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Unimig KUMJR350K, Operating Manual

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Unimig KUMJR350K Operating Manual Download Page 3

3

CONTENTS PAGE

Warranty 2
Safety  

4-5

Caution, Maintenance and Trouble Shooting 

6-7

Technical Data, Product Information 

8-9 

Machine Layout Pictogram 

10

Installation & Operation for MMA (stick) Welding 

11 

MMA (Stick) Welding) 

12-13 

Installation & Operation for MIG Welding 

14-15

Wire Feed Drive Rollers 

16 

Wire Installation and Wire Feeder Set Up 

17

Mig Torch Liner Installation 

18

Torch and Wire Feeder Setup for Aluminium Wire 

19-20

Mig Welding Guide 

21-26

Spool Gun Setup 

27-28 

Installation & Operation for DC Tig Welding 

29-30 

DC Tig Welding 

31-32

Tungsten Electrodes 

33-34

MIG Torch Parts Breakdown 

35-36

Spool Gun Torch Parts Breakdown 

37-38

TIG Torch Parts Breakdown 

39-40 

Mig Welding Trouble Shooting Guide 

41-42 

Tig Welding Trouble Shooting Guide 

43 

MMA (Stick) Welding Trouble Shooting Guide 

44 

Machine Spare Parts Breakdown 

45

Warranty Terms 

46-48

Summary of Contents for KUMJR350K

Page 1: ...Plasm Standard MIG MAG Lift Arc DC TIG Plasma CUT Stand MIG M Lift Arc D Plasma YEARS Warranty Power Source 3 ADVANTAGE MIG TIG STICK BUIL T IN MIG TIG STICK TECHNOLOGY ADVANTAGE TECHNOLOGY TECHNOLOGY MIG TIG STICK BUIL T IN TECHNOLOGY MIG TIG STICK TECHNOLOGY OPERATING MANUAL KUMJR350K Welding Guns Of Australia PTY LTD 2012 V oltage Reduction Device ...

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: ... Feeder Set Up 17 Mig Torch Liner Installation 18 Torch and Wire Feeder Setup for Aluminium Wire 19 20 Mig Welding Guide 21 26 Spool Gun Setup 27 28 Installation Operation for DC Tig Welding 29 30 DC Tig Welding 31 32 Tungsten Electrodes 33 34 MIG Torch Parts Breakdown 35 36 Spool Gun Torch Parts Breakdown 37 38 TIG Torch Parts Breakdown 39 40 Mig Welding Trouble Shooting Guide 41 42 Tig Welding T...

Page 4: ...ect 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 harm...

Page 5: ...ecause 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 cylinder do not dr...

Page 6: ...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 of automatic voltage compensation which enables the maintaining of the voltage range within the given range In case that the voltage of input p...

Page 7: ...or 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 gas...

Page 8: ...xH 900x400x670mm Weight 60 Kg Warranty 3 years on machine The KUMJR350K is an inverter based multi function Mig welding machine with added MMA and Tig function The Mig function allows you to weld with both Gas Shielded and Gasless wire applications Easy step less adjustment of voltage and wire feed make for easy setting of welding parameters giving excellent professional welding results Wire inch ...

Page 9: ...tor MIG MAG 11 Voltage Adjustment Knob MIG MAG 12 Amperage Adjustment Knob MMA TIG 13 Thermal Overload LED 14 Mains Power LED 15 VRD LED 16 Gas Check Weld Mode Selector Switch 17 Inductance Adjustment Knob 11 5 2 1 12 9 6 8 7 4 BACK PANEL LAYOUT 18 Input power cable 19 Power switch 20 Fan 21 Data Plate 22 Gas Inlet INTERNAL PANEL LAYOUT 23 Burn back control 24 Spool holder assembly 25 Wire feeder ...

Page 10: ...ld be paid to the polarity refer to the electrode manufacturers information for the correct polarity DC Electrode 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 3 Set the welding current using the amperage control dial 6 Hold the electrode slightly above the...

Page 11: ...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 12: ... 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 13: ...re 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 8 Carefully feed the wire over the drive roller into the outlet guide tube feed through about 150mm into the torch receptacle Check that the drive roller being used complies with the wire diameter replace the roller if necessary 1 Set Tig MMA Mig ...

Page 14: ...5 Set the welding parameters using the wire feed and voltage control knobs 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 10 Remove the gas nozzle and contact tip from the front end of the mig torch 13 Fit the gas nozzle to the torch head 15 Set welding parameters ...

Page 15: ...h a V shape groove for optimum grip and drive capability Solid wires can have more tension applied to the wire from the top pressure roller that holds the wire in the groove and the V shape groove is more suited for this Solid wires are more forgiving to feed due to their higher cross sectional column strength they are stiffer and don t bend so easy Soft Wire like Aluminium requires a U shape groo...

Page 16: ...et 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 pres...

Page 17: ...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 18: ...her 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 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the liner 4 Carefully unravel the new liner 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 5 ...

Page 19: ...m contact tip of the correct size to match the diameter of the wire being used 16 Fit the remaining front end parts to the torch neck ready for welding 16 Fit the remaining front end parts to the torch neck ready for welding 10 Remove the inlet guide tube using long nose pliers 11 Carefully feed the Polymide liner into the inlet guide tube hole of the torch euro receptacle 13 Tighten and secure th...

Page 20: ...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 21: ...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 22: ... 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 23: ...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 24: ...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 25: ...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 26: ... the receptacle and tighten it 4 Insert the earth cable plug into the Negative socket on the front of the machine and tighten it 5 Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder 6 Connect the Weld power cable to the Positive socket 7 Take the Spool Gun and push the Cover Release Button to unlock the wire feed spool cover 8 Place the Wire Spool onto the Spool Ho...

Page 27: ...ire feed and voltage control knobs 17 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 9 Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube Squeezing the tension arm adjustment knob to release the pressure of th...

Page 28: ...sitive 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 1 Set TIG MMA Mig selector switch to TIG 4 Connect the gas line to the regulator and connect to the gas cylinder 2 Connect the TIG torch cable connector to 3 Connect earth lead to 5 Assemble front end parts of the TIG torch 7 Set the welding cu...

Page 29: ...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 Lift Arc ignition allows the arc to be started easily in DC Tig by simply touching the tungsten to the work piece and lifting it up to start the arc This prevents the tungsten tip sticking to the work piece and breaking the tip from the tu...

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: ...B36 Suregrip Ergo Torch Package SB36 3 SB36 4 SB36 5 Spare Parts Part Number Description 1 SNK36 Swan Neck 8 BZLH Ergo handle complete with Trigger 9 BX0020 Trigger 1 2 3 4 6 5 7 8 9 10 20 19 18 17 16 15 14 13 11 12 Front end parts shown on opposite page Liners shown on opposite page These parts are manufactured in China and are offered as replacement parts suitable for BINZEL style torches Suregr...

Page 35: ... Tip Aluminium M8 1 0mm PCTAL0005 12 Contact Tip Aluminium M8 1 2mm PCTAL0005 16 Contact Tip Aluminium M8 1 6mm SB36 Tip Holder M6 Part Number Description PCTH36M6L Contact Tip Holder M6 Long PCTH36M8L Contact Tip Holder M8 Long SB36 Gas Nozzle Part Number Description PGN36CYL Cylindrical Nozzle PGN36CON Conical Nozzle PGN36TAP Tapered Nozzle SB36 MIG TORCH SB36 Tip Holder M8 Part Number Descripti...

Page 36: ...Roll Assembly 10 LMZ2016 Wire Nipple 11 LMT2101 Spool Shaft 12 LMH2112 Right Gun Case 13 LMH2113 Upper Gun Case 14 LMJ2101 Switch Part Number Description 15 LMZ2014 Potentiometer 16 LMZ2015 Push Roll 17 LMK2001 Conducting Board 18 EF1101 Conducting Tube 19 SEE PAGE 38 Tip Holder 20 SEE PAGE 38 Contact Tip 21 SEE PAGE 38 Gas Nozzle 22 LML2140 Welding Cable 23 ES1201 Spring Support Back 24 EH2201 Ad...

Page 37: ...9 Contact Tip Aluminium 0 9mm PCTAL0009 10 Contact Tip Aluminium 1 0mm PCTAL0009 12 Contact Tip Aluminium 1 2mm 26 0 M6 x 1 0 M6 x 1 0 SB24 Tip Holder Part Number Description PCTH24 Contact Tip Holder SB24 Gas Diffuser Part Number Description PCGD24 Gas Diffuser Ceramic PCGDR24 Gas Diffuser Rubber SB24 Gas Nozzle Part Number Description PGN24CYL Cylindrical Nozzle PGN24CON Conical Nozzle PGN24TAP ...

Page 38: ...ion 1 WP26 Torch head WP26V Torch head c w valve WP26F Torch head flexible WP26VF Torch head flex c w valve WP18 Torch head water cooled 3 57Y02 Back cap long 3a 57Y03 Medium back cap 3b 57Y04 Short back cap 8 HWP26 Torch handle 200A AIR COOLED TIG WELDING TORCH Rating 200Amp DC 140Amp AC 35 duty cycle SR26V ERGO TIG TORCH All rights reserved No part of this publication may be reproduced stored in...

Page 39: ...s 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 thoriated tungsten...

Page 40: ... 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 41: ...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 42: ...min flow rate Alumina gas nozzle too small Increase the size of the alumina gas nozzle 5 Unstable Arc during DC welding Possible Reason Suggested Remedy Torch connected to DC Connect the torch to the DC output terminal Contaminated base metal Remove materials like paint grease oil and dirt including mill scale from base metal Tungsten is contaminated Remove 10mm of contaminated tungsten and re gri...

Page 43: ... 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 assist ance 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 44: ... B05110 Power PCB 20 B09133 Burn Back 2W 100K ohm 21 B04260 Control PCB Part Number Description 22 B06096 EMC PCB 23 B02466 On Off Switch 24 J22011 Shunt 25 D16027 1 Reactor 26 D03211 Transformer 27 B06112 Peak Current Sampling PCB 28 B16037 Inverter PCB 29 B15054 Fan 220V 30 J27044 Top Cylinder Retaining Bracket 31 J27044 Bottom Cylinder Retaining Bracket 32 J24363 Wheel 33 C13010 Cable Support A...

Page 45: ... 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 46: ...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 47: ...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 48: ...2 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 UNI FLAME UNI FLAME AUTOLIFT Welding Guns Of Australia PTY LTD 2012 ...

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