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Unimig RazorWeld MS500, Operating Manual

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Unimig RazorWeld MS500 Operating Manual Download Page 4

4

SECTION 1- SAFETY SPECIFICATION

Advice to the user about the safety:

 

N.B: the information contained in the manual can be changed without notice.

MEANING OF THE WARNINGS 
Watch out! There are possible hazards with its procedure. The possible hazards are show in the following pages 5-10.

These symbols mean Warning! Watch out! Possible electric shock, Moving parts hazard, Hot parts hazard 
consult  symbols and related instruction below for necessary actions to avoid hazards
 

These symbols warn of danger for persons as well as possible damage to the machine.

When you see these symbols watch out, and follow the related instruction to avoid the hazards.
•  Only qualified personal should install ,maintain ,operate or repair this unit .
•  During operation, keep everybody, especially children away,
 

ATTENTION

CAUTION

WARNING

ATTENTION

CAUTION

WARNING

ATTENTION

CAUTION

WARNING

SAFETY

IMPORTANT:

 

BEFORE INSTALLING, OPERATING OR CARRYING OUT  

MAINTENANCE ON THIS MACHINE, READ THE CONTENTS OF THIS MANUAL 
CAREFULLY, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS 
FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.  
PAY PARTICULAR ATTENTION TO THE SAFETY RULES.  

This manual refers to safety measures that must be adhered to for safe operation of your Mine Spec 500 Generator 
Welder. Please read and understand these warnings and instructions before use. Failure to do so could result in  
serious injury or death. Mine Spec 500 Generator Welder should only be used by operators who are properly trained 
and qualified in the safe use of this type of equipment. We recommend that you read technical information published 
by the Welding Technology Institute of Australia (WTIA): WTIA Technical Note 7 Health and safety in welding (2004)
Further information and copies of these publications, and technical support in welding and related activities, are  
available from WTIA Tel: +61 (0)2 9748 4443 Fax; +61 (0)2 9748 2858 or email [email protected]. For information 
about other publications and the activities of the WTIA and WGA visit www.wtia.com.au. or www.unimig.com.au

Summary of Contents for RazorWeld MS500

Page 1: ...ease read and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL MS500 Welding Guns Of Australia PTY LTD 2013 YEARS Warranty Power Source 2 ...

Page 2: ...ct range represents 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 inter...

Page 3: ...0 31 Stop engine 31 Safety Features 36 37 Gouging Mode Setup Operation Gouging mode setup operation 38 39 Gouging tecninal notes 40 41 Cellulose MMA Mode Setup Operation Cellulose MMA mode setup operation 42 43 MMA tecnical notes 44 45 DC TIG Mode Setup Operation DC TIG mode setup operation 46 47 TIG tecnical notes 48 49 MIG FCAW Setup Operation MIG FCAW mode setup operation 50 Remote control conn...

Page 4: ... OUT MAINTENANCE ON THIS MACHINE READ THE CONTENTS OF THIS MANUAL CAREFULLY WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE OPERATIVE LIFE SPAN OF THE MACHINE PAY PARTICULAR ATTENTION TO THE SAFETY RULES This manual refers to safety measures that must be adhered to for safe operation of your Mine Spec 500 Generator Welder Please read and understand these warnings and instructi...

Page 5: ...n making input connections attach proper grounding conductor first double check connections Turn off all equipment when not in use If earth grounding of the work piece is required ground it directly with a separate cable Do not touch the electrode if you are in contact with the work ground or another electrode from a different welder Use only well maintained equipment repair or replace damaged par...

Page 6: ...explosion even though the vessel has been cleaned Vent hollow castings or containers before heating cutting or welding They may explode Do not weld where the atmosphere may contain flammable dust gas or liquid vapours such as petrol Have a fire extinguisher nearby and know how to use it Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to a...

Page 7: ...essive 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 drape welding cables over the cylinder Never weld on a pressurised gas cylinder it will explode and kill you Open the cylinder valve slowly and turn your face ...

Page 8: ...e engine is warm and checking is needed and there is no overflow tank follow the next statements Wear safety glasses and gloves and put a rag over radiator cap turn cap slightly and let pressure escape slowly before completely removing cap Engine exhaust gases can kill Use equipment outside in open well ventilated areas Battery acid can burn skin and eyes Do not tip battery Replace damaged battery...

Page 9: ...r unplug electric motors or equipment before starting or stopping engine HIGH VOLTAGE attention high voltage Where high voltage is present it can be dangerous to touch High voltage can kill Flying sparks can cause injury Wear a face shield to protect eyes and face Sharpen tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and any body protection Spark...

Page 10: ...c welding can cause injury Electromagnetic energy can interfere with sensitive electronic equipment Such as microprocessors computers and computer driven equipment such as robots be sure all equipment in the welding area is electromagnetically compatible to reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding equipment 1...

Page 11: ...onnect instead to engine block 11 Jumper cables Observe polarity and make connection in numbered sequence shown 12 Once dead battery is charged disconnect cables in sequence shown 1 Warning watch out There are possible hazards as shown by the symbols 2 Moving parts such as engine s fans motors and belts and the generator s rotors can cut fingers hands and cause injury keep away from moving parts E...

Page 12: ...rind or drill on base of unit 1 Warning Watch out There are possible hazards as shown by the symbols 2 Falling equipment can cause serious injury and damage 3 Use lifting eye to lift or move unit only Use proper equipment when lifting 4 Do not use lifting eye to lift and support unit and trailer or other heavy devices or accessories 1 Warning watch out There are possible hazards as shown by the sy...

Page 13: ... to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding do not weld near flammables 3 2 Welding sparks can cause fires have a fire extinguisher nearly and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt Collar...

Page 14: ...el 1150kg DUTY CYCLE X RATED CURRENT AMPERAGE RANGE 30 500 A 21 2 40 V 60 100 500A 387A RATED VOLTAGE 40V 35 5V OCV 75V TIG DC AMPERAGE RANGE DUTY CYCLE X RATED CURRENT RATED VOLTAGE OCV STICK DC 30 500A 11 2 30V 30V 25 5V 75V 60 100 500A 387A RANGE VOLTAGE DUTY CYCLE X RATED CURRENT RATED VOLTAGE OCV 15 5 40V 30 500A 39V 34V 75V 60 100 500A 387A MIG DC 500A or 20KW 6 4LPH 400A 5 2LPH 300A 3 8LPH ...

Page 15: ... Current range 30 500A 11 30V Duty cycle 60 100 Rated current 500A 387A Rated voltage 30V 25 5V O C V 75V MIG flux cored Voltage range 15 40V 20 500A Duty cycle 60 100 Rated current 500A 387A Rated voltage 39V 34V O C V 75V Fuel consumption 500A OR 20KW 7 1LPH 400A 5 4LPH 300A 3 9LPH 200A 3 0LPH 100A 2 3LPH NO LOAD RUN 1 8LPH Generator AC Frequency 50HZ Phases 1P 3P Max power 4 6KW 26KW with no we...

Page 16: ... the following ambient temperature 25O C relative humidity 30 Altitude 500m above sea level In an approximate way one reduces of 1 every 100m Altitude and of 2 0 for every 5O C above 25O C Dimension and weight and operating angle ...

Page 17: ...el surface Check that the air gets rotated completely and the hot air sent out does not come back inside the set so as to cause a dangerous increase of the temperature Make sure that the machine does not move during its operation secure it properly so that is cannot move during operation Before moving check that the engine is off and all cables are disconnected ...

Page 18: ...there is danger of electric shock which can cause death or serious burns The electrode and welding cables etc Are live when the unit is operating do not touch any electrical parts or the electrode while standing in water or with wet hands feet or clothes Insulate yourself from the work surface while welding Use insulating materials to avoid physical contact with the work surface and the floor Alwa...

Page 19: ...Use in open space air swept or vent exhaust gases far from the work area Movement Always securely fasten welding generator onto transport vehicle or trailer and comply with all transport rules and other applicable codes ...

Page 20: ...s fuel and other liquids such as oil coolant ect and conforms to local rules and regulations Before starting engine Battery check Check the state of the battery if the reading of battery voltmeter is below 12V the battery should be charged If the battery can not be charged please replace the dead battery Do not open the battery ...

Page 21: ... viscosity grade of lubricating oil is used for the ambient temperature range in which the engine will run as shown in the chart below Air filter Fuel Check that the dry air filter is correctly installed and that there are no leaks around the filter which could lead to infiltrations of non filtered air to the inside of the engine To get the correct power and performance from the engine use good qu...

Page 22: ...rcuit restore the level with water To replace the liquid coolant follow the operations described in the engine operating manual To drain the coolant open the coolant outlet at the bottom of the unit base Open the radiator cap to allow complete drainage tighten the valve and refill with a 50 50 antifreeze water solution use an automotive grade low silicate ethylene glycol antifreeze The cooling sys...

Page 23: ...and or grease Remove any excessive dirt or grease buildup Repair any faults that were identified during inspection Inspect the cooling system for cracks and loose clamps Inspect the alternator and accessory drive belt for cracks breaks and other damage Inspect the wiring for loose connections and for worn or frayed wires Check the fuel supply drain water for water separator Check the oil level dai...

Page 24: ...iesel fuel can gel in cold weather contact local fuel supplier for fuel information Use correct grade oil for cold weather Fuel filter Solenoid speed control Oil filling port Oil filter Oil dipstick Fuel primary filter water separator Drip tray Coolant filling port ATTENTION CAUTION WARNING This unit has a low oil pressure shutdown switch However some conditions may cause engine damage before the ...

Page 25: ...t run up position auto down position 2 when run position is selected the engine running speed will be 1500rpm 3 when the auto position is selected if the generator has no load the running speed will be 1150rpm the engine running speed will reduce from 1500rpm to 1150rpm if the welding is stopped or there is no auxiliary power being used The engine running speed will rise from 1150rpm to 1500rpm im...

Page 26: ...ush button switch 2 it is only used to start the engine 3 when the engine is running do not push the button or it will cause damage to engine 1 Oil pressure warning lamp 2 Red lamp 3 During engine running if the oil pressure is below 69kpa the engine will stop and the lamp lights up 1 high water temperature warning lamp 2 Red lamp 3 If the engine water temperature is too high the lamp lights and t...

Page 27: ...about 2 0 5 0 100kpa When the oil pressure is below 1 0 100kpa the light will become red And will generate a alarm signal 1 Indicator of the fuel level of the tank 2 It has a internal lamp to read the gauge at night 3 When the fuel level is below 10mm the fuel level device will generate a alarm signal to stop engine Battery isolation switch When the battery isolation switch is selected to the ON p...

Page 28: ...r auto position 4 Before using the welder or auxiliary power let the engine warm up run the engine at idle for 3 5 minutes and per form a walk around inspection for any fluid leaks and check all gauges during warm up period Engine speed control switch position Run Auto Engine running Speed 1500rpm 1150 1500 1150 Description Engine Running speed will be 1500rpm continously Whether the welder or aux...

Page 29: ...ut 6 engine block Engine preheating device 1 Preheating 1 When ambient temperature is below 0O C you can use the preheating 2 Press the preheat and hold on for 30 seconds to a maximum of 60 seconds If temperature is lower then more preheat time is required 3 Release the preheating and then start engine 4 Do not press the preheating button while engine is running ATTENTION CAUTION WARNING 2 3 4 5 6...

Page 30: ... 1550rpm 80 99O C 2 5 100kpa 14 14 5VDC The reading changing from left line 1 2 right line according to the fuel capacity All lights will all turn off Item Description Start the engine please refer to the figure 1 Before starting the engine turn the battery isolation switch to the ON position 1 Turn the engine control switch 3 to ON position Turn the speed control switch 2 to auto Check the five g...

Page 31: ...for the first time or after and extended period of time not operating it will take longer than normal to start because the fuel pump has to fill the fuel system Please bleed the fuel system as indicated in Perkins instruction manual Stop engine please refer to the figure 1 Disconnect or shut off any loads which are connected to the unit auxiliary outputs Stop welding Set the engine speed control s...

Page 32: ...0 4 0 2x70 2ea 2 0 2x70 2ea 2 0 2x95 2ea 3 0 50 1 70 2 0 95 3 0 120 4 0 2x70 2ea 2 0 2x95 2ea 3 0 2x95 2ea 3 0 2x120 2ea 4 0 60 1 0 95 3 0 120 4 0 2x70 2ea 2 0 2x95 2ea 3 0 2x95 2ea 3 0 2x120 2ea 4 0 2x95 2ea 3 0 60 1 0 95 3 0 120 4 0 2x70 2ea 2 0 2x95 2ea 3 0 2x120 2ea 4 0 2x120 2ea 4 0 2x95 2ea 3 0 Weld cable size and total cable copper length in weld circuit Not exceeding 30m 45m 60m 70m 90m 10...

Page 33: ... is overloaded The duty cycle has been exceeded the thermal relay will shut off the inverter the protection light will turn ON The welding machine will still be supplied with AC input power therefore the fan will still work to cool the machine Once the machine is cooled the thermal overload will reset and welding can recomence Welding operation controls Figure 3 front panel of the welding and auxi...

Page 34: ...rt function to help electrode start and arc force function DC TIG PROCESS CC 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 tungsten electrode There is a particular technique called rocking the cup used in the ...

Page 35: ...e adjusted to optimise welding ARC charcteristics with a variety of electrodes and is only used when MMA or CELLULOSE mode is selected It is used for MIG FCAW mode when this switch is ON the OCV for CV mode is about 73VDC When this switch is OFF the OCV is controlled by remote control or vlotage regulation knob Item 12 13 14 15 16 17 18 19 20 21 22 23 24 Name VRD on VRD off Gas out CB1 1 230v 15A ...

Page 36: ...d metal to metal contact VRD Voltage Reduction Device lowers the voltage in CC MMA and CC air arc gouging modes to below 12 volts in less than 300 milliseconds Mine Specification Safety Features Emergency engine stop button located at eye level to quickly shut MS500 down in case of emergency VRD Voltage Reduction Device lowers the voltage in CC MMA CC CELLULOSE and CC air arc gouging modes to belo...

Page 37: ...chanically using lockable doors All wiring looms are encased in conduit with rubber boots fitted to avoid mechanical wear and damage RCD protection for all high voltage circuits Lockable dual pole battery isolation selector for safer maintenance Note can only be locked in off position ...

Page 38: ...orch and set airpressure to 80 100 psi 5 Connect the Earth lead to the output socket 6 Select Gouging using the welding selector mode switch 5 Connect earth lead to negative output socket 3 Connect Air gouging torch to the constant current positive output socket 1 Ensure the weld terminal switch is turned to the OFF position before starting engine 6 Select Gouging using the welding selector mode s...

Page 39: ... blow away an molten metal produced 12 Strike the carbon arc electrode against the workpiece to create and arc and hold the electrode steady to maintain the arc 13 Start cutting slowly Hold the carbon arc electrode slightly above the work maintaining the arc while travelling at an even speed 14 Wait for the metal to cool and carefully chip away the dross to reveal the gouged metal below 9 Set the ...

Page 40: ...lly at the molten pool This was not very successful but with great ingenuity and further development Stepath invented the Air Carbon Arc torch whereby compressed air is fed through the torch head and exited behind and beneath the carbon electrode the localised air blast provided fast and efficient removal of molten material from the molten pool Air Carbon Arc Gouging now provided a perfect process ...

Page 41: ...ot suitable for air carbon arc gouging Most three phase welding power sources of sufficient amperage output may be used for air arc gouging The arc voltage required for air carbon arc gouging and cutting ranges from 35 to 56 volts therefore the open circuit voltage needs to be at least 60 volts For most applications the carbon electrode is connected DC and the electrode should not extend more than ...

Page 42: ...des require a different polarity for optimum results refer to the electrode manufacturers information for the correct polarity Most GP electrodes are Electrode connected to output socket whereas CELLULOSE electrodes are connected to the negative output socket earth connected to the output socket for most GP electrodes and connected to the posivtive for CELLULOSE electrodes 3 Select CELLULOSE or MM...

Page 43: ...or CELLULOSE mode is selected ARC FORCE Adjusting the arc force during welding will change the short circuit current It can be adjusted to optimise welding ARC charcteristics with a variety of electrodes and is only used when MMA or CELLULOSE mode is selected 5 Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer 6 Place the electr...

Page 44: ... 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 electrodes are identified by the wi...

Page 45: ...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 46: ...nt current 6 a Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder b Connect the gas line to the quick lock gas inlet connector gas in 1 Weld terminal switched to the OFF position 3 Select TIG using the welding selector mode switch 6 Connect gas line to Gas Regulator and connect the gas regulator to the Gas Cylinder b Connect the gas line to the quick lock gas inlet...

Page 47: ...1 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 12 Release the torch switch to bring an end to the welding sequence 7 Assemble the front end torch parts use the correct size and type of tungsten electrode for the job the tungsten electrode requires a sharpened point for DC welding 9 Lay the outside edge of the Gas Cup on the wo...

Page 48: ...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 49: ...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 50: ...torch to Euro connection on voltage sensing wire feeder 8 Connect the Earth lead on Voltage sensing wire feeder wire feeder to the output socket and clamp to work peice 9 Select Positive or Negative on voltage sensing wire feeder depending on type of wire being used 10 Turn the weld terminals to the ON position 1 Weld terminal switched to the OFF position 3 Select MIG FCAW using the welding select...

Page 51: ...eder YH120 in this case it is necessary to switch the welder and wire feeder so they can operate and it can adjust the welding voltage in the wire feeder and you can read the pre voltage on the digital meter of the wire feeder YH120 MIG MODE The remote control can be connected from the front panel to the connector on the wire feeder CS501 in this case it is necessary to switch the welder so the op...

Page 52: ...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 53: ...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 54: ... 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 55: ...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 56: ...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 57: ...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 58: ... 6 6 for start procedure 3 Select MIG FCAW using the welding selector mode switch 4 Connect the RWS wire feeder to the constant voltage output socket 5 Connect the Earth lead on MINE SPEC 500 to the output socket and clamp to work peice 6 Connect gas hose from RWS wire feeder to Gas Regulator and connect the gas regulator to the Gas Cylinder 7 Connect MIG torch to Euro connection on RWS wire feede...

Page 59: ...input circuit of welder power source This is 3P 32A circuit breaker and R C D it control the 3 phase auxiliary power 3 400VAC This is 2P 15A circuit breaker and R C D it control 1 phase 230VAC auxiliary power 5 4 3 2 1 Item 1 2 3 4 Name Circuit breaker Grounding stud 3 phase auxiliary power socket 1 phase auxiliary power socket Description 15A circuit breaker protect 1 phase auxiliary power output...

Page 60: ... necessary Disconnect the loads and wait a few minutes to allow the thermal protection to cool down before resetting by pressing the central button and then connect the load again If the protection should intervene again replace it with another one with matching intervention current specifications and or contact the service department Caution do not forcibly hold the central button of the thermal ...

Page 61: ... Please read carefully the engine manual to server the engine Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period check inspect change or adjust clean replace to be done by factory authorized service agent reference Every 8 hours Water separator Check fuel level Check coolant level Check oil level and oil quality Clean the oil leakage Every...

Page 62: ...ter Dirty condition 250hours or less Normal condition 400hours Oil filter Perkins 2654403 Oil capacity 7 8L Oil capacity with filter change 8 3L Fuel capacity 60L fuel grade 1 D or 2 D Cetane NO 40 MIN Primary filter water separator Perkins 2656F823 pre fuel filter ASSY Perkins 26550005 filter secondary filter Perkins 2654403 filter fill filter with fuel before installing refer to instruction on f...

Page 63: ...Valve clearance cold Perkins 1103A Intake 0 008in 0 20mm Exhaust 0 018in 0 45mm Perkins 1103A Fan belt Perkins 2614B655 Perkins 1103A Injectors 2645k016 injector assy Nozzle 2645k613 Intake air heater 2666A016 Glow plug Have only trained technician maintain injection pump and injectors AIR WATER or GASOLINE will harm the injection system if engine has run out of fuel or fuel filter is changed blee...

Page 64: ...too dirty 3 Presence of air in the supplying fuel circuit 4 Fuel valve and fuel pump are not powered 5 Fuel valve is powered but is not functioning properly or mechanic de vice is clamped bond 6 Fuel filter dirty clogged What to do 1 Turn the battery isolate switch to on 2 Try again 3 Charge the battery or change 4 Reset the circuit breaker 1 Charge the battery or change 1 Refill tank and bleed th...

Page 65: ...diator coolant temperature What to do 1 Check fuel and oil and coolant level See engine manual 1 Please confirm to turn off the engine control switch when you do not use the unit 2 Check the connections of the battery terminals and isolator switch and charging circuit Tighten the connection 3 Replace the battery 1 Check the connection terminal of engine idle solenoid Test the voltage between the t...

Page 66: ... 3 Water in fuel 4 Faulty fuel injector What to do 1 Inspect or clean or replace filter as needed fuel engine oil or air filter 2 If water found in tank empty the tank and refill and then purge fuel pipe 3 Check or replace the fuel injector contact the local authorized engine service shop 1 see engine manual 2 consult the authorized engine service shop ...

Page 67: ...switch is on digital meter has reading but fan does not run Overheat warning lamp is lighting welding power source has no output Welder power has no welding output Problem Cause What to do Consult the authorized unimig service shop Consult the authorized unimig service shop Consult the authorized unimig service shop Consult the authorized unimig service shop Consult the authorized unimig service s...

Page 68: ...Cause Problem Cause Loose Remote control connection Gun trigger circuit is open Faulty gun trigger the gun trigger switch can not contact well Gas hose or gas valve are blocked What to do Consult the authorized unimig service shop Consult the authorized unimig service shop Consult the authorized unimig service shop What to do Make sure that the remote control plug is stay in good contact with the ...

Page 69: ...l and guide tubes Gun cable kinked and or twisted Drive roll loose Worn drive roll Gun cable dirty Worn nozzle or cable liner Partially flashed or melted contact tip Wire reel brake tension set too high or low What to do Check and make certain that the connection is good Replace the gun trigger switch Check and make sure that remote control cable connectors are in good contact Check and clean the ...

Page 70: ...tripped due to excessive current 3 RCD is tripped due to faulty ground current 1 Engine speed is running at the idle The engine speed is about 1200rpm What to do Call service centre 1 Check the main power switch and 3P switch then turn on 2 Check the wire and sockets and make sure no faults ground in the circuits or tools connected turn on the 3P switch with RCD 3 Make sure that 3P wire stay in go...

Page 71: ...71 Section 9 Electric diagrams Circuit diagram for CS 501 wire feeder TIG remote control connector ...

Page 72: ...72 Circuit diagram for LN 25P wire feeder adapter ...

Page 73: ...73 Circuit diagram for engine control system ...

Page 74: ...74 Circuit diagram for generator output welding power and auxiliary power ...

Page 75: ...75 Circuit diagram for welding power source ...

Page 76: ...76 Circuit diagram for welding power source ...

Page 77: ...acket 3 Welding power source 4 Front panel assembly 5 Rear cover assembly 6 Isolate switch assembly 7 Electric distribution cabinet 8 Main control box assembly 9 Left side cover assembly 10 Right side cover assembly 11 Top cover assembly 12 Front protection cover ...

Page 78: ...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 79: ...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 80: ...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 84: ...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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