RAZOR TIG 200 ACDC Manual

OPERATING MANUAL
3 YEAR
KUM-M-RTIG200ACDC WARRANTY
(POWER SOURCE)
Please read and understand this instruction manual carefully

before the installation and operation of this equipment. © Welding Guns Of Australia PTY LTD 2019
WARRANTY
Thank you for your purchase of your RAZOR TIG 200 AC/DC Welding Machine.
We are proud of our range of plasma cutting and 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. The
expertise gained from our long involvement with inverter technology has proven to be invaluable towards the evolution and future development of our
equipment range. This experience gives us the inside knowledge on what the arc characteristics, performance and interface between man and machine
should be.
Within our team are specialist welders that have a proven history of welding knowledge and expertise, giving vital input towards ensuring that our
machines deliver control and performance to the utmost professional level.
We employ an expert team of professional sales, marketing and technical personnel that provide us with market trends, market feedback and customer
comments and requirements. 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.
UNIMIG welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1, guaranteeing you electrical safety and performance.
WARRANTY
• 3 Years from date of purchase.
• Welding Guns Of Australia PTY LTD Ltd warranties all goods as specified by the manufacturer of those goods.
• This Warranty does not cover freight or goods that have been interfered with.
• All goods in question must be repaired by an authorised repair agent as appointed by this company.
• Warranty does not cover abuse, misuse, accident, theft, general wear and tear.
• New product will not be supplied unless Welding Guns Of Australia PTY LTD 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.unimig.com.au/warranty-registration/ or at the back of this manual.
REGISTER YOUR MACHINE ONLINE TO RECEIVE AN

ADDITIONAL 6 MONTHS ON YOUR WARRANTY
Visit unimig.com.au/warranty-registration/ to register your machine.
2 | RAZOR TIG 200 AC/DC Manual

CONTENTS
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 FREQUENCY CONTROL 20
AC TIG WELDING GUIDE 21
AC PULSE TIG SETUP 23
TUNGSTEN ELECTRODES 25
MMA (STICK) WELDING SET UP 28
MMA (STICK) WELDING GUIDE 29
T2 TIG TORCH & SPARES 31
T2 TIG TORCH TUNGSTEN ELECTRODES 33
TIG WELDING TROUBLE SHOOTING 34
MMA (STICK) WELDING TROUBLE SHOOTING 35
WARRANTY TERMS 36
NOTES 39
RAZOR TIG 200 AC/DC Manual | 3

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.
Machine Operating Safety
• Do not switch the function modes while the machine is operating. Switching of the function modes during welding can damage the
machine. Damage caused in this manner will not be covered under warranty.
• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing should the electrode be in
contact with the work piece.
• Operators should be trained and or qualified.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. In MIG/
MAG welding, the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is dangerous.
• Connect the primary input cable according to Australian and New Zealand standards and regulations.
• Avoid all contact with live electrical parts of the welding/cutting circuit, electrodes and wires with bare hands.
• The operator must wear dry welding gloves while he/she performs the welding/cutting task.
• The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable 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 health. Welding
produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding/cutting fumes and gases.
• In confined or heavy fume environments always wear an approved air-supplied respirator.
• Welding/cutting fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.
• Do not weld/cut in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapours to
form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic fumes when welded/cut. Do
not weld/cut these materials unless the area is very well ventilated, and or wearing an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding/cutting process produce intense visible and invisible ultraviolet
and infrared rays that can burn eyes and skin.

Always wear a welding helmet with correct shade of filter lens and suitable protective clothing including welding gloves whilst the
welding/cutting operation is performed.
• Measures should be taken to protect people in or near the surrounding working area. Use protective screens or barriers to protect
others from flash,glare and sparks; warn others not to watch the arc.

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 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.
• The welding/cutting sparks & spatter may cause fire, therefore remove any flammable materials well away from the working area.
Cover flammable materials and containers with approved covers if unable to be moved from the welding/cutting area.
• Do not weld/cut on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to the required
Safety Standards to insure that flammable or toxic vapours and substances are totally removed, these can cause an explosion even
though the vessel has been “cleaned”. Vent hollow castings or containers before heating, cutting or welding. They may explode.
• Do not weld/cut where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)
• Have a fire extinguisher nearby and know how to use it. Be alert that welding/cutting sparks and hot materials from welding/cutting
can easily go through small cracks and openings to adjacent areas. Be aware that welding/cutting on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders 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 drape welding cables over the cylinder.
• Never weld/cut on a pressurised gas cylinder, it will explode and kill you.
• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.
Gas build up. The build up of gas can causes a toxic environment, deplete the oxygen content in the air resulting in death or injury. Many
gases use in welding/cutting are invisible and odourless.
• Shut off shielding gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.
Electronic magnetic fields. MAGNETIC FIELDS can affect Implanted Medical Devices.
• Wearers of Pacemakers and other Implanted Medical Devices should keep away.
• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near any electric welding,
cutting or heating operation.

Noise can damage hearing. Noise from some processes or equipment can damage hearing.
• Wear approved ear protection if noise level is high.
Hot parts. Items being welded/cut generate and hold high heat and can cause severe burns.
o not touch hot parts with bare hands. Allow a cooling period before working on the welding/cutting gun. Use insulated welding gloves
D
and clothing to handle hot parts and prevent burns.

SAFETY
CAUTION
1. Working Environment.
i. 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.
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 heat
generated by this equipment during the welding/cutting operation. Important: Maintain good ventilation of the louvres of this equipment. The
minimum distance between this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is of critical
importance 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 the
Thermal Overload Switch will be activated and the machine will cease to operate. Under this circumstance, leave the machine switched on to
keep the built-in fan working to bring down the temperature inside the equipment. The machine will be ready for use again when the internal
temperature 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 voltage
compensation, which enables the maintaining of the voltage 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, damp, or corrosive air is damaging to the welding/cutting machine. In order to prevent any possible failure or fault of this
welding/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 the
machine has been modified, attempt to take apart the machine or open the factory-made sealing of the machine without the consent of an authorized
representative of the manufacturer.
TROUBLE SHOOTING
Caution: Only qualified technicians are authorized to undertake the repair of this welding/cutting equipment. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed in this manual.

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. 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 towards
zero 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 an
extended 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 check
after 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 leakage
point.
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 the
cylinder 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 for
the loss of any gas.

RAZOR TIG 200 AC/DC FEATURES
3 YEAR
WARRANTY
(POWER SOURCE)
FEATURES OVERVIEW
• 15 AMP Plug The RAZOR TIG 200 AC/DC is the perfect AC/DC TIG & STICK Welder for professional
• AC/DC H/F TIG & PULSE TIG welder wanting both AC and DC TIG welding capabilities. Fitted with a 15 AMP Plug,
this machine is suited to light to medium industrial work.
-- Pre Gas 0.1 - 3.0 sec
The RAZOR TIG 200 AC/DC allows for full control over the TIG welding process to
-- Start Amperage 10 - 200A
ensure you can maximise your results from start to finish. Controllable parameters
-- Up Slope 0 - 10 sec include Pre Gas Time, Start Current, Up Slope and Down Slope Time, Finish Current
-- Peak Amp 10 - 200A Level and Post Gas Time, among many others.
-- AC Square Wave 20 - 250Hz The all-new ARC TORCHOLOGY T2 TIG Torch comes standard with the RAZOR TIG
-- AC Balance Control ±10 200 AC/DC, offering up to 30% more power and longer consumable life-cycles. A
Remote Foot Control (UTJRFC-4) can also be plugged into the machine for even more
-- Down Slope 0 - 15 sec
versatility.
-- Adjustable Finish Amperage 10 - 200A
With all of these features packed into an compact package, the RAZOR TIG 200 AC/
-- Post Gas 0.5 - 15.0 sec
DC is a must-have for any professional welder or TIG enthusiast.
• STICK (MMA) with ARC FORCE
• Thermal overload protection MACHINE 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 Manual

RAZOR TIG 200 AC/DC TECHNICAL DATA
TECHNICAL DATA STICK SPECIFICATIONS

MACHINE RAZOR TIG 200 AC/DC STICK WELDING CURRENT RANGE 10-160A
SKU KUM-M-RTIG200ACDC STICK DUTY CYCLE @ 40°C 30% @ 160A
PRIMARY INPUT VOLTAGE 240V Single Phase STICK ELECTRODE RANGE 2.5-4.0mm
SUPPLY PLUG 15 AMP STICK WELDING THICKNESS

2mm - 12mm
RANGE
RATED INPUT POWER (kVA) 6.0
ARC FORCE 0-40
Ieff (A) 15.0
Imax (A) 29.0

SIZE & WEIGHT
DIMENSIONS (mm) 426x162x326mm
RATED OUTPUT 10-200A/18.0V
WEIGHT (kg) 10kg
NO LOAD VOLTAGE (V) 9-68
PROTECTION CLASS IP21S MACHINE FEATURES

INSULATION CLASS F VRD Yes
POWER FACTOR 0.7 FOOT CONTROL READY Yes (UTJCFC-4)
MINIMUM GENERATOR (kVA) 9.0 CRATER CURRENT CONTROL Yes
DINSE CONNECTOR 35/50 THERMAL OVERLOAD

Yes
PROTECTION
STANDARD AS/NZ60974-1
Mild Steel, Stainless Steel, Cast Iron,
WELDS Silicon Bronze, Copper, Aluminium, Zinc
Alloys
WARRANTY (Years) 3
TIG SPECIFICATIONS
TIG FUNCTION TYPE AC/DC HF TIG & AC/DC Pulse
TIG WELDING CURRENT RANGE 10-200A
TIG DUTY CYCLE @ 40°C 25% @ 200A
TIG WELDING THICKNESS RANGE 1mm - 8mm
AC/DC TIG PARAMETERS

PRE GAS 0.1-3.0s
START AMP 10-200A
UP SLOPE 0-10s
PEAK AMP 10-200A
AC SQUARE WAVE 20-250Hz
AC BALANCE CONTROL ±10
DOWN SLOPE 0-15s
FINISH AMP 10-200A
POST GAS 0.5-15.0s
PULSE FREQUENCY 0.2-200Hz
PULSE WIDTH 10-90%
SPOT 0.5-10s

MACHINE PARTS LAYOUT
FRONT PANEL LAYOUT

1. Weld Function Selector
8
2. 2T / 4T / Spot Selector
7 3. Positive Output Terminal
1
2 4. Negative Output Terminal
5. Quick Lock Gas Connector

3 6. Torch Switch - Remote Connector
7. Encoder Knob
8. Weld Cycle Display
4 6
5
9
BACK PANEL LAYOUT
9. Power Switch
10 10. Mains Power Input Cable
11. Fan
11
12. Inlet Gas Connector
12

FRONT PANEL OPERATION
Mode Selector
Enables selection of required welding mode:
• AC TIG
• AC PULSE TIG
• DC TIG
• DC PULSE TIG
• DC MMA (Stick)
Torch Switch Mode Selector

Controls 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 control
of 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 sequence
for the period of time set using the spot timer.
Encoder Knob
Provides 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.

WELD PROGRAM OPERATION
Arc Force Spot AC Hz Pulse Hz % Pulse

4 10
12 3 6 11
Base
Peak Amp
2 Amp 7
Start
5 Finish
1 Amp Amp 8
9
AC Balance
1. Pre Gas Timer 10. 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
2. Start Amp -) during AC TIG welding. (20-250 Hz)
• Provides selection for the amount of amps required at the start of the weld.
(5 - 160 AMP)
11. Pulse Hz / % Pulse
• The Pulse Hz / % Pulse combines two functions under the same section. Upon
3. Up Slope Time first illuminating, the display will refer to he Pulse Hz value. Push the Encoder Knob
once more to display the % Pulse value.
• Sets the transition time from Start Amperage to Welding Amperage. (0-10s)
PULSE HZ
4. Peak Amp • Provides selection of the pulse frequency of the welding output current. Allows
adjustment of frequency that the output current transistions from Peak Amp to
• Provides selection for the Maximum Welding Amperage required during welding. Base Amp. (0.02-200 Hz)
(5 - 180 AMP)
% PULSE
5. Base Amp • Provides selection of the on time ratio of the Peak Amp during the pulse welding
• Provides selection for the Base Amperage during the Pulse Welding cycle. cycle (Pulse Width). Allows adjustment of the % of time that the Peak Amp is on
(5-180 AMP) during each pulse cycle. (10-90%)
6. Down Slope Time 12. 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 TIG
Mode, and SPOT is selected from the Torch Switch Mode Slector, the section will
refer 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. SPOT
(5-180 AMP) • Provides selection of a pre-set time period for welding current output. Allows
adjustment of the time that machine will deliver amperage output from trigger
8. Post Gas Timer activation. (0.5-10s)
• Provides selection for continued gas flow time at the end of the welding after the ARC FORCE
arc is out. (0.5-15s)
• 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)
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 during
AC TIG welding. (-5 to +5)

ADDITIONAL FRONT PANEL OPERATION
Remote
The remote icon illuminates when the remote function is active.
• Remote Hand Control: Press the torch switch and hold for 5 seconds the icon will
illuminate when remote function is activated.
• Remote Foot Control: Remote function will become active when the foot control
is connected.
Tungsten electrode Ømm

• For selection of Tungsten electrode and MMA electrode diameter. (Value is mm)
Parameter Warning
The warning parameter icon illuminates when the the weld parameter settings do not
match the electrode size selection.
The machine will still function but it is a warning to the operator that the weld
parameters chosen are outside the generally accepted capabilities of the electrode
size selected. For example excessive amperage selected may overheat and destroy
the tungsten electrode.

H/F DC TIG SETUP
DC TIG PARAMETERS
5
SELECTION:
i. Select DC TIG
ii. Set Tungsten Diameter
iii. Set Pre-Gas Time 6
iv. Set Start Amps
v. Set Up Slope Time
vi. Set Peak Amp 4

1
vii. Set Down Slope
viii. Set Finish Amp 2
ix. Set Post Gas

3
1. Connect the TIG Torch connector to the negative terminal and tighten it. 6. Connect the gas line to the quick lock gas inlet connector at the rear of
the machine. Check for gas leaks - Welding Guns of Australia PTY LTD
2. Insert the torch gas connector into the quick lock gas receptacle.
nor it’s representatives will be responsible for any gas loss.
3. Connect the torch switch remote lead into the torch remote socket.
7. Switch on the machine using the On/Off switch at the rear of the
4. Connect the Earth Cable connector into the positive terminal and machine.
tighten it.
8. Set the weld parameters using the front panel
5. Connect gas line to Gas Regulator and connect the gas regulator to
the Gas Cylinder. Slowly open the valve on the gas cylinder and set gas
flow to the required rate.
Weld start procedure for HF DC TIG welding
(1) Lay the outside edge of the Gas Cup on the work (2) Press the torch switch and the arc will ignite (3) Release the torch switch to bring in the end of
piece with the Tungsten Electrode 1- 3mm from the across the gap between the tungsten and work piece. the welding sequence dependant of 2T or 4T trigger
work piece. Hold even distance of about 2mm gap between the function choice
tungsten and work piece to maintain the arc.

DC TIG WELDING GUIDE
DC TIG WELDING
30% 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. 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 the
TIG torch will be connected to (this rule applies to all the other forms of DC welding as well ).
70%
Argon gas
DC TIG welding is a process in which an arc is struck between a TUNGSTEN electrode and the metal
work 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 superheated
changing it’s molecular structure which converts it into a plasma stream. This plasma stream
Power source Nozzle 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 concentrated arc which provides the controlled melting of most metals into a
weld pool. TIG welding offers the user the greatest amount of flexibility to weld the widest range of
material 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 welder
regulates the welding current to adjust the power of the arc. Typically thin material requires a
less powerful arc with less heat to melt the material so less current (amps) is required, thicker
High
material requires a more powerful arc with more heat so more current (amps) are necessary
Low current
current to melt the material.
HF ARC IGNITION FOR TIG (TUNGSTEN INERT GAS) WELDING

HF (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 the
machine will activate the gas flow and introduce the HF (high frequency) (high voltage) spark, this “ionizes” the air gap making it conductive allowing an
arc 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 gas
that changes the molecular structure into producing a plasma stream. This plasma stream provides heat and energy that allows us to melt and fuse
metals in an inert gas shielded environment know as TIG (tungsten inert gas) welding.
Gas
Gas flow
HF Plasma
molecules . .
.... . .. stream
.. .. .

DC PULSE TIG WELDING GUIDE
DC PULSE TIG WELDING GENERAL DESCRIPTION

Pulse 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 as
peak 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 base
current). During pulse welding the weld pool cools during the low amperage period. This allows a lower overall heat input into the base metal. It allows
for 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 Width
Setting 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 values
for 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 percentage
of 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 Pulse
TIG frequency generally ranges from 20 to 300 HZ depending on the job application. Control of the pulse frequency also determines the appearance of
the 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 is
with 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 the
base current. Increasing the pulse width percentage adds more heat to the job, while decreasing pulse width percentage reduces heat
Current
peak
background
Time
ON OFF
DC Pulse Tig welding allows faster welding speeds with better control of the heat input to the job, reducing the heat input minimising distortion and
warping of the work and is of particular advantage in the welding of thin stainless steel and carbon steel applications. The high pulse frequency capability
of the advanced inverter agitates the weld puddle and allows you to move quickly without transferring too much heat to the surrounding metal. Pulsing
also constricts and focuses the arc thus increasing arc stability, penetration and travel speeds.
high frequency no pulse

pulsing no pulse high frequency pulsing

DC PULSE TIG SETUP
DC PULSE TIG WELDING SET UP PROCEDURE

Thhis machine has digital pulse frequency control. All the parameters for DC Pulse Tig welding - Peak Amp, Base Amp, Pulse Frequency and Pulse Width
are easy to set via the digital control panel.
EXAMPLE OF PULSE DC TIG WELDING - SETUP PARAMETERS:

Material = Stainless Steel x 2.0mm / Tungsten Electrode = 1.6mm 2% Thoriated / Gas = Argon
The following steps are a guide as a starting point for you to set the machine up in Pulse mode to give an example of welding in Pulse mode function.
You can experiment by changing any of the variables to see what effect it has over the welding and what the end result can be, but it is suggested to
change only one variable at a time and then check the welding to see what the result is, in this way you acquire a better understanding of how each
variable affects the welding current.
100
Base
Peak Amp
Amp
Start Finish
Amp Amp
AC Balance
1. Select DC Pulse by pushing selector button 2. Select Peak Amp by pressing the encoder 3. Rotate the Encoder Knob to set the Peak
to cycle through to illuminate DC Pulse icon. knob to cycle through to illuminate the Peak Amp at 100A, it will show in the digital
Amp Icon. display. (Range is 5-180 Amps)
Peak
Amp
100A
30
Base
Peak Amp
Amp
Start Finish
Amp Amp
Base
AC Balance
Amp
30A
4. Select the Base Amp by pushing the 5. Rotate the Encoder Knob to set the Base
encoder knob to cycle through to illuminate Amp at 30A - (Range is 5-180 Amps)
the Base Amp Icon.
Time = 1 Second (hz)
Peak Peak
Amp Amp
2
100A 100A
Base
Peak Amp Base Base
Amp Amp Amp
6. Select the Pulse Frequency
Start
by pushing the 7. Rotate the Adjustment Encoder Knob to set
Finish 30A 30A
encoder knob to cycleAmp
through to illuminate the Pulse Frequency to 2 Hz - (0.5 - 200Hz)
Amp
AC Balance
the Pulse Hz Icon.
Pulse Width
60
100A 100A
Arc Force Spot AC Hz Pulse Hz % Pulse 60%
Base
Peak Amp
Amp
8. Select the Pulse Width (on time of the Peak

Start
9. Rotate the Adjustment Encoder Knob to set
Finish 30A 30A
Amp) by pushing the Ampselector button to the PulseAmp
Width at 60% - (Range is 10 - 90%) 40%
AC Balance
cycle through to illuminate the % Pulse Icon.

MANUAL TIG WELDING TECHNIQUE
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. Similar to Oxygen 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. However, some welds combining thin materials can be accomplished without filler
metal like edge, corner, and butt joints. This is known as Fusion welding where the edges of the metal pieces are
melted together using only the heat and arc force generated by the TIG arc. Once the arc is started the torch
tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating
a weld pool of the desired size. Once the weld pool is established tilt the torch at about a 75° angle and move
smoothly and evenly along the joint while fusing the materials together.
75°
Travel direction
Form a weld pool Angle torch Move the torch slowly and
evenly forward
TIG WELDING WITH FILLER WIRE TECHNIQUE

It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld
reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld
pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size. Once
the weld pool is established tilt the torch at about a 75° angle and move smoothly and evenly along the joint. The
filler metal is introduced to the leading edge of the weld pool. The filler wire is usually held at about a 15° angle
and fed into the leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is
moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire is fed
into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward. It is
important during the welding to keep the molten end of the filler wire inside the gas shield as this protects the end
of the wire from being oxidised and contaminating the weld pool.
75°
Travel direction
15°
Form a weld pool Angle torch Add Tig filler wire
Gas shield
Retract the filler wire Move the torch forward to the front of Repeat the process
the weld pool

H/F AC TIG SETUP
AC TIG PARAMETERS
5
SELECTION:
i. Select AC TIG
ii. Set Tungsten Diameter
iii. Set Pre-Gas Time 6
iv. Set Start Amps
v. Set Up Slope Time
vi. Set Peak Amp 4

1
vii. Set AC Square Wave Frequency
viii. Set AC Balance 2
ix. Set Down Slope

3
x. Set Finish Amp
xi. Set Post Gas
1. Connect the TIG Torch connector to the negative terminal and tighten it. 6. Connect the gas line to the quick lock gas inlet connector at the rear of
the machine. Check for gas leaks - Welding Guns of Australia PTY LTD
2. Insert the torch gas connector into the quick lock gas receptacle.
nor it’s representatives will be responsible for any gas loss.
3. Connect the torch switch remote lead into the torch remote socket.
7. Switch on the machine using the On/Off switch at the rear of the
4. Connect the Earth Cable connector into the positive terminal and machine.
tighten it.
8. Set the weld parameters using the front panel
5. Connect gas line to Gas Regulator and connect the gas regulator to
the Gas Cylinder. Slowly open the valve on the gas cylinder and set gas
flow to the required rate.
Weld start procedure for HF DC TIG welding
(1) Lay the outside edge of the Gas Cup on the work (2) Press the torch switch and the arc will ignite (3) Release the torch switch to bring in the end of
piece with the Tungsten Electrode 1- 3mm from the across the gap between the tungsten and work piece. the welding sequence dependant of 2T or 4T trigger
work piece. Hold even distance of about 2mm gap between the function choice.
tungsten and work piece to maintain the arc.

AC SQUARE WAVE FREQUENCY
CONTROL
It is possible with this machine to adjust the frequency of the AC Square Wave output. It means that the amount of time that it takes the AC square wave to complete a full
cycle switch from positive (+) to negative (-) can be adjusted from 20Hz (20 times per second) to 200Hz
Increasing frequency (Hz) causes the current to change direction more often, which means that it spends less time per cycle in both DC electrode negative and DC electrode
positive mode. By spending less time at each polarity, the arc cone has less time to expand.
A higher frequency produces a narrower arc cone producing an arc that is tighter with more focus at the exact spot the electrode is pointing. The result is improved arc stability,
ideal for fillet welds and other fit ups requiring precise penetration. Decreasing the frequency softens the arc and broadens the weld pool producing a wider bead, produces
good overall penetration and ideal for build up applications.
AC Square Wave Hz
Current
Increasing Square Wave Frequency
Slower AC Square Wave Hz

Slower AC Square Wave Hz
Wider Cleaning
Action
Wider Weld Bead

Current
Wider Arc Broader Weld Pool
Faster AC Square Wave Hz

Faster AC Square Wave Hz
Narrower Cleaning
Action
Narrower Weld Bead

Current Faster Weld Speed
Narrow Arc Narrower Weld Pool

AC TIG WELDING GUIDE
AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminium, Magnesium and Aluminium Alloys. These materials have an insulating
surface oxide layer that melts at a higher temperature than the base metal making it difficult to weld the base metal if the oxides are not removed. AC
welding current is ideal because the nature of the AC wave form assists in breaking the surface oxide layer.
AC (alternating current) has a current cycle that flows from + (direct) polarity to - (reverse) polarity. The reversing of the polarity breaks the surface oxide
while the direct polarity melts the base material.
direct polarity
current
reverse polarity
There are inherent problems that come with AC TIG arc rectification, arc stutter, arc wandering and arc stoppage. These problems typically occur during
the transition between + and - cycles. The current is less (30%) during the half of the cycle when the electrode is positive and there is a resistance of the
electron flow during this half cycle (rectification). The lack of current flow during this half cycle makes the AC arc unstable.
direct polarity 30% 30%

current
reverse polarity
To overcome this lack of flow during one half of the cycle, a high-frequency (HF) voltage is generated and fed into the welding circuit. The HF maintains
the arc stability during the half cycle when the electrode is positive.
+ HF
_ direct polarity 30% 30%

current
reverse polarity
High-frequency voltage flows continually in the welding circuit and keeps the shielding arc in the welding area in an ionized state. When the arc is ionized
the arc is maintained during the half of the cycle when the electrode is positive. However while the arc is maintained less current flows during this half of
the AC cycle, producing an unbalanced wave.

AC TIG WELDING GUIDE
In older machines, a balanced current output wave was achieved using a large number of capacitors in series or a battery in the welding circuit. Modern
TIG power sources use electronics to create and maintain a balanced wave and now most AC TIG power sources produce a square wave current output.
direct polarity
current
reverse polarity
A square wave power supply can change the current from electrode + positive to electrode - negative very quickly. This produces high voltage as the current
switches polarities allowing the arc to restart easily. The arc can be maintained without the use of high-frequency or any other arc stabilising methods.
LESS POSITIVE MORE POSITIVE
EVEN BALANCE
BALANCE BALANCE
BALANCED SQUARE WAVE FORM
direct polarity
current
reverse polarity
Even Penetration - Stable Arc More Penetration - Faster Welding Less Penetration - Oxide Cleaning
More Electrode Capacity Less Electrode Capacity
The output current and voltage are controlled electronically so the amount of current electrode positive and the amount of current electrode negative
can be adjusted. This allows the welder to adjust the amount of cleaning and the amount of penetration. This is achieved electronically by adjusting
the balance control dial on the welding machine. More current flow from the + direct polarity produces stronger arc energy and current flow from the
tungsten and is good for removing the oxidized surface of the work piece. However too much + current flow can drive too much energy to the tungsten
causing it to overheat and melt the tungsten electrode.
LESS POSITIVE MORE POSITIVE

E
BALANCE BALANCE Balance Adjusted for More Penetration - Cooler Tungsten
25%
direct polarity
current
reverse polarity
ble Arc More Penetration - Faster Welding Less Penetration - Oxide Cleaning
More Electrode Capacity Less Electrode Capacity
MORE POSITIVE
BALANCE Balance Adjusted for More Oxide Cleansing Action - Hotter Tungsten
25%
direct polarity
current
reverse polarity
ng Less Penetration - Oxide Cleaning

Less Electrode Capacity

AC PULSE TIG SETUP
AC PULSE TIG WELDING SET UP PROCEDURE

Thhis machine has digital pulse frequency control. All the parameters for AC Pulse TIG welding - Peak Amp, Base Amp, Pulse Frequency and Pulse Width
are easy to set via the digital control panel.
EXAMPLE OF PULSE AC TIG WELDING - SETUP PARAMETERS:

Material = Aluminium x 3.0mm / Tungsten Electrode = 2.4mm Zirconiated / Gas = Argon
The following steps are a guide as a starting point for you to set the machine up in Pulse mode to give an example of welding in Pulse mode function.
You can experiment by changing any of the variables to see what effect it has over the welding and what the end result can be, but it is suggested to
change only one variable at a time and then check the welding to see what the result is, in this way you acquire a better understanding of how each
variable affects the welding current.
150
Base
Peak Amp
Amp
Start Finish
Amp Amp
AC Balance
1. Select AC Pulse by pushing selector button 2. Select Peak Amp by pressing the encoder 3. Rotate the Encoder Knob to set the Peak
to cycle through to illuminate DC Pulse icon. knob to cycle through to illuminate the Peak Amp at 150A, it will show in the digital
Amp Icon. display. (Range is 5-180 Amps)
Peak
Amp
150A
60
Base
Peak Amp
Amp
Start Finish
Amp Amp
Base
AC Balance
Amp
60A
4. Select the Base Amp by pushing the 5. Rotate the Encoder Knob to set the Base
encoder knob to cycle through to illuminate Amp at 60A - (Range is 5-180 Amps)
the Base Amp Icon.
Time = 1 Second (hz)
Peak Peak
Amp Amp
2
150A 150A
Base
Peak Amp Base Base
Amp Amp Amp
6. Select the Pulse Frequency
Start
by pushing the 7. Rotate the Adjustment Encoder Knob to set
Finish 60A 60A
encoder knob to cycleAmp
through to illuminate the Pulse Frequency to 2 Hz - (0.5 - 200Hz)
Amp
AC Balance
the Pulse Hz Icon.
Pulse Width
60
150A 150A
Arc Force Spot AC Hz Pulse Hz % Pulse 60%
Base
Peak Amp
Amp
8. Select the Pulse Width (on time of the Peak

Start
9. Rotate the Adjustment Encoder Knob to set
Finish 60A 60A
Amp) by pushing the Ampselector button to the PulseAmp
Width at 60% - (Range is 10 - 90%) 40%
AC Balance
cycle through to illuminate the % Pulse Icon.

CONNECTION AND OPERATION OF
THE REMOTE FOOT CONTROL UTJRFC-4
1. Connect the remote control 7 pin plug 2. Select 2T trigger function by pushing the 3. Activate by holding down the foot pedal for
from the Tig Torch switch lead to the 7 pin button to cycle through until the 2T icon 5 seconds, the remote icon will illuminate.
remote receptacle on the front panel of the illuminates. Up & down travel of the foot pedal will adjust
machine. the welding amperage during welding. The
side potentiometer knob will allow manual
set and adjustment.

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. Choosing the correct tungsten depends on the material being welded, the amount of amps required and whether you are using AC or DC
welding current.
Tungsten electrodes are colour-coded at the end for easy identification.
Below are the most commonly used tungsten electrodes found in the New Zealand and Australian market.
THORIATED
Thoriated tungsten electrodes (AWS classifi cation EWTh-2) contain a minimum of 97.30 percent tungsten and 1.70 to 2.20 percent thorium and are
called 2 percent thoriated. They are the most commonly used electrodes today and are preferred for their longevity and ease of use. Thorium however
is a low-level radioactive hazard and many users have switched to other alternatives. Regarding the radioactivity, thorium is an alpha emitter but when
it is enclosed in a tungsten matrix the risks are negligible. Thoriated tungsten should not get in contact with open cuts or wounds. The more signifi cant
danger to welders can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours during welding or from ingestion of
material/dust in the grinding of the tungsten. Follow the manufacturer’s warnings, instructions, and the Material Safety Data Sheet (MSDS) for its use.
E3 (COLOR CODE: PURPLE)

E3 tungsten electrodes (AWS classifi cation EWG) contain a minimum of 98% percent tungsten and up to 1.5 percent Lanthanum and small percentages
of Zirconium and Yttrium they are called E3 Tungsten. E3 Tungsten Electrodes provide conductivity similar to that of thoriated electrodes. Typically,
this means that E3 Tungsten Electrodes are exchangeable with thoriated electrodes without requiring signifi cant welding process changes. E3 deliver
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, E3 Tungsten Electrodes run cooler than
2% thoriated tungsten, thereby extending overall tip lifetime. E3 Tungsten Electrodes work well on AC or DC. They can be used DC electrode positive or
negative with a pointed end, or balled for use with AC power sources.
CERIATED (COLOR CODE: ORANGE)

Ceriated tungsten electrodes (AWS classifi cation EWCe-2) contain a minimum of 97.30 percent tungsten and 1.80 to 2.20 percent cerium and are
referred to as 2 percent ceriated. Ceriated tungstens perform best in DC welding at low current settings. They have excellent arc starts at low amperages
and become popular in such applications as orbital tube welding, thin sheet metal work. They are best used to weld carbon steel, stainless steel, nickel
alloys, and titanium, and in some cases it can replace 2 percent thoriated electrodes. Ceriated tungsten is best suited for lower amperages it should last
longer than Thoriated tungsten higher amperage applications are best left to Thoriated or Lanthanated tungsten.
LANTHANATED (COLOR CODE: GOLD)

Lanthanated tungsten electrodes (AWS classifi cation EWLa-1.5) contain a minimum of 97.80 percent tungsten and 1.30 percent to 1.70 percent
lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent arc starting, a low burn off rate, good arc stability, and excellent
re-ignition characteristics. Lanthanated tungstens also share the conductivity characteristics of 2 percent thoriated tungsten. Lanthanated tungsten
electrodes are ideal if you want to optimise your welding capabilities. They work well on AC or DC electrode negative with a pointed end, or they can be
balled for use with AC sine wave power sources. Lanthanated tungsten maintains a sharpened point well, which is an advantage for welding steel and
stainless steel on DC or AC from square wave power sources.
ZIRCONIATED (COLOR CODE: WHITE)

Zirconiated tungsten electrodes (AWS classifi cation EWZr-1) contain a minimum of 99.10 percent tungsten and 0.15 to 0.40 percent zirconium. Most
commonly used for AC welding Zirconiated tungsten produces a very stable arc and is resistant to tungsten spitting. It is ideal for AC welding because
it retains a balled tip and has a high resistance to contamination. Its current-carrying capacity is equal to or greater than that of thoriated tungsten.
Zirconiated tungsten is not recommended for DC welding.

TUNGSTEN ELECTRODES
TUNGSTEN ELECTRODES RATING FOR WELDING CURRENTS

DC Current Amps Torch Negative AC Current Amps Un-Balanced Wave AC Current Amps Balanced Wave
Tungsten Diameter (mm)
2% Thoriated 0.8% Zirconiated 0.8% Zirconiated
1.0mm 15 - 80 15 - 80 20 - 60
1.6mm 70 -150 70 - 150 60 - 120
2.4mm 150- 250 140 - 235 100 - 180
3.2mm 250 - 400 225 - 325 160 - 250
4.0mm 400 - 500 300 - 400 200 - 320
Tungsten Diameter (mm) Diameter at the Tip (mm) Constant Included Angle (°) Current Range (Amps) Current Range (Pulsed Amps)
1.0mm 0.25 20 11079 22037
1.6mm 0.5 25 18476 05 - 100
1.6mm 0.8 30 25842 10 - 140
2.4mm 0.8 35 33208 12 - 180
2.4mm 1.1 45 15 - 150 15 - 250
3.2mm 1.1 60 20 - 200 20 - 300
3.2mm 1.5 90 25 - 250 25 - 350
TUNGSTEN PREPARATION
Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a 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 contribute to weld inconsistency and weld defects.
Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel. Tungsten electrodes are manufactured with the molecular structure
of 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.
grind longitudinal on the don’t grind across

grinding wheel the grinding wheel
ELECTRODE TIP/FLAT
The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection of tip/flat size will balance the need
for several advantages. The bigger the flat, the more likely arc wander will occur and the more difficult it will be to arc start. However, increasing the flat
to the maximum level that still allows arc start and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders
still grind electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from melting at the tip and the
possibility of the point falling off into the weld pool.
2.5 times tungsten diameter
flat tip pointed tip

TUNGSTEN ELECTRODES
ELECTRODE INCLUDED ANGLE/TAPER - DC WELDING

Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a specific included angle in conjunction
with the tip/flat preparation. Different angles produce different arc shapes and offer different weld penetration capabilities. In general, blunter electrodes
that have a larger included angle provide the following benefits:
• Last Longer
• Have better weld penetration

flat spot diameter
• Have a narrower arc shape
• Can handle more amperage without eroding.
Sharper electrodes with smaller included angle provide: included angle

• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration increases and bead width decreases.
TUNGSTEN PREPARATION AC WELDING

To obtain full current capacity from a pure or zirconiated tungsten electrode when used with AC current output the electrode is not ground to a point.
The welding during positive polarity melts the point of the tungsten that becomes rounded. The ball shape formed at the end of the tungsten is desirable
because it reduces current rectification and allows the arc to flow more easily.
balled tip
Arc shape from balled Arc shape from ground

tungsten AC welding pointed tungsten DC welding
SAFETY WITH TUNGSTEN ELECTRODES

Tungsten welding electrodes should never be manually ground on an abrasive belt or wheel (particularly silicone carbide). Always use diamond wheels
when grinding and cutting tungstens. The risk of injury when hand (manually) grinding a very hard brittle material like tungsten is quite high. It is
important to always follow standard safety guidelines when operating high speed grinding equipment.
• Wear approved safety glasses
• No loose clothing which may get caught in moving parts
• Wear protective hair covering to contain long hair
• Wear safety shoes with non-slip sole
• A vacuum system is recommended to remove tungsten, especially thorium dust
• Never operate power tools when tired, intoxicated or when taking medication that causes drowsiness
The most common injuries to the manual tungsten electrode grinder are eye and finger related. Holding and grinding the tungsten electrode by hand has
resulted in burned fingers, laceration to fingers and splintered tungsten electrodes in hand or fingers. Eye injury generally occurs from manually grinding
tungsten electrodes without a safety shield or safety glasses. Small slivers of tungsten electrode may become stuck in the operator’s eye.

MMA (STICK) WELDING SET UP
1. Turn the power source on, and select ‘MMA’ from the weld process
selector.
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. However
various electrodes require a different polarity for optimum results 1
and careful attention should be paid to the polarity, refer to the
electrode manufacturers information for the correct polarity.
2 (+)
DC+ Electrode connected to output socket.
DC- Electrode connected to output socket.

2 (-)
3b 3a
(3a) Push the encoder knob until ‘Peak Amp’ illuminates, (4) Place the electrode into the electrode holder and (5) Strike the electrode against the work-piece to
then turn the knob to set the desired amperage. clamp tight. create an arc and hold the electrode steady to maintain
(3b) Push the encoder knob until ‘Arc Force’ illuminates, the arc.
then turn the knob to set the desired Arc Force Vale
(6)Hold the electrode slightly above the work (7) To ﬁnish the weld, break the arc by quickly snapping (8) Wait for the weld to cool and carefully chip away
maintaining the arc while travelling at an even speed. the electrode away from the work piece. the slag to reveal the weld metal below.

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 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 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. The electrode core itself acts as filler material the residue from the flux that forms a slag covering over the
weld metal must be chipped away after welding.
Core wire
+
Flux coating
Gas shield from flux melt

Power Source
Arc with core wire melt
Flux residue forms slag cover
Weld metal
▬
Core wire
Flux coating • The arc is initiated by momentarily touching the electrode to the base metal.
• The heat of the arc melts the surface of the base metal to form a molten pool at the end of the
electrode.
Base metal • The melted 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
Manual metal arc ( stick) electrodes have a solid metal wire core and a flux coating. These electrodes
are identified by the wire diameter and by a series of letters and numbers. The letters and numbers
identify the metal alloy and the intended use of the electrode.
Protective gas The Metal Wire Core works as conductor of the current that maintains the arc. The core wire melts
and is deposited into the welding pool.
Arc The covering on a shielded metal arc welding electrode is called Flux. The flux on the electrode
performs many different functions.
These include:
• Producing a protective gas around the weld area
• Providing fluxing elements and de-oxidisers
• Creating a protective slag coating over the weld as it cools
• Establishing arc characteristics
• Adding alloying elements.
Covered electrodes serve many purposes in addition to adding filler metal to the molten pool. These
additional functions are provided mainly by the covering on the electrode.
Slag
Weld pool

MMA (STICK) WELDING GUIDE
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. It is
recommend to consult your welding supplier for the correct selection of electrode.
Maximum Recommended
The size of the electrode generally depends on the thickness of the section
Average Thickness of Material being welded, and the thicker the section the larger the electrode required.
Electrode Diameter
1.0 - 2.0mm 2.5mm The table gives the maximum size of electrodes that maybe used for
various thicknesses of section based on using a general purpose type
2.0 - 5.0mm 3.2mm
6013 electrode.
5.0 - 8.0mm 4.0mm
8.0 - > mm 5.0mm
Electrode Size (ø mm) Current Range (Amps) Correct current selection for a particular job is an important factor in
arc welding. With the current set too low, difficulty is experienced in
2.5mm 60 - 100
striking and maintaining a stable arc. The electrode tends to MMA to
3.2mm 100 - 130
the work, penetration is poor and beads with a distinct rounded profile
4.0mm 130 - 165 will be deposited. Too high current is accompanied by overheating of the
5.0mm 165 - 260 electrode resulting undercut and burning through of the base metal and
producing excessive spatter. Normal current for a particular job may be
considered as the maximum, which can be used without burning through
the work, over-heating the electrode or producing a rough spattered
surface. The table shows current ranges generally recommended for a
general purpose type 6013 electrode.
ARC LENGTH
To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple rule for the proper arc length; it should
be the shortest arc that gives a good surface to the weld. An arc too long reduces penetration, produces spatter and gives a rough surface finish to the
weld. An excessively short arc will cause sticking of the electrode and result in poor quality 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 vertical up welding the angle of the
electrode should be between 80 and 90 degrees to the work piece.
TRAVEL SPEED
The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the
electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow
a rate of travel will frequently lead to arc instability,slag inclusions and poor mechanical properties.
MATERIAL AND JOINT PREPARATION

The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or any other material that will hinder the arc and
contaminate the weld material. Joint preparation will depend on the method used include sawing, punching, shearing, machining, flame cutting and
others. In all cases edges should be clean and free of any contaminates. The type of joint will be determined by the chosen application.

T2 TIG TORCH & SPARES
T2 TIG TORCH | HIGH PERFORMANCE SERIES

AIR COOLED TIG WELDING TORCH
RATING: 190A DC / 135A AC @35% DUTY CYCLE. 1.6 TO 3.2MM ELECTRODE
7 4
6
5
3
10
8
9
11
Part No.
Length 4m 8m
T2 TIG Torch T2-S1-4M-SL-GS1 T2-S1-8M-SL-GS1
Part-No Description Part-No Description

1 UM-C-T2HG T2/T3W HEAD GASKET 7 UM-C-TMK-10KP 10K POTENTIOMETER
2 UM-C-T2SN T2/T3W HEAT ZONE ISOLATOR 8 UM-C-TSPAN SPANNER
3 UM-C-T2TH-F T2 TORCH HEAD "FLEXIBLE HEAD" 9 See following page Collet Body
4 UM-C-T2LBC T2/T3W LONG BACK CAP 10 See following page Gas Lens Collet Body
5 UM-C-T2SBC T2/T3W SHORT BACK CAP 11 See following page Ceramic Cup
6 UM-C-TMS 1 BUTTON MOMENTARY

T2 TIG TORCH & SPARES
T2 FRONT END CONSUMABLES

COLLET BODY
Part-No Description Bore Size QTY
UM-C-T2CB10 T2/T3W Collet Body 1.6mm 1
GAS LENS COLLET BODY

Part-No Description Bore Size QTY
UM-C-T2GL10 T2/T3W Gas Lens Collet Body 1.6mm 1
CERAMIC CUP
Part-No Description Nozzle Bore Size QTY
UM-C-T2C04 T2/T3W Ceramic Cup #4 6mm 1
UM-C-T2C08 T2/T3W Ceramic Cup #8 12.5mm 1

T2 TIG TORCH TUNGSTEN ELECTRODES
WC20 2.0% CERIATED

TUNGSTEN ELECTRODE
Part-No Description QTY
TR0003-10 1.0mm x 175mm ceriated tungsten electrode 2.0% 10
WT20 2% THORIATED
TUNGSTEN ELECTRODE
TR0004-10 1.0mm x 175mm thoriated tungsten electrode 2% 10
E3 1.5% LANTHANUM
TUNGSTEN ELECTRODE
98% percent tungsten and up to 1.5 percent Lanthanum and small percentages of Zirconium and Yttrium

TR0005-10 1.0mm x 175mm lanthanum tungsten electrode 1.5% 10
WZ8 0.8% ZIRCONIATED

TUNGSTEN ELECTRODE
TR0006-10 1.0mm x 175mm zirconiated tungsten electrode 0.8% 10

TIG WELDING TROUBLE SHOOTING
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. Check cylinder has gas, 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.
Back cap not fitted correctly Make sure the torch back cap is fitted so that the o-ring is inside the torch body
Torch connected to DC + Connect the torch to the DC- output terminal
Incorrect tungsten being used Check and change the tungsten type if necessary
Tungsten being oxidised after weld is finished Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10 amps of weld current.
Inadequate gas flow or too much gas flow Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 6-12 l/min
flow rate. Check hoses and fittings for holes, leaks etc
Protect the welding zone from wind and drafts
2: Contaminated tungsten
Touching tungsten into the weld Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work piece 2 - 5mm
pool
Touching the filler wire to the tungsten Keep the filler wire from touching the tungsten during welding, feed the filler wire into the leading edge of the weld
pool in front of the tungsten.
3: Porosity - poor weld appearance and colour
Wrong gas / poor gas flow /gas leaks Use pure argon. Gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between
6-12 l/min. Check hoses and fittings for holes, leaks etc.,
Contaminated base metal Remove moisture and materials like paint, grease, oil, and dirt from base metal
Contaminated filler wire Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire Check the filler wire and change if necessary
4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten
Incorrect Gas Use pure Argon gas
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
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 contaminated Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long Lower torch so that the tungsten is off of the work piece 2 - 5mm
6: Arc wanders during DC welding
Poor gas flow Check and set the gas flow between 10 - 15 l/min flow rate
Incorrect arc length Lower torch so that the tungsten is off of the work piece 2 - 5mm
Tungsten incorrect or in poor condition Check that correct type of tungsten is being used. Remove 10mm from the weld end of the tungsten and re sharpen
the tungsten
Poorly prepared tungsten Grind marks should run lengthwise with tungsten, not circular. Use proper grinding method and wheel.
Contaminated base metal or filler wire Remove contaminating materials like paint, grease, oil, and dirt, including mill scale from base metal. Remove all
grease, oil, or moisture from filler metal.
7: Arc difficult to start or will not start DC welding
Incorrect machine set up Check machine set up is correct
No gas, incorrect gas flow Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted. Set the gas
flow between 10 - 15 l/min flow rate
Incorrect tungsten size or type Check and change the size and or the tungsten if required
Loose connection Check all connectors and tighten
Earth clamp not connected to work Connect the earth clamp directly to the work piece wherever possible

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
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: Porosity − small cavities or holes resulting from gas pockets in weld metal.
Arc length too long Shorten the arc length
Work piece dirty, contaminated or moisture Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal
Damp electrodes Use only dry electrodes
3: Excessive Spatter
Amperage too high Decrease the amperage or choose a larger electrode
Arc length too long Shorten the arc length
3: Weld sits on top, lack of fusion
Insufficient heat input Increase the amperage or choose a larger electrode
Work piece dirty, contaminated or moisture Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal
Poor welding technique Use the correct welding technique or seek assistance for the correct technique
4: Lack of penetration
Insufficient heat input Increase the amperage or choose a larger electrode
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
5: Excessive penetration - burn through
Excessive heat input Reduce the amperage or use a smaller electrode
Incorrect travel speed Try increasing the weld travel speed
6: Uneven weld appearance
Unsteady hand, wavering hand Use two hands where possible to steady up, practise your technique
7: Distortion − movement of base metal during welding
Excessive heat input Reduce the amperage or use a smaller electrode
Poor joint preparation and or joint design 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
7: Electrode welds with different or unusual arc characteristic
Incorrect polarity Change the polarity, check the electrode manufacturer for correct polarity

WARRANTY TERMS
Welding Guns Of Australia Pty Ltd (‘Us’, ‘We’) warrants that the following products under UNIMIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-
8SS & ROTA, supplied by Us and purchased by you from an Authorised UNIMIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA Dealer
throughout Australia are free of Material and Faulty Workmanship defects except for those products listed under ‘Warranty Exclusions’.
These terms and conditions supersede and exclude all former and other representations and arrangements relating to any warranties on these products.
WARRANTY PERIOD
We offer the following ‘Warranty Periods’ from ‘date of purchase’:
An Extended Warranty Period of 6 months total shall apply only to Machinery where offered and warranty is registered online.
UNIMIG WELDING MACHINES

UNIMIG DIY Series (Power Source Only) 2 Years (Clause 3)
UNIMIG Procraft Series (Power Source Only) 3 Years (Clause 1&3)
UNIMIG Trade Series (Power Source Only) 3 Years (Clause 1&3)
UNIMIG Trade Series SWF (Power Source / Separate Wire Feeder Only) 3 Years (Clause 1&3))
UNIMIG Workshop Series (Power Source Only) 3 Years (Clause 1&3)
UNIMIG Workshop Series SWF (Power Source / Separate Wire Feeder Only) 3 Years (Clause 1&3)
UNIMIG Jasic Inverter MIG (Power Source Only) 3 Years (Clause 3)
UNIMIG Jasic Inverter MIG SWF (Power Source / Separate Wire Feeder Only) 3 Years (Clause 3)
UNI-TIG Jasic Inverter TIG (Power Source Only) 3 Years (Clause 3)
UNIMIG Water Cooler 1 Year (Clause 3)
T&R Pulse MIG (Power Source Only) 2 Year (Clause 3)
T&R Pulse MIG SWF (Power Source / Separate Wire Feeder Only) 2 Year (Clause 3)
UNI-PLAS (Power Source Only) 3 Years (Clause 3)
UNI-PLAS Jasic Series (Power Source Only) 2 Years (Clause 3)
UNI-PLAS Site Cut Series (Power Source Only) 1 Year (Clause 3)
UNI-FLAME Gas Cutting and Welding Kits 3 Months (Clause 2&3)
UNI-FLAME Straight Line & Gas Cutting Machines (Power Source Only) 1 Year (Clause 3)
UNI-FLAME Regulators Argon/ Acetylene / Oxygen / LPG / Bobbin Flowmeter 1 Year
UNI-FLAME Automatic Welding Helmet 2 Years
UNIMIG Automatic Welding Helmets 2 Years
TECNA (Power Source Only) 1 Year (Clause 3)
HIT-8SS Automatic Carriage (Power Source Only) 1 Year (Clause 3)
ROTA 102 Rotating table 1 Year
HOTBOX Electrode Oven 1 Year
SPOTCAR 3500 1 Year (Clause 3)
TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,
INTERCONNECTING CABLES, GAS HOSE 3 Months (Clause 3)
UNIMIG VIPER RANGE 1 Year
UNIMIG VIPER MIG 185 / VIPER TIG 180 AC/DC 2 Years
(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB, and all other components, .
(Clause 2) Gas Hose, Flashbacks are subject to and covered by the Manufacturer’s Individual Warranty, Contact the manufacturer for details
(Clause 3) This only Covers Manufactures defaults on all accessories for the first three months after date of purchase.

WARRANTY TERMS
WARRANTY / RETURNS / EXCHANGES

We understand that sometimes you may need to return a product you have purchased from Welding Guns Of Australia PTY LTD Authorised Dealer
Network, to assist you, we have set out below the Welding Guns Of Australia PTY LTD Returns Policy that you should know.
Our Returns Policy includes the rights you have under the Australian Consumer Law and other relevant laws.
Your Rights under the Australian Consumer Law - Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled
to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
• You shall inspect the Goods on delivery and shall within seven (7) days of delivery (time being of the essence) notify Welding Guns Of Australia PTY
LTD of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.
• You shall also afford Welding Guns Of Australia PTY LTD the opportunity to inspect the Goods within a reasonable time following delivery if you believe
the Goods are defective in any way.
• If you shall fail to comply with these provisions the Goods shall be presumed to be free from any defect or damage. For defective Goods, which
Welding Guns Of Australia PTY LTD has agreed in writing that you are entitled to reject, Welding Guns Of Australia PTY LTD liability is limited to either (at
the Welding Guns Of Australia PTY LTD discretion) replacing the Goods or repairing the Goods except where you have acquired Goods as a consumer
within the meaning of the Trade Practices Act 1974 or the Fair Trading Acts of the relevant state or territories of Australia, and is 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. Welding Guns Of Australia PTY LTD will not be liable for Goods which have not been stored or used in a proper manner, and
d. The Goods are returned in the condition in which they were delivered and with all packaging material, brochures and instruction material in as new
condition as is reasonably possible in the circumstances.
• Welding Guns Of Australia PTY LTD Accepts no responsibility for products lost, damaged or mislaid whilst in transit
• Welding Guns Of Australia PTY LTD may (at their sole discretion) accept the return of Goods for credit but this may incur a handling fee of up to fifteen
percent (15%) of the value of the returned Goods plus any freight costs.
• Where a failure does not amount to a major failure, Welding Guns Of Australia PTY LTD is entitled to choose between providing you with a repair,
replacement or other suitable remedy.
• Your rights under the Australian Consumer Law are not limited by a defined time. However, the Australian Consumer Law does recognise that the
relevant time period can vary from product to product, depending on factors such as the nature of the product and the price. Welding Guns Of Australia
PTY LTD adopts the same approach. As you can appreciate, the type of remedy we can offer you may also vary depending on how long it takes you to return
the product to us.
MAKING A CLAIM
If you wish to make a claim under this Warranty, you should:
• Return the product to the point of purchase either in person or on a prepaid courier; or
• Contact Us by Telephone on 02 9870 4200 or Mail PO Box 3033 Lansvale NSW 2166.
When returned, the product must be accompanied with the original invoice including the purchase price and disclosing the purchase date
All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the Customer.
To the extent permitted by law, our total liability for loss or damage of every kind related to the product in any way whatsoever is limited to the amount
paid to the retailer by you for the product or the value of the product.
No responsibility will be taken for products lost, damaged or mislaid whilst in transit.

WARRANTY TERMS
WARRANTY EXCLUSIONS
This Warranty covers Material and Faulty Workmanship defects only.
This Warranty does not cover damage caused by:
• Normal wear and tear due to usage
• Misuse or abusive use of the UNIMIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA, instructions supplied with the product.
• Failure to clean or improper cleaning of the product
• Failure to maintain the equipment such as regular services etc
• Incorrect voltage or non-authorised electrical connections
• Improper installation
• Use of non-authorised/non-standard parts
• Abnormal product performance caused by any ancillary equipment interference or other external factors
• Failure or any breakage caused by overload, dropping or abusive treatment or use by the customer
• R
epair, modifications or other work carried out on the product other than by an Authorised UNIMIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-
8SS & ROTA Service Dealer
Unless it is a manufacturing fault, this Warranty does not cover the following parts:
MIG Welding Torches and Consumables to suit, such as:

Gas Nozzles, Gas Diffusers, Contact Tip holder, Contact tip, Swan Necks, Trigger, Handle, Liners,Wire Guide, Drive Roller, Gas Nozzle Spring. Neck
Spring, Connector Block, Insulator, Gas Nipple, Cap, Euro Block, Head Assembly, Gas Block, Trigger Spring, Spring Cable Support, Neck Insulator, Shroud
Spring,Gun Plug Cover, Lock Nut, Snap On Head, Spring Cap, Ball, Motor 42 Volt, Pot 10K standard, Knob, Drive Roll Seat, Washer, Bow, Ball Bearing,
Wire Conduit Nipple, Central Plug, Printed Circuit Board, Gun Plug House, Cable Support, Gas Connector, Handle To Suit PP36 with Knobs, All Xcel-Arc/
Magmaweld MIG Welding Wires & Electrodes, Arc Leads, Welding Cable, Electrode Holder, Earth Clamps
TIG Welding Torches and Consumables to suit, 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 UNIMIG TIG Welding Rods, All Xcel-Arc/ Magmaweld Electrodes, Arc Leads, Welding Cable, Electrode
Holder, Earth Clamps.
PLASMA Cutting Torches and Consumables to suit, such as:

All Cutting Tips, All Diffuser/Swirl Ring, All Electrode, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps, All Air and Power Cables, All Switches,
All O-rings, All Springs, All Circle Guides and Cutting Kits, Torch Bodies, Air Filter Regulator, Arc Leads, Welding Cable, Electrode Holder, Earth Clamps
STRAIGHT LINE CUTTING MACHINES and Consumables to suit, such as:

Hoses, Fittings, Track, Cutting Nozzles.
HIT-8SS Welding Carriage Consumables to suit, such as:

Input Cord, Inter-connecting Cord, Triggering Cable.
This Warranty does not cover products purchased:
• From a non-authorised UNIMIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA,T&R, HIT-8SS & ROTA Dealer (such as purchases from unauthorised retailers
and purchases over the Internet from unauthorised local/international sellers or sites such as EBay)
• At an auction;
• From a private seller
Unless it is a manufacturing fault, this Warranty does not apply to any products sold to Hire Companies.
These conditions may only be varied with the written approval of the Directors of Welding Guns Of Australia PTY LTD
REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.

NOTES

Welding Guns Of Australia Pty Ltd
ABN: 14 001 804 422
112 Christina Rd, Villawood, NSW 2163

Phone: 1300 864 644
Fax: (02) 9780 4244
Email: [email protected]
www.unimig.com.au
© Welding Guns Of Australia PTY LTD 2019

RAZOR TIG 200 ACDC Manual

Uploaded by

Copyright:

Available Formats

RAZOR TIG 200 ACDC Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

RAZOR TIG 200 ACDC Manual

Uploaded by

Copyright:

Available Formats

OPERATING MANUAL

Please read and understand this instruction manual carefully

• Product will only be replaced if repair is not possible

REGISTER YOUR MACHINE ONLINE TO RECEIVE AN

2 | RAZOR TIG 200 AC/DC Manual

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 FREQUENCY CONTROL 20

AC TIG WELDING GUIDE 21

AC PULSE TIG SETUP 23

MMA (STICK) WELDING SET UP 28

MMA (STICK) WELDING GUIDE 29

T2 TIG TORCH & SPARES 31

T2 TIG TORCH TUNGSTEN ELECTRODES 33

TIG WELDING TROUBLE SHOOTING 34

MMA (STICK) WELDING TROUBLE SHOOTING 35

RAZOR TIG 200 AC/DC Manual | 3

Machine Operating Safety

• Operators should be trained and or qualified.

• Do not use damaged, under sized, or badly joined cables.

• Do not drape cables over your body.

• In confined or heavy fume environments always wear an approved air-supplied respirator.

4 | RAZOR TIG 200 AC/DC Manual

• Shut off shielding gas supply when not in use.

• Always ventilate confined spaces or use approved air-supplied respirator.

• Wear approved ear protection if noise level is high.

RAZOR TIG 200 AC/DC Manual | 5

iii. Keep this equipment 30cm distant from the wall.

iv. Ensure the working environment is well ventilated.

ii. Thermal Overload protection.

iii. Over-Voltage Supply

6 | RAZOR TIG 200 AC/DC Manual

ATTENTION! - CHECK FOR GAS LEAKAGE

Recommended procedure is as follows:

2. Slowly open the cylinder valve.

3. Set the flow rate on the regulator to approximately 8-10 L/min.

6. Tighten clamps or fittings to eliminate gas leakage.

RAZOR TIG 200 AC/DC Manual | 7

8 | RAZOR TIG 200 AC/DC Manual

TECHNICAL DATA STICK SPECIFICATIONS

SKU KUM-M-RTIG200ACDC STICK DUTY CYCLE @ 40°C 30% @ 160A

SUPPLY PLUG 15 AMP STICK WELDING THICKNESS

Imax (A) 29.0

PROTECTION CLASS IP21S MACHINE FEATURES

POWER FACTOR 0.7 FOOT CONTROL READY Yes (UTJCFC-4)

MINIMUM GENERATOR (kVA) 9.0 CRATER CURRENT CONTROL Yes

DINSE CONNECTOR 35/50 THERMAL OVERLOAD

TIG WELDING CURRENT RANGE 10-200A

TIG DUTY CYCLE @ 40°C 25% @ 200A

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 FREQUENCY CONTROL 20

AC TIG WELDING GUIDE 21

AC PULSE TIG SETUP 23

MMA (STICK) WELDING SET UP 28

MMA (STICK) WELDING GUIDE 29

T2 TIG TORCH & SPARES 31

T2 TIG TORCH TUNGSTEN ELECTRODES 33

TIG WELDING TROUBLE SHOOTING 34

MMA (STICK) WELDING TROUBLE SHOOTING 35

ii. Thermal Overload protection.

iii. Over-Voltage Supply