Unimig KUMJRDP210 Manual
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Unimig KUMJRDP210 Manual

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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
MIG-TIG-STICK BUIL T-IN
ADVANTAGE
KUMJRDP210
KUMJRDP250
TECHNOLOGY
TECHNOLOGY
MIG-TIG-STICK
TECHNOLOGY
MIG-TIG-STICK
3
YEARS
©
Welding Guns Of Australia PTY LTD 2012
(Power Source)
1

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  • Page 1 MIG-TIG-STICK BUIL T-IN TECHNOLOGY OPERATING MANUAL MIG-TIG-STICK BUIL T-IN ADVANTAGE KUMJRDP210 KUMJRDP250 TECHNOLOGY TECHNOLOGY TECHNOLOGY MIG-TIG-STICK TECHNOLOGY ADVANTAGE MIG-TIG-STICK YEARS Warranty (Power Source) 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: Table Of Contents

    CONTENTS PAGE Warranty Technical Data, Product Information Safety - Cautions Machine Layout Pictogram Installation Operation Cautions Installation & Operation for MMA (Stick) Welding MMA (Stick) Welding Information 12-13 Installation & Operation for MIG Welding with Gas - Digital Torch set up 14-15 Wire Feed Drive Roller Selection Wire Installation Set up Guide...
  • Page 4 Designed and built to our specifi cation. Certifi ed to - AS/NZ60974.1 2006 MACHINE PACKAGE: KUMJRDP210 UNI-MIG 210 Digital Multifunction Welding Inverter / SB24 Digital 4M UNI-MIG Sure Grip MIG torch with Euro connector...
  • Page 5 Designed and built to our specifi cation. Certifi ed to - AS/NZ60974.1 2006 MACHINE PACKAGE: KUMJRDP250 UNI-MIG 250 Digital Multifunction Welding Inverter / SB26 Digital 4M UNIMIG Sure Grip MIG torch with Euro connector 4M ARC lead set 35/50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator...
  • Page 6 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 7 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 8: Working Environment

    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 9 FRONT PANEL LAYOUT Amperage Meter Voltage Meter VRD LED Mig/MMA/Tig/Spool Gun Mode Selector Switch Wire Feed Adjustment Knob (MIG/MAG) (TIG/MMA) Amperage control Voltage Adjustment Knob (MIG/MAG) Arc force Adjustment (MMA) Downslope time adjustment Torch operation Post flow gas time 10. Inductance adjustment knob (MIG/MAG) 11.
  • Page 10 INSTALLATION & OPERATION Please install the machine strictly according to the following steps. The protection class of this machine is IP21S, so avoid using it in wet areas. Connection of Input Cables Primary input cable is supplied with this welding equipment. Connect the primary input cable with power supply of required input voltage.
  • Page 11 Installation set up for MMA (Stick) Welding with UNI-MIG-MIG210/250 DIGITAL MTS (1) Turn the power source on and select the MMA function with the Tig/MMA/MIG/SPOOL GUN selector switch. (2) Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown 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 with Gas for UNI-MIG-MIG210/250 DIGITAL MTS (1) Connect Mig Torch IMPORTANT : When connecting the torch be sure to tighten the connection. Additionally Digital MIG torch must be connected prior to power being turned on otherwise remote control will not work (2) Connect the earth lead to (3) Select the MIG function with the Tig/MMA/MIG/SPOOL GUN selector switch.
  • Page 15 Continued set up for MIG with Gas for UNI-MIG-MIG210/250 DIGITAL MTS (9) Connect weld power lead to GAS (10) Place wire onto spool holder - (spool retaining nut is left hand thread ) Feed the wire through the inlet guide tube on to the drive roller. (11) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx 150mm (12) 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 roller, lock the pressure arm into place.
  • Page 16 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 17 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 18 Installation set up for MIG with Gasless for UNI-MIG-MIG210/250 DIGITAL MTS (1) Connect Mig Torch IMPORTANT : When connecting the torch be sure to tighten the connection. Additionally Digital MIG torch must be connected prior to power being turned on otherwise remote control will not work (2) Connect the earth lead to (3) Select the MIG function with the Tig/MMA/MIG/SPOOL GUN selector switch.
  • Page 19 Continued set up for MIG with Gasless for UNI-MIG-MIG210/250 DIGITAL MTS (8) Connect the weld power cable plug inside the wire feeder to the output socket NO GAS, and tighten it. (9) Fit the correct size Knurled drive roller for Gas Less Flux Core wire. (10) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread.
  • Page 20 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 they are colour codes for diferent wire sizes BLUE = 0.6 -0.8mm, RED = 0.9-1.2 carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will damage it and will require replacement.
  • Page 21 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 Polymide or liner, fix torch neck sprint onto line 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 22 Continued Torch & Wire Feed Set Up for Aluminium Wire (10) Loosen off the inlet guide tube retaining screw (11) Remove the inlet guide tube from the front end machine euro connector using long nose pliers. (12) Carefully feed the extended Polymide liner section into the inlet guide tube hole of the machine euro connector (13) Feed the extended Polymide liner all the way up and over the drive roller (14) Tighten the torch euro connection to the machine euro connector...
  • Page 23 Installation set up of the Spool Gun with UNI-MIG-MIG210/250 DIGITAL MTS (1) Connect the spool gun control cable and gun cable connector. IMPORTANT : When connecting the torch be sure to tighten the connection. (2) Connect the earth lead to (3) Select the SPOOL GUN function with the Tig/MMA/MIG/SPOOL GUN selector switch.
  • Page 24 Continued set up of the Spool Gun with UNI-MIG-MIG210/250 DIGITAL MTS Connect weld power lead to GAS (10) Take the Spool Gun and push the Cover Release Button to unlock the wire feed / spool cover. (11) Place the Wire Spool 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.

  • Page 25: Mig (Metal Inert Gas) Welding

    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 26 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 27 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 28 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 29 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 30 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 31: Dc Tig Welding

    Installation and set up for DC TIG welding for UNI-MIG-MIG210/250 DIGITAL MTS (1) Connect TIG torch to power socket, trigger control socket and gas socket. IMPORTANT : When connecting the torch be sure to tighten the connection. (2) Connect earth lead to (3) Select the TIG function with the Tig/MMA/MIG/SPOOL GUN selector switch.

  • Page 32: Tungsten Electrodes

    LIFT ARC DC TIG Operation for UNI-MIG-MIG210/250 DIGITAL MTS 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 33 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 34 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 35 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 36: Tungsten Preparation

    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 37 Suregrip Series DM24 DIGITAL MIG TORCH DM240A AIR COOLED MIG WELDING TORCH Rating:250A CO² 220A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires Wear parts page next page Wear parts page next page Torch Model Description Part Number 5 Mt 3 Mt 4 Mt...
  • Page 38 Suregrip Series DM24 DIGITAL MIG TORCH Front end consumables DM24 Contact Tips Part Number Description PCT0009-06 Contact Tip Steel (0.6mm) PCT0009-08 Contact Tip Steel (0.8mm) PCT0009-09 Contact Tip Steel (0.9mm) PCT0009-10 Contact Tip Steel (1.0mm) PCT0009-12 Contact Tip Steel (1.2mm) 28.0 PCT0009-16 Contact Tip Steel (1.6mm) PCTZR009-09 Contact Tip Steel Long Life (0.9mm) 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) DM24 Tip Holder Part Number Description PCTH24...
  • Page 39 Suregrip Series DM26 DIGITAL MIG TORCH DM260A AIR COOLED MIG WELDING TORCH Rating: 270A CO2 240A mixed gas, EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires Wear parts page next page Wear parts page next page Torch Model Description Part Number 3 Mt 4 Mt...
  • Page 40 Suregrip Series DM26 DIGITAL MIG TORCH Front end consumables DM26 Contact Tips M6 Part Number Description PCT0009-06 Contact Tip Steel (0.6mm) PCT0009-08 Contact Tip Steel (0.8mm) PCT0009-09 Contact Tip Steel (0.9mm) 28.0 PCT0009-10 Contact Tip Steel (1.0mm) PCT0009-12 Contact Tip Steel (1.2mm) PCT0009-16 Contact Tip Steel (1.6mm) PCTZR009-09 Contact Tip Steel Long Life (0.9mm) 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) 30.0 DM26 Tip Holder M8 Part Number Description...
  • Page 41 L135YE SPOOL GUN SPG135 AMP SPOOL GUN Duty Cycle 30% @ 135Amp Torch Model Description Part Number XcelArc Spool Gun SPG135 x 6m SPG135 Spare Parts Part Number Description Part Number Description LGJ2003 Trigger LGX2018 LMH2001 Handle LGX2019U DriveRoll U Groove 0.8-0.9mm LMT2001 Spool Cover Total Assembly LZ3603...
  • Page 42 SPG135 AMP SPOOL GUN Duty Cycle 30% @ 135Amp Front end consumables SB15 Contact Tips Part Number Description 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) 25.0 PCTAL0008-10 Contact Tip Aluminium (1.0mm) SB15 Tip Holder Part Number Description PCTH15 Contact Tip Holder (Suit SB15) 42.0 PCTH195 Contact Tip Holder Suit Procraft 195 / BP15 Torch SB15 Gas Nozzle...
  • Page 43 SPG200II AMP SPOOL GUN Duty Cycle 35% @ 200Amp Torch Model Description Part Number XcelArc Spool Gun x 6m SPG200II Spare Parts Part Number Description Part Number Description LMZ2017 Speed Adjusting Knob LMZ2014 Potentiometer LMH2114 Open/Close Button LMZ2015 Push Roll LMH2111 Left-Gun Case LMK2001 Conducting Board LMH2115 Hang Hook EF1101 Conducting Tube LMS2101 Spring Support SEE PAGE 38...
  • Page 44 SPG200II AMP SPOOL GUN Front end consumables SB24 Contact Tips Part Number Description PCT0009-06 Contact Tip Steel (0.6mm) PCT0009-08 Contact Tip Steel (0.8mm) PCT0009-09 Contact Tip Steel (0.9mm) PCT0009-10 Contact Tip Steel (1.0mm) PCT0009-12 Contact Tip Steel (1.2mm) 28.0 PCT0009-16 Contact Tip Steel (1.6mm) PCTZR009-09 Contact Tip Steel Long Life (0.9mm) 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) SB24 Tip Holder Part Number Description PCTH24 Contact Tip Holder...
  • Page 45 Suregrip Series SR17 ERGO TIG TORCH 150A AIR COOLED TIG WELDING TORCH Rating: 150A DC, 105A AC @35% ducy cycle. Wear Parts Identification Next Page Torch Model Description Part Number SR17 Suregrip Tig Torch Package QF Gas Connect SR-17-4MCP25 SR-17-8MCP25 SR-17-4MCP50 SR-17-8MCP50 Spare Parts Part Number Description Part Number Description WP17...
  • Page 46 Suregrip Series SR17 ERGO 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 8mm #5L 10N31 Collet Body 1.6mm 53N48L Long Alumina Nozzle Ø 10mm #6L 10N32 Collet Body 2.4mm 53N47L Long Alumina Nozzle Ø 11mm #7L 10N28 Collet Body 3.2mm Part # Description Part # Description 10N22 Collet 1.0mm...
  • Page 47 Suregrip Series SR26 ERGO TIG TORCH 180A AIR COOLED TIG WELDING TORCH Rating:180Amp DC, 125Amp AC @35% duty cycle. Wear Parts Identification Next Page Torch Model Description Part Number SR26 Suregrip Tig Torch Package c/w QF Gas Connect SR-26-4MCP50 SR-26-8MCP50 Spare Parts Part Number Description Part Number Description WP26 Torch head UERNCL-32...
  • Page 48 Suregrip Series SR26 ERGO 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 8mm #5L 10N31 Collet Body 1.6mm 53N48L Long Alumina Nozzle Ø 10mm #6L 10N32 Collet Body 2.4mm 53N47L Long Alumina Nozzle Ø 11mm #7L 10N28 Collet Body 3.2mm Part # Description Part # Description 10N22 Collet 1.0mm...
  • Page 49 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 50 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 51: Tig Welding Trouble Shooting

    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 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 54: Warranty

    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 (‘Us’, ‘We’) warrants that the following products under UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS &...
  • Page 55 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 56 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 57 NOTES:...
  • Page 58 NOTES:...
  • Page 59 NOTES:...
  • Page 60 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...

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