Unimig KUMJRRW200AC/DC Operating Manual Download

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Summary of Contents for KUMJRRW200AC/DC

Page 1: ...read and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KUMJRRW200AC DC Welding Guns Of Australia PTY LTD 2013 YEARS Warranty Power Source 3 ...

Page 2: ...epresents 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 betwe...

Page 3: ...tick Electrode Selection Setting 14 Ignition Current 14 Ignition Time 14 Weld Current 15 Arc Force 15 LED Display Functions Alarm LED Codes 16 17 Weld Settings Storage Job Recall 17 MMA Stick Welding Setup Operation 18 19 MMA Stick Welding Fundamentals 20 21 DC HF TIG Welding Setup Operation 23 DC TIG Welding Fundamentals 24 TIG Welding Fusion Filler Wire Technique 25 Pulse TIG Welding Fundamental...

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: ...ment 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 2 4 Do not come into contact with the output terminals while the machine is in op...

Page 7: ...ow at the tungsten allowing to set the AC TIG arc for maximised cleaning of the oxide layer on aluminium to adjustment for a deeper penetrating weld Combined functions of the RAZOR200AC DC ensures comprehensive control of welding parameters when welding AC and DC weldable materials to produce high quality TIG welds Our unique Torch Remote Control Interface provides remote amperage control from the...

Page 8: ...or 5 Remote Foot Control Connector 6 Remote Torch Control Connector 7 Positive power connector 8 Mains switch 9 Adjustment control 1 2 3 4 5 6 7 8 9 Front Machine Layout Description 11 10 Rear Machine Layout Description 10 Data Plate 10 Primary Input Power Lead 12 Gas Inlet Connector 13 Serial Number Plate 12 13 Razorweld ...

Page 9: ...h Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse Hz OFF 2 3 4 5 6 AC TIG Select by pushing the selector key to cycle through to illuminate the AC icon AC Pulse TIG Select by pushing the selector key to cycle through to illuminate AC Pulse icon DC TIG Select by pushing...

Page 10: ...ge Display Selector When selected shows the output voltage on the digital display Torch Cycle Selector Controls the on off cycle of the machine using the torch switch while incorporating the weld program parameters selections Job Recall Selector Allows the setting and recall of welding parameters 5 job settings and memory recalls for each welding mode See page 17 for operational instruction Volts ...

Page 11: ... Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse Hz OFF AC AC DC ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current t Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse...

Page 12: ...rrent value Range is 10 200A Peak Current Select by pushing selector key to cycle through to illuminate the Peak Current icon The value selected shows on the digital display It is the maximum set value of amperage the machine will deliver AC AC DC ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time...

Page 13: ... Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse Hz OFF Pulse Frequency Select by pushing selector key to cycle through to illuminate the Pulse Hz icon Pulse Width Select by pushing selector key to cycle through to illuminate the Pulse icon Turn the Encoder Knob to set the Pulse Frequency Range is 0 5 200 Hz Turn the Encoder Knob to set the Pulse Width Range is ...

Page 14: ...orce ON Power Remote ON OFF AC Hz Pulse Pulse Hz OFF Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF Pulse Hz OFF Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF Pulse Hz OFF Ignition Current Select by pushing selector key to cycle through to...

Page 15: ...ount current amps delivered during welding in MMA Mode Stick Electrode The value selected is shown in the digital display The value selected is the amount of Arc Force applied to the electrode during welding Current Provides setting of the main welding current amps delivered in MMA Mode stick electrode Arc Force Provides setting of extra current being applied to the electrode when the arc length b...

Page 16: ...Version Software AC AC DC ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse Hz OFF Other parameter settings will be displayed as selected such as preset current time pulse ratio pulse frequency etc Alarm E 1 Indicates over curr...

Page 17: ...t Ignition Time Current Arc Force ON Power Remote ON OFF e Hz OFF Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF Pulse Hz OFF Turn the encoder to select the Job number required Welding Parameter Storage Allows the setting and recall of welding parameters Job recall 5 job settings and memory recalls for each welding mod...

Page 18: ...ocket 2 Turn the power source on using the on off switch located on the front control panel 3 Select you preferred MMA mode using the MODE selector key 1 Connect Electrode Lead the terminal 2 Turn on the Power source using the on off switch at the rear of the machine 1 Connect the Earth Lead lead to terminal MMA Current Set MMA Ignition Current Set MMA Stick Electrode Welding Set and Operation AC ...

Page 19: ...ng the Adjustment Knob The set Ignition time will show in the Digital Display Refer to Page 14 for instruction on Ignition Time AC AC DC ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse Hz OFF MMA Ignition Time Set 7 To set th...

Page 20: ...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 21: ... 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 22: ...onnect the gas regulator to the Gas Cylinder Connect the gas line to the quick lock gas inlet connector at the rear of the machine 7 Connect the regulator to the cylinder Connect the gas lead to the regulator Set the flow to 8 12 l min 4 Connect the Earth cable connector to the terminal 5 Connect the torch switch lead to the torch remote receptacle 1 Turn on the machine using the ON OFF switch 2 S...

Page 23: ...Cup on the work piece with the Tungsten Electrode 1 3mm from the work piece this method will provide a clean positive arc ignition 5 Press the torch switch and the arc will ignite across the gap between the tungsten and work piece Hold even distance of about 2mm gap between the tungsten and work piece to maintain the arc 6 Release the torch switch to bring in the end of the welding sequence depend...

Page 24: ...rs 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 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 ...

Page 25: ...ecessary 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 ...

Page 26: ...ps is a percentage of peak amperage As a rule use enough background cur rent 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 P...

Page 27: ... 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 AC AC DC ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balanc...

Page 28: ...nect the gas regulator to the Gas Cylinder Connect the gas line to the quick lock gas inlet connector at the rear of the machine 7 Connect the regulator to the cylinder Connect the gas lead to the regulator Set the flow to 8 12 l min 4 Connect the Earth cable connector to the terminal 5 Connect the torch switch lead to the torch remote receptacle 1 Turn on the machine using the ON OFF switch 2 Sel...

Page 29: ...he welding current is maintained by the torch remaining on 2 Releasing the torch switch stops the welding by introducing down slope and the current falls to minimum level and then terminates the welding current and introduces the post flow gas 4T Selection provides 4 times function of the torch switch 1 Pressing the torch switch gives arc ignition and initializes the welding current 2 Releasing th...

Page 30: ...e 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 resist ance of the electron flow during this half cycle rectification The lack of current flow during this half cycle makes the AC arc unstable To overcome this lack of flow during one half of the cycle a high frequency HF voltage is ...

Page 31: ...elding machine More current flow from the direct polarity produces stronger arc energy and cur rent 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 BALANCED SQUARE WAVE FORM Balance Adjusted for More Oxide Cleansing Action Hotter Tung...

Page 32: ... Torch Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse Hz OFF AC AC DC ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz P...

Page 33: ...eriment 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 result AC AC DC ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remo...

Page 34: ...ending 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 ...

Page 35: ...ALARM AC PULSE DC PULSE DC Job Recall Torch Cycle Volts ADJUSTMENT Finish Current Start Current Peak Current Base Current Ignition Current Ignition Time Current Arc Force ON Power Remote ON OFF AC Balance AC Hz Pulse Pulse Hz OFF 3 Activate the remote control Press the Remote ON OFF key the LED will illuminate when the Remote Function is on Remote Hand Amp Control Connection AC AC DC ALARM AC PULS...

Page 36: ...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 37: ...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 38: ...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 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 ...

Page 39: ...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 Part Description TR0006 10 1 0mm x 175mm zirconiated tungsten electrode 1 TR0006 16 1 6mm x 175mm zirconiated tungsten electrode 1 TR0006 24 2 4mm x 175mm zirconiated tungsten electrode 1 TR0006 32 3 2mm x 175mm zirconiated tungsten ...

Page 40: ...0 15 l min flow rate Check hoses and fittings for holes leaks etc Moisture on the base metal Remove all moisture from base metal before welding Contaminated base 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 ...

Page 41: ...tal Incorrect filler wire Check the filler wire and change if necessary 8 Arc difficult to start or will not start DC welding Possible Reason Suggested Remedy 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 Tungsten ...

Page 42: ... 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 43: ...r Only 3 Years Clause 3 UNI 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 Claus...

Page 44: ...oods 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...

Page 45: ...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 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 Bo...

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Page 48: ...W 2166 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 ABN 14 001 804 422 Welding Guns Of Australia PTY LTD 2013 ...

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