative pole (terminal) to thepositive pole (terminal). In the DC electrical circuit there is an electrical principle at work which shouldalways be taken into account when using any DC circuit. With a DC circuit 70% of the energy (heat)is always on the positive side. This needs to be understood because it determines what terminal theTIG torch will be connected to (this rule applies to all the other forms of DC welding as well ).70%Argon gasPower sourceLowcurrentNozzleDC TIG welding is a process in which an arc is struck between a TUNGSTEN electrode and the metalwork piece. The weld area is shielded by an inert gas flow to prevent contamination of the tungsten,molten pool and weld area. When the TIG arc is struck the inert gas is ionized and superheatedchanging it’s molecular structure which converts it into a plasma stream. This plasma streamflowing 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 concentrated arc which provides the controlled melting of most metals into aweld pool. TIG welding offers the user the greatest amount of flexibility to weld the widest range ofmaterial 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 welderregulates the welding current to adjust the power of the arc. Typically thin material requires aless powerful arc with less heat to melt the material so less current (amps) is required, thickermaterial requires a more powerful arc with more heat so more current (amps) are necessaryto melt the material.HighcurrentHF ARC IGNITION FOR TIG (TUNGSTEN INERT GAS) WELDINGHF (high frequency) ignition allows the arc to be started in Tig welding without touching the tungsten to the work piece. By pressing the torch switch themachine will activate the gas flow and introduce the HF (high frequency) (high voltage) spark, this “ionizes” the air gap making it conductive allowing anarc to be created without touching the tungsten to the work piece. The gas molecules are superheated by the arc creating a stream of super heated gasthat changes the molecular structure into producing a plasma stream. This plasma stream provides heat and energy that allows us to melt and fusemetals in an inert gas shielded environment know as TIG (tungsten inert gas) welding.Gas flowGasmolecules. . . . . .HFPlasmastreamRAZOR TIG 200 AC/DC Manual 15

DC PULSE TIG WELDING GUIDEDC PULSE TIG WELDING GENERAL DESCRIPTIONPulse TIG welding is when the current output (amperage) changes between high and low current.Electronics within the welding machine create the pulse cycle. Welding is done during the high-amperage interval (this high amperage is referred to aspeak current). During the low amperage period, the arc is maintained but the current output of the arc is reduced (this low amperage is referred to as basecurrent). During pulse welding the weld pool cools during the low amperage period. This allows a lower overall heat input into the base metal. It allowsfor controlled heating and cooling periods during welding providing better control of heat input, weld penetration, operator control and weld appearance.There are 4 variables within the pulse cycle: Peak Current - Base Current - Pulse Frequency - Pulse WidthSetting and manipulation of these variables will determine the nature of the weld current output and is at the discretion of the operator.Peak Current is the main welding current (amps) set to melt the material being welded and works much the same as setting maximum amperage valuesfor regular DC TIG: as a guide use 30-40 amps for every 1mm of material thickness.Base Current is the set level of background current (amps) which cools the weld puddle and affects overall heat input. Background Amps is a percentageof peak amperage. As a rule, use enough background current to reduce the weld 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 percent of peak amperage.Pulse Frequency is the control of the amount of times per second (Hz) that the welding current switches from Peak Current to Base Current. DC PulseTIG frequency generally ranges from 20 to 300 HZ depending on the job application. Control of the pulse frequency also determines the appearance ofthe weld.Pulse Width is the control of the percentage of time during one pulsing cycle the power source spends at the peak current (main amperage). Example iswith the Pulse Width set at 80 percent and a rate of 1 pulse per second (PPS), the machine will spend 80% of the pulse at peak amperage and 20% at thebase current. Increasing the pulse width percentage adds more heat to the job, while decreasing pulse width percentage reduces heatCurrentpeakbackgroundONOFFTimeDC Pulse Tig welding allows faster welding speeds with better control of the heat input to the job, reducing the heat input minimising distortion andwarping of the work and is of particular advantage in the welding of thin stainless steel and carbon steel applications. The high pulse frequency capabilityof the advanced inverter agitates the weld puddle and allows you to move quickly without transferring too much heat to the surrounding metal. Pulsingalso constricts and focuses the arc thus increasing arc stability, penetration and travel speeds.high frequencypulsing16 RAZOR TIG 200 AC/DC Manualno pulsehigh frequency pulsingno pulse

DC PULSE TIG SETUPDC PULSE TIG WELDING SET UP PROCEDUREThhis machine has digital pulse frequency control. All the parameters for DC Pulse Tig welding - Peak Amp, Base Amp, Pulse Frequency and Pulse Widthare easy to set via the digital control panel.EXAMPLE OF PULSE DC TIG WELDING - SETUP PARAMETERS:Material Stainless

warranty 2 safety 4 razor tig 200 ac/dc features 8 razor tig 200 ac/dc technical data 9 machine parts layout 10 front panel operation 11 weld program operation 12 additional front panel operation 13 h/f dc tig setup 14 dc tig welding guide 15 dc pulse tig setup 17 manual tig welding technique 18 h/f ac tig setup 19 ac square wave frequenc