Unimig KUMJRRW200DC, Operating Manual

Page 1: ... read and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KUMJRRW200DC Welding Guns Of Australia PTY LTD 2013 YEARS Warranty Power Source 3 ...

Page 2: ...resents the latest developments in Inverter technology put together by our professional team of highly skilled engineers The expertise gained from our long involvement with inverter technology has proven to be invaluable towards the evolution and future development of our equipment range This experience gives us the inside knowledge on what the arc characteristics performance and interface between...

Page 3: ...ation for DC TIG Welding 16 17 DC TIG Welding DC Pulse TIG Welding 18 19 Set Operation for Pulse DC TIG with RAZOR 200 TIG 20 TIG Welding Fusion and Filler Wire Technique 21 Remote Controls Installation and Operation 22 Tungsten Electrode Selection Preparation 23 24 SR26 TIG Torch Parts Breakdown 25 26 Machine Spare Parts Identification 28 Trouble Shooting Guide TIG Welding 29 30 Trouble Shooting ...

Page 4: ...protected from hot metal and sparks Frequently inspect 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 Fumes and gases are dangerous Smoke and gas generated whilst welding or cutting can be harmful to people s health Welding produces fumes and ...

Page 5: ...n explode Because 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 cylinde...

Page 6: ...ment 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 Do not come into contact with the output terminals while the machine is in op...

Page 7: ...rent Level Up Slope Time Down Slope Time Finish Current Level and Post Gas Time combined with the choice of 2 or 4T trigger function allows you to control the start and finish of the weld process at the highest professional level The Digital Control Pulse Frequency allows full parameter setting of Peak Current Base Current Pulse Frequency and Pulse Width allowing to manipulate the heat input to th...

Page 8: ...pad 4T uses 4 actions of the torch switch while incorporating weld program parameter selections 4T provides operator control of the Start and Finish periods of the weld sequence refer to page 11 for instruction of 4T function SPOT Select the SPOT icon using the selector pad Spot uses a single action of the torch switch 1 Pressing the torch switch gives arc igni tion and initializes the welding seq...

Page 9: ...r to set the Start Amp value Range is 10 200A Pre Gas Time Select by pushing selector pad to cycle through to illuminate the Start Amp icon The value selected shows on the digital display It is the amount of amps the machine will deliver at the start of the welding sequence Turn the Encoder to set the Up Slope value Range is 0 60 Sec Up Slope Time Select by pushing selector pad to cycle through to...

Page 10: ...Up Slope value Range is 0 60 Sec The value selected shows on the digital display It is the amount of time it takes for the welding amperage to drop down to the set Finish Amperage Continued Front Panel Operation Weld Program Sequence Control Razor 2OO TIG MMA Up Slope Time Select by pushing selector pad to cycle through to illuminate the Up Slope icon Post Gas Timer Provides selection for continue...

Page 11: ... Only for MMA function Select by pushing selector pad to cycle through to illuminate the IGNITION icon Allows to set the time period of the arc ignition 4T Selection provides 4 times function of the torch switch SPOT Selection provides a set weld sequence time IGNITION TIME For MMA Stick welding only Selection allows for high amperage start for a selected time period ARC FORCE Select MMA by pushin...

Page 12: ... DC MMA Function Push the button until the DC icon illuminates green 4 Set the weld amperage by rotating the Adjustment Encoder Knob Set the amper age according to the electrode type and size being used as recommended by the electrode manufacturer The Peak Amp icon will be illuminated and the set amperage will show in the Digital Display 5 Select Ignition and Arc Force Push the button until the Ig...

Page 13: ...r the weld to cool and carefully chip away the slag to reveal the weld metal below Continued Set Up Procedure for MMA Stick Welding Razor 2OO TIG MMA 6 Connect the Earth Clamp securely to the work piece or the work bench 7 Place and clamp an electrode into the Electrode Hand Piece 8 Strike the electrode against the work piece to create an arc lift slightly and hold the electrode steady to maintain...

Page 14: ...cross the arc into the molten pool and becomes the deposited weld metal The deposit is covered and protected by a slag which comes from the electrode coating The arc and the immediate area are enveloped by an atmosphere of protective gas Core wire Flux coating Base metal Protective gas Arc Slag Weld pool Manual metal arc stick electrodes have a solid metal wire core and a flux coating These electr...

Page 15: ... 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 ...

Page 16: ... connect the gas regulator to the Gas Cylinder Connect the gas line to the quick lock gas inlet connector at the rear of the machine 7 Connect the regulator to the cylinder Connect the gas lead to the regulator Set the flow to 8 12 l min 4 Connect the Earth cable connector to the terminal 5 Connect the torch switch lead to the torch remote receptacle 1 Turn on the machine using the ON OFF switch a...

Page 17: ...easing the torch switch terminates the welding operation and introduces the post flow gas 3 Choose the preferred welding current amperage to suit the tungsten size material type and thickness to be welded 4 Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1 3mm from the work piece this method will provide a clean positive arc ignition 5 Press the torch switch and t...

Page 18: ...ers the user the greatest amount of flexibility to weld the widest range of material and thickness and types DC TIG welding is also the cleanest weld with no sparks or spatter HF ARC IGNITION for TIG tungsten inert gas Welding 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...

Page 19: ...ps is a percentage of peak amperage As a rule use enough background cur rent to reduce the weld pool to about half its normal size while still keeping the weld pool fluid As a guide start by setting the background amperage at 20 to 30 percent of peak amperage Pulse Frequency is the control of the amount of times per second Hz that the welding current switches from Peak Current to Base Current DC P...

Page 20: ... Select the Pulse Frequency by pushing the selector button to cycle through to illuminate the Hz Pulse Icon 9 Rotate the Adjustment Encoder Knob to set the Pulse Frequency to 2 Hz 0 5 200Hz Peak Amp Base Amp 100A 60 30A 40 100A 60 30A 40 The Razorweld 200 machine has digital pulse frequency control All the parameters for DC Pulse TIG welding Peak Amp Base Amp Pulse Frequency and Pulse Width are ea...

Page 21: ... 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 22: ...ntrol 7 pin plug from the TIG Torch switch lead to the 7 pin remote receptacle on the front panel of the machine 2 Activate the remote control Press and hold down the torch switch for 5 seconds The machine will give an audible beep single indicate the remote is activated Repeat the procedure to de activate the remote control 3 The thermal LED will illuminate RED to indicate the machine is in remot...

Page 23: ...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 24: ...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 25: ...ERSWL8 Trigger Lead 25ft 7 UERSP1 Screw Pack 8 UERH200 Large Ergo Tig Handle 9 UERKJ200 Large Knuckle Joint 10 UERLC200 08 Leather Cover X 0 8mt 11 UERJK200 Jointing Repair Kit Part Number Description 12 UERNCL 32 Neoprene Cover X 3 2mt UERNCL 72 Neoprene Cover X 7 2mt 13 UERCO200 40 Sheath X 12 5ft Inc Leather Cover UERCO200 80 Sheath X 25ft Inc Leather Cover 14 USLH26 S Cable Support Large 15 US...

Page 26: ...V27 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 thoriated tungsten electrode 2 Pa...

Page 27: ...d line for an extended time period In this situation it is recommended to open the cylinder valve set the flow rate to 8 10 l min close the cylinder valve and check after a minimum of 15 minutes 5 If there is a gas loss then check all connectors and clamps for leakage by brushing orspraying with soapy water bubbles will appear at the leakage point 6 Tighten clamps or fittings to eliminate gas leak...

Page 28: ...10004957 ON OFF switch 10 10037345 Single phase rectifier bridge GBPC3510 35A 1000V Part Number Description 11 10029693 IGBT FGH60N60SMD 12 10042799 main PCB W209 22 PN 55 A1 13 10044929 control PCB W21201 21 PK 234 A0 14 10037764 thermal switch TBT301G20 15 10043379 cover 16 10037796 fan and wire DC24V 2X2 130 4500rpm 17 10042320 base plate 18 10016391 gas nozzle front panel 19 10042342 gas nozzl...

Page 29: ...8 12 l min flow rate Check hoses and fittings for holes leaks etc Moisture on the base metal Remove all moisture from base metal before welding Contaminated base metal Remove materials like paint grease oil and dirt including mill scale from base metal Contaminated filler wire Remove all grease oil or moisture from filler metal Incorrect filler wire Check the filler wire and change if necessary 4 ...

Page 30: ...tal Incorrect filler wire Check the filler wire and change if necessary 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 Set the gas flow between 10 15 l min flow rate Tungsten ...

Page 31: ... 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 fit up make sure the material is not too thick Seek assist ance for the correct joint design and fit up 5 Excessive penetration burn through Possible Reason Suggested Remedy Excessive heat input Reduce the amperage or use a smalle...

Page 32: ...r 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 Years Clause 3 UNI PLAS Site Cut Series Power Source Only 1 Year Claus...

Page 33: ...e you have acquired Goods as a consumer within the meaning of the Trade Practices Act 1974 or the Fair Trading Acts of the relevant state or territories of Australia and is therefore also entitled to at the consumer s discretion either a refund of the purchase price of the Goods or repair of the Goods or replacement of the Goods Returns will only be accepted provided that a You have complied with ...

Page 34: ...ions Improper installation Use of non authorised non standard parts Abnormal product performance caused by any ancillary equipment interference or other external factors 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 UNI TIG UNI PLAS UNI FLAME TECNA T R...

Page 35: ...Consumables to suit such as Input Cord Inter connecting Cord Triggering Cable This Warranty does not cover products purchased From a non authorised UNI MIG UNI TIG UNI PLAS UNI FLAME TECNA T R HIT 8SS ROTA Dealer such as purchases from unauthorised retailers and purchases over the Internet from unauthorised local international sellers or sites such as EBay At an auction From a private seller Unles...

Page 36: ...W 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 2013 ...