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Unimig KUMJRDP210 Manual Download Page 60

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PO Box 3033, Lansvale NSW 2166, AUSTRALIA
112 Christina Rd, Villawood, NSW 2163
Phone: 

(02) 9780 4200

Fax:  

(02) 9780 4244

Email: [email protected] / 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

Summary of Contents for KUMJRDP210

Page 1: ...LOGY 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 OPERATING MANUAL KUMJRDP210 KUMJRDP250 Welding Guns Of Australia PTY LTD 2012 YEARS Warranty Power Source 3 ...

Page 2: ... 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 UNI MIG welders are manufactured and compliant with AS NZ60974 1 2006 AS60974 6 2006 guaranteeing you electrical safety and performance WARRANTY 3...

Page 3: ...lation 20 Mig Torch and Wire Feeder Set Up Guide for Aluminium Mig Wire 21 22 Installation Operation for MIG Welding with Spool Gun 23 24 MIG Metal Inert Gas Welding 25 26 Basic MIG Welding Guide 27 30 Installation Operation for DC TIG Welding with Lift Arc 31 32 DC TIG Welding 33 34 Tungsten Electrodes 35 36 24 Digital MIG Torch Parts Breakdown 37 38 26 Digital MIG Torch Parts Breakdown 39 40 SPG...

Page 4: ...e addition of the SB24 Digital Control mig torch allows you to adjust wire feed speed and voltage settings during real time welding providing you the ultimate in control The MIG function allows you to weld with both Gas Shielded and Gasless wire Wire inch provides feeding of the wire during set up without gas wastage Added MMA welding capability delivers easy electrode welding with high quality re...

Page 5: ...g results The addition of the SB24 Digital Control mig torch allows you to adjust wire feed speed and voltage settings during real time welding providing you the ultimate in control The MIG function allows you to weld with both Gas Shielded and Gasless wire Wire inch provides feeding of the wire during set up without gas wastage Added MMA welding capability delivers easy electrode welding with hig...

Page 6: ...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 7: ...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 8: ...side 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 power supply am...

Page 9: ... terminal 12 SpoolGun TIG Torch trigger Connection 13 Output terminal 14 Quick connector gas TIG torch 15 Euro Mig Torch Connector MIG MAG 16 Thermal Overload LED 1 2 3 4 7 5 6 10 11 12 13 15 BACK PANEL LAYOUT 17 Input power cable 18 Power switch 19 Fan 20 Gas Inlet Note Serperate gas inlet for MIG TIG Model 210 21 Data Plate 20 17 18 19 21 INTERNAL PANEL LAYOUT 22 Wire Inch Button 23 Gas Check bu...

Page 10: ...ith this welding equipment Connect the primary input cable with power supply of required input voltage Refer to data plate on machine for Input voltage IMAX and IEFF Before MMA Stick Welding Disconnect the cable with twist lock connector that is attached to the wire feeder from the output socket s GAS NO GAS on the backboard If cable is not disconnected welding voltage is present on MIG torch and ...

Page 11: ...rode 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 Spool Gun 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 maintaining the arc while travelling...

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 a...

Page 14: ...d for welding above 120Amps only 5 If required select downslope time for crater fill 6 Select post gas flow time 7 Adjust inductance control Hard or Soft Arc 8 Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder WARNING Disconnect the Electrode Holder cable from the machine before using MIG function If cable is not disconnected welding voltage is present and can cau...

Page 15: ...oltage control knobs on power source OR 20 Press and hold wire speed voltage button and hold down for approx two seconds to active torch control Pressing the button allows voltage display U or wire speed S to be selected control of the parameters can then be regulated by the or buttons on the torch handle Pressing and holding down wirespeed voltage button for approx 2 seconds after adjustments hav...

Page 16: ...lied 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 groove Aluminium wire has a lot less column strength can bend easily and is therefore more difficu...

Page 17: ...w and then loosen the outlet guide tube retaining nut too make adjustment if required Carefully retighten the locking nut and screw to hold the new position adjust wire tensioner so that adequate presser is supplied to wire so it does not slip 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 ...

Page 18: ...onnected prior to power being turned on otherwise remote control will not work 2 Connect the earth lead to 3 Select the MIG function with the Tig MMA MIG SPOOL GUN selector switch 4 Set torch operation 2T 4T When 2T operation is selected press trigger Arc starts release trigger Arc stops When 2T operation is selected with downslope time of either 2 or 3 seconds press trigger Arc starts release tri...

Page 19: ...ool 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 11 Feed wire over the drive roller into the outlet guide tube Push the wire through approx 150mm 12 Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller lock the pressu...

Page 20: ...ining nut and screw down only 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 ensu...

Page 21: ... 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 Carefull...

Page 22: ...over liner reconnect torch to machine 17 Fit an Aluminium contact tip of the correct size to match the diameter of the wire being used 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 Polymide liner into the inlet guide tube hole of the torch euro receptacle 14 Tighten and secure the torch euro conn...

Page 23: ...tarts Press and hold trigger after 2 or 3 seconds depending on the downslope time selected Arc crater fill downslopes to factory preset level release trigger Arc stops NOTE This feature is recommend for welding above 120Amps only 5 If required select downslope time for crater fill 6 Select post gas flow time 7 Adjust inductance control Hard or Soft Arc 8 Connect Gas Line to Gas Regulator and conne...

Page 24: ...e wire through it screw the contact tip into the tip holder of the torch neck and nip it up tightly 18 Fit the gas nozzle to the torch head and close the wire spool cover 19 Carefully open the gas cylinder valve and set the flow rate to between 12 15 l min 20 Set the welding parameters using the wire feed and voltage control knobs 12 Carefully feed the wire through the inlet guide tube onto the dr...

Page 25: ...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 26: ...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 27: ... 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 28: ...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 29: ...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 30: ...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 31: ... Gas starts touch and lift arc start press and release trigger Gas and Arc stops When 4T operation is selected with downslope time of either 2 or 3 seconds press and release trigger Gas starts touch and lift arc start Press and hold trigger after 2 or 3 seconds depending on the downslope time selected Arc crater fill downslopes crater fill operation is automatic to factory preset level release tri...

Page 32: ... work piece with the Tungsten Electrode 1 2mm from the work piece 12 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 13 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc WARNING Disconnect the Electrode Holder cable from the machine before using MIG function If cable is not dis...

Page 33: ...ypes 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 34: ... 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 35: ...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 36: ...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 37: ...e 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 DM2514 KJ Digi Mig Handle Kit 9 DM2516 Standard Trigger Assembly 10 DM2516L Extended Trigger Assembly Part Number Description 11 UB2517 Hanger Hook 12 UB1522 Cable Terminal Male 13 UPA20...

Page 38: ... 1 0 M6 x 1 0 DM24 Tip Holder Part Number Description PCTH24 Contact Tip Holder DM24 Gas Diffuser Part Number Description PCGD24 Gas Diffuser Ceramic PCGDR24 Gas Diffuser Rubber DM24 Gas Nozzle Part Number Description PGN24CYL Cylindrical Nozzle PGN24CON Conical Nozzle PGN24TAP Tapered Nozzle PGN24SPOT Spot Nozzle DM24 DIGITAL MIG TORCH 25 0 Ø 13 1 Ø 14 5 DM24 Liners Part Number Description SLR3M ...

Page 39: ...on Body 4 UB1505 Lock Nut 5 UG8015 Handle Cable Support C W Ball Joint 6 UB1521 Cable Terminal 7 UB1521 C Cable Terminal Cover 8 UB2503 30 Hyperflex Cable Assembly x 3mt UB2503 40 Hyperflex Cable Assembly x 4mt UB2503 50 Hyperflex Cable Assembly x 5mt 9 DM2514 KJ Digi Mig Handle Kit 10 DM2516 Standard Trigger Assembly Part Number Description 11 DM2516L Extended Trigger Assembly 12 UB2517 Hanger Ho...

Page 40: ... Tip Holder M8 Part Number Description PCTH26M6S Contact Tip Holder M6 Short DM26 Gas Diffuser Part Number Description PCGD26 Gas Diffuser 27 5 Ø 14 5 Ø 12 19 5 M6 x 1 0 M8 x 1 25 30 0 Ø 10 0 M8 x 1 25 DM26 Liners Part Number Description SLR3M Red Steel Liner 3 Metre SLR4M Red Steel Liner 4 Metre SLR5M Red Steel Liner 5 Metre SLY3M Yellow Steel Liner 3 Metre SLY4M Yellow Steel Liner 4 Metre SLY5M ...

Page 41: ...ear Box Assembly 18 LMX2011 Inlet Guide Part Number Description 19 LGX2018 Key 20 LGX2019U DriveRoll U Groove 0 8 0 9mm 21 LZ3603 Motor 22 LYFE1001 Gun Neck 23 SEE PAGE 41 Gas Nozzle 24 SEE PAGE 41 Contact Tip 25 SEE PAGE 41 Diffuser Tip Holder with Spring 26 LYFE1011 Gun Neck Body 27 LW0101 Gas Hose 28 LGK2011 Conducting Board 29 LYH1012 Cable Support 30 LYH1013 Handle Nut 31 LYL1640 Cable Assemb...

Page 42: ...teel 0 9mm PCT0008 10 Contact Tip Steel 1 0mm PCTAL0008 09 Contact Tip Aluminium 0 9mm PCTAL0008 10 Contact Tip Aluminium 1 0mm SB15 Tip Holder Part Number Description PCTH15 Contact Tip Holder Suit SB15 PCTH195 Contact Tip Holder Suit Procraft 195 BP15 Torch Bore SB15 Gas Nozzle Part Number Description PGN15CYL Cylindrical Nozzle PGN15CON Conical Nozzle PGN15TAP Tapered Nozzle Ø 12 5 53 0 Ø 18 0 ...

Page 43: ...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 Adaptor...

Page 44: ...t 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 Tapered ...

Page 45: ...ion of Uniarc the copyright holder Suregrip Series Spare Parts Part Number Description 1 WP17 Torch head WP17F Torch head flexible 2 57Y02 Back cap long 3 57Y03 Medium back cap 4 57Y04 Short back cap 5 UER1MS Momentary Kit 6 UERSWL4 Trigger Lead 12 5ft UERSWL8 Trigger Lead 25ft 7 UERSP1 Screw Pack 8 UERH100 Small Ergo Tig Handle 9 UERKJ100 Small Knuckle Joint 10 UERLC200 08 Leather Cover X 0 8mt 1...

Page 46: ...ed in a retrieval system or transmitted by any means electronic mechanical photocopying or otherwise without the prior permission of Uniarc the copyright holder 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 electrode 2 Pa...

Page 47: ...ERSWL8 Trigger Lead 25ft 7 UERSP1 Screw Pack 8 UERH200 Large Ergo Tig Handle 9 UERKJ200 Large Knuckle Joint 10 UERLC200 08 Leather Cover X 0 8mt 11 UERJK200 Jointing Repair Kit Part Number Description 12 UERNCL 32 Neoprene Cover X 3 2mt UERNCL 72 Neoprene Cover X 7 2mt 13 UERCO200 40 Sheath X 12 5ft Inc Leather Cover UERCO200 80 Sheath X 25ft Inc Leather Cover 14 USLH26 S Cable Support Large 15 US...

Page 48: ...V27 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 electrode 2 Pa...

Page 49: ... 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 50: ...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 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: ... 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 54: ... 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 55: ... 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 pos...

Page 56: ...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 57: ...57 NOTES ...

Page 58: ...58 NOTES ...

Page 59: ...59 NOTES ...

Page 60: ...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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