Unimig KUMJRRW250 Operating Manual
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Unimig KUMJRRW250 Operating Manual

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OPERATING MANUAL
KUMJRRW250
3
YEARS
Warranty
(Power Source)
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
©
1
Welding Guns Of Australia PTY LTD 2016

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Summary of Contents for Unimig KUMJRRW250

  • Page 1 OPERATING MANUAL KUMJRRW250 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 2016...
  • 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 11-12 Installation & Operation for MIG Welding with Gas 13-14 Wire Feed Drive Roller Selection Wire Installation Set up Guide Installation &...

  • Page 4: Warranty

    Ideal for general engineers, maintenance workshop and rural workshop. Designed and built to our specification. Certified to - AS/NZ60974-1 MACHINE PACKAGE: KUMJRRW250 RAZOR 250 Multifunction Welding Inverter, SB24 4M Sure Grip MIG torch, 4M Arc lead set, UNI-FLAME Twin Gauge Argon Regulator, 2M Gas Hose.
  • Page 5 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 6 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 7 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 8 FRONT PANEL LAYOUT Amperage Meter Voltage Meter VRD LED MIG/TIG/MMA Mode Selector Switch Wire Feed Adjustment Knob (MIG/MAG) Standard Mig / Spoolgun Selector Switch Inductance Meter “-” Output terminal SpoolGun Power Supply Connection 10. “+” Output terminal 11. Euro Mig Torch Connector (MIG/MAG) 12.

  • Page 9: Installation Operation Cautions

    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 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 10 Installation set up for MMA (Stick) Welding with RAZORWED-MIG250MTS (1) Turn the power source on and select the MMA function with the MIG/TIG/MMA 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 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 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 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.
  • Page 13 Installation set up for MIG with Gas for RAZORWED-MIG250MTS (1) Select the MIG function with the MIG/TIG/MMA selector switch. (2) Select Standard using the Standard/Spool Gun selector switch. (3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it. When connecting the torch be sure to tighten the connection.
  • Page 14 Continued set up for MIG with Gas for RAZORWED-MIG250MTS (9) 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. (10) Apply a medium amount of pressure to the drive roller.

  • Page 15: Wire Feed Drive Roller Selection

    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 16: Wire Installation Set Up Guide

    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 17 Installation set up for MIG with Gasless wire for RAZORWED-MIG250MTS (1) Switch on the machine, select the MIG function with the MIG/TIG/MMA selector switch. (2) Select Standard using the Standard/Spool Gun selector switch. (3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it. When connecting the torch be sure to tighten the connection.
  • Page 18 Continued set up for MIG with Gasless wire for RAZORWED-MIG250MTS (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 correct drive roller is being used. (9) 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 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 Teflon liner and carefully unravel it without kinking it.
  • Page 21 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 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 (14) Tighten the torch euro connection to the machine euro connector...
  • Page 22 Installation set up of the Spool Gun with RAZORWED-MIG250MTS (1) Switch on the machine, select the MIG function with the MIG/TIG/MMA selector switch. (2) Select Spool Gun using the Standard/Spool Gun selector switch. (3) Connect the Spool Gun to the Euro Mig torch connection socket on the front panel, and tighten it. Connect the Spool Gun control cable to the receptacle and tighten it.
  • Page 23 Continued set up of the Spool Gun with RAZORWED-MIG250MTS Carefully feed the wire over the drive roller into the outlet guide tube, feed through into the torch neck. Check that the drive roller being used complies with the wire diameter, replace the roller if necessary. (10) Align the wire into the groove of the drive roller and release the tension arm making sure the wire is in the groove of the drive roller.

  • Page 24: 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 25 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 26: Basic Mig Welding Guide

    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 27 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 28 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 29 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 30 Installation and set up for DC TIG welding for UNI-MIG MIG250 MTS (1) Switch on the machine, select the TIG function with the MIG/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 31 LIFT ARC DC TIG Operation for UNI-MIG MIG250 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 32: 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.
  • Page 33 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 34: 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 35 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 36 Suregrip Series SB24 MIG TORCH 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 3 Mt 4 Mt 5 Mt SB Suregrip Ergo Torch Package...
  • Page 37 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...
  • Page 38 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...
  • Page 39 SPG200II AMP SPOOL GUN Front end consumables SPG200II Contact Tips Part Number Description PCTH24 Contact Tip Holder PCT0009-06 Contact Tip Steel (0.6mm) PCT0009-08 Contact Tip Steel (0.8mm) PCT0009-09 Contact Tip Steel (0.9mm) 28.0 26.0 PCT0009-10 Contact Tip Steel (1.0mm) PCT0009-12 Contact Tip Steel (1.2mm) PCT0009-16 Contact Tip Steel (1.6mm)
  • Page 40 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 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 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 43 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 44 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 45 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 46 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 47 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 48 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 49: Warranty

    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 51 UNI-FLAME 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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