Unimig KUMJRRW160, Operating Instructions Manual

Page 1: ...d and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KUMJRRW200 KUMJRRW160 Welding Guns Of Australia PTY LTD 2015 YEARS Warranty Power Source 3 ...

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Page 3: ...valuable towards the evolution and future development of our equipment range This experience gives us the inside knowledge on what the arc characteris tics performance and interface between man and machine should be Within our team are specialist welders that have a proven history of welding knowledge and exper tise giving vital input towards ensuring that our machines deliver control and performa...

Page 4: ...ect input power cable for wear and tear replace the cable immediately if damaged bare wiring is dangerous and can kill Do not use damaged under sized or badly joined cables Do not drape cables over your body We recommend RCD safety switch is used with this equipment to detect any leakage of current to earth Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harm...

Page 5: ... gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damaged Protect gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Insure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding electrode or earth clamp to touch the gas cylinder do not drape we...

Page 6: ... voltage range of the machine please refer to Main parameter table This equipment is of automatic voltage compensation which enables the maintaining of the voltage range within the given range In case that the voltage of input power supply amperage exceeds the stipulated value it is possible to cause damage to the components of this equipment Please ensure your primary power supply is correct 2 4 ...

Page 7: ... Lift Arc function is superb and delivers perfect arc ignition every time without any sticking of the tungsten electrode to the work piece a remarkably smooth stable arc produces high quality TIG welds The ARC160 is an exceptional machine that is suitable for a wide range of industrial applications including site welding farming along with repair and maintenance applications ARC160 is packaged in ...

Page 8: ... stainless steel bronze and copper The Lift Arc function is superb and delivers perfect arc ignition every time without any sticking of the tungsten electrode to the work piece a remarkably smooth stable arc produces high quality TIG welds The ARC2000 is an exceptional machine that is suitable for a wide range of industrial applications including site welding farming along with repair and maintena...

Page 9: ...OCV is the voltage measured across the terminals when not welding The VRD unit will turn on welding power when the resistance between the electrode and work is less than 200 Ohms typically metal to metal contact The Safe Function VRD allows the reduction of the no load voltage in the power source to a very safe level Uo 24V This function can be started up with the safe key indicated in the picture...

Page 10: ...er 4 Place the electrode into the electrode holder and clamp tight 5 Strike the electrode on the work to create the 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 to create and even weld deposition 7 To finish the weld break the arc by quickly snapping the electrode away from the work pie...

Page 11: ...r metal to the molten pool These additional functions are provided mainly by the cover ing on the electrode 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 ...

Page 12: ...length no greater than the diameter of the core wire Electrode Angle The angle that the electrode makes with the work is important to ensure a smooth even transfer of metal When welding in down hand fillet horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel When vertical up welding the angle of the electrode should be between 80 a...

Page 13: ...uitable for hardfacing of parts subjected to heavy abrasion with moderate impact Required hardness and abrasion resistance can be obtained in the first layer even on low alloy steels The hardfacing layers have a very smooth surface and machinable only by grinding Suitable to use in excavator teeth leading edges of excavator buckets mixer blades gravel pumps conveyor worn screws conveyor belts Poss...

Page 14: ...as line of the TIG torch to regulator and connect the regulator to the gas cylinder Carefully open the gas cylinder valve and set the flow rate to between 8 10 l min 5 Set the welding current using the amperage control dial Note Photos show TIG torch with Suregrip option 5 Set the welding current using the amperage control dial 4 Carefully open the valve of the gas cylinder set the flow to 8 10 l ...

Page 15: ...a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece 10 Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc 7 Turn on the Gas Valve 8 Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1 2mm from the work piece 9 With a small movement rotate the Gas Cup forwa...

Page 16: ...types DC TIG welding is also the cleanest weld with no sparks or spatter LIFT ARC IGNITION for TIG tungsten inert gas Welding Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts with a current limit of one or two amps well below the limit that causes metal to transfer and contamination of the weld or electrode When the machine detects that the...

Page 17: ... pool Travel direction Angle torch Add TIG filler wire Retract the filler wire Move the torch forward to the front of the weld pool Repeat the process gas shield 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 elect...

Page 18: ...for its use Ceriated Color Code Orange Ceriated tungsten electrodes AWS classification EWCe 2 contain a minimum of 97 30 percent tungsten and 1 80 to 2 20 percent cerium and are referred to as 2 percent ceriated Ceriated tungstens perform best in DC welding at low current settings They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding thin s...

Page 19: ...n running lengthwise and thus grinding crosswise is grinding against the grain If electrodes are ground crosswise the electrons have to jump across the grinding marks and the arc can start before the tip and wander Grinding longitudinally with the grain the electrons flow steadily and easily to the end of the tungsten tip The arc starts straight and remains narrow concentrated and stable grind lon...

Page 20: ...ber Description 1 WP17V Torch head WP17VF Torch head flexible 2 57Y02 Back cap long 3 57Y03 Meduim back cap 4 57Y04 Short back cap 5 UERBS Blank Kitt 6 UERSP1 Screw Pack 7 UERH100 Small Ergo Tig Handle 8 UERKJ100 Small Knuckle Joint 9 UERLC200 08 Leather Cover X 0 8mt 10 UERJK100 Jointing Repair Kit Part Number Description 11 UERNCL 32 Neoprene Cover X 3 2mt UERNCL 72 Neoprene Cover X 7 2mt 12 UER...

Page 21: ... 45V26 Gas Lens Body 2 4mm 45V27 Gas Lens Body 3 2mm Part Description 54N14 Gas lens ceramic 8 0mm 54N15 Gas lens ceramic 7 0mm 54N17 Gas lens ceramic 5 0mm Compact Gas Lens Front End Parts Part Description TR0004 10 1 0mm x 175mm thoriated tungsten electrode 2 TR0004 16 1 6mm x 175mm thoriated tungsten electrode 2 TR0004 24 2 4mm x 175mm thoriated tungsten electrode 2 TR0004 32 3 2mm x 175mm thor...

Page 22: ...WP26VF Torch head flexible 2 57Y02 Back cap long 3 57Y03 Meduim back cap 4 57Y04 Short back cap 5 UERBS Blank Kit 6 UERSP1 Screw Pack 7 UERH200 Large Ergo Tig Handle 8 UERKJ200 Large Knuckle Joint 9 UERLC200 08 Leather Cover X 0 8mt 10 UERJK200 Jointing Repair Kit Part Number Description 11 UERNCL 32 Neoprene Cover X 3 2mt UERNCL 72 Neoprene Cover X 7 2mt 12 UERCO200 40 Sheath X 12 5ft Inc Leather...

Page 23: ... 45V26 Gas Lens Body 2 4mm 45V27 Gas Lens Body 3 2mm Part Description 54N14 Gas lens ceramic 8 0mm 54N15 Gas lens ceramic 7 0mm 54N17 Gas lens ceramic 5 0mm Compact Gas Lens Front End Parts Part Description TR0004 10 1 0mm x 175mm thoriated tungsten electrode 2 TR0004 16 1 6mm x 175mm thoriated tungsten electrode 2 TR0004 24 2 4mm x 175mm thoriated tungsten electrode 2 TR0004 32 3 2mm x 175mm thor...

Page 24: ...ation Possible Reason Suggested Remedy Insuf cient heat input Increase the amperage or choose a larger electrode Poor welding technique Use the correct welding technique or seek assistance for the correct technique Poor joint preparation Check the joint design and t up make sure the material is not too thick Seek assist ance for the correct joint design and t up 5 Excessive penetration burn throug...

Page 25: ...se metal Remove materials like paint grease oil and dirt including mill scale from base metal Contaminated ller wire Remove all grease oil or moisture from ller metal Incorrect ller wire Check the ller wire and change if necessary 4 Yellowish residue smoke on the alumina nozzle discoloured tungsten Possible Reason Suggested Remedy Incorrect Gas Use pure Argon gas Inadequate gas ow Set the gas ow b...

Page 26: ...ten size and or tung sten being used Check and change the size and or the tungsten if required Loose connection Check all connectors and tighten Earth clamp not connected to work Connect the earth clamp directly to the work piece wherever possible At initial set up and at regular intervals we recommend to check for gas leakage Recommended procedure is as follows 1 Connect the regulator and gas hos...

Page 27: ...panel adhesive sticker 6 30000103 Amperage knob 7 10052306 cable support assembly 8 10052508 rear plastic panel 9 10004949 ON OFF switch Part Number Description 10 10006650 Single phase rectifier bridge 11 10043327 main PCB 12 10052250 control PCB 13 10037766 thermal switch 14 10052310 cover 15 10044009 fan 24V DC 16 10042320 base plate 17 10043959 Insulation Sheet 2 3 4 1 5 6 7 8 9 14 10 11 12 14...

Page 28: ...panel adhesive sticker 6 30000103 Amperage knob 7 10042876 cable support assembly 8 10045764 rear plastic panel 9 10004949 ON OFF switch Part Number Description 10 10037345 Single phase rectifier bridge 11 10046842 main PCB 12 10046844 control PCB 13 10037766 thermal switch 14 10048366 cover 15 10047583 fan 24V DC 16 10042320 base plate 17 10043959 Insulation Sheet 2 3 4 1 5 6 7 8 9 14 10 11 12 14...

Page 29: ... 3 UNI MIG Jasic Inverter MIG SWF Power Source Separate Wire Feeder Only 3 Years Clause 3 UNI TIG Jasic Inverter TIG Power Source Only 3 Years Clause 3 UNI MIG Water Cooler 1 Year Clause 3 T R Pulse MIG Power Source Only 2 Year Clause 3 T R Pulse MIG SWF Power Source Separate Wire Feeder Only 2 Year Clause 3 UNI PLAS Power Source Only 3 Years Clause 3 UNI PLAS Jasic Series Power Source Only 2 Year...

Page 30: ...oods are unable to be repaired the Goods are returned at your cost within thirty 30 days of the delivery date and c Welding Guns Of Australia PTY LTD will not be liable for Goods which have not been stored or used in a proper manner and d the Goods are returned in the condition in which they were delivered and with all packaging material brochures and instruction material in as new condition as is...

Page 31: ...Printed Circuit Board Gun Plug House Cable Support Gas Connector Handle To Suit PP36 with Knobs All Xcel Arc Magmaweld Mig Welding Wires Electrodes Arc Leads Welding Cable Electrode Holder Eatch Clamps TIG Welding Torches and Consumables to suit such as Tungsten Electrodes Collet Collet Body Alumina Nozzle Torch Head Torch Head water Cooled Torch Head Flexible Back Caps Gas Lens Torch Handle Cup G...

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Page 36: ...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 Welding Guns Of Australia Pty Ltd ABN 14 001 804 422 Welding Guns Of Australia PTY LTD 2015 ...