Unimig KUMJRRW250MIG Operating Manual Download Page 42

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1: No arc

Possible Reason

Suggested Remedy

Incomplete welding circuit

Check earth lead is connected. Check all cable connections.

Wrong mode selected

Check the MMA selector switch is selected

No power supply

Check that the machine is switched on and has a power supply

2: Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Reason

Suggested Remedy

Arc length too long

Shorten the arc length

Work piece dirty, contaminated or moisture

Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal

Damp electrodes

Use only dry electrodes

3: Excessive Spatter

Possible Reason

Suggested Remedy

Amperage too high

Decrease the amperage or choose a larger electrode

Arc length too long

Shorten the arc length

3: Weld sits on top, lack of fusion

Possible Reason

Suggested Remedy

Insufficient heat input

Increase the amperage or choose a larger electrode

Work piece dirty, contaminated or moisture

Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal

Poor welding technique

Use the correct welding technique or seek assistance for the correct technique

4: Lack of penetration

Possible Reason

Suggested Remedy

Insufficient heat input

Increase the amperage or choose a 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 assistance 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 smaller electrode

Incorrect travel speed

Try increasing the weld travel speed

6: Uneven weld appearance

Possible Reason

Suggested Remedy

Unsteady hand, wavering hand

Use two hands where possible to steady up, practise your technique

7: Distortion − movement of base metal during welding

Possible Reason

Suggested Remedy

Excessive heat input

Reduce the amperage or use a smaller electrode

Poor welding technique

Use the correct welding technique or seek assistance for the correct technique

Poor joint preparation and or joint design

Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the
correct joint design and fit up

7: Electrode welds with different or unusual arc characteristic

Possible Reason

Suggested Remedy

Incorrect polarity

Change the polarity, check the electrode manufacturer for correct polarity

The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction, the manufacturer’s recommendations
should be strictly adhered to and followed.

| RAZOR MIG 250 Manual

MMA (STICK) WELDING TROUBLE

SHOOTING

Summary of Contents for KUMJRRW250MIG

Page 1: ...KUMJRRW250MIG OPERATING MANUAL Please read and understand this instruction manual carefully before the installation and operation of this equipment Welding Guns Of Australia PTY LTD 2019 ...

Page 2: ...ments 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 UNIMIG welders and plasma cutters are manufactured to be compliant with AS NZ 60974 1 guaranteeing you electrical safety and performance WARRANTY 2 Years from date of purchase Welding Guns Of Australia PTY LTD Ltd warr...

Page 3: ...ED SET UP FOR ALUMINIUM WIRE 18 MIG WELDING GUIDE 20 SPOOL GUN SETUP 26 LIFT ARC DC TIG WELDING SETUP 28 LIFT ARC DC TIG OPERATION 29 DC TIG WELDING GUIDE 30 MMA STICK WELDING SET UP 34 MMA STICK WELDING GUIDE 35 SB24 MIG TORCH SPARES 37 MIG WELDING TROUBLE SHOOTING 39 MIG WIRE FEED TROUBLE SHOOTING 40 TIG WELDING TROUBLE SHOOTING 41 MMA STICK WELDING TROUBLE SHOOTING 42 SPARE PARTS IDENTIFICATION...

Page 4: ...t 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 harmful to p...

Page 5: ...ecause gas cylinders are normally part of the welding cutting 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 cutting electrode or earth clamp to touch the gas cy...

Page 6: ...emperature inside the equipment The machine will be ready for use again when the internal temperature reaches safe level iii 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 po...

Page 7: ... 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 5 If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying with soapy water bubbles will appear at the leakage point 6 Tighten clamps or fittings ...

Page 8: ...g a portable machine This makes the RAZOR MIG 250 ideal for welders needing powerful performance both in the workshop and site work With a Spool Gun connection and the ability to run all MIG Wire spool sizes the RAZOR MIG 250 is a must have for every serious welder MACHINE PACKAGE KUMJRRW250MIG RAZOR MIG 250 Power Source 4m SB24 Sure Grip MIG Torch including consumables 4m Twist Lock Electrode Hol...

Page 9: ...E 40 C 30 250A MIG WIRE SIZE RANGE 0 6 1 2mm MIG WIRE SPOOL SIZE 1kg 5kg MIG WELDING THICKNESS RANGE 2mm 12mm DRIVE ROLLER SIZE 30 22 TIG SPECIFICATIONS TIG FUNCTION TYPE DC Lift Arc TIG WELDING CURRENT RANGE 10 250A TIG DUTY CYCLE 40 C 30 250A TIG WELDING THICKNESS RANGE 1mm 6mm STICK SPECIFICATIONS STICK WELDING CURRENT RANGE 10 250A STICK DUTY CYCLE 40 C 30 250A STICK ELECTRODE RANGE 2 5 4 0mm ...

Page 10: ...isplay 10 VRD LED 11 Wire Feed Adjustment Knob 12 Inductance Control 13 MIG TIG MMA Selector 14 MIG Spool Gun Selector 15 Spool Gun Connection 16 Power Switch 17 Gas Inlet 18 Power Cable 19 Data Plate 20 Wire Spool Holder 21 Burn Back Adjustment 22 Wire Inch Button 23 Geared Wire Drive 9 10 11 12 13 14 15 18 19 23 22 21 20 1 2 3 4 5 6 7 8 16 17 10 RAZOR MIG 250 Manual MACHINE PARTS LAYOUT ...

Page 11: ...ires The weld power cable goes into the opposing negative or positive socket 5 Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder 6 Fit the correct type and size of drive rollers V Groove for Hard Wires U Groove for Aluminium Knurled for Flux Cored 7 Place wire onto spool holder spool retaining nut is left hand thread Feed the wire through the inlet guide tube into...

Page 12: ...der 16 Adjust the burn back control to prevent the wire sticking in the weld pool Burn back control is located above the wire feed motor 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 11 Press and hold the inch wire button to feed the wire down the torch cable through to the torch head 14 Carefully open the valve of the gas cyli...

Page 13: ...en it IMPORTANT When connecting the torch be sure to tighten the connection A loose connection can result in the connector arcing and damaging the machine and gun connector This damage is not covered under warranty 6 Fit the correct size Knurled drive roller for Gas Less Flux Core wire 7 Place wire onto spool holder spool retaining nut is left hand thread Feed the wire through the inlet guide tube...

Page 14: ... size contact tip over the wire and fasten tightly into the tip holder 16 Adjust the burn back control to prevent the wire sticking in the weld pool Burn back control is located above the wire feed motor 11 Remove the gas nozzle and contact tip from the front end of the MIG torch 14 Fit the gas nozzle to the torch head 12 Press and hold the inch wire button to feed the wire down the torch cable th...

Page 15: ... push the wire out of shape 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 ha...

Page 16: ...t and screw to hold the new position 2 Note the tension spring adjuster and spool locating pin 5 Feed the wire through the drive roller and into the outlet guide tube of the wire feeder 8 A simple check for the correct drive tension is to bend the end of the wire over hold it about 100mm from your hand and let it run into your hand it should coil round in your hand without stopping and slipping at...

Page 17: ...ont end parts 9 Fully screw down the liner retaining nut and nip it up tight This compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed 3 Carefully pull out and completely remove the liner 6 Fit the liner retaining nut and screw only 1 2 way down 4 Carefully unravel the new liner avoiding creating any kinks in the liner RAZOR MIG 250 Manual...

Page 18: ... the way to exit the torch neck Be careful not to kink the liner 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 for the diameter wire being used 3 Carefully pull out and completely remove the liner 6 Replace the front end parts 4 Carefully unravel the new liner 18 RAZOR MIG 250 Manual TORCH WIRE FEED SET UP FOR ...

Page 19: ... to the machine Euro receptacle 17 Fit the remaining front end parts to the torch neck ready for welding 12 Carefully feed the Polymide liner into the inlet guide tube hole of the torch Euro receptacle 15 Cut the extended Polymide liner with a sharp Stanley knife just in front of the drive roller 13 Take the extended Polymide liner all the way up and over the drive roller RAZOR MIG 250 Manual 19 T...

Page 20: ...er spray transfer and pulsed spray each of which has distinct properties and corresponding advantages and limitations To perform MIG welding the basic necessary equipment 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 thr...

Page 21: ... 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 circuit transfer is the ...

Page 22: ...he weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration useful for welding thin materials The welds are wider and flatter allowing for minimal clean up grinding time Perpendicular Technique The wire is fed directly into the weld this technique is used primarily for automated situations or when conditions make it necessary The weld profile is generally h...

Page 23: ...duces a good level of control over the weld pool A travel angle greater that 20 will give an unstable arc condition with poor weld metal transfer less penetration high levels of spatter poor gas shield and poor quality finished weld Angle to Work The work angle is the forward back angle of the gun relative to the work piece The correct work angle provides good bead shape prevents undercut uneven p...

Page 24: ... deposit of poor quality Travel Speed Travel speed is the rate that the gun is moved along the weld joint and is usually measured in mm per minute Travel speeds can vary depending on conditions and the welders skill and is limited to the welders ability to control the weld pool Push technique allows faster travel speeds than Drag technique Gas flow must also correspond with the travel speed increa...

Page 25: ...lding zone from the atmosphere Too low flow will give inadequate coverage and result in weld defects and unstable arc conditions Too high flow can cause air to be drawn into the gas column and contaminate the weld zone Use the correct shielding gas Co2 is good for steel and offers good penetration characteristics the weld profile is narrower and slightly more raised than the weld profile obtained ...

Page 26: ...t 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 2 Set Spool Gun Standard selector to Spool Gun 7 Push the cover release button to unlock the wire feed spool cover 8 Place a spool of wire onto the Spool holder Note the...

Page 27: ...ugh the neck until it exits the contact tip holder 16 Set welding parameters using the voltage and wire feed controls 17 Adjust the burn back control to prevent the wire sticking in the weld pool Burn back control is located above the wire feed motor 10 Check to make sure that the wire passes cleanly through the drive roller into the outlet guide tube 13 Fit the contact tip over the wire and screw...

Page 28: ...th 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 Assemble front end parts of the TIG torch 6 Carefully open the valve of the gas cylinder set the flow to 6 10 l min 7 Set the welding current using the amperage control dial 1 2 3 4 28 RAZOR MIG 250 Manual LIFT ARC DC...

Page 29: ...en electrode There is a particular technique called rocking the cup used in the Lift Arc process that provides easy use of the Lift Arc function 4 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 1 Make sure the front end parts of the TIG torch are correctly assembled use the correct size and type of tungsten electrode for the job the tungsten ...

Page 30: ...ng it s molecular structure which converts it into a plasma stream This plasma stream flowing between the tungsten and the work piece is the TIG arc and can be as hot as 19 000 C It is a very pure and concentrated arc which provides the controlled melting of most metals into a weld pool TIG welding offers the user the greatest amount of flexibility to weld the widest range of material and thicknes...

Page 31: ...cular 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 smoothly and evenly along the joint while fusing the materials together It is necessary 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...

Page 32: ...t ignition delay with E3 Tungsten Electrodes actually improves over time while 2 thoriated tungsten starts to deteriorate after only 25 starts At equivalent energy output E3 Tungsten Electrodes run cooler than 2 thoriated tungsten thereby extending overall tip lifetime E3 Tungsten Electrodes work well on AC or DC They can be used DC electrode positive or negative with a pointed end or balled for u...

Page 33: ...tip The arc starts straight and remains narrow concentrated and stable ELECTRODE TIP FLAT The shape of the tungsten electrode tip is an important process variable in precision arc welding A good selection of tip flat size will balance the need for several advantages The bigger the flat the more likely arc wander will occur and the more difficult it will be to arc start However increasing the flat ...

Page 34: ...nufacturers information for the correct polarity DC Electrode connected to output socket DC Electrode connected to output socket 3 Set the welding current using the amperage control dial 6 Hold the electrode slightly above the work maintaining the arc while travelling at an even speed 4 Place the electrode into the electrode holder and clamp tight 7 To ﬁnish the weld break the arc by quickly snapp...

Page 35: ...e melted electrode metal is transferred across 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 Manual metal arc stick electrodes have a solid metal wire core and a flux coating These electrodes are identified by the ...

Page 36: ...ow a rate of travel will frequently lead to arc instability slag inclusions and poor mechanical properties MATERIAL AND JOINT PREPARATION The material to be welded should be clean and free of any moisture paint oil grease mill scale rust or any other material that will hinder the arc and contaminate the weld material Joint preparation will depend on the method used include sawing punching shearing...

Page 37: ...cription 1 SNK24 Swan Neck Assembly 2 UG1515 Ergo Handle Location Body 3 UG2514 Ergo Handle Kit C W Lock Nut 4 BXU2516 Medium Large Ergo Trigger 5 UB2517 Hanger Hook Part No Description 6 UB1518 Gun Plug Housing C W Nut 7 UB1519 S Gun Plug Nut 8 UC1528 Hybrid Gun Plug Body C W Spring Pins 9 UB1524 Gun Plug O Ring 10 UB1525 Liner Nut 1 5 4 7 2 3 8 9 10 6 RAZOR MIG 250 Manual 37 SB24 MIG TORCH SPARE...

Page 38: ... Gas Diffuser QTY2 SB24 GAS NOZZLE Part No Description QTY PGN24CYL Cylindrical Nozzle QTY2 PGN24CON Conical Nozzle QTY2 PGN24TAP Tapered Nozzle QTY2 PGN24SPOT Spot Nozzle QTY2 SB24 LINERS Part No Description SLB3M Blue Steel Liner 3 Metre 0 6 0 8mm SLB4M Blue Steel Liner 4 Metre 0 6 0 8mm SLB5M Blue Steel Liner 5 Metre 0 6 0 8mm SLR3M Red Steel Liner 3 Metre 0 9 1 2mm SLR4M Red Steel Liner 4 Metr...

Page 39: ... 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 4 Lack of Fusion failure of weld metal to fuse completely with base metal or a proceeding weld bead Possible Reason Suggested Remedy Contamin...

Page 40: ...st 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 Fit the corre...

Page 41: ... 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 grind the tungst...

Page 42: ...rode 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 assistance 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 smaller electrode In...

Page 43: ...oor holder 19 10052909 cover 20 10052708 loose sheet 21 10052563 front panel bracket Part Number Description 22 10052570 potentiometer 23 10046712 display meter 24 10062440 rocker switch 25 30000103 knob 26 10052964 brand cover 27 10052585 plug 28 10004638 quick socket 29 10052971 front panel 30 10052663 column 31 10052595 long column 32 10052602 thermoswitch 33 10052565 rectifying heat sink 34 10...

Page 44: ...rate Wire Feeder Only 3 Years Clause 3 UNI TIG Jasic Inverter TIG Power Source Only 3 Years Clause 3 UNIMIG 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 Onl...

Page 45: ...d 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 instruction material ...

Page 46: ...e 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 Body Gas Valve O ring A...

Page 47: ... RAZOR MIG 250 Manual 47 NOTES ...

Page 48: ...ia Pty Ltd ABN 14 001 804 422 PO Box 3033 Lansvale NSW 2166 AUSTRALIA 112 Christina Rd Villawood NSW 2163 Phone 1300 864 644 Fax 02 9780 4244 Email sales unimig com au www unimig com au Welding Guns Of Australia PTY LTD 2018 ...

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