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Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
OPERATING MANUAL
TECHNOLOGY
ADVANTAGE
MIG-TIG-STICK BUIL T-IN
TECHNOLOGY
KUMJR250SWF
V oltage Reduction Device
KUMJR350SWF
MIG-TIG-STICK BUIL T-IN
KUMJR500SWF
ADVANTAGE
TECHNOLOGY
TECHNOLOGY
MIG-TIG-STICK
TECHNOLOGY
MIG-TIG-STICK
©
Welding Guns Of Australia PTY LTD 2012
1
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Summary of Contents for Unimig KUMJR250SWF
- Page 1 OPERATING MANUAL MIG-TIG-STICK BUIL T-IN TECHNOLOGY KUMJR250SWF V oltage Reduction Device KUMJR350SWF MIG-TIG-STICK BUIL T-IN KUMJR500SWF ADVANTAGE TECHNOLOGY TECHNOLOGY TECHNOLOGY MIG-TIG-STICK TECHNOLOGY ADVANTAGE MIG-TIG-STICK Please read and understand this instruction manual carefully before the installation and operation of this equipment.
- Page 2 • Product will only be replaced if repair is not possible • Please view full Warranty term and conditions supplied with machine or at www.uniMIG.com.au/ warranty.asp or at the back of this manual.
- Page 3 CONTENTS PAGE Warranty Safety Caution, Maintenance and Trouble Shooting Technical Data, Product Information Machine Layout Pictogram Machine Assembly MMA (Stick) Welding) 11-13 Installation & Operation for MIG Welding 14-16 Wire Feed Drive Rollers Wire Installation and Wire Feeder Set Up MIG Torch Liner Installation Torch and Wire Feeder Setup for Aluminium Wire 20-21...
- Page 4 SAFETY Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations. Read and understand this instruction manual carefully before the installation and operation of this equipment.
- Page 5 Fire hazard. Welding on closed containers, such as tanks,drums, or pipes, can cause them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
- Page 6 CAUTION 1. Working Environment. 1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity. 1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc; the temperature of working environment should be maintained within -10°C to +40°C.
- Page 7 ATTENTION! - CHECK FOR GAS LEAKAGE At initial set up and at regular intervals we recommend to check for gas leakage Recommended procedure is as follows: 1. Connect the regulator and gas hose assembly and Tighten all connectors and clamps. 2.
- Page 8 Ideal for heavy and structural welding applications through to general engineers, maintenance workshops, light engineering, rural workshops and home workshops. Designed and built to our specification. Certified to - AS/NZ60974.1 MACHINE PACKAGE: KUMJR250SWF UNI-MIG 250SWF Multifunction Welding Inverter / SB24 4M Sure Grip MIG torch with Euro connector, 10M ARC lead set 35-50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator 2M Gas Hose Complete with fittings, 10M Inter connection Cables, Trolley.
- Page 9 Machine Layout Description Power Source Front Panel Layout 1. Amperage Meter 2. Mains Power LED 3. Thermal Overload LED 4. Over Current LED 5. Voltage Meter 6. 2T - 4T Trigger Switch 7. Gas Check Switch 8. MIG/MMA/TIG Mode Selector Switch 9.
- Page 10 MACHINE ASSEMBLY Please install the machine according to the following steps. (1) Unpack the trolley and locate the (2) Connect and fasten down the retaining (3) Mount power source to the trolley, lock in assembly parts inside the trolley drawer side panels onto the trolley using the screws place by fastening to the mounting brackets provided.
- Page 11 Installation set up for MMA (Stick) Welding with MIG250/350/500 SWF Welder (1) Select the MMA function with the TIG/MMA/MIG selector switch. (2) Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DC+ polarity.
- Page 12 MMA (Manual Metal Arc) Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric cur- rent is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
- Page 13 MMA (Stick) Welding Fundamentals Electrode Selection As a general rule, the selection of an electrode is straight forward,in that it is only a matter of selecting an electrode of similar composition to the parent metal. However, for some metals there is a choice of several electrodes, each of which has particular properties to suit specific classes of work.
- Page 14 Installation set up for MIG Welding with MIG250/350/500 SWF Welder (1) Select the MIG function with the MMA/MIG selector switch. (2) Insert the earth cable plug into the required polarity and tighten - negative for gas shielded wires positive for gas less wires. The weld power cable goes into the opposing negative or positive socket. With Separate Wire Feeder machines the positive MIG socket is located at the rear of the power source (3) Plug the welding torch into the Euro MIG torch connection socket on the front panel, and Tighten it.
- Page 15 Continued set up of the MIG250/350/500 SWF Welder for MIG Welding (8) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive rollers, lock the pressure arm into place. Apply a medium amount of pressure to the drive roller.
- Page 16 Continued set up of the MIG250/350/500 SWF Welder for MIG Welding Crater Current Control Setting: The purpose of the crater control setting is to be able to reduce of eliminate the crater that is left behind at the end of the weld. The Crater Current Control only works in 4T Trigger Function.
- Page 17 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.
- Page 18 Wire Installation and Set Up Guide Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and consistent wire feed.
- Page 19 MIG Torch Liner Installation (1) Lay the torch out straight on the ground and remove the front end parts (2) Remove the liner retaining nut. (3) Carefully pull the liner out of the torch cable assembly (4) Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will make it no good and will require replacement.
- Page 20 Torch & Wire Feed Set Up for Aluminium Wire (1) Lay the torch out straight on the ground and remove the front end parts (2) Remove the liner retaining nut. (3) Carefully pull the liner out of the torch cable assembly (4) Select a PA or liner, carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end.
- Page 21 Continued Torch & Wire Feed Set Up for Aluminium Wire (10) Loosen off the inlet guide tube retaining screw Push the inlet guide tube forward with a pair of long nose pliers. (11) Remove the inlet guide tube from the front end machine euro connector using long nose pliers. (12) Carefully feed the extended PA liner section into the inlet guide tube hole of the machine euro connector (13) Feed the extended PA liner all the way up and over the drive roller...
- Page 22 MIG (Metal Inert Gas) Welding Definition of MIG Welding MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a weld- ing gun.
- Page 23 MIG (Metal Inert Gas) Welding Short Circuit Transfer - 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 piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool.
- Page 24 Basic MIG Welding Good weld quality and weld profile depends on gun angle, direction of travel, electrode extension (stick out), travel speed, thickness of base metal, wire feed speed (amperage) and arc voltage. To follow are some basic guides to assist with your setup. Gun Position - Travel Direction, Work Angle Gun position or technique usually refers to how the wire is directed at the base metal, the angle and travel direction chosen.
- Page 25 Travel Angle - Travel angle is the right to left angle relative to the direction of welding. A travel angle of 5°- 15° is ideal and produces 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.
- Page 26 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.
- Page 27 Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel, aluminium wires for aluminium and steel wires for steel. Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger machine, check the recommended welding capability of you machine.
- Page 28 Installation and set up for DC TIG welding for MIG250/350/500 SWF Welder (1) Switch on the machine, select the MMA function with the MMA/MIG selector switch. (2) Insert the power cable plug of the TIG torch into the Negative socket on the front of the machine and Tighten it.
- Page 29 LIFT ARC DC TIG Operation for MIG250/350/500 SWF Welder 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.
- Page 30 DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main elec- trical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical principle at work which should always be taken into account when using any DC circuit.
- Page 31 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 electrode and the workpiece. Similar to Oxygen Acety- lene torch welding, TIG welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other.
- Page 32 Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tung- sten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius. Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an al- loy of tungsten and other rare earth elements.
- Page 33 Tungsten Preparation Always use wheels when grinding and cutting. While tungsten is a very hard material, the surface of a DIAMOND diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contrib- ute to weld inconsistency and weld defects.
- Page 34 Suregrip Series SB24 MIG TORCH SUIT - KUMJR250SWF 250A AIR COOLED MIG WELDING TORCH Rating:250A CO² 220A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires Wear parts next page Wear parts next page Torch Model Description Part Number...
- Page 35 Suregrip Series SB24 MIG TORCH Front end consumables SB24 Contact Tips Part Number Description PCT0009-06 Contact Tip Steel (0.6mm) QTY10 PCT0009-08 Contact Tip Steel (0.8mm) QTY10 PCT0009-09 Contact Tip Steel (0.9mm) QTY10 PCT0009-10 Contact Tip Steel (1.0mm) QTY10 PCT0009-12 Contact Tip Steel (1.2mm) QTY10 28.0 PCT0009-16 Contact Tip Steel (1.6mm) QTY10 PCTZR009-09 Contact Tip Steel Long Life (0.9mm) QTY10 PCTZR009-12 Contact Tip Steel Long Life (1.2mm) QTY10 PCTAL0009-09 Contact Tip Aluminium (0.9mm) QTY10 PCTAL0009-10...
- Page 36 Suregrip Series SB36 MIG TORCH SUIT - KUMJR350SWF 300A AIR COOLED MIG WELDING TORCH Rating:300A CO² 270A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires Wear parts next page Wear parts next page Torch Model Description Part Number 3 Mt 4 Mt 5 Mt...
- Page 37 Suregrip Series SB36 MIG TORCH SB36 Contact Tips M6 Part Number Description Front end consumables PCT0009-06 Contact Tip Steel (0.6mm) QTY10 PCT0009-08 Contact Tip Steel (0.8mm) QTY10 PCT0009-09 Contact Tip Steel (0.9mm) QTY10 PCT0009-10 Contact Tip Steel (1.0mm) QTY10 PCT0009-12 Contact Tip Steel (1.2mm) QTY10 PCT0009-16 Contact Tip Steel (1.6mm) QTY10 PCTZR009-09 Contact Tip Steel Long Life (0.9mm) QTY10 PCTZR009-12 Contact Tip Steel Long Life (1.2mm) QTY10 28.0 PCTAL0009-09 Contact Tip Aluminium (0.9mm) QTY10...
- Page 38 Suregrip Series TWC5 STYLE MIG TORCH SUIT - KUMJR500SWF TWC5 Air Cooled MIG Welding Torch Rating: 500A CO2 4000A mixed gas, EN60974-7 @ 60% duty cycle. 0.9 to 2.8mm wires Wear parts next page Wear parts next page Torch Model Description Part Number 12ft...
- Page 39 Suregrip Series TWC5 STYLE MIG TORCH Front end consumables TWC5 Contact Tips H/D Part Number Description PWGA15H-35 Contact Heavy Duty Tip 0.9mm QTY10 PWGA15H-40 Contact Heavy Duty Tip 1.0mm QTY10 PWGA15H-45 Contact Heavy Duty Tip 1.2mm QTY10 PWGA15H-52 Contact Heavy Duty Tip 1.3mm QTY10 PWGA15H-116 Contact Heavy Duty Tip 1.6mm QTY10 PWGA15H-564 Contact Heavy Duty Tip 2.0mm QTY10 PWGA15-AH45 Contact Heavy Duty Tip 1.2mm Aluminium QTY10 PWGA15-AH116 Contact Heavy Duty Tip 1.6mm Aluminiumm QTY10 TWC5 Contact Tips Holder Part Number Description PWGA55...
- Page 40 Suregrip Series 26V TIG TORCH 200A AIR COOLED TIG WELDING TORCH Rating:200A DC, 140A AC @35% ducy cycle. Wear Parts Identification Next Page Torch Model Description Part Number 26V TIG Torch Package c/w 2m Gas Hose 26V-4MCP50 26V-8MCP50 26V-8MCP25 Spare Parts Part Number Description Part Number...
- Page 41 Suregrip Series 26V TIG TORCH Standard Front End Parts Part # Description Part # Description Part # Description 18CG Cup Gasket 10N30 Collet Body 1.0mm 10N49L Long Alumina Nozzle Ø 10mm 10N31 Collet Body 1.6mm 53N48L Long Alumina Nozzle Ø 11mm 10N32 Collet Body 2.4mm...
- Page 42 SPARE PARTS IDENTIFICATION - KUMJR250SWF Description Part Number POWER SUPPLY AND WIRE FEED PCB 10000816 CONTROL PCB 10000519 IGBT PCB 10000889 EMC BOARD 10000930 OUTPUT DIODES PCB 10000321 FILTER BOARD PCB 10000460 MAIN TRANSFORMER 10006064 CHOKE 10006559 SHUNT 10016424 ON/OFF SWITCH...
- Page 44 SPARE PARTS IDENTIFICATION - KUMJR350SWF Description Part Number POWER SUPPLY AND WIRE FEED PCB 10000865 CONTROL PCB 10000558 IGBT PCB 10001940 EMC BOARD 10000844 OUTPUT DIODES PCB 10000332 CAPACITOR 1250V DC 40µF 10005913 MAIN TRANSFORMER 10006120 SHUNT 10016424 ON/OFF SWITCH 10004925 PEAK CURRENT SONSOR PCB 10000836...
- Page 46 SPARE PARTS IDENTIFICATION - KUMJR500SWF Description Part Number POWER SUPPLY AND WIRE FEED PCB 10000573 CONTROL PCB 10000527 IGBT PCB 10001948 EMC BOARD 10000844 OUTPUT DIODES PCB 10000345 CAPACITOR 1250V DC 40µF 10005913 MAIN TRANSFORMER 10006068 CHOKE 10002010 SHUNT 10016425 ON/OFF SWITCH 10004925 FRONT PANEL...
- Page 48 MIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manu- facturer’s recommendations should be strictly adhered to and followed. 1: Excessive Spatter Possible Reason Suggested Remedy Wire feed speed set too high Select lower wire feed speed Voltage too high...
- Page 49 MIG WIRE FEED TROUBLE SHOOTING The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: No wire feed Possible Reason Suggested Remedy Wrong mode selected Check that the TIG/MMA/MIG selector switch set to MIG position...
- Page 50 MMA (Stick) WELDING TROUBLE SHOOTING 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. 1: No arc Possible Reason Suggested Remedy Incomplete welding circuit Check earth lead is connected.
- Page 51 TIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of DC TIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: Tungsten burning away quickly Possible Reason Suggested Remedy Incorrect Gas Check that pure Argon is being used...
- Page 52 continued- TIG WELDING TROUBLE SHOOTING 8: Arc difficult to start or will not start DC welding Possible Reason Suggested Remedy Incorrect machine set up Check machine set up is correct No gas, incorrect gas flow Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted.
- Page 53 Fax: (02) 9780 4244 Welding Guns Of Australia Pty Ltd Email: sales@uniMIG.com.au / Web: www.uniMIG.com.au ABN: 14 001 804 422 Welding Guns Of Australia Pty Ltd (‘Us’, ‘We’) warrants that the following products under UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA, supplied by Us and purchased by you from an Authorised UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS &...
- Page 54 WARRANTY / RETURNS / EXCHANGES We understand that sometimes you may need to return a product you have purchased from Welding Guns Of Australia PTY LTD Authorised Dealer Network, to assist you, we have set out below the Welding Guns Of Australia PTY LTD Returns Policy that you should know.
- Page 55 WARRANTY EXCLUSIONS This Warranty covers Material and Faulty Workmanship defects only. This Warranty does not cover damage caused by: • Normal wear and tear due to usage • Misuse or abusive use of the UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA, instructions supplied with the product.
- Page 56 Welding Guns Of Australia PTY LTD 2012 Welding Guns Of Australia PTY LTD Pty Ltd ABN: 14 001 804 422 PO Box 3033, Lansvale NSW 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...