Related Manuals for Unimig RazorWeld MS500
Summary of Contents for Unimig RazorWeld MS500
- Page 1 OPERATING MANUAL MS500 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 2013...
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Page 2: Warranty
UNIMIG welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1, guaranteeing you electrical safety and performance. -
Page 3: Table Of Contents
CONTENTS PAGE Warranty Safety - Cautions 4-10 Definitions of Symbols 11-13 Rating Labels 14-15 Size / Position / Movement ■ Dimensions ■ Position ■ Installation & Movement 18-19 ■ Lifting Before Starting Engine ■ Battery check ■ Lubrication oil ■ Air filter ■... -
Page 4: Safety - Cautions
Further information and copies of these publications, and technical support in welding and related activities, are available from WTIA Tel: +61 (0)2 9748 4443 Fax; +61 (0)2 9748 2858 or email info@wtia.com.au. For information about other publications and the activities of the WTIA and WGA visit www.wtia.com.au. or www.unimig.com.au SECTION 1- SAFETY SPECIFICATION Advice to the user about the safety: N.B: the information contained in the manual can be changed without notice. -
Page 5: Electric Shock Can Kill
ELECTRIC SHOCK CAN KILL Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding, the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are electrically live. - Page 6 FUMES and gases can be hazardous. Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. •...
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Page 7: Engine Hazards
Flying metal can injure eyes • Welding, chipping, wire brushing, and grinding cause sparks, flying metal as welds cool, they can throw off slag. • Wear approved safety glasses with side shields even under your welding helmet. HOT parts can cause severe burns. •... -
Page 8: Compressed Air Hazards
Moving parts can cause injury • Keep away from belts, rotors, fans. • Keep all doors, panels ,covers and guards closed and securely in place. • Stop engine before installing or connecting unit. • Have only qualified people remove guards or cover for maintenance and troubleshooting as necessary. -
Page 9: Additional Symbols For Installation Operation And Maintenance
HOT PARTS can cause burns and injury. • Do not touch hot compressor or air system parts. • Let system cool down before touching or servicing . Trapped air pressure and whipping hose can cause injury • Release air pressure from system and tools before servicing, adding or changing attachment or opening compressor oil drain or oil fill cap. - Page 10 Read instructions • Use only genuine replacement parts • Perform engine and compressor (if applicable) maintenance and service according to this manual and the engine or air compressors (if applicable) manual. H.F RADIATION CAN CAUSE INTERFERENCE • High-frequency (H.F ) can interfere with radio navigation, safety services , computers and communication equipment.
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Page 11: Definitions Of Symbols
Definition of the symbols Warning label definitions: 1. Warning! Watch out! There are possible hazards as shown by symbols. 2. Do not smoke and keep fire and flame away from the equipment. 3. Sparks can cause battery gases to explode. Exploding Battery can cause blindness and injuries. always wear a face shield. - Page 12 1. Warning, watch out. There are possible hazards as shown by the symbols. 2. Engine fuel exposed to flames or sparks can cause fire or explosion. 3. Do not smoke while fuelling or if near fuel 4. Stop engine before fuelling 5.
- Page 13 1. Warning! Watch out! There are possible hazards as shown by the symbols. 2. Become trained and read the instructions before working on the machine or welding. Electric shock from welding electrode with bare hand. Do not wear wet or damaged gloves. Protect yourself from electric shock by insulating yourself from work and ground.
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Page 14: Rating Labels
Manufacturer’s rating label Dimension: 1660D x 850W x 1430H mm Weight with Fuel: 1150kg 30-500 A/21.2-40 V AMPERAGE RANGE 1. Remove unit from shipping crate. Remove owner’s 100% manual from unit. Follow instruction to install muffler DUTY CYCLE STICK (if the muffler has been removed before shipping) 500A 387A RATED CURRENT... -
Page 15: Fuel Consumption
Engine type Perkins 1103A-33G Rated power 28.4KW/1500RPM Displacement 3.3L Cylinder Cooling Water-cooled Fuel tank Battery 120AH/12V Rated speed 1500RPM Idle speed 1150RPM Current range 30-500A/20-40V Duty cycle 100% Rated current 500A 387A Rated voltage 35.5V O.C.V DC TIG Current range 30-500A/11-30V Duty cycle 100%... -
Page 16: Dimensions
OUTPUT Declared power at the following ambient temperature 25 C,relative humidity 30% .Altitude 500m above sea level. In an approximate way one reduces: of 1% every 100m Altitude and of 2.0% for every 5 C above 25 Dimension and weight and operating angle... -
Page 17: Position
Position Place the machine on a level surface at a distance of at least 1 meter from buildings or other plants. Maximum leaning of the machine (in case of unlevel surface). Check that the air gets rotated completely and the hot air sent out does not come back inside the set so as to cause a dangerous increase of the temperature. -
Page 18: Installation & Movement
Installation and movement Installation and advice before use: The operator of the welder is responsible for the safety of the people who work with the welder and for those in the vicinity. The safety measures must satisfy the rules and regulations for engine driven welders. The information given below is in addition to the local safety norms: Check the work area for possible electromagnetic problems, taking into account the following indications. - Page 19 Diesel engines Use in open space, air swept or vent exhaust gases far from the work area Movement Always securely fasten welding generator onto transport vehicle or trailer and comply with all transport rules and other applicable codes.
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Page 20: Lifting
Using lift eye Be sure that the lifting devices are correctly mounted and are adequate for the weight of the machine with it’s fuel and other liquids such as oil, coolant ect, and conforms to local rules and regulations. Before starting engine Battery check. -
Page 21: Lubrication Oil
Lubricating oil Recommended oil: Recommended engine oil specification: API service classification CH-4. Please select the recommended viscosity referring to the operating temperature Viscosity chart: A = recommended viscosity grades B = Ambient temperature ATTENTION CAUTION 1. The above oils are to the minimum specification recommended for use in Perkins engine. Higher grades may be used but not until after the first service. -
Page 22: Cooling Liquid
Low temperatures fuels. Special winter fuels may be available for engine operation at temperatures below 0 C. These fuels limit the formation of wax in the fuel at low temperatures. If wax forms in the fuel , this could stop the flow of fuel through the filter. -
Page 23: Grounding Connection
Grounding connection • Electrically join generator frame to vehicle frame by metal-to metal contact • Tray Liners, shipping skids and some running gears insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frames as shown. - Page 24 Coolant filling port Keep radiator and air intake clean and free of dirt. • Incorrect engine temperature can damage engine. Do not run engine without a radiator cap. To improve cold weather starting: • Use starting aid switch (preheating ) •...
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Page 25: Engine Start
Engine start 6.1 Introduction of the engine starting control system FIGURE 1. front panel (welding and engine control operation panel) This is the front panel, it include the welding operation controls and the engine start or stop operation controls. Item Name Functional and operation instruction Preheat button... - Page 26 Item Name Functional and operation instruction Circuit breaker 1. It is a 15 Amp circuit breaker to protect the engine control system. 2. If the circuit current of engine control system is overloaded with more than 15A for a certain time, it will shut off the circuit, and will require cooling down for minutes, 3.
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Page 27: Battery Isolation Switch
Item Name Functional and operation instruction Water temperature 1. Indicator of the water temperature. Gauge 2. CURTIS light-dash gauge, it has a internal lamp to help read at night. 3. The water temperature is normally about 80-95 C ,and the light is green ,when the temperature is above 99 C,the light-dash become red. -
Page 28: Engine Speed Control
Engine speed control Engine idle/run speed control switch (please refer to the figure 1 / number 2) position Engine running Description Speed 1500rpm Engine Engine Running speed will be 1500rpm continously. Whether the welder or auxiliary power is loading or not speed control switch... -
Page 29: Engine Idel/Run Speed Control
Engine idle/run speed control device 1: solenoid, 12V pull type 2: throttle rod (plunger) 3: engine fuel level control 4: engine idle speed adjustment screw 5: engine run speed adjustment screw and lock nut 6: engine block Engine preheating device 1. -
Page 30: Engine Starting Instructions
Engine starting instruction. • Start the engine (please refer to the figure 1) Before starting the engine, turn the battery isolation switch to the “ON” position! 1. Turn the “engine control ” switch (3) to “ ON” position. Turn the speed control switch (2) to “auto”. Check the five gauges and five alarm lamps according to the table below. -
Page 31: Stop Engine
ATTENTION CAUTION • Do not crank the engine for more than 20 seconds, allow the electric starting motor to cool for 2 minutes before cranking the engine again. ATTENTION WARNING • Do not use aerosol types of starting aids such as ether. It could result in an explosion and personal injury. - Page 32 Welding operation and using auxiliary power selecting weld cable size Welder output Weld cable size and total cable (copper) length in weld circuit Not exceeding Terminal • stop engine before 105m 120m connect to the (100ft) (150ft) (200ft) (250ft) (300ft) (350ft) (400ft) weld output or less...
- Page 33 Welding operation controls Figure 3: front panel of the welding and auxiliary power output Item Name Functional and operation instruction Digital Amps Meter Display the pre-set current and the actual welding current. Thermal Overload If the welding power source is overloaded (The duty cycle has Indicating Light been exceeded) , the thermal relay will shut off the inverter, the protection light will turn ON.
- Page 34 Item Name Functional and operation instruction Welding Mode Selector Welding mode switch. selecting the welding process: Switch GOUGING / CELLULOSE / MMA / TIG / MIG -FCAW GOUGING: (CC) Air carbon arc cutting, previously known as air arc cutting, is an arc cutting process where metal is cut and melted by the heat of a carbon arc.
- Page 35 Item Name Functional and operation instruction Current regulation This function adjust’s the output current of the welding power source. Turning the knob pre-set’s the desired current. It is only used for MMA / TIG / CELLULOSE / GOUGING. Voltage regulation This function adjust”s the output voltage of the welding power source.
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Page 36: Safety Features
CC-MMA / CELLULOSE and GOUGING mode this indicates that the VRD is not working please contact your nearest UNIMIG service agent. Due to the low OCV and the Australian Standard requirement’s of resistance in the curcuit to be low for VRD to operate electrode starting is more difficult. - Page 37 RCD protection for all high voltage circuits Both welding and auxiliary power outlets can be isolated both electrically and mechanically using lockable doors. All wiring looms are encased in Lockable dual pole battery isolation conduit with rubber boots fitted to avoid selector for safer maintenance mechanical wear and damage.
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Page 38: Gouging Mode Setup & Operation
GOUGING MODE 1. Ensure the weld terminal switch is turned to the OFF position before starting engine. 2. Start Generator MINE SPEC 500 refer to section 6.6 for start procedure 3. Connect Air gouging torch to the constant current output socket 4. - Page 39 7. Prepare the area in which you will be air carbon arc gouging. Safety precautions must be made before you start the carbon arc gouging process because the air pressure will cause the molten metal to travel a long distance. The molten metal can easily become a fire hazard.
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Page 40: Gouging Tecninal Notes
AIR CARBON-ARC GOUGING History Air carbon-arc gouging has been used since the early 1940ʼs. Initially developed from the Carbon Arc cutting process, it was used to remove welds, rivets heads and cut metal but relied on gravity for removal of the molten material. An engineer by the name of Myron Stepath came up with idea of introducing a jet of air behind and on the underside of the gouging carbon to remove the molten material, initially a second operator was used to hold an air gun to direct the jet of air manually at the molten pool. - Page 41 AIR CARBON-ARC GOUGING Process Air Carbon-Arc Gouging, also known as Air Arc Gouging is an arc cutting/gouging process. A copper coated carbon electrode connected to a welding power source is used to create an intense arc at the work, the heat of a carbon arc establishes a molten pool on the work piece. The molten metal is then removed by a continuous stream of compressed air.
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Page 42: Cellulose / Mma Mode Setup & Operation
InSTALLATIOn SET uP FOR CELLuLOSE / MMA (STICk) WELDInG MINE SPEC 500 1. Ensure the weld terminal switch is turned to the OFF position before starting engine. 2. Start Generator MINE SPEC 500 refer to section 6.6 for start procedure 3. -
Page 43: Arc Force
5. Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer. 6. Place the electrode into the electrode holder and clamp tight 7. Strike the electrode on the workpiece to create the arc and hold the electrode steady to maintain the arc 8. -
Page 44: Mma Tecnical Notes
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 current 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. The electrode core itself acts as filler material the residue from the flux that forms a slag covering over the weld metal must be chipped away after welding. - Page 45 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.
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Page 46: Dc Tig Mode Setup & Operation
DC TIG WELDING MODE 1. Ensure the weld terminal switch is turned to the OFF position before starting engine. 2. Start Generator MINE SPEC 500 refer to section 6.6 for start procedure 3. Select TIG using the welding selector mode switch 4. - Page 47 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 48: Tig Tecnical Notes
DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical 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. -
Page 49: Tig Welding With Filler Wire 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 work piece. 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 50: Mig / Fcaw Mode Setup & Operation
MIG / FCAW WELDING MODE MINE SPEC 500 can be used with many different voltage sensing wire feeders. please consult your instruction manual for the type of voltage sensing wire feeder you intend to use before use. 1. Ensure the weld terminal switch is turned to the OFF position before starting engine. 2. -
Page 51: Remote Control Connection
Remote control connection: It is possible to connect the remote control to TIG torch and CS501 wire feeder, YH120 WIRE FEEDER and the adapter for LN-25. The remote control circuit can regulate the welding voltage in the CV mode and switch the welding power source, it is connected to the front panel by means of multi-pole connector when the remote control is connected to the wire feeder or gun trigger plug, it is functional and automatically excludes the front panel regulation especially for the CC mode.(optional) -
Page 52: Mig / Fcaw Technical Notes
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 53 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 54 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 55 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 56 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. Gas flow must also correspond with the travel speed, increas- ing with faster travel speed and decreasing with slower speed.
- Page 57 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.
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Page 58: Pulse Mig / Double Pulse / Synergic Mig & Manual Mig Setup & Operation
PULSE MIG / DOUBLE PULSE MIG / SYNERGIC MIG / MANUAL MIG WELDING MODE 1. Ensure the weld terminal switch is turned to the OFF position before starting engine. 2. Start Generator MINE SPEC 500 refer to section 6.6 for start procedure 3. -
Page 59: Auxiliary Power
7-6 Use of the Auxiliary power Description of the electric distribution cabinet and auxiliary power sockets Item Name Description A.C voltmeter It display the line-voltage of the generator output Main power switch Main power switch is a circuit breaker. if main power switch is off, no weld and auxiliary power output. - Page 60 Note: THIS IS FOR BOTH 3-PHASE AND 1-PHASE RCD’s 1. 1-phase auxiliary power switch is a high-sensitivity (30MA) ground fault interrupter switch. It guarantee’s protection against indirect contact due to faulty ground currents. When the RCD switch pick up a faulty ground current that is more than 30MA, It intervene immediately by cutting off power to 1-phase socket.
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Page 61: Maintenance
Section 8: Maintenance (troubleshooting) Section 8: Maintenance (troubleshooting) 8-1: Routine maintenance 8-1: Routine maintenance Please read carefully the engine manual to server the engine. Please read carefully the engine manual to service the engine. Follow the storage procedure in the engine owner’s manual if the unit will not be used for Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. -
Page 62: Maintenance Label
Maintenance label See engine manual for complete engine care Give engine specification and serial number when ordering parts Recommended oil: API service classification: CH-4 ! Perkins 1103A Oil change & filter Dirty condition 250hours or less Normal condition 400hours Oil filter Perkins 2654403 Oil capacity: 7.8L... - Page 63 air filter service: 50hours or less see owner’s manual air filter element: 2652c117 (air filter ASSY.) 26510362(main filter) air filter safety element: Perkins 2652C805 ( indicator) air filter service: 50hours or less see owner’s manual air filter element: 2652c117 (air filter ASSY.) 26510362(main filter) air filter safety element: Perkins 2652C805 ( indicator) battery:...
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Page 64: 8-3 Troubleshooting
8-3 troubleshooting Engine troubleshooting Problem Problem Cause What to do Engine control switch is “on”, but no 1. Battery isolate switch is “off” 1. Turn the battery isolate switch to power, the indicator or gauge is not 2. if the engine control switch is held “on”... - Page 65 Problem Problem Cause What to do Engine suddenly stop 1. Automatic shut off system stop 1. Check fuel and oil and coolant Engine shut down shortly after starting engine if fuel level or oil pressure is level. too low or coolant temperature is too high.
- Page 66 Problem Problem Cause What to do Engine runs rough 1. Dirty fuel or air filter. 1. Inspect or clean or replace filter as 2. Dirty engine oil and oil filter needed.(fuel /engine oil or air filter) 3. Water in fuel. 2.
- Page 67 Welding general troubleshooting Problem Problem Cause What to do Welder power switch (circuit breaker) Consult the authorized unimig can not hold on after turned to on service shop position When welder power switch is on, no Consult the authorized unimig...
- Page 68 MMA/Cellulose troubleshooting Problem Problem Cause What to do Current digital meter display 000 or Consult the authorized unimig preset reading can not be adjusted service shop correctly Display for digital meter is correct, Consult the authorized unimig but no welding output...
- Page 69 MIG troubleshooting Problem Problem Cause What to do Press gun trigger, wire dose not feed • Remote control cable connector are Check and make certain that the and gas does not flow not connected securely to the connection is good receptacle •...
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Page 70: Troubleshooting
Generator & Auxiliary Power output troubleshooting Problem Problem Cause What to do Voltmeter show no voltage but actual • Voltmeter is damaged or faulty Call service centre voltage at socket is OK No three-phase voltage present at 1. Main power switch is off 1. -
Page 71: Electric Diagrams
Section 9: Electric diagrams Circuit diagram for CS-501 wire feeder /TIG remote control connector... - Page 72 Circuit diagram for LN-25P wire feeder adapter.
- Page 73 Circuit diagram for engine control system...
- Page 74 Circuit diagram for generator output (welding power and auxiliary power)
- Page 75 Circuit diagram for welding power source...
- Page 76 Circuit diagram for welding power source...
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Page 77: Parts List
Section 10 : Parts list Postion Description base Cover bracket Welding power source Front panel assembly Rear cover assembly Isolate switch assembly Electric distribution cabinet Main control box assembly Left side cover assembly Right side cover assembly Top cover assembly Front protection cover... -
Page 78: Full Warranty And Conditions
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 79 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 80 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 84 Welding Guns Of Australia PTY LTD 2013 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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