3YEARS Warranty MIG-TIG-STICK BUILT-IN TECHNOLOGY (Power Source) MIG-TIG-STICK BUILT-IN Lift Arc DC/TIG ADVANTAGE 240 Volt Standard TECHNOLOGY L MIG / MAG TECHNOLOGY TECHNOLOGY Plasma CUTMIG-TIG-STICK TECHNOLOGY ADVANTAGE OPERATING MANUAL MIG-TIG-STICK KUMJR250 Please read and understand this instruction manual carefully before the installation and operation of this equipment.
Thank you for your purchase of your UNI-MIG welding machine. We are proud of our range of welding equipment that has a proven track record of innovation, performance and reliability. Our product range represents 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.
CONTENTS PAGE Warranty 2 Technical Data, Product Information 4 Safety - Cautions 5-7 Machine Layout Pictogram 8 Installation Operation Cautions 9 Installation & Operation for MMA (stick) Welding 10 MMA (Stick) Welding Information 11-12 Installation & Operation for MIG Welding with Gas 13-14 Wire Feed Drive Roller Selection 16 Wire Installation Set up Guide 16 Installation & Operation for MIG Welding with No Gas 17-18 Installation Guide for Mig Torch Liner Installation 19 Mig Torch
2YEARS Warranty KUMJR250 (Power Source) MIG/MMA/TIG - 250 Amp DC Welding Machine Lightweight & Portable Welds: Steels, Stainless, Cast Iron, Bronze, Aluminium, Copper Features • • • • • • • • • • • • • • Latest IGBT inverter technology Mig/Mag with Gas and Gasless wire function Stick electrode (MMA) function DC Tig welding with Lift Arc Start Industrial application Optional trolley Internal wire feeder, gear driven for up to 300mm Ø spool Euro mig torch connection IP21S rating for environmental/safety
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. Machine Operating Safety • Do not switch the function modes while the machine is operating.
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. Check and be sure the area is safe before doing any welding. • The welding sparks & spatter may cause fire, therefore remove any flammable materials well away from the working area.
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. 1.3 Keep this equipment 30cm distant from the wall. 1.
1 2 3 4 5 FRONT PANEL LAYOUT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
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. Refer to data plate on machine for Input voltage, IMAX and IEFF.
Installation set up for MMA (Stick) Welding with UNI-MIG MIG250 MTS (1) Turn the power source on and select the MMA function with the Tig/MMA/Mig selector switch. (2) Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DC+ polarity.
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’.
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.
Installation set up for MIG with Gas for UNI-MIG MIG250 MTS (1) Select the MIG function with the Tig/MMA/Mig selector switch. (2) Select Standard using the Standard/Spool Gun selector switch. (3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it. IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can result in the connector arcing and damaging the machine and gun connector. This damage is not covered under warranty.
Continued set up for MIG with Gas for UNI-MIG MIG250 MTS (9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller, lock the pressure arm into place. (10) Apply a medium amount of pressure to the drive roller. (11) Remove the gas nozzle and contact tip from the torch neck, (12) Press and hold the inch button to feed the wire through to the torch neck, release the inch button when the wire exits the torch neck.
Wire Feed Roller Selection The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. Simply put the smoother the wire feed then the better the welding will be. Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun. Feed rollers are designed to be used for certain types of welding wire and they have different types of grooves machined in them to accommodate the different types of wire.
Wire Installation and Set Up Guide Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and consistent wire feed. A high percentage of faults with mig welders emanate from poor set up of the wire into the wire feeder. The guide below will assist in the correct setup of your wire feeder. (1) Remove the spool retaining nut.
Installation set up for MIG with Gasless wire for UNI-MIG MIG250 MTS (1) Switch on the machine, select the MIG function with the Tig/MMA/Mig selector switch. (2) Select Standard using the Standard/Spool Gun selector switch. (3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it. IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can result in the connector arcing and damaging the machine and gun connector.
Continued set up for MIG with Gasless wire for UNI-MIG MIG250 MTS (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 correct drive roller is being used. (9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller, lock the pressure arm into place. (10) Apply a light amount of pressure to the drive roller.
Mig Torch Liner Installation (1) (2) (3) (4) (5) (6) (7) (8) (9) Lay the torch out straight on the ground and remove the front end parts Remove the liner retaining nut. Carefully pull the liner out of the torch cable assembly Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will make it no good and will require replacement.
Torch & Wire Feed Set Up for Aluminium Wire (1) (2) (3) (4) (5) (5) (8) (9) 20 Lay the torch out straight on the ground and remove the front end parts Remove the liner retaining nut. Carefully pull the liner out of the torch cable assembly Select a Polymide or liner, carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end. Avoid kinking the liner, kinking the liner will ruin it and require replacement.
Continued Torch & Wire Feed Set Up for Aluminium Wire (10) Loosen off the inlet guide tube retaining screw (11) Remove the inlet guide tube from the front end machine euro connector using long nose pliers.
Installation set up of the Spool Gun with UNI-MIG-MIG250MTS (1) Switch on the machine, select the MIG function with the Tig/MMA/Mig selector switch. (2) Select Spool Gun using the Standard/Spool Gun selector switch. (3) Connect the Spool Gun to the Euro Mig torch connection socket on the front panel, and tighten it. Connect the Spool Gun control cable to the receptacle and tighten it. (4) Insert the earth cable plug into the Negative socket on the front of the machine and tighten it.
Continued set up of the Spool Gun with UNI-MIG-MIG250MTS (9) (10) (11) (12) (13) (14) (15) (16) (17) Carefully feed the wire over the drive roller into the outlet guide tube, feed through into the torch neck. Check that the drive roller being used complies with the wire diameter, replace the roller if necessary. Align the wire into the groove of the drive roller and release the tension arm making sure the wire is in the groove of the drive roller.
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 welding gun. A constant voltage, direct current power source is most commonly used with MIG welding.
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.
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.
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.
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, increasing with faster travel speed and decreasing with slower speed.
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. As a guide refer to the “Welding Wire Thickness Chart” below.
Installation and set up for DC TIG welding for UNI-MIG MIG250 MTS (1) Switch on the machine, select the TIG function with the Tig/MMA/Mig selector switch. (2) Insert the power cable plug of the Tig torch into the Negative socket on the front of the machine and tighten it. (3 Insert the earth cable plug into the Positive socket on the front of the machine and tighten it. (4) Connect the gas line of the Tig torch to regulator and connect the regulator to the gas cylinder.
LIFT ARC DC TIG Operation for UNI-MIG MIG250 MTS 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. There is a particular technique called “rocking the cup” used in the Lift Arc process that provides easy use of the Lift Arc function.
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.
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.
Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’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 alloy of tungsten and other rare earth elements.
Tungsten Preparation Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a 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. Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel.
UNI-FLAME AUTOLIFT UNI-FLAME Suregrip Series SB24 MIG TORCH 250A AIR COOLED MIG WELDING TORCH Rating:250A CO² 220A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.
UNI-FLAME AUTOLIFT UNI-FLAME Suregrip Series SB24 MIG TORCH Front end consumables SB24 Contact Tips Ø 8.0 M6 x 1.0 Part Number PCT0009-06 PCT0009-08 PCT0009-09 PCT0009-10 PCT0009-12 PCT0009-16 PCTZR009-09 PCTZR009-12 PCTAL0009-09 PCTAL0009-10 PCTAL0009-12 M6 x 1.0 M6 x 1.0 28.0 Description Contact Tip Steel (0.6mm) Contact Tip Steel (0.8mm) Contact Tip Steel (0.9mm) Contact Tip Steel (1.0mm) Contact Tip Steel (1.2mm) Contact Tip Steel (1.6mm) Contact Tip Steel Long Life (0.
UNI-FLAME AUTOLIFT UNI-FLAME SPG200 Torch Model Description Part Number XcelArc Spool Gun x 6m SPG200II Spare Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 38 Part Number LMZ2017 LMH2114 LMH2111 LMH2115 LMS2101 LMZ2001 LMZ2011 LMZ2012 LMZ2013 LMZ2016 LMT2101 LMH2112 LMH2113 LMJ2101 Description Speed Adjusting Knob Open/Close Button Left-Gun Case Hang Hook Spring Support Motor Motor Plate Suspension Screw Drive Roll Assembly Wire Nipple Spool Shaft Right-Gun Case Upper-Gun Case Switch 15 16 17 18 19 20
UNI-FLAME AUTOLIFT UNI-FLAME SPG20011 Front end consumables SB24 Contact Tips Ø 8.0 M6 x 1.0 Part Number PCT0009-06 PCT0009-08 PCT0009-09 PCT0009-10 PCT0009-12 PCT0009-16 PCTZR009-09 PCTZR009-12 PCTAL0009-09 PCTAL0009-10 PCTAL0009-12 M6 x 1.0 M6 x 1.0 28.0 Description Contact Tip Steel (0.6mm) Contact Tip Steel (0.8mm) Contact Tip Steel (0.9mm) Contact Tip Steel (1.0mm) Contact Tip Steel (1.2mm) Contact Tip Steel (1.6mm) Contact Tip Steel Long Life (0.9mm) Contact Tip Steel Long Life (1.
UNI-FLAME AUTOLIFT UNI-FLAME 17V TIG TORCH 150A AIR COOLED TIG WELDING TORCH Rating: 150Amp DC, 105Amp AC @35% duty cycle.
UNI-FLAME AUTOLIFT 17V TIG TORCH UNI-FLAME Standard Front End Parts Part # 18CG Description Cup Gasket Part # 10N30 10N31 10N32 10N28 Part # 10N22 10N23 10N24 10N25 Description Collet Body 1.0mm Collet Body 1.6mm Collet Body 2.4mm Collet Body 3.2mm Description Collet 1.0mm Collet 1.6mm Collet 2.4mm Collet 3.
MIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.
MIG WIRE FEED TROUBLE SHOOTING The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.
TIG WELDING TROUBLE SHOOTING The following chart addresses some of the common problems of DC TIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.
continued- TIG WELDING TROUBLE SHOOTING 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.
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. Check all cable connections.
Spare Parts Identification - MIG250 MTS 19 8 9 10 11 12 13 14 15 18 17 16 1 2 25 3 4 5 6 7 20 31 32 33 30 21 22 23 37 36 24 26 27 28 29 35 38 39 34 40 # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part Number B22170 B2290 B22278 B22276 C02066 C02065 B20667 B20669 C02066 C02065 B25018 D30050 J10519 J10518 J24020 J030156 D20037 D20037 B22171 B22172 B09124 B09123 B09125 B09123 B09125 B09125 C14003 B04274 B04272 B04273 B05108 B05222 J
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.
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. Our Returns Policy includes the rights you have under the Australian Consumer Law and other relevant laws.
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.
© Welding Guns Of Australia PTY LTD 2012 UNI-FLAME AUTOLIFT UNI-FLAME Welding Guns Of Australia PTY LTD 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.
