Unimig KUMJR250SWF Operating Manual Download Page 42

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SPARE PARTS IDENTIFICATION - KUMJR250SWF

Description

Part Number

POWER SUPPLY AND WIRE FEED PCB

10000816

CONTROL PCB

10000519

IGBT PCB

10000889

EMC BOARD

10000930

OUTPUT DIODES PCB

10000321

FILTER BOARD PCB

10000460

MAIN TRANSFORMER

10006064

8 CHOKE

10006559

9 SHUNT

10016424

ON/OFF SWITCH

10004926

PEAK CURRENT SONSOR PCB

10000871

FRONT PANEL

10011728

REAR PANEL

10013239

BASE PLATE

10011309

POT FOR CURRENT ADJUSTMENT 4.7K 2W

10001209

POT FOR VOLTAGE ADJUSTMENT 4.7K 2W

10001209

MIG/MMA/TIG SELECTOR SWITCH

10003592

MIG/MMA SELECTOR SWITCH

10003593

DIGITAL METER ( VOLT AND AMP)

10006797

KNOB BLACK

10004906

FAN MOTOR

10007325

POWER SUUPLY CABLE

10001471

AUXILARY TRANSFORMER T2-1

10006030

AUXILARY TRANSFORMER T2-2

10006045

POT FOR CRATER VOLTAGE ADJUSTMENT

10006506

POT FOR CRATER CURRENT ADJUSTMENT

10006506

POT FOR BURN BACK ADJUSTMENT

10006508

INOUT BRIDGE RECTIFIER MBS-100

10006625

6 PIN PANEL FEMALE SOCKET

10004686

35/50 PANEL DINSE CONNECTOER FEMALE

CX0031

2T/4T SELECTOR SWITCH

10004944

WELD/GAS CHECK SELECTOR SWITCH

10004944

MIG/MMA CHECK SELECTOR SWITCH

10004944

Summary of Contents for KUMJR250SWF

Page 1: ...N MIG TIG STICK TECHNOLOGY ADVANTAGE TECHNOLOGY TECHNOLOGY MIG TIG STICK BUIL T IN TECHNOLOGY MIG TIG STICK TECHNOLOGY Please read and understand this instruction manual carefully before the installation and operation of this equipment Welding Guns Of Australia PTY LTD 2012 V oltage Reduction Device OPERATING MANUAL KUMJR250SWF KUMJR350SWF KUMJR500SWF ...

Page 2: ...onnel 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 con fidence that they will be well satisfied both now and in the future UNI MIG welders are manufactured and compliant with AS NZ60974 1 2006 guaranteeing you electrical safety and performance WARRAN...

Page 3: ...ion Operation for MIG Welding 14 16 Wire Feed Drive Rollers 17 Wire Installation and Wire Feeder Set Up 18 MIG Torch Liner Installation 19 Torch and Wire Feeder Setup for Aluminium Wire 20 21 MIG Welding Guide 22 27 DC TIG Welding 28 29 TIG Welding Guide 30 33 MIG Torch Parts Breakdown 34 39 TIG Torch Parts Breakdown 40 41 Spare Parts Breakdown 42 47 Trouble Shooting Guide 48 52 Warranty terms 53 ...

Page 4: ...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 Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harmful to people s health Welding produces fumes and ...

Page 5: ...n explode Because gas cylinders are normally part of the welding 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 electrode or earth clamp to touch the gas cylinde...

Page 6: ...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 2 3 Over Voltage Supply Regarding the power supply voltage range of the machine please refer to Main parameter table This equipment is ...

Page 7: ...ulator 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 orspraying with soapy water bubbles will appear at the leakage point 6 Tighten clamps or fittings to eliminate...

Page 8: ...necting Cables Excellent arc stability for MIG TIG MMA welding Technical Data MIG500SWF MIG350SWF MIG250SWF Power Supply Phases V Ph AC415V 15 50 60Hz 415V 3 Phase 240V 1 Phase Duty Cycle 40 c to AS NZ60974 60 500 Amps MIG 60 350 Amps MIG 35 250Amps MIG 60 500 Amps MMA 60 350 Amps MIG 35 225Amps MMA Output Current Range MIG 50A 16 5V 500A 39 0V 50A 16 5V 350A 31 5V 30A 15 5V 250 26 5V Output Curre...

Page 9: ...r Switch 14 Wire Feeder Control Cable Receptacle 15 Wire Feeder Weld Power Cable Receptacle 16 Burn Back Control 17 Primary Input Cable 18 Data Plate 19 Fan WIRE FEEDER LAYOUT 20 Voltage Control 21 Wire Speed Control 22 Inch Wire Feed Button 23 Euro Torch Connector 24 Gas Connection 25 Torch Holder 26 Control Cable Receptacle 27 Weld Power Cable Receptacle 28 Interface Cable Assembly Clamp 29 Spoo...

Page 10: ...er source to the trolley lock in place by fastening to the mounting brackets front and back Assemble the handle and wire feeder mounting assembly 4 Place the wire feeder by locating the mounting hole on the wire feeder base over the locating pin on the wire feeder mounting bracket 5 Connect the control cable assembly and fasten firmly in place with the cable retaining bracket 6 Connect the other e...

Page 11: ...trode connected to output socket DC Electrode connected to output socket 3 Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer 2 Connect earth lead to 1 Set TIG MMA MIG selector switch to MMA 2 Connect the electrode lead to 3 Set the welding current using the amperage control dial 6 Hold the electrode slightly above the work maint...

Page 12: ...cross the arc into the molten pool and becomes the deposited weld metal The deposit is covered and protected by a slag which comes from the electrode coating The arc and the immediate area are enveloped by an atmosphere of protective gas Core wire Flux coating Base metal Protective gas Arc Slag Weld pool Manual metal arc stick electrodes have a solid metal wire core and a flux coating These electr...

Page 13: ... 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 ...

Page 14: ...rive rollers to the wire feed drive unit 6 Place the Wire Spool onto the Spool Holder Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling Feed the wire into the wire feeder inlet guide tube through to the drive roller 7 Feed wire over the drive roller into the outlet guide tube Push the wire through approx 150mm 6 Place wire onto spool holder Feed the wire through t...

Page 15: ... soft for a wider softer arc setting it half way is a good starting point 16 Using the Burn Back control set the amount of wire to burn back after you release the torch trigger This prevents the wire becoming stuck in the weld pool when finishing the weld 14 Set welding parameters using the voltage and wire feed controls 15 Set the inductance control on the front panel of the power source to get t...

Page 16: ...e front panel of the power source This dial controls the amount of voltage applied at the finish of the weld Test the Crater Current settings by welding IMPORTANT Remember to pay attention to the 4T trigger selection This means that pulling the torch switch 1T will start the welding cycle releasing the trigger switch 2T will allow you to continue welding without holding down the trigger pulling th...

Page 17: ... and cause it to catch in the contact tip Flux Core Gasless Wire these wires are made up of a thin metal sheath that has fluxing and metal compounds layered onto it and then rolled into a cylinder to form the finished wire The wire cannot take too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied A knurled drive roller has been developed and it has...

Page 18: ...t guide tube retaining nut too make adjustment if required Carefully reTighten the locking nut and screw to hold the new position 4 Snip the wire carefully be sure to hold the wire to prevent the spool uncoiling Carefully feed the wire into the inlet guide tube of the wire feed unit 5 Feed the wire through the drive roller and into the outlet guide tube of the wire feeder 6 Lock down the top press...

Page 19: ...1 2 way 7 Leaving the torch straight snip the liner approximately 3mm past the end of the torch neck 8 Place the tip holder over the end of the liner and screw into the torch neck nipping it up TIGht 9 Screw down the liner nut the remaining 1 2 and nip it up TIGht This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed 2 Remove th...

Page 20: ... with the liner o ring 8 Push the liner firmly into the torch lead and Tighten the liner retaining nut 9 Install a U groove drive roller of the correct size to match the wire diameter being used 9 Install U groove drive rollers of the correct size for the diameter wire being used 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the liner 4 Carefully unravel the new liner...

Page 21: ...t size to match the diameter of the wire being used 17 Fit the remaining front end parts to the torch neck ready for welding 18 Fit the remaining front end parts to the torch neck ready for welding 11 Remove the inlet guide tube using long nose pliers 12 Carefully feed the PA liner into the inlet guide tube hole of the torch euro receptacle 14 Tighten and secure the torch euro connector to the mac...

Page 22: ...roperties and corresponding advantages and limitations To perform MIG welding the basic necessary equip ment is a welding gun a wire feed unit a welding power supply an electrode wire and a shielding gas supply Short circuit transfer is the most common used method whereby the wire electrode is fed continuously down the welding torch through to and exiting the contact tip The wire touches the work ...

Page 23: ...eat and force of the arc flattens out the droplet into the weld pool The heat of the arc melts the end of the wire slightly as it feeds towards the base metal The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short circuit and repeat the cycle droplet separates arc flattens the droplet cycle repeats MIG Metal Inert Gas Welding Short Circuit Transfer Short ...

Page 24: ... bead profile and degree of weld penetration Push Technique The wire is located at the leading edge of the weld pool and pushed towards the un melted work surface This technique offers a better view of the weld joint and direction of the wire into the weld joint Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penet...

Page 25: ...hape prevents undercut uneven penetration poor gas shield and poor quality finished weld Correct angle Not enough angle Too much angle good level of control over the weld pool even flat weld less control over the weld pool more spatter poor control unstable arc less penetration lots of spatter Stick Out Stick out is the length of the unmelted wire protruding from the end of the contact tip A const...

Page 26: ...d resulting in a weld deposit of poor quality cold lap lack of fusion lack of joint penetration porosity large wide bead Too Slow Travel Speed Correct Travel Speed The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration fusion and wetting out of the weld pool producing a weld deposit of good quality good to...

Page 27: ...tect shield the wire the arc and the molten weld metal from the atmosphere Most metals when heated to a molten state will react with the air in the atmosphere without the protection of the shielding gas the weld produced would contain defects like porosity lack of fusion and slag inclusions Additionally some of the gas becomes ionised electrically charged and helps the current flow smoothly The co...

Page 28: ...MA MIG selector switch 2 Insert the power cable plug of the TIG torch into the Negative socket on the front of the machine and Tighten it 3 Insert the earth cable plug into the Positive socket on the front of the machine and Tighten it 4 Connect the gas line of the TIG torch to regulator and connect the regulator to the gas cylinder 5 Carefully open the valve of the gas cylinder set the flow to 6 ...

Page 29: ...e Gas Cup on the work piece with the Tungsten Electrode 1 2mm from the work piece 8 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 9 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc Caution Disconnect the Electrode Holder cable from the machine before using MIG function If ca...

Page 30: ...types DC TIG welding is also the cleanest weld with no sparks or spatter LIFT ARC IGNITION for TIG tungsten inert gas Welding Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts with a current limit of one or two amps well below the limit that causes metal to transfer and contamination of the weld or electrode When the machine detects that the...

Page 31: ... pool Travel direction Angle torch Add TIG filler wire Retract the filler wire Move the torch forward to the front of the weld pool Repeat the process gas shield TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes Because the welder must maintain a short arc length great care and skill are required to prevent contact between the elect...

Page 32: ...for its use Ceriated Color Code Orange Ceriated tungsten electrodes AWS classification 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 s...

Page 33: ...n 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 lon...

Page 34: ...ndle Cable Support C W Ball Joint 5 UB1521 Cable Terminal 6 UB1521 C Cable Terminal Cover 7 UB2603 30 Hyperflex Cable Assembly x 3mt UB2603 40 Hyperflex Cable Assembly x 4mt UB2603 50 Hyperflex Cable Assembly x 5mt 8 UG2514 Ergo Handle Kit C W Lock Nut 9 UG2516 Medium Large Ergo Trigger Part Number Description 10 UB2517 Hanger Hook 11 UB1522 Cable Terminal Male 12 UPA2041 Cable Support 13 UB1518 G...

Page 35: ...s Diffuser Part Number Description PCGD24 Gas Diffuser Ceramic QTY2 SB24 Gas Nozzle Part Number Description PGN24CYL Cylindrical Nozzle QTY2 PGN24CON Conical Nozzle QTY2 PGN24TAP Tapered Nozzle QTY2 PGN24SPOT Spot Nozzle QTY2 25 0 Ø 13 1 Ø 14 5 Liners SB24 Liners Part Number Description SLB3M Blue Steel Liner 3 Metre SLB4M Blue Steel Liner 4 Metre SLB5M Blue Steel Liner 5 Metre SLR3M Red Steel Lin...

Page 36: ...6 Handle Cable Support C W Ball Joint 5 UB1521 Cable Terminal 6 UB1521 C Cable Terminal Cover 7 UB3609 30 Hyperflex Cable Assembly x 3mt UB3609 40 Hyperflex Cable Assembly x 4mt UB3609 50 Hyperflex Cable Assembly x 5mt 8 8UG2514 Ergo Handle Kit C W Lock Nut Part Number Description 9 UG2516 Medium Large Ergo Trigger 10 UB2517 Hanger Hook 11 UB1522 Cable Terminal Male 12 UC8026 Housing Spring 13 UB1...

Page 37: ...ber Description PCTH36M6L Contact Tip Holder M6 Long QTY2 PCTH36M8L Contact Tip Holder M8 Long QTY2 SB36 Gas Nozzle Part Number Description PGN36CYL Cylindrical Nozzle QTY2 PGN36CON Conical Nozzle QTY2 PGN36TAP Tapered Nozzle QTY2 SB36 MIG TORCH SB36 Tip Holder M8 Part Number Description PCTH36M6S Contact Tip Holder M6 Short QTY2 PCTH36M8S Contact Tip Holder M8 Short QTY2 SB36 Gas Diffuser Part Nu...

Page 38: ...0 Heavy Duty Swan Neck 60 Degree 2 U104 Connection Block C W Spacer 3 U244T Control Wire Terminals 4 U134 14 Cable Hose Clamp 5 UBE8018 Spring Cable Support Ball Joint 6 U500 10E Hyperflex C Assy X 10ft Euro U500 12E Hyperflex C Assy X 12ft Euro U500 15E Hyperflex C Assy X 15ft Euro U500 10 Hyperflex C Assy X 10ft U500 12 Hyperflex C Assy X 12ft U500 15 Hyperflex C Assy X 15ft Part Number Descript...

Page 39: ...GA55 Contact Tip Holder 1 6 2 0mm QTY2 PWGA55 SW Contact Tip Holder 0 9 1 2mm QTY2 PWGA55 H Contact Tip Holder 2 4 2 8mm QTY2 TWC5 Insulator Part Number Description PWGA35CT Insulator QTY2 TWC5 Torch Nozzle Fixed Part Number Description PWGA25CT62 Standard 16mm fixed QTY2 PWGA25CT75 Standard 20mm fixed QTY2 Liners TWC5 Liners Part Number Description WGA44 3545 15 Liner 15 ft 0 9 1 2mm WGA44 116 15...

Page 40: ...RSP1 Screw Pack 7 UERH200 Large Ergo TIG Handle 8 UERKJ200 Large Knuckle Joint 9 UERLC200 08 Leather Cover X 0 8mt 10 UERJK200 Jointing Repair Kit Part Number Description 11 UERNCL 32 Neoprene Cover X 3 2mt UERNCL 72 Neoprene Cover X 7 2mt 12 UERCO200 40 Sheath X 12 5ft Inc Leather Cover UERCO200 80 Sheath X 25ft Inc Leather Cover 13 USLH26 S Cable Support Large 14 USLH26 H Surelok Housing Large 1...

Page 41: ... 45V26 Gas Lens Body 2 4mm 45V27 Gas Lens Body 3 2mm Part Description 54N14 Gas lens ceramic 8 0mm 54N15 Gas lens ceramic 7 0mm 54N17 Gas lens ceramic 5 0mm Compact Gas Lens Front End Parts Part Description TR0004 10 1 0mm x 175mm thoriated tungsten electrode 2 TR0004 16 1 6mm x 175mm thoriated tungsten electrode 2 TR0004 24 2 4mm x 175mm thoriated tungsten electrode 2 TR0004 32 3 2mm x 175mm thor...

Page 42: ...NT 4 7K 2W 10001209 17 MIG MMA TIG SELECTOR SWITCH 10003592 18 MIG MMA SELECTOR SWITCH 10003593 19 DIGITAL METER VOLT AND AMP 10006797 20 KNOB BLACK 10004906 21 FAN MOTOR 10007325 22 POWER SUUPLY CABLE 10001471 23 AUXILARY TRANSFORMER T2 1 10006030 24 AUXILARY TRANSFORMER T2 2 10006045 25 POT FOR CRATER VOLTAGE ADJUSTMENT 10006506 26 POT FOR CRATER CURRENT ADJUSTMENT 10006506 27 POT FOR BURN BACK ...

Page 43: ...43 9 19 18 7 8 3 1 20 2 21 4 5 25 13 13 ...

Page 44: ...01209 15 POT FOR VOLTAGE ADJUSTMENT 4 7K 2W 10001209 16 DIGITAL METER VOLT AND AMP 10006797 17 KNOB BLACK 10004906 18 FAN MOTOR 10007306 19 POWER SUPPLY CABLE 10001429 20 AUXILARY TRANSFORMER T2 1 10006032 21 AUXILARY TRANSFORMER T2 2 10006045 22 POT FOR CRATER VOLTAGE ADJUSTMENT 10006506 23 POT FOR CRATER CURRENT ADJUSTMENT 10006506 24 POT FOR BURN BACK ADJUSTMENT 10006508 25 INPUT BRIDGE RECTIFI...

Page 45: ...45 9 19 18 7 8 3 1 20 2 21 4 5 25 13 13 ...

Page 46: ...01209 16 DIGITAL METER VOLT AND AMP 10006797 17 KNOB BLACK 10004906 18 FAN MOTOR 10007306 19 POWER SUPPLY CABLE 10001429 20 AUXILARY TRANSFORMER T2 1 10006032 21 AUXILARY TRANSFORMER T2 2 10006045 22 POT FOR CRATER VOLTAGE ADJUSTMENT 10006506 23 POT FOR CRATER CURRENT ADJUSTMENT 10006506 24 POT FOR BURN BACK ADJUSTMENT 10006508 25 INOUT BRIDGE RECTIFIER MBS 100 10006623 26 6 PIN PANEL FEMALE SOCKE...

Page 47: ...47 9 19 18 7 8 3 1 20 2 21 4 5 25 13 13 ...

Page 48: ... Wire stubbing during welding Possible Reason Suggested Remedy Holding the torch too far away Bring the torch closer to the work and maintain stick out of 5 10mm Welding voltage set too low Increase the voltage Wire Speed set too high Decrease the wire feed speed 5 Lack of Fusion failure of weld metal to fuse completely with base metal or a proceeding weld bead Possible Reason Suggested Remedy Con...

Page 49: ...ogged the most common causes of bad feeding Try to clear the liner by blowing out with compressed air as a temporary cure it is recommended to replace the liner Wrong size liner Install the correct size liner Blocked or worn inlet guide tube Clear or replace the inlet guide tube Wire misaligned in drive roller groove Locate the wire into the groove of the drive roller Incorrect drive roller size F...

Page 50: ... larger electrode Poor welding technique Use the correct welding technique or seek assistance for the correct technique Poor joint preparation Check the joint design and fit up make sure the material is not too thick Seek assis tance for the correct joint design and fit up 5 Excessive penetration burn through Possible Reason Suggested Remedy Excessive heat input Reduce the amperage or use a smalle...

Page 51: ... metal Remove materials like paint grease oil and dirt including mill scale 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 Possible Reason Suggested Remedy Incorrect Gas Use pure Argon gas Inadequate gas flow Set the ...

Page 52: ...the regulator to approximately 6 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 ...

Page 53: ... TIG Jasic Inverter TIG Power Source Only 3 Years Clause 3 UNI MIG 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 a...

Page 54: ...he 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 ...

Page 55: ...t 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 Eatch 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 Bo...

Page 56: ...66 AUSTRALIA 112 Christina Rd Villawood NSW 2163 Phone 02 9780 4200 Fax 02 9780 4244 Email sales uniMIG com au Web www uniMIG com au Welding Guns Of Australia PTY LTD Pty Ltd ABN 14 001 804 422 Welding Guns Of Australia PTY LTD 2012 ...

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