MIG-TIG-STICK BUILT-IN TECHNOLOGY ADVANTAGE OPERATING MANUAL MIG-TIG-STICK BUILT-IN KUMJRDP210 KUMJRDP250 TECHNOLOGY TECHNOLOGY TECHNOLOGY MIG-TIG-STICK TECHNOLOGY ADVANTAGE MIG-TIG-STICK 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 4-5 Safety - Cautions 6-8 Machine Layout Pictogram 9 Installation Operation Cautions 10 Installation & Operation for MMA (Stick) Welding 11 MMA (Stick) Welding Information 12-13 Installation & Operation for MIG Welding with Gas - Digital Torch set up 14-15 Wire Feed Drive Roller Selection 16 Wire Installation Set up Guide 17 Installation & Operation for MIG Welding with No Gas (Gasless Welding) 18-19 Installation Guide for
3YEARS Warranty KUMJRDP210 (Power Source) MIG/MMA/TIG - 210 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 200mm Ø spool Euro mig torch connection IP21S rating for environmental/safet
3YEARS Warranty KUMJRDP250 (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 200mm Ø spool Euro mig torch connection IP21S rating for environmental/safet
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.
FRONT PANEL LAYOUT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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 wet areas. 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-MIG210/250 DIGITAL MTS (1) Turn the power source on and select the MMA function with the Tig/MMA/MIG/SPOOL GUN 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-MIG210/250 DIGITAL MTS (1) Connect Mig Torch IMPORTANT : When connecting the torch be sure to tighten the connection. Additionally Digital MIG torch must be connected prior to power being turned on otherwise remote control will not work (2) Connect the earth lead to (3) Select the MIG function with the Tig/MMA/MIG/SPOOL GUN selector switch. (4) Set torch operation 2T / 4T. • When 2T operation is selected press trigger Arc starts, release trigger Arc stops.
Continued set up for MIG with Gas for UNI-MIG-MIG210/250 DIGITAL MTS (9) Connect weld power lead to GAS (10) Place wire onto spool holder - (spool retaining nut is left hand thread ) Feed the wire through the inlet guide tube on to the drive roller.
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 for UNI-MIG-MIG210/250 DIGITAL MTS (1) Connect Mig Torch IMPORTANT : When connecting the torch be sure to tighten the connection. Additionally Digital MIG torch must be connected prior to power being turned on otherwise remote control will not work (2) Connect the earth lead to (3) Select the MIG function with the Tig/MMA/MIG/SPOOL GUN selector switch. (4) Set torch operation 2T / 4T.
Continued set up for MIG with Gasless for UNI-MIG-MIG210/250 DIGITAL MTS (8) Connect the weld power cable plug inside the wire feeder to the output socket NO GAS, and tighten it. (9) Fit the correct size Knurled drive roller for Gas Less Flux Core wire. (10) 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.
Mig Torch Liner Installation (1) (2) (3) (4) (5) (6) (7) (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 the correct new liner they are colour codes for diferent wire sizes BLUE = 0.6 -0.8mm, RED = 0.9-1.2 carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will damage it and will require replacement.
Torch & Wire Feed Set Up for Aluminium Wire (1) (2) (3) (4) (5) (5) (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 a Polymide or liner, fix torch neck sprint onto line carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end.
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-MIG210/250 DIGITAL MTS (1) Connect the spool gun control cable and gun cable connector. IMPORTANT : When connecting the torch be sure to tighten the connection. (2) Connect the earth lead to (3) Select the SPOOL GUN function with the Tig/MMA/MIG/SPOOL GUN selector switch. (4) Set torch operation 2T / 4T. • When 2T operation is selected press trigger Arc starts, release trigger Arc stops.
Continued set up of the Spool Gun with UNI-MIG-MIG210/250 DIGITAL MTS (9) Connect weld power lead to GAS (10) Take the Spool Gun and push the Cover Release Button to unlock the wire feed / spool cover. (11) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread. Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling. (12) Carefully feed the wire over the drive roller into the outlet guide tube, feed through into the torch neck.
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-MIG210/250 DIGITAL MTS (1) Connect TIG torch to power socket, trigger control socket and gas socket. IMPORTANT : When connecting the torch be sure to tighten the connection. (2) Connect earth lead to (3) Select the TIG function with the Tig/MMA/MIG/SPOOL GUN selector switch. (4) Set torch operation 2T / 4T. • When 2T operation is selected press trigger Gas starts, touch and lift arc start, release trigger Gas and Arc stops.
LIFT ARC DC TIG Operation for UNI-MIG-MIG210/250 DIGITAL 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.
Suregrip Series DM24 DIGITAL MIG TORCH DM240A AIR COOLED MIG WELDING TORCH Rating:250A CO² 220A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.
Suregrip Series DM24 DIGITAL MIG TORCH Front end consumables DM24 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.
Suregrip Series DM26 DIGITAL MIG TORCH DM260A AIR COOLED MIG WELDING TORCH Rating: 270A CO2 240A mixed gas, EN60974-7 @ 60% duty cycle. 0.8 to 1.
Suregrip Series DM26 DIGITAL MIG TORCH Ø 8.0 M6 x 1.0 DM26 Contact Tips M6 Part Number PCT0009-06 PCT0009-08 PCT0009-09 PCT0009-10 PCT0009-12 PCT0009-16 PCTZR009-09 PCTZR009-12 PCTAL0009-09 PCTAL0009-10 PCTAL0009-12 M8 x 1.25 28.0 Ø 10.0 Front end consumables 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.
L135YE SPOOL GUN SPG135 AMP SPOOL GUN Duty Cycle 30% @ 135Amp Torch Model Description Part Number XcelArc Spool Gun SPG135 x 6m SPG135 Spare Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number Description LGJ2003 LMH2001 LMT2001 LMT2016 LMT2015 LMT2014 LMT2013 LMT2012 LMT2011 LGH2011 LGX2016U LGX2015 LGX2014 LGX2012 LGX2011 LGF2111 LX1040 LMX2011 Trigger Handle Spool Cover Total Assembly Spool Cover Shell Spool Shaft Rubber Resistance Bush Locating Bush Adjusting Nut Locking Screw Drive
SPG135 AMP SPOOL GUN Duty Cycle 30% @ 135Amp Front end consumables Ø 6.0 M6 x 1.0 Part Number PCT0008-06 PCT0008-08 PCT0008-09 PCT0008-10 PCTAL0008-09 PCTAL0008-10 M6 x 1.0 M8 x 1.0-L 25.0 Part Number PCTH15 PCTH195 Ø 12.5 Bore Ø 18.0 53.0 Description Contact Tip Steel (0.6mm) Contact Tip Steel (0.8mm) Contact Tip Steel (0.9mm) Contact Tip Steel (1.0mm) Contact Tip Aluminium (0.9mm) Contact Tip Aluminium (1.0mm) SB15 Tip Holder 42.
SPG200II AMP SPOOL GUN Duty Cycle 35% @ 200Amp 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 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
SPG200II AMP SPOOL GUN 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.
Suregrip Series SR17 ERGO TIG TORCH 150A AIR COOLED TIG WELDING TORCH 5 Rating: 150A DC, 105A AC @35% ducy cycle.
Suregrip Series SR17 ERGO TIG TORCH Standard Front End Parts Part # 18CG Part # 10N49L 53N48L 53N47L 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.
Suregrip Series SR26 ERGO TIG TORCH 5 8 3 2 180A AIR COOLED TIG WELDING TORCH Rating:180Amp DC, 125Amp AC @35% duty cycle.
Suregrip Series SR26 ERGO TIG TORCH 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.
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.
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© Welding Guns Of Australia PTY LTD 2012 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.
