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Drive Rollers

Wire Feed Roller Selection

The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.

Simply put the smoother the wire feed then the better the welding will be.

Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.

Feed rollers are designed to be used for certain types of welding wire and they have different types of

grooves machined in them to accommodate the different types of wire. The wire is held in the groove by

the top roller of the wire drive unit and is referred to as the pressure roller, pressure is applied by a tension

arm that can be adjusted to increase or decrease the pressure as required. The type of wire will determine

how much pressure can be applied and what type of drive roller is best suited to obtain optimum wire feed.

Solid Hard Wire - like Steel, Stainless Steel require a drive roller with a V shape groove for optimum grip

and drive capability. Solid wires can have more tension 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 difficult to feed. Soft wires can easily buckle at the wire feeder where the

wire is fed into inlet guide tube of the torch. The U-shaped roller offers more surface area grip and traction

to help feed the softer wire. Softer wires also require less tension from the top pressure roller to avoid de-

forming the shape of the wire, too much tension will 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 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 knurled wire

feed roller on flux cored wire is it will slowly over time bit by bit eat away at the surface of the welding wire,

and these small pieces will eventually go down into the liner. This will cause clogging in the liner and added

friction that will lead to welding wire feed problems. A U groove wire can also be used for flux core wire

without the wire particles coming of the wire surface. However it is considered that the knurled roller will

give a more positive feed of flux core wire without any deformation of the wire shape.

V Groove

U Groove

Knurled Groove

Wire

Top Pressure Roller

22mm

30mm

10mm

V Groove Drive Roller - Steel Wire

Part Number

Description

0.6-0.8V30/22

Drive Roll V Groove 0.6-0.8mm

0.8-1.0V30/22

Drive Roll V Groove 0.8-1.0mm

0.9-1.2V30/22

Drive Roll V Groove 0.9-1.2mm

1.0-1.2V30/22

Drive Roll V Groove 1.0-1.2mm

1.2-1.6V30/22

Drive Roll V Groove 1.2-1.6mm

Knurled Drive Roller - Flux Core Wire

Part Number

Description

0.6-0.8F30/22

Drive Roll Knurled 0.6-0.9mm

0.8-0.9F30/22

Drive Roll Knurled 0.8-0.9mm

0.9-1.2F30/22

Drive Roll Knurled 0.9-1.2mm

1.2-1.6F30/22

Drive Roll Knurled 1.2-1.6mm

U Groove Drive Roller - Soft Wire

Part Number

Description

0.8-1.0U30/22

Drive Roll U Groove 1.0-1.2mm

0.9-1.0U30/22

Drive Roll U Groove 0.9-1.0mm

0.9-1.2U30/22

Drive Roll U Groove 0.9-1.2mm

1.0-1.2U30/22

Drive Roll U Groove 1.0-1.2mm

Содержание KUMJRRW205MIG

Страница 1: ... read and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KUMJRRW205MIG Welding Guns Of Australia PTY LTD 2013 YEARS Warranty Power Source 3 ...

Страница 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...

Страница 3: ...h Liner Installation 18 MIG Torch and Wire Feeder Set Up Guide for Aluminium MIG Wire 19 20 Installation Operation for MIG Welding with Spool Gun 21 22 MIG Metal Inert Gas Welding 23 24 Basic MIG Welding Guide 25 28 Installation Operation for TIG Welding 29 30 TIG Fusion Technique 31 Tungsten Electrodes Preparation 32 33 SB25 MIG Torch Parts Breakdown 34 35 SPGRW200 Spool Gun Torch Parts Breakdown...

Страница 4: ...nze and copper The Lift Arc function is superb and delivers perfect arc ignition every time without any sticking of the tungsten electrode to the work piece a remarkably smooth stable arc produces high quality TIG welds An additional feature 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 str...

Страница 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...

Страница 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...

Страница 7: ...ature inside 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 s...

Страница 8: ... Button 9 Output terminal 10 Euro MIG TIG Torch Connector MIG MAG 11 Output terminal 12 SpoolGun Power Supply Connection 1 3 2 4 5 6 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 Spoolgun Standard selector switch 18 Inch wire feed button 19 Gas Check button 20 Spool holder assembly 21 Geared Wire feed assembly 18 21 20...

Страница 9: ...rode connected to output socket DC Electrode connected to output socket 2 Turn the power source on and select the MMA function with the MIG TIG MMA selector switch 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 and adjust arcforce if required 6 Hold the electrode sli...

Страница 10: ...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...

Страница 11: ... 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 ...

Страница 12: ...ect the weld power lead to Positive socket 4 Turn the power source on and select the MIG function with the MIG TIG MMA selector switch 5 Set torch operation 2T 4T When 2T operation is selected press trigger Arc starts release trigger Arc stops burnback operation is automatic and preset When 4T operation is selected press and release trigger Arc starts press and release trigger Arc stops burnback o...

Страница 13: ...3 Fit the correct sized contact tip and feed the wire through it screw the contact tip into the tip holder of the torch head and nip it up tightly 14 Fit the gas nozzle to the torch head 15 Carefully open the gas cylinder valve and set the flow rate to between 5 10 l min 16 Set the welding parameters using the wire feed and voltage control knobs 12 Press and hold the inch wire button to feed the w...

Страница 14: ...re 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 has been devel...

Страница 15: ...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...

Страница 16: ...nnect the earth lead to Positive socket 3 Connect the weld power lead to Negative socket 4 Turn the power source on and select the MIG function with the MIG TIG MMA selector switch 5 Set torch operation 2T 4T When 2T operation is selected press trigger Arc starts release trigger Arc stops burnback operation is automatic and preset When 4T operation is selected press and release trigger Arc starts ...

Страница 17: ...utton to feed the wire through to the torch neck release the inch button when the wire exits the torch neck 13 Fit the correct sized contact tip and feed the wire through it screw the contact tip into the tip holder of the torch head and nip it up tightly 14 Fit the gas nozzle to the torch head 15 Set the welding parameters using the wire feed and voltage control knobs 15 Set welding parameters us...

Страница 18: ...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...

Страница 19: ...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...

Страница 20: ...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...

Страница 21: ... onto the Spool Holder Note the spool retaining nut is Left Hand thread Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling 3 Connect earth lead to 1 Set Standard Spoolgun selector switch inside door to Spoolgun 5 Connect the gas line to the regulator and connect to the gas cylinder 6 Set MIG TIG MMA selector switch to MIG IMPORTANT When connecting the torc...

Страница 22: ...nd close the wire spool cover 16 Carefully open the gas cylinder valve and set the flow rate to between 12 15 l min 17 Set the welding parameters using the wire feed and voltage control knobs 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 allow ...

Страница 23: ...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 ...

Страница 24: ...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 ...

Страница 25: ... 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...

Страница 26: ...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...

Страница 27: ...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...

Страница 28: ...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...

Страница 29: ...operation is automatic to factory preset level When 4T operation is selected press and release trigger Gas starts touch and lift arc start press and release trigger Gas and Arc stops When 4T operation is selected with downslope time of either 1 to 10 seconds press and release trigger Gas starts touch and lift arc start Press and hold trigger after 1 to 10 seconds depending on the downslope time se...

Страница 30: ... the Gas Cup on the work piece with the Tungsten Electrode 1 2mm from the work piece Press the trigger button on TIG torch to start the gas flow 11 With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 12 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 10 Lay the outside edge of th...

Страница 31: ... 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...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ...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...

Страница 35: ...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...

Страница 36: ...l 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 Sup...

Страница 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...

Страница 38: ...y cycle SR26 ERGO TIG TORCH Spare Parts Part Number Description 1 WP26 Torch head WP26F Torch head flexible 2 57Y02 Back cap long 3 57Y03 Medium back cap 4 57Y04 Short back cap 5 UER1MS Momentary Kit 6 UERSWL4 Trigger Lead 12 5ft UERSWL8 Trigger Lead 25ft 7 UERSP1 Screw Pack 8 UERH200 Large Ergo Tig Handle 9 UERKJ200 Large Knuckle Joint 10 UERLC200 08 Leather Cover X 0 8mt 11 UERJK200 Jointing Rep...

Страница 39: ...2 TR0004 16 1 6mm x 175mm thoriated tungsten electrode 2 TR0004 24 2 4mm x 175mm thoriated tungsten electrode 2 TR0004 32 3 2mm x 175mm thoriated tungsten electrode 2 Part Description TR0006 10 1 0mm x 175mm zirconiated tungsten electrode 1 TR0006 16 1 6mm x 175mm zirconiated tungsten electrode 1 TR0006 24 2 4mm x 175mm zirconiated tungsten electrode 1 TR0006 32 3 2mm x 175mm zirconiated tungsten ...

Страница 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...

Страница 41: ... 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...

Страница 42: ...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...

Страница 43: ... 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 ...

Страница 44: ...point 6 Tighten clamps or fittings to eliminate gas leakage Important We strongly recommend that you check for gas leakage prior to operation of your machine We recommend that you close the cylinder valve when the machine is not in use Welding Guns Of Australia PTY LTD authorised representatives or agents of Welding Guns Of Australia will not be liable or responsible for the loss of any gas ATTENT...

Страница 45: ...41416 9 pin female socket 9 10043404 rear panel 10 10004949 power switch 11 10041723 gas inlet Part Number Description 12 10041446 fan DC24V 13 10042876 power cable 14 10049247 display pcb 15 10040667 plastic packaged solenoid valve 16 10037485 silicon bridge plate 17 10049246 Control pcb 18 10049264 wire feeder motor 19 10045881 mainboard 20 Insluation sheet 21 10041449 Spool holder 22 10041284 S...

Страница 46: ...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...

Страница 47: ...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 ...

Страница 48: ...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...

Страница 49: ...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...

Страница 50: ...50 Notes ...

Страница 51: ...51 Notes ...

Страница 52: ...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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