Uni-Mig KUMJR200AC/DC Operating Manual
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Uni-Mig KUMJR200AC/DC Operating Manual

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2
YEARS
Warranty
(Power Source)
240 Volt
L
OPERATING MANUAL
KUMJR200AC/DC
Please read and understand this instruction manual carefully
©
before the installation and operation of this equipment.
1
Welding Guns Of Australia PTY LTD 2012

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Summary of Contents for Uni-Mig KUMJR200AC/DC

  • Page 1 YEARS Warranty (Power Source) 240 Volt OPERATING MANUAL KUMJR200AC/DC Please read and understand this instruction manual carefully © before the installation and operation of this equipment. Welding Guns Of Australia PTY LTD 2012...

  • Page 2: Warranty

    UNI-MIG welders are manufactured to comply with - AS/NZ60974.1 2006 - AS60974-6:2006 WARRANTY •...
  • Page 3 CONTENTS PAGE Warranty Safety - Cautions Technical Data, Product Information Machine Layout & Descriptions Front Panel Selector Switch Function Descriptions Front Panel Control Dial Function Descriptions 10-11 Machine Installation & Operation Installation & Operation for MMA (Stick) Welding 14-15 MMA (Stick) Welding 16-17 Installation &...
  • 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: Maintenance

    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: Technical Data

    Robust & reliable, built to our specification and manufactured in compliance to AS/NZ60974.1 Product Code: KUMJR200AC/DC Standard option includes: KUMJR200AC/DC Machine, SR26 Tig Torch x 4m, Earth Lead & Arc Lead 25mm x 4m, Argon Regulator, 2M Gas Hose with fittings...
  • Page 8 Front Machine Layout Description Amperage Display Function Alarm Thermal Alarm Gas Pre Flow Peak Current Control Dial Control Dial Base Current Remote Control Selector Control Dial ON/OFF Switch Down Slope Control Dial TIG/MMA Selector Post Flow Gas Control Dial 2T/4T Selector AC Balance Control Dial AC/DC Selector...
  • Page 9 Selector Switch Function Descriptions ON/OFF: This switch powers the machine up when switched to the on position and powers the machine off when switched to the off position. Remote: Provides selection of the remote output current (amps) control function Selecting the ON position allows use of the remote current (amperage) controls Selecting the OFF postion allows current (amperage) control from the front panel Peak current control.
  • Page 10 Control Dial Function Descriptions Gas Pre Flow: Provides a pre-flow of gas to purge tig torch gas line prior to the initialisation of the arc. Helps arc ignition and prevents porosity in the weld start. Adjustment is 0-1sec. Peak Current: Provides adjustment and control of the main welding current. Adjustment range 10-200 Amps.
  • Page 11 Control Dial Function Descriptions - continued Pulse Frequency: Provides adjustment and setting of the pulse frequency when the machine is set in Pulse mode. It adjust the amount of times per second (Hz) the output current switches from the Peak current setting to Base current setting. Adjustment is 0.5-300Hz.
  • Page 12 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 13 Installation set up for MMA (Stick) Welding with KUMJR200AC/DC (1) Turn the power source on and select the MMA function with the 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 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 14 continued set up and operation for MMA (Stick) Welding (3) Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer (4) Place the electrode into the electrode holder and clamp tight (5) Strike the electrode against the workpiece to create and arc and hold the electrode steady to maintain the arc (6) Hold the electrode slightly above the work piece to maintain the arc while travelling at an even speed...
  • Page 15 MMA (Manual Metal Arc) Welding General Description 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 16: Mma (Stick) Welding Fundamentals

    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 17 Installation set up for DC TIG Welding with KUMJR200AC/DC (1) Turn on the machine using the ON/OFF switch (2) Select the TIG function with the TIG/MMA selector switch. (3) Select DC using the AC/DC selector switch. (4) Connect the Tig Torch connector to the negative terminal and tighten it.
  • Page 18 DC HF TIG Operation with KUMJR200AC/DC HF (high frequency) ignition allows the arc to be started in Tig welding without touching the tungsten to the work piece. By pressing the torch switch the machine will activate the gas flow and the HF ignition result- ing in the arc igniting across the gap between the tungsten electrode and the work piece.
  • Page 19 DC TIG Welding General Description 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 20 DC Pulse TIG Welding General Description Pulse TIG welding is when the current output (amperage) changes between high and low current. Electronics within the welding machine create the pulse cycle. Welding is done during the high-amperage interval (this high amperage is referred to as peak current). During the low amperage period, the arc is maintained but the current output of the arc is reduced (this low amperage is referred to as base current).
  • Page 21 EXAMPLE 1 OF PULSE DC TIG WELDING - SETUP PARAMETERS: Material = Stainless Steel x 2.0mm / Tungsten Electrode = 1.6mm 2% Thoriated / Gas = Argon The following steps are a guide as a starting point for you to set the machine up in Pulse mode to give an example of welding in Pulse mode function.

  • Page 22: Tig Welding Fusion Technique

    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 Acetylene 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 23 Set up and operation for AC TIG Welding - KUMJR200AC/DC (1) Turn on the machine using the ON/OFF swicth (2) Select the TIG function with the TIG/MMA selector switch. (3) Select AC using the AC/DC selector switch. (4) Connect the Tig Torch connector to the negative terminal and tighten it.
  • Page 24 - Set up and operation for AC TIG Welding - KUMJR200AC/DC AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminium, Aluminium Alloys and Magnesium. These materials have an insulating surface oxide layer that melts at a higher temperature than the base metal making it difficult to weld the base metal if the oxides are not removed.
  • Page 25 AC Welding AC (alternating current) enables us to TIG weld non ferrous alloys like Aluminium, Magnesium and Alumin- ium Alloys. These materials have an insulating surface oxide layer that melts at a higher temperature than the base metal making it difficult to weld the base metal if the oxides are not removed. AC welding current is ideal because the nature of the AC wave form assists in breaking the surface oxide layer.
  • Page 26 In older machines, a balanced current output wave was achieved using a large number of capacitors in series or a battery in the welding circuit. Modern TIG power sources use electronics to create and maintain a balanced wave and now most AC TIG power sources produce a square wave current output. direct polarity current reverse polarity...

  • Page 27: Pulse Ac Tig Welding Setup (Example)

    EXAMPLE 1: PULSE AC TIG WELDING - SETUP PARAMETERS: Material = Aluminium x 3.0mm / Tungsten Electrode = 2.4mm Zirconiated / Gas = Argon The following steps are a guide as a starting point for you to set the machine up in AC Pulse mode to give an example of welding in AC Pulse TIG function.
  • Page 28 Remote Amperage Controls - Installation and Operation Remote amperage controls allow for the welding current to adjusted remotely from the welding machine during welding. Generally there several types of remote amperage control available; (1) Hand amperage control located in the torch handle allowing the operator to adjust the welding current by rolling the potentiometer wheel to increase or decrease the amount of amperage desired.

  • Page 29: 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 30: 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 contribute to weld inconsistency and weld defects.
  • Page 31 Tungsten preparation AC Welding To obtain full current capacity from a pure or zirconiated tungsten electrode when used with AC current output the electrode is not ground to a point. The welding during positive polarity melts the point of the tungsten that becomes rounded.

  • Page 32: 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 33: Tig Welding Trouble Shooting

    TIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of 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 No gas...

  • Page 34: Arc Wanders During Dc Welding

    6: HF present but no welding power Possible Reason Suggested Remedy Incomplete welding circuit Check earth lead is connected. Check all cable connections. If using a water cooled torch check that the power cable is not separated. No gas Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted.
  • Page 35 UNI-FLAME AUTOLIFT UNI-FLAME Suregrip Series SR26 ERGO TIG TORCH 200A AIR COOLED TIG WELDING TORCH Rating:200Amp DC, 140Amp AC @35% duty cycle. Front end parts identification on opposite page Switch & remote control wires Torch Model Description Part Number SR26 Suregrip Tig Torch Package c/w QF Gas Connect SR-26-4MCP50 SR-26-8MCP50 Spare Parts...
  • Page 36 UNI-FLAME AUTOLIFT SR26 ERGO TIG TORCH UNI-FLAME Suregrip Series Standard Front End Parts Part # Description Part # Description Part # Description Long Alumina Nozzle Ø 8mm #5L 18CG Cup Gasket 10N30 Collet Body 1.0mm 10N49L Long Alumina Nozzle Ø 10mm #6L 10N31 Collet Body 1.6mm 53N48L...

  • Page 37: Spare Parts Identification

    Spare Parts Identification 11 12 13 27 28...
  • Page 38 Spare Parts Identification Part Number Description J10A10 Front Plastic Panel D20006 Digital Display Meter C16017 On/Off Switch B22310 Remote Control Selector Switch B22329 2T/4T Trigger Selector Switch B22311 Tig/MMA Selector Switch B22330 AC/DC Selector Switch B22328 Pulse Mode Selector Switch C02066 Panel Socket 35-50 J24011...

  • Page 39: Warranty Period

    WARRANTY CARD Welding Guns Of Australia Pty Ltd (‘Us’, ‘We’) warrants that the following products under UNI-MIG, 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, UNI-TIG, UNI-PLAS, UNI-FLAME, XCEL-ARC, TECNA, T&R, HIT-8SS &...

  • Page 40: Warranty Exclusions

    Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled, Torch Head Flexible,Back Caps, Gas Lens, Torch Handle, Cup Gasket, Torch Body Gas Valve, O-ring, All UNI-MIG TIG Welding Rods, All Xcel-Arc/ Magmaweld Electrodes, Arc Leads, Welding Cable, Electrode Holder, Earth Clamps.
  • Page 41 © Welding Guns Of Australia PTY LTD 2012 UNI-FLAME AUTOLIFT UNI-FLAME 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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