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- Page 1 OPERATING MANUAL KUMJRRW140 KUMJRRW180 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...
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Page 3: Table Of Contents
Secondly they provide a customer support service that is second to none, thus ensuring our customers have con- fidence that they will be well satisfied both now and in the future. UNI-MIG welders are manufactured and compliant with - AS/NZ60974.1 2006 - AS60974-6:2006 guaranteeing you electrical safety and performance. WARRANTY •... -
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 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 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.
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Page 7: Technical Data, Product Information
MMA/TIG - 140Amp DC Welding Machine Small, Lightweight and Portable Welds: Steels, Stainless, Cast Iron, Bronze, Copper KUMJRRW140CA YEARS Warranty (Power Source) Features • Latest IGBT inverter technology • MMA (stick electrode) • Hot start (improves electrode starting) • VRD (Voltage Reduction Device) •... - Page 8 MMA/TIG - 180Amp DC Welding Machine Small, Lightweight and Portable Welds: Steels, Stainless, Cast Iron, Bronze, Copper KUMJRRW180CA YEARS Warranty (Power Source) Features • Latest IGBT inverter technology • MMA (stick electrode) • Hot start (improves electrode starting) • VRD (Voltage Reduction Device) •...
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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 Negative Output Positive Output Terminal Terminal Rear Machine Layout Description On /Off Switch On /Off Power Switch Primary Input Power Lead VRD reduces the welding power source’s open circuit voltage (OCV). -
Page 10: Installation & Operation For Mma (Stick) Welding
INSTALLATION SET UP FOR MMA (STICK) WELDING WITH MMA-TIG180 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 General Description
MMA (Manual Metal Arc) Welding MMA (Manual Metal Arc) General Description One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric cur- One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric 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 RECOMMENDED ELECTRODE CLASSIFICATION & SELECTION CHART APPLICATION DIAMETER PACKAGE PART No ESR11 2.5 / 3.2mm HANDYPACK ESR-11-BLISTER General-purpose electrode for structural steelwork, workshop 2.5mm 2.5KG PACK ESR-11-2.5mm-2.5kg and maintenance welding. Easily operated in positional welding, including vertically-down. Good gap-bridging. Possible to use 2.5mm 5.0KG PACK ESR-11-2.5mm-5kg...
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Page 14: Installation & Operation For Dc Tig Welding With Lift Arc
INSTALLATION AND SET UP FOR DC TIG WELDING FOR MMA-TIG180 (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-TIG180 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.
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Page 16: Dc Tig General Description
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 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 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.
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Page 20: Tig Torch Parts Breakdown
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 17V-4MCP50... - 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...
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Page 22: 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 23: 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 24 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.
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Page 25: Sapre Part Identification
SPARE PARTS IDENTIFICATION - RAZOR ARC140DC Part Number Description Part Number Description 1. 10037128 front plastic panel 10. 10037345 Single-phase rectifier bridge 2. 10043477 carry strap / handle 11. 10007251 IGBT 3. 10004966 TIG/MMA selector switch 12. 10056946 main PCB 4. 10037152 panel socket 35-50 13. - Page 26 SPARE PARTS IDENTIFICATION - RAZOR ARC180DC Part Number Description Part Number Description 1. 10043405 front plastic panel 10. 10006650 Single-phase rectifier bridge 2. 10043477 carry strap / handle 11. 10007251 IGBT 3. 10004966 TIG/MMA selector switch 12. 10052484 main PCB 4. 10037151 panel socket 35-50 13.
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Page 27: Warranty Terms
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 28 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 29 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, RAZORWELD, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA Service Dealer...
- Page 32 © Welding Guns Of Australia PTY LTD 2016 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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