Unimig KMM180, Operating Manual

Page 1: ...c DC TIG Plasma CUT YEARS Warranty Power Source 2 Please read and understand this instruction manual carefully before the installation and operation of this equipment OPERATING MANUAL KMM180 Welding Guns Of Australia PTY LTD 2012 15 AMP ...

Page 2: ...n authorised repair agent as appointed by this company Warranty does not cover abuse mis use accident theft general wear and tear New product will not be supplied unless Welding Guns Of Australia PTY LTD has inspected product returned for warranty and agree s to replace product Product will only be replaced if repair is not possible Please view full Warranty term and conditions supplied with machi...

Page 3: ...ween man and machine should be Within our team are specialist welders that have a proven history of welding knowledge and expertise giving vital input towards ensuring that our machines deliver control and performance to the utmost professional level We employ an expert team of professional sales marketing and technical personnel that provide us with market trends market feedback and customer comm...

Page 4: ...9 20 Installation Guide for Mig Torch Liner Installation 21 Mig Torch and Wire Feeder Set Up Guide for Aluminium Mig Wire 22 23 Installation Operation for MIG Welding with Spool Gun 24 25 MIG Metal Inert Gas Welding 26 27 Basic MIG Welding Guide 28 31 Installation Operation for DC TIG Welding with Lift Arc 32 33 DC TIG Welding 34 35 Tungsten Electrodes 36 37 24 MIG Torch Parts Breakdown 38 39 SP13...

Page 5: ...gun for use with thin or softer wires that don t have the column strength required to feed through standard MIG torches such as aluminium wire A high quality non commercial machine it is compact and portable An optional trolley provides off the floor operation and better manoeuvrability around the workshop Being 240v single phase gives great portability it can be run from any 15 Amp power socket p...

Page 6: ...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 7: ...ecause 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 dr...

Page 8: ...rature inside the equipment The machine will be ready for use again when the internal temperature reaches safe level 2 3 Over Voltage Supply Regarding the power supply 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 ...

Page 9: ...tion 6 Earth Lead 7 Primary Power Supply Connection 8 Standard Mig Spool Gun Selector Switch 9 Euro Mig Torch Connector MIG MAG 9 1 2 3 4 5 7 BACK PANEL LAYOUT 10 Gas Inlet 11 Fan 12 Data Plate 12 11 INTERNAL PANEL LAYOUT 13 DC Positive output terminal 14 DC Negative output terminal 15 Wire feeder mechanism 16 Spool holder assembly 14 13 15 16 10 6 8 ...

Page 10: ...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 Refer to data plate on machine for Input voltage IMAX and IEFF ...

Page 11: ...thread Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling Feed the wire into the wire feeder inlet guide tube through to the drive roller 8 Carefully feed the wire over the drive roller into the outlet guide tube feed through about 150mm into the torch receptacle Check that the drive roller being used complies with the wire diameter replace the roller if necessary ...

Page 12: ...it up tightly 14 Fit the gas nozzle to the torch head 15 Carefully open the gas cylinder valve and set the flow rate to between 5 10 l min 16 Set the welding parameters using the wire feed and voltage control knobs 12 Press and hold the trigger on the mig torch until wire is visable at the tip holder 11 Remove the gas nozzle and contact tip from the front end of the mig torch 13 Fit the correct si...

Page 13: ...iving to feed due to their higher cross sectional column strength they are stiffer and don t bend so easy Soft Wire like Aluminium requires a U shape groove Aluminium wire has a lot less column strength can bend easily and is therefore more difficult to feed Soft wires can easily buckle at the wire feeder where the wire is fed into inlet guide tube of the torch The U shaped roller offers more surf...

Page 14: ...t guide tube retaining nut too make adjustment if required Carefully retighten the locking nut and screw to hold the new position 4 Snip the wire carefully be sure to hold the wire to prevent the spool uncoiling Carefully feed the wire into the inlet guide tube of the wire feed unit 5 Feed the wire through the drive roller and into the outlet guide tube of the wire feeder 6 Lock down the top press...

Page 15: ... Fit the correct sized Knurled Drive roller for Gas Less Flux Cored wire 7 Place the Wire Spool onto the Spool Holder Note the spool retaining nut is Left Hand thread Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling Feed the wire into the wire feeder inlet guide tube through to the drive roller 5 Connect weld power lead to NO GAS as show in picture inside machine...

Page 16: ...ect sized contact tip and feed the wire through it screw the contact tip into the tip holder of the torch head and nip it up tightly 14 Fit the gas nozzle to the torch head 15 Set the welding parameters using the wire feed and voltage control knobs 15 Set welding parameters using the voltage and wire feed controls 9 Close down the top roller bracket and clip the pressure arm into place 10 Apply a ...

Page 17: ...1 2 way 7 Leaving the torch straight snip the liner approximately 3mm past the end of the torch neck 8 Place the tip holder over the end of the liner and screw into the torch neck nipping it up tight 9 Screw down the liner nut the remaining 1 2 and nip it up tight This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed 2 Remove th...

Page 18: ... with the liner o ring 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 9 Install a U groove drive roller of the correct size to match the wire diameter being used 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the liner 4 Carefully unravel the new liner 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 5 Car...

Page 19: ...h a sharp Stanley knife just in front of the drive roller 16 Fit an Aluminium contact tip of the correct size to match the diameter of the wire being used 17 Fit the remaining front end parts to the torch neck ready for welding 11 Remove the inlet guide tube using long nose pliers 12 Carefully feed the PA liner into the inlet guide tube hole of the torch euro receptacle 14 Tighten and secure the t...

Page 20: ...s Cylinder 7 Connect weld power lead to GAS Remove wire from the drive unit as show in picture inside machine 8 Take the Spool Gun and remove the spool cover 9 Place the Wire Spool onto the Spool Holder Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling 9 Place a spool of wire onto the Spool holder 8 Remove the spool cover by unscrewing the retaining nut a...

Page 21: ... too much pressure 15 Fit the gas nozzle to the torch head 16 Carefully open the gas cylinder valve and set the flow rate to between 8 12 l min 17 Set the welding parameters using the wire feed and voltage control knobs 10 Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube Push down the tension arm lever to release the pressure of the driv...

Page 22: ...roperties and corresponding advantages and limitations To perform MIG welding the basic necessary equip ment is a welding gun a wire feed unit a welding power supply an electrode wire and a shielding gas supply 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 ...

Page 23: ...eat and force of the arc flattens out the droplet into the weld pool The heat of the arc melts the end of the wire slightly as it feeds towards the base metal The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short circuit and repeat the cycle droplet separates arc flattens the droplet cycle repeats MIG Metal Inert Gas Welding Short Circuit Transfer Short ...

Page 24: ... bead profile and degree of weld penetration Push Technique The wire is located at the leading edge of the weld pool and pushed towards the un melted work surface This technique offers a better view of the weld joint and direction of the wire into the weld joint Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penet...

Page 25: ...hape prevents undercut uneven penetration poor gas shield and poor quality finished weld Correct angle Not enough angle Too much angle good level of control over the weld pool even flat weld less control over the weld pool more spatter poor control unstable arc less penetration lots of spatter Stick Out Stick out is the length of the unmelted wire protruding from the end of the contact tip A const...

Page 26: ...d resulting in a weld deposit of poor quality cold lap lack of fusion lack of joint penetration porosity large wide bead Too Slow Travel Speed Correct Travel Speed The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration fusion and wetting out of the weld pool producing a weld deposit of good quality good to...

Page 27: ...tect shield the wire the arc and the molten weld metal from the atmosphere Most metals when heated to a molten state will react with the air in the atmosphere without the protection of the shielding gas the weld produced would contain defects like porosity lack of fusion and slag inclusions Additionally some of the gas becomes ionised electrically charged and helps the current flow smoothly The co...

Page 28: ...15 Ergo Handle Location Body 6 UB1505 Lock Nut 7 UB1521 Cable Terminal 8 UB1521 C Cable Terminal Cover 9 UG8015 Handle Cable Support C W Ball Joint 10 UB1517 30 Hyperflex Cable Assembly x 3mt UB1517 40 Hyperflex Cable Assembly x 4mt UB1517 50 Hyperflex Cable Assembly x 5mt Part Number Description 11 UG2514 Ergo Handle Kit C W Lock Nut 12 UG2516 Medium Large Ergo Trigger 13 UB2517 Hanger Hook 14 UB...

Page 29: ...Description PGN15CYL Cylindrical Nozzle QTY2 PGN15CON Conical Nozzle QTY2 PGN15TAP Tapered Nozzle QTY2 PGN15SPOT Spot Nozzle QTY2 Liners SB15 Liners Part Number Description SLB3M Blue Steel Liner 3 Metre SLB4M Blue Steel Liner 4 Metre SLB5M Blue Steel Liner 5 Metre SLR3M Red Steel Liner 3 Metre SLR4M Red Steel Liner 4 Metre SLR5M Red Steel Liner 5 Metre TLB3M Blue Aluminium Liner 3 Metre TLB4M Blu...

Page 30: ...1040 Gear Box Assembly 18 LMX2011 Inlet Guide Part Number Description 19 LGX2018 Key 20 LGX2019U DriveRoll U Groove 0 8 0 9mm 21 LZ3603 Motor 22 LYFE1001 Gun Neck 23 SEE PAGE 41 Gas Nozzle 24 SEE PAGE 41 Contact Tip 25 SEE PAGE 41 Diffuser Tip Holder with Spring 26 LYFE1011 Gun Neck Body 27 LW0101 Gas Hose 28 LGK2011 Conducting Board 29 LYH1012 Cable Support 30 LYH1013 Handle Nut 31 LYL1640 Cable ...

Page 31: ...cription PCT0008 06 Contact Tip Steel 0 6mm PCT0008 08 Contact Tip Steel 0 8mm PCT0008 09 Contact Tip Steel 0 9mm PCT0008 10 Contact Tip Steel 1 0mm PCTAL0008 09 Contact Tip Aluminium 0 9mm PCTAL0008 10 Contact Tip Aluminium 1 0mm SPG135 Tip Holder Part Number Description PCTH15 Contact Tip Holder Bore Ø 12 5 53 0 Ø 18 0 42 0 M6 x 1 0 M8 x 1 0 L U Groove Drive Roller Soft Wire Part Number Descript...

Page 32: ... Wire stubbing during welding Possible Reason Suggested Remedy Holding the torch too far away Bring the torch closer to the work and maintain stick out of 5 10mm Welding voltage set too low Increase the voltage Wire Speed set too high Decrease the wire feed speed 5 Lack of Fusion failure of weld metal to fuse completely with base metal or a proceeding weld bead Possible Reason Suggested Remedy Con...

Page 33: ...ogged the most common causes of bad feeding Try to clear the liner by blowing out with compressed air as a temporary cure it is recommended to replace the liner Wrong size liner Install the correct size liner Blocked or worn inlet guide tube Clear or replace the inlet guide tube Wire misaligned in drive roller groove Locate the wire into the groove of the drive roller Incorrect drive roller size F...

Page 34: ...gulator and 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 eliminat...

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Page 36: ...66 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 Pty Ltd ABN 14 001 804 422 Welding Guns Of Australia PTY LTD 2012 ...