Unimig KUMJRRW200 Operating Instructions Manual
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Unimig KUMJRRW200 Operating Instructions Manual

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Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
OPERATING MANUAL
3
1
KUMJRRW200
KUMJRRW160
YEARS
Warranty
(Power Source)
©
Welding Guns Of Australia PTY LTD 2015

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Summary of Contents for Unimig KUMJRRW200

  • Page 1 OPERATING MANUAL KUMJRRW200 KUMJRRW160 YEARS Warranty (Power Source) Please read and understand this instruction manual carefully before the installation and operation of this equipment. © Welding Guns Of Australia PTY LTD 2015...

  • Page 3: Table Of Contents

    • New product will not be supplied unless Welding Guns Of Australia PTY LTD has inspected product returned for warranty and agree’s to replace product. • 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 4: Safety

    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: Safety

    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. Check and be sure the area is safe before doing any welding. • The cutting sparks may cause fire, therefore remove any flammable materials well away from the working area. Cover flammable materials and containers with approved covers if unable to be moved from the welding area. • Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to the required Safety Standards to insure that flammable or toxic vapors and substances are totally removed, these can cause an explosion even though the vessel has been “cleaned”.

  • Page 6: 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. 1.3 Keep this equipment 30cm distant from the wall. 1.4 Ensure the working environment is well ventilated.

  • Page 7: Technical Data

    RAZORWELD ARC 160 MMA/TIG - 160 Amp DC Inverter Welder Razorweld Welds: Steels, Stainless, Cast Iron, Bronze, Copper ™ ™ Selectable VRD on/off Industrial Rated (Voltage Reduction Device) 10 AMP 240V Single Phase 160 Amp DC Welder Small, Lightweight and Portable Features •...
  • Page 8 RAZORWELD ARC 200 MMA/TIG - 200 Amp DC Inverter Welder Razorweld Welds: Steels, Stainless, Cast Iron, Bronze, Copper ™ ™ Industrial Rated 15 AMP 240V Single Phase 200 Amp DC Welder Small, Lightweight and Portable Features • Single PCB construction •...

  • Page 9: Machine Layout Descriptions

    FRONT MACHINE LAYOUT DESCRIPTION Thermal Alarm LED Primary Power LED VRD LED Voltage Reduction Device Amperage Control Dial MMA /TIG Selector Switch Positive Output Terminal Negative Output Terminal Rear Machine Layout Description On /Off Power Switch Primary Input Power Lead VRD (Safe Function) Description - Note 160PFC Only VRD reduces the welding power source’s open circuit voltage (OCV).
  • Page 10 INSTALLATION SET UP FOR MMA (STICK) WELDING WITH MMA-TIG160/200PFC Please install the machine strictly according to the following steps. The protection class of this machine is IP21, so avoid using it in rain. 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 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 MMA (Manual Metal Arc) General Description current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric cur- rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives rent is used to strike an arc between the base material and a consumable electrode rod or ‘stick’.
  • Page 12 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. It is recommend to consult your welding supplier for the correct selection of electrode.
  • Page 13 Fine metal droplet transfer, good fusion of joint faces, finely rippled bead surface, easy slag removal. For a full range of recommended MAGMAWELD welding electrodes please visit our website @ WWW.UNIMIG.COM.AU The above chart is a reference only and are not included in this kit.
  • Page 14 INSTALLATION AND SET UP FOR DC TIG WELDING FOR MMA-TIG160/200PFC (1) Switch on the machine, select the TIG function with the TIG/MMA 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 15 LIFT ARC DC TIG OPERATION FOR MMA-TIG160/200PFC 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 16: Dc Tig Welding

    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. With a DC circuit 70% of the energy (heat) is always on the positive side. This needs to be understood because it determines what terminal the TIG torch will be connected to (this rule applies to all the other forms of DC welding as well ).
  • Page 17 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 18: Tungsten Electrodes

    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 19: 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. Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel.
  • Page 20 Suregrip Series 17V TIG TORCH 150A AIR COOLED TIG WELDING TORCH Rating: 150Amp DC, 105Amp AC @35% duty cycle. For use with non gas solenoid machines Wear Parts Identification Next Page Torch Model Description Part Number 17V Suregrip Tig Torch Package c/w 2m Gas Hose 17V-4MCP25 17V-8MCP25 Spare Parts...
  • Page 21 Suregrip Series 17V 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 22 Suregrip Series 26V TIG TORCH 200A AIR COOLED TIG WELDING TORCH Rating:180Amp DC, 125Amp AC @35% duty cycle. Wear Parts Identification Next Page Torch Model Description Part Number 26V Tig Torch Package c/w 2m Gas Hose 26V-8MCP25 26V-4MCP50 26V-8MCP50 Spare Parts Part Number Description Part Number...
  • Page 23 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 24: Mma (Stick) Welding Trouble Shooting

    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 25: 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 26 8: Arc dif cult 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  ow Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted.
  • Page 27 SPARE PARTS IDENTIFICATION - ARC160PFC Part Number Description Part Number Description 10045765 front plastic panel 10. 10006650 Single-phase rectifier bridge 10043476 carry strap / handle 11. 10043327 main PCB 10004966 TIG/MMA selector switch 12. 10052250 control PCB 10004636 panel socket 35-50 13. 10037766 thermal switch 10052313 front panel adhesive sticker...
  • Page 28 SPARE PARTS IDENTIFICATION - ARC200PFC Part Number Description Part Number Description 1. 10045765 front plastic panel 10. 10037345 Single-phase rectifier bridge 2. 10043476 carry strap / handle 11. 10046842 main PCB 3. 10004966 TIG/MMA selector switch 12. 10046844 control PCB 10004636 panel socket 35-50 13.
  • Page 29 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, RAZORWELD.UNI-TIG, UNI-PLAS, UNI-FLAME, XCEL-ARC, TECNA, T&R, HIT-8SS & ROTA, supplied by Us and purchased by you from an Authorised UNI-MIG, RAZORWELD, UNI-TIG, UNI-PLAS, UNI-FLAME, XCEL-ARC, TECNA, T&R, HIT-8SS &...
  • Page 30 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 31 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, RAZORWELD, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS &...
  • Page 32 Notes...
  • Page 36 Welding Guns Of Australia PTY LTD 2015 Welding Guns Of Australia 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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