Unimig KUMJRRW175MIG Operating Manual Download

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Please read and understand this instruction manual carefully
before the installation and operation of this equipment.

OPERATING MANUAL

KUMJRRW175MIG
KUMJRRW200MIG

Welding Guns Of Australia PTY LTD 2013

YEARS

Warranty

(Power Source)

Summary of Contents for KUMJRRW175MIG

Page 1: ...nd understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KUMJRRW175MIG KUMJRRW200MIG Welding Guns Of Australia PTY LTD 2013 YEARS Warranty Power Source 3 ...

Page 2: ...ge 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 interface b...

Page 3: ...Guide 15 Installation Operation for MIG Welding with No Gas 16 17 Installation Guide for Mig Torch Liner Installation 18 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 SB24 SB25 MIG Torch Parts Breakdown 30 31 SPGRW135 SPGRW200 Spool Gun Torch Parts Break...

Page 4: ...lding with high quality results including cast Iron stainless and low hydrogen An additional feature is the Spoolgun ready function that allows the simple connection of the SPGRW135 Spoolgun for the use of thin or softer wires that don t have the column strength to feed through standard MIG torches such as aluminium wire This is an industrial machine that is both lightweight and portable Being 240...

Page 5: ...ivers easy electrode welding with high quality results including cast Iron stainless and low hydrogen An additional fea ture is the Spoolgun ready function that allows the simple connection of the SPGRW200II Spoolgun for the use of thin or softer wires that don t have the column strength to feed through standard MIG torches such as aluminium wire This is an industrial machine that is both lightwei...

Page 6: ...ect input power cable for wear and tear replace the cable immediately if damaged bare wiring is dangerous and can kill Do not use damaged under sized or badly joined cables Do not drape cables over your body We recommend RCD safety switch is used with this equipment to detect any leakage of current to earth Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harm...

Page 7: ...ecause gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damaged Protect gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Insure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding electrode or earth clamp to touch the gas cylinder do not dr...

Page 8: ...ide 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 amp...

Page 9: ...inal 9 Euro Mig Torch Connector MIG MAG 10 Output terminal 11 SpoolGun Power Supply Connection 1 2 3 4 5 BACK PANEL LAYOUT 12 Power switch 13 Gas Inlet 14 Fan 15 Input power cable 16 Data Plate 15 13 16 12 INTERNAL PANEL LAYOUT 17 Burn back control 18 Spoolgun Standard selector switch 19 Inch wire feed button 20 Spool holder assembly 21 Wire feed assembly NOTE MIG 165 not geared 18 21 20 6 7 8 9 1...

Page 10: ... be paid to the polarity refer to the electrode manufacturers information for the correct polarity 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 3 Set the welding current using the amperage control dial 6 Hold the electrode slightly above the w...

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 ...

Page 13: ...d 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 Electrode Holder cable from th...

Page 14: ...in 16 Set the welding parameters using the wire feed 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 contact...

Page 15: ...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 has been developed and it has small serrations in the groove the serrations grip the wire and assist to drive it without too much pressure from the top roller The down side to the knurle...

Page 16: ...adjustment if required Carefully retighten the locking nut and screw to hold the new position NOTE MIG 165 not geared 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 NOTE MIG 165 not geared 6 Lock down t...

Page 17: ...ire 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 machine before using MIG function If cable is not disconnected welding voltage is p...

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

Page 19: ...1 2 way 7 Leaving the torch straight snip the liner approximately 3mm past the end of the torch neck 8 Place the tip holder over the end of the liner and screw into the torch neck nipping it up tight 9 Screw down the liner nut the remaining 1 2 and nip it up tight This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed 2 Remove th...

Page 20: ...ith the liner o ring 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 9 Install a U groove drive roller of the correct size to match the wire diameter being used 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the liner 4 Carefully unravel the new liner 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 5 Caref...

Page 21: ...t 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 NOTE MIG 165 not geared 7 Place aluminium wire onto spool holder Feed the wire through the inle...

Page 22: ...Gas Regulator and connect the gas regulator to the Gas Cylinder 6 Take the Spool Gun and remove the spool cover 7 Place the Wire Spool onto the Spool Holder Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling 4 Connect earth lead to 2 Set Standard Spoolgun selector switch inside door to Standard 5 Connect the gas line to the regulator and connect to the gas...

Page 23: ...obs 16 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 8 Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube Push down the tension arm lever to release the pressure of the drive roller allowing the wire to be gu...

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: ...ed 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 t...

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: ...G8015 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 13 ...

Page 31: ... 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 R...

Page 32: ...on Body 4 UB1505 Lock Nut 5 UG8015 Handle Cable Support C W Ball Joint 6 UB1521 Cable Terminal 7 UB1521 C Cable Terminal Cover 8 UB2503 30 Hyperflex Cable Assembly x 3mt UB2503 40 Hyperflex Cable Assembly x 4mt UB2503 50 Hyperflex Cable Assembly x 5mt 9 UG2514 Ergo Handle Kit C W Lock Nut Part Number Description 10 UG2516 Medium Large Ergo Trigger 11 UB2517 Hanger Hook 12 UB1522 Cable Terminal Mal...

Page 33: ...TY2 PGNS25 Shroud Spring QTY2 SB25 Gas Nozzle Part Number Description PGN25CYL Cylindrical Nozzle QTY2 PGN25CON Conical Nozzle QTY2 PGN25TAP Tapered Nozzle QTY2 PGN25SPOT Spot Nozzle QTY2 SB25 Liners Part Number Description SLB3M Blue Steel Liner 3 Metre SLB4M Blue Steel Liner 4 Metre SLB5M Blue Steel Liner 5 Metre SLR3M Red Steel Liner 3 Metre SLR4M Red Steel Liner 4 Metre SLR5M Red Steel Liner 5...

Page 34: ...LX1040 Gear Box Assembly 18 LMX2011 Inlet Guide Part Number Description 19 LGX2018 Key 20 LGX2019U DriveRoll U Groove 0 8 0 9mm 21 LZ3603 Motor 22 LYFE1001 Gun Neck 23 SEE PAGE 41 Gas Nozzle 24 SEE PAGE 41 Contact Tip 25 SEE PAGE 41 Diffuser Tip Holder with Spring 26 LYFE1011 Gun Neck Body 27 LW0101 Gas Hose 28 LGK2011 Conducting Board 29 LYH1012 Cable Support 30 LYH1013 Handle Nut 31 LYL1640 Cabl...

Page 35: ...cription PCT0008 06 Contact Tip Steel 0 6mm PCT0008 08 Contact Tip Steel 0 8mm PCT0008 09 Contact Tip Steel 0 9mm PCT0008 10 Contact Tip Steel 1 0mm PCTAL0008 09 Contact Tip Aluminium 0 9mm PCTAL0008 10 Contact Tip Aluminium 1 0mm SPG135 Tip Holder Part Number Description PCTH15 Contact Tip Holder Bore Ø 12 5 53 0 Ø 18 0 42 0 M6 x 1 0 M8 x 1 0 L U Groove Drive Roller Soft Wire Part Number Descript...

Page 36: ...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 37: ...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 38: ... 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 39: ...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 40: ... 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 41: ...gulator 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 orspraying with soapy water bubbles will appear at the leakage point 6 Tighten clamps or fittings to eliminat...

Page 42: ...ro Connector 10041419 9 Female Dinse Panel Socket 35 50 10037151 10 Spoolgun Socket 10041416 11 Metal Side Cover 10043377 12 On Off Switch 10004957 13 Gas Connector 10041723 14 Fan internal located 10041446 15 Rear Cover 10043404 Description Part Number 16 Power Input Cable 10043418 17 Gas hose 18 Gas Solenoid 10040667 19 Rectifier bridge 10039915 20 Wire Feeder Motor 10042965 21 Main PCB 10043414...

Page 43: ...041426 8 Euro Connector 10041419 9 Female Dinse Panel Socket 35 50 10037151 10 Spoolgun Socket 10041416 11 Metal Side Cover 10043377 12 On Off Switch 10004957 13 Gas Connector 10041723 14 Fan internal located 10041446 15 Rear Cover 10043404 Description Part Number 16 Power Input Cable 10043418 17 Gas hose 18 Gas Solenoid 10040667 19 Rectifier bridge 10039915 20 Wire Feeder Motor 10042965 21 Main P...

Page 44: ...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 45: ...e you have acquired Goods as a consumer within the meaning of the Trade Practices Act 1974 or the Fair Trading Acts of the relevant state or territories of Australia and is therefore also entitled to at the consumer s discretion either a refund of the purchase price of the Goods or repair of the Goods or replacement of the Goods Returns will only be accepted provided that a You have complied with ...

Page 46: ...ions Improper installation Use of non authorised non standard parts Abnormal product performance caused by any ancillary equipment interference or other external factors Failure or any breakage caused by overload dropping or abusive treatment or use by the customer Repair modifications or other work carried out on the product other than by an Authorised UNI MIG UNI TIG UNI PLAS UNI FLAME TECNA T R...

Page 47: ...Consumables to suit such as Input Cord Inter connecting Cord Triggering Cable This Warranty does not cover products purchased From a non authorised UNI MIG UNI TIG UNI PLAS UNI FLAME TECNA T R HIT 8SS ROTA Dealer such as purchases from unauthorised retailers and purchases over the Internet from unauthorised local international sellers or sites such as EBay At an auction From a private seller Unles...

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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