Unimig KUMJRRW250 Operating Manual Download Page 3

Page: 3 / 51

CONTENTS PAGE

Warranty 2
Technical Data, Product Information

Safety - Cautions

5-7

Machine Layout Pictogram

Installation Operation Cautions

Installation & Operation for MMA (stick) Welding

MMA (Stick) Welding Information

11-12

Installation & Operation for MIG Welding with Gas

13-14

Wire Feed Drive Roller Selection

Wire Installation Set up Guide

Installation & Operation for MIG Welding with No Gas

17-18

Installation Guide for Mig Torch Liner Installation

MIG Torch and Wire Feeder Set Up Guide for Aluminium Mig Wire

20-21

Installation & Operation for MIG Welding with Spool Gun

22-23

MIG (Metal Inert Gas) Welding

24-25

Basic MIG Welding Guide

26-29

Installation & Operation for DC TIG Welding with Lift Arc

30-31

DC TIG Welding

32-33

Tungsten Electrodes

34-35

SB24 MIG Torch Parts Breakdown

36-37

SPG200 Spool Gun Torch Parts Breakdown

38-39

26VTIG Torch Parts Breakdown

40-41

MIG Welding Shooting Guide

42-43

TIG Welding Shooting Guide

44-45

MMA Welding Trouble Shooting Guide

Machine Spare Parts Breakdown

Warranty 48-50

Summary of Contents for KUMJRRW250

Page 1: ...e read and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KUMJRRW250 YEARS Warranty Power Source 3 Welding Guns Of Australia PTY LTD 2016 ...

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

Page 3: ...lation Guide for Mig Torch Liner Installation 19 MIG Torch and Wire Feeder Set Up Guide for Aluminium Mig Wire 20 21 Installation Operation for MIG Welding with Spool Gun 22 23 MIG Metal Inert Gas Welding 24 25 Basic MIG Welding Guide 26 29 Installation Operation for DC TIG Welding with Lift Arc 30 31 DC TIG Welding 32 33 Tungsten Electrodes 34 35 SB24 MIG Torch Parts Breakdown 36 37 SPG200 Spool ...

Page 4: ...machine with added MMA and TIG function The MIG function allows you to weld with both Gas Shielded and Gasless wire applications Easy stepless adjustment of voltage and wire feed make for easy setting of welding parameters giving excellent professional welding results Wire inch gives easy feeding of the wire during set up without gas wastage and the Burn Back adjustment leaves the wire out ready f...

Page 5: ...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 6: ...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 7: ...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 8: ...nection 10 Output terminal 11 Euro Mig Torch Connector MIG MAG 12 Voltage Adjustment Knob MIG MAG 13 Amperage Adjustment Knob MMA TIG 14 Thermal Overload LED 15 Mains Power LED 14 15 1 3 2 12 10 11 8 19 18 13 4 5 6 7 9 BACK PANEL LAYOUT 16 Input power cable 17 Power switch 18 Fan 19 Gas Inlet 20 Data Plate 16 20 17 INTERNAL PANEL LAYOUT 21 Wire Inch Button 22 Burn back control 23 Spool holder asse...

Page 9: ...tents 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 ...

Page 10: ...ty 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 2 Connect earth lead to 1 Set MIG TIG MMA 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 ...

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 a...

Page 13: ...he 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 Caution Disconnect the Elec...

Page 14: ...the welding parameters using the wire feed inductance 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 12 Press and hold the inch wire button to feed the wire down the torch cable through to the torch head 11 Remove the gas nozzle and contac...

Page 15: ...n 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 groove Aluminium wire has a lot less column strength can bend easily and is therefore more di...

Page 16: ...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 pressure roller and apply a ...

Page 17: ...ghten it 6 Fit the correct size Knurled drive roller for Gas Less Flux Core wire 7 Place the Wire Spool onto the Spool Holder Note the spool retaining nut is Left Hand thread 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 Caution Disconnect the Electrode Holder cable from the machin...

Page 18: ... gas nozzle to the torch head 16 Set the welding parameters using the voltage inductance and wire feed 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 17 Adjust the burn back control to prevent the wire sticking in the weld pool 16 Set welding paramete...

Page 19: ...orch 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 the liner retaining nut 3...

Page 20: ...ner retaining nut together with the liner o ring 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 9 Cut the liner flush with the end of liner retaining nut using a sharp box cutter knife 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 li...

Page 21: ...ct tip of the correct size to match the diameter of the wire being used 17 Fit the remaining front end parts to the torch neck ready for welding 17 Fit the remaining front end parts to the torch neck ready for welding 11 Install a U groove drive roller of the correct size for the diameter wire being used 7 Place aluminium wire onto spool holder Feed the wire through the inlet guide tube on to the ...

Page 22: ...uro Mig torch connection socket on the front panel and tighten it Connect the Spool Gun control cable to 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 pu...

Page 23: ...ntrol 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 the tension arm will allo...

Page 24: ...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 25: ...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 26: ... 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 27: ...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 28: ...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 29: ...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 30: ...ket 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 10 l min 6 Set the welding current using the amperage control dial 3 Connect earth lead to ...

Page 31: ...6 Turn on the Gas Valve located on the tig torch handle 7 Lay the outside edge of the 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 6 Turn on ...

Page 32: ...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 33: ... 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 34: ...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 35: ...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 36: ... UG8015 Handle 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 1...

Page 37: ...ip Holder QTY2 SB24 Gas Diffuser Part Number Description PCGD24 Gas Diffuser 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...

Page 38: ...ll 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 NEXT PAGE Tip Holder 20 NEXT PAGE Contact Tip 21 NEXT PAGE Gas Nozzle 22 LML2140 Welding Cable 23 ES1201 Spring Support Back 24 EH2201 Adaptor Su...

Page 39: ...m PCTZR009 12 Contact Tip Steel Long Life 1 2mm PCTAL0009 09 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 SPG200II Gas Diffuser Part Number Description PCGD24 Gas Diffuser Ceramic SPG200II Gas Nozzle Part Number Description PGN24CYL Cylindrical Nozzle PGN24CON Conical Nozzle PGN24TAP Tapered Nozzle V Groove Dri...

Page 40: ...d WP26VF Torch head flexible 2 57Y02 Back cap long 3 57Y03 Meduim back cap 4 57Y04 Short back cap 5 UERBS Blank Kit 6 UERSP1 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 Leath...

Page 41: ...mm 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 th...

Page 42: ... 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 43: ...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 44: ...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 g...

Page 45: ...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 ...

Page 46: ... 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 47: ... 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 48: ...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 49: ...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 50: ...51 ...

Page 51: ...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 2016 ...

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