RAZOR 180ARC Manual

RAZOR 180ARC Manual
OPERATING MANUAL
KUMJRRW180CA
3YEARS Warranty
(Power Source)
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
1
© Welding Guns Of Australia PTY LTD 2012
CONTENTSPAGE
Warranty
2
Safety 4-5
Technical Data, Product Information
6
Machine Layout Descriptions
7
Installation & Operation for MMA (stick) Welding
8
MMA General Description
9-11
Installation & Operation for DC TIG Welding with Lift Arc
12-13
DC TIG General Description
14-16
17V TIG Torch Parts Breakdown
18-19
MMA (Stick) Welding Trouble Shooting
20
TIG Welding Trouble Shooting
21-22
Sapre Part Identification
23
Warranty terms
24-27
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. This experience gives us the inside knowledge on what the arc characteristics, performance and interface between 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 comments and requirements. Secondly they
provide a customer support service that is second to none, thus ensuring our customers have confidence that they will be well satisfied both now and in the future.
UNI-MIG welders are manufactured and compliant with - AS/NZ60974.1 2006 - AS60974-6:2006
guaranteeing you electrical safety and performance.
• 3 Years from date of purchase.
WARRANTY
•Welding Guns Of Australia PTY LTD Ltd warranties all goods as specified by the manufacturer of those goods.
•This Warranty does not cover freight or goods that have been interfered with.
•All goods in question must be repaired by an 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 machine or at www.unimig.com.au/
warranty.asp or at the back of this manual.
2
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. Switching of the function modes during
welding can damage the machine. Damage caused in this manner will not be covered under warranty.
•Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing
should the electrode be in contact with the work piece.
•Operators should be trained and or qualified.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe
burns. The electrode and work circuit is electrically live whenever the output is on. The input
power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding,
the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment is dangerous.
•Connect the primary input cable according to Australian and New Zealand standards and regulations.
•Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.
The operator must wear dry welding gloves while he/she performs the welding task.
•The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and 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 gases. Breathing these fumes and
gases can be hazardous to your health. •Do
not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
•Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
•In confined or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
•Do not weld in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.
•Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic
fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding process produce
intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
•Always
wear a welding helmet with correct shade of filter lens and suitable protective clothing including
welding gloves whilst the welding operation is performed.
•Measures should be taken to protect people in or near the surrounding working area. Use protective
screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
3
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 may cause fire, therefore remove
any flammable materials away from the working
area, at least 12m from the welding arc. Cover flammable materials and containers with approved covers
if unable to be moved from the welding area.
•Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared
according to the required Safety Standards to insure that flammable or toxic vapors and substances are
totally removed, these can cause an explosion even though the vessel has been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
•Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)
•Have a fire extinguisher nearby and know how to use it. Be alert that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding
on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can 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 cylinder, do not drape welding cables
over the cylinder.
•Never weld on a pressurised gas cylinder, it will explode and kill you.
•Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.
Gas
build up. The build up of gas can causes a toxic environment, deplete the oxygen content
in the air resulting in death or injury. Many gases used in welding are invisible and odourless.
•Shut off shielding gas supply when not in use.
•Always ventilate confined spaces or use approved air-supplied respirator.
Electronic magnetic fields. MAGNETIC FIELDS can affect Implanted Medical Devices.
•Wearers of Pacemakers and other Implanted Medical Devices should keep away.
•Implanted Medical Device wearers should consult their doctor and the device manufacturer before going
near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.
Wear approved hearing protection if noise level is high.
Hot parts. Items being welded generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the welding
gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns.
4
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.
1.4 Ensure the working environment is well ventilated.
2. Safety Tips.
2.1 Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is
of critical importance for the normal performance and service life of this equipment.
2.2
Thermal Overload protection.
2.3
Over-Voltage Supply
Should the machine be used to an excessive level, or in high temperature environment, poorly
ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the
machine will cease to operate. Under this circumstance, leave the machine switched on to keep the
built-in fan working to bring down the temperature inside the equipment. The machine will be ready for
use again when the internal temperature reaches safe level.
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 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 operation. An electric shock
may possibly occur.
MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to prevent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and
dry compressed air of required pressure.
Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of
this welding equipment will be void if the machine has been modified, attempt to take apart the machine or
open the factory-made sealing of the machine without the consent of an authorized representative of the
manufacturer.
TROUBLE SHOOTING
Caution: Only qualified technicians are authorized to undertake the repair of this welding equipment.
For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.
Note:
Minimum Motor Generator Power Suggested:- 9KVA - ARC180
EMC DECLARATION
IEC
60974-10:2007
Arc Welding equipment - Part 10: Electromagnetic compatibility (EMC) requirements (Classification of ISM
Equipment - According to IEC 60974-10:2007 and CISPR 11: 2033+A1:2004 Clause 4.1 and 4.2. The EUT
Belongs to Apparatus Group2 Class A)
5
MMA/TIG - 180Amp DC Welding Machine
Small, Lightweight and Portable
Welds: Steels, Stainless, Cast Iron, Bronze, Copper
3YEARS Warranty
KUMJRRW180CA
(Power Source)
Features
• Latest IGBT inverter technology
• MMA (stick electrode)
• Hot start (improves electrode starting)
• VRD (Voltage Reduction Device)
• Arc Force
(boosts current to prevent electrode extinguishing)
• Excellent arc stability with all electrodes
• DC TIG
• Lift Arc ignition
(prevents tungsten sticking during arc ignition)
• Ultra smooth DC TIG welding current
• Thermal overload protection
• Generator compatible
(recommend 9.0 KVA minimum)
• Tolerant to variable power supplies
Technical Data
Power Supply / Phases (V-Ph)
240V - 1 ±15%
Rated Input Power (KVA) 9
Ieff
15.3A MMA / 15.3A TIG
Imax
34.3A MMA / 21.7A TIG
Rated Output 180A/27.2V MMA
180A/17.2V TIG
Welding Current Range 10~180A
No-Load Voltage (V) 9V
Duty Cycle @ 40ºC as per AS/NZ60974-1 20%@180Amps MMA
50%@180Amps TIG
Power Factor 0.7
Protection Class
IP21
Insulation Class F
Size (mm) 313 x 250 x 130
Weight (kg) 4.7
Warranty
3 years on power source
ARC180CA Standard option
• MMA-TIG 180DC
• ARC LEAD SET 4M
• PVC CARRY CASE
ARC180CT TIG Option
• MMA-TIG 180DC
• ARC LEAD SET
• ARGON REGULATOR
• 17V TIG TORCH 4M
• PVC CARRY CASE
Overview
The ARC180 is an inverter-based welding machine produced using the latest in IGBT technology. This machine is reliable, robust
and stacked with features that you can expect from a quality welder. The DC MMA welding capability delivers a smooth and
incredibly stable arc allowing easy welding with electrodes producing high quality welds including cast Iron, stainless and low
hydrogen. The ARC180 is equipped with DC Lift Arc function, connection of the 17V TIG torch allows quality DC TIG welding of steel,
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 ARC180 is an
exceptional machine that is suitable for a wide range of applications including light industrial use, site welding, farming, along with
repair and maintenance applications. The Arc180 is packaged in a tough PVC carry case with your choice of MMA option accessories
or MMA/TIG option accessories. The-ARC180 gives you the best of both worlds great portability, with the power to get the job done.
Built to our specification and manufactured in compliance to AS/NZ60974.1
Product Code: KUMJRRW180CA
MMA option includes: ARC180 Machine, Earth Lead & Arc Lead 16mm x 4m, PVC Carry Case
Product Code: KUMJRRW180CT
TIG option includes: ARC180 Machine, Earth Lead & Arc Lead 16mm x 4m, 17V x 4m TIG Torch, Argon Regulator and
PVC Carry Case
6
Front Machine Layout Description
Thermal Alarm LED
Primary Power LED
VRD LED
Voltage Reduction Device
Amperage Control
Dial
MMA /TIG Selector
Switch
Negative Output
Terminal
Positive Output
Terminal
Rear Machine Layout Description
On /Off Power Switch
Primary Input
Power Lead
7
Installation set up for MMA (Stick) Welding with MMA-TIG180
Please install the machine strictly according to the following steps.
The protection class of this machine is IP21, 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.
(1) Turn the power source on and select the MMA function with the TIG/MMA selector switch.
(2) Connection of Output Cables: Various electrodes require a different polarity for optimum results refer to the electrode manufacturers information for the correct polarity. Most GP electrodes are Electrode connected to
output socket, Earth Connected to the
output socket
(3) Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer.
(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 piece.
(8) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal underneath.
(1) Set TIG/MMA selector
switch to MMA
(2) Connect earth
lead to
(2) Connect the electrode
lead to
(3) Set the welding current using the amperage (4) Place the electrode into the electrode holder (5) Strike the electrode against the workpiece to
create and arc and hold the electrode steady to
control dial.
and clamp tight.
maintain the arc.
(6) Hold the electrode slightly above the work
maintaining the arc while travelling at an even
speed.
(7) To finish the weld, break the arc by quickly
snapping the electrode away from the work
piece.
8
(8) Wait for the weld to cool and carefully chip
away the slag to reveal the weld metal below.
MMA (Manual
Metal
Arc) Arc)
General
Description
MMA
(Manual
Metal
Welding
One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current of
is the
used
to strike
an arc
between
base is
material
a consumable
‘stick’. The
electrode rod
One
most
common
types
of arc the
welding
manualand
metal
arc welding electrode
(MMA) or rod
stickorwelding.
An electric
is madeis of
a material
compatible
withbase
the base
material
welded electrode
and is covered
a ux
gives off
current
used
to strikethat
an is
arc
between the
material
and abeing
consumable
rod orwith
‘stick’.
Thethat
electrode
gaseous
vapours
that serve
a shielding gas
providing
a layer
of slag,
both
of is
which
protect
weldthat
area
from
rod
is made
of a material
thatas
is compatible
with and
the base
material
being
welded
and
covered
withthe
a flux
gives
atmospheric
contamination.
Theaselectrode
core
itself
as llera material
the residue
theprotect
ux that
slag
off
gaseous vapours
that serve
a shielding
gas
andacts
providing
layer of slag,
both offrom
which
theforms
weld aarea
covering
over thecontamination.
weld metal must
beelectrode
chipped away
after acts
welding.
from
atmospheric
The
core itself
as filler material the residue from the flux that forms a
slag covering over the weld metal must be chipped away after welding.
Core
Corewire
wire
++
Flux
Fluxcoating
coating
Gas
Gasshield
shieldfrom
fromflux
uxmelt
melt
Arc
with
core
wire
melt
Arc with core wire melt
Power
PowerSource
Source
Flux
Fluxresidue
residueforms
formsslag
slagcover
cover
Weld
Weldmetal
metal
▬
▬
Core
Corewire
wire
Flux
Fluxcoating
coating
Base
Basemetal
metal
• •The
Thearc
arcisisinitiated
initiatedby
bymomentarily
momentarilytouching
touchingthe
theelectrode
electrodetotothe
thebase
basemetal.
metal.
• •The
Theheat
heatofofthe
thearc
arcmelts
meltsthe
thesurface
surfaceofofthe
thebase
basemetal
metaltotoform
formaamolten
moltenpool
pool
atatthe
end
of
the
electrode.
the end of the electrode.
• •The
Themelted
meltedelectrode
electrodemetal
metalisistransferred
transferredacross
acrossthe
thearc
arcinto
intothe
themolten
moltenpool
pool
and
becomes
the
deposited
weld
metal.
and becomes the deposited weld metal.
• •The
Thedeposit
depositisiscovered
coveredand
andprotected
protectedby
byaaslag
slagwhich
whichcomes
comesfrom
fromthe
the
electrode
coating.
electrode coating.
• •The
Thearc
arcand
andthe
theimmediate
immediatearea
areaare
areenveloped
envelopedby
byan
anatmosphere
atmosphereofof
protective
gas
protective gas
Protective
Protectivegas
gas
Arc
Arc
Manual
Manualmetal
metalarc
arc( (stick)
stick)electrodes
electrodeshave
haveaasolid
solidmetal
metalwire
wirecore
coreand
andaaflux
ux
coating.
coating.These
Theseelectrodes
electrodesare
areidentified
identiedby
bythe
thewire
wirediameter
diameterand
andby
by
aaseries
seriesofofletters
lettersand
andnumbers.
numbers.The
Theletters
lettersand
andnumbers
numbersidentify
identifythe
themetal
metal
alloy
alloyand
andthe
theintended
intendeduse
useofofthe
theelectrode.
electrode.
The
TheMetal
MetalWire
WireCore
Coreworks
worksas
asconductor
conductorofofthe
thecurrent
currentthat
thatmaintains
maintainsthe
thearc.
arc.
The
Thecore
corewire
wiremelts
meltsand
andisisdeposited
depositedinto
intothe
thewelding
weldingpool.
pool.
Slag
Slag
Weld
Weldpool
pool
The
Thecovering
coveringon
onaashielded
shieldedmetal
metalarc
arcwelding
weldingelectrode
electrodeisiscalled
calledFlux.
Flux.
The
Theflux
uxon
onthe
theelectrode
electrodeperforms
performsmany
manydifferent
differentfunctions.
functions.
These
Theseinclude:
include:
●●producing
the weld
areathe weld area.
producingaaprotective
protectivegas
gasaround
atmosphere
around
●●providing
providingfluxing
uxingelements
elementsand
anddeoxidizers
deoxidizers.
●●creating
creatingaaprotective
protectiveslag
slagcoating
coatingover
overthe
theweld
weldas
asititcools
cools.
●●establishing
establishingarc
arccharacteristics
characteristics.
●●adding
addingalloying
alloyingelements.
elements.
Covered
Coveredelectrodes
electrodesserve
servemany
manypurposes
purposesininaddition
additiontotoadding
addingfiller
llermetal
metaltoto
the
themolten
moltenpool.
pool.These
Theseadditional
additionalfunctions
functionsare
areprovided
providedmainly
mainlyby
bythe
thecovercovering
ingon
onthe
theelectrode.
electrode.
9
10
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.
Electrode Size
Average Thickness
of Material
Maximum Recommended
Electrode Diameter
1.0 - 2.0mm
2.0 - 5.0mm
5.0 - 8.0mm
8.0 - > mm
2.5mm
3.2mm
4.0mm
5.0mm
The size of the electrode generally depends on the
thickness of the section being welded, and the thicker
the section the larger the electrode required. The table
gives the maximum size of electrodes that maybe used
for various thicknesses of section based on using a
general purpose type 6013 electrode.
Welding Current (Amperage)
Correct current selection for a particular job is an
important factor in arc welding. With the current set too
low, difficulty is experienced in striking and maintaining
a stable arc. The electrode tends to stick to the work,
2.5mm
60 - 100
penetration is poor and beads with a distinct rounded
3.2mm
100 - 130
profile will be deposited. Too high current is
4.0mm
130 - 165
accompanied by overheating of the electrode resulting
5.0mm
165 - 260
undercut and burning through of the base metal and
producing excessive spatter. Normal current for a particular job may be considered as the maximum, which
can be used without burning through the work, over-heating the electrode or producing a rough spattered
surface.The table shows current ranges generally recommended for a general purpose type 6013
electrode.
Electrode Size
ø mm
Current Range
(Amps)
Arc Length
To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a
simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An
arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld.
An excessively short arc will cause sticking of the electrode and result in poor quality welds. General rule of
thumb for down hand welding is to have an arc 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 and 90 degrees to the work piece.
Travel Speed
The electrode should be moved along in the direction of the joint being welded at a speed that will give the
size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all
times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel
will frequently lead to arc instability,slag inclusions and poor mechanical properties.
Material and Joint Preparation
The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or
any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend
on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases
edges should be clean and free of any contaminates. The type of joint will be determined by the chosen
application.
10
RECOMMENDED
ELECTRODE CLASSIFICATION & SELECTION CHART
MILD STEEL
APPLICATION
DIAMETER
ESR11
2.5 / 3.2mm HANDYPACK
ESR-11-BLISTER
2.5mm
2.5KG PACK
ESR-11-2.5mm-2.5kg
2.5mm
5.0KG PACK
ESR-11-2.5mm-5kg
3.2mm
2.5KG PACK
ESR-11-3.2mm-2.5kg
3.2mm
5.0KG PACK
ESR-11-3.2mm-5kg
4.0mm
5.0mKG PACK ESR-11-4.0mm-5kg
General-purpose electrode for structural steelwork, workshop
and maintenance welding. Easily operated in positional welding,
including vertically-down. Good gap-bridging. Possible to use
equally well both with AC and DC. Smooth arc, well suited for
tack-welding due to it’s easy arc striking and restriking
properties. Welds are smooth, slightly concave and blending
into base metal without undercutting. Slag is self-releasing in
most cases. Suitable for welding on galvanized, primer painted
and slightly rusted components.
ESB-44
LOW
HYDROGEN
Multi-purpose electrode suitable for structural steelwork,
workshop and maintenance welding. Smooth and clean welds,
blending into base metal without undercuts. Excellent gap
bridging properties. The double covering of this electrode
produces a stable, concentrated and directed arc, thus being
ideally suited for root pass and positional welding. Welds are of
X-ray quality.
PACKAGE
PART No
2.5 / 3.2mm HANDYPACK
ESB-44-BLISTER
2.5mm
5.0KG PACK
ESB-44-2.5mm-5kg
3.2mm
2.5KG PACK
ESB-44-3.2mm-2.5kg
3.2mm
5.0KG PACK
ESB-44-3.2mm-5kg
4.0mm
6.5KG PACK
ESB-44-4.0mm-6.5kg
STAINLESS STEEL
EI 316L
Electrode for welding austenitic stainless Cr-Ni-Mo steels or
cast steels, having an extra low carbon content. For operating
temperatures of up to +400˚C. Especially suitable for welding
of stainless steel chemical tanks and pipes in chemical, textile,
paint, paper industries. Possible to use equally well both with
AC and DC. Easy arc striking and restriking. Fine metal droplet
transfer, good fusion of joint faces, finely rippled bead surface,
easily removable slag.
2.5 / 3.2mm HANDYPACK
EI316L-BLISTER
2.5mm
1.75KG PACK EI316L-2.5mm-1.75kg
3.2mm
2.0KG PACK
EI316L-3.2mm-2.0kg
4.0mm
2.0KG PACK
EI316L-4.0mm-2kg
3.2mm
HANDYPACK
EH-531-BLISTER
3.2mm
5.0KG PACK
EH-531-3.2mm-5kg
4.0mm
5.0KG PACK
EH-531-4.0mm-5kg
5.0mm
5.0KG PACK
EH-531-5.0mm-5kg
EH531
HARD FACING
Heavy coated, high recovery (235%) hardfacing electrode,
depositing evenly distributed Cr, B carbides in austenitic
stainless steel matrix. Suitable 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.
Possible to use with both DC and AC.
ENI-416
CAST IRON
Electrode having a nickel-iron core wire for welding cast iron
with or without preheating. The weld metal features a low
coefficient of thermal expansion and as a result , little shrinkage.
It has higher strength properties than pure nickel weld metal
and is therefore preferable used for welding nodular cast iron,
white and black heart malleable cast iron, as well as austenitic
nodular cast iron or joining these metals to components made of
steel, copper or nickel materials. Easy arc striking and restriking,
stable arc, smooth bead. Weld metal is machinable. Weld short
beads.
2.5 / 3.2mm HANDYPACK
ENI-416-BLISTER
2.5mm
1.75KG PACK ENI-416-2.5mm-1.75kg
3.2mm
1.75KG PACK ENI-416-3.2mm-1.75kg
4.0mm
2.25KG PACK ENI-416-4.0mm-2.25kg
EI 312
DISIMILAR
METALS
Electrode for joining dissimilar steels and depositing claddings
on ferritic steels. The ferritic-austenitic Cr-Ni weld metal contains
approximately 50% of delta-ferrite and is non-scaling up to
+1100˚C. It features high resistance to cracking and is therefore
suited for joining difficult to weld steels and depositing
stress-relaxing buffer layers on crack sensitive base metals.
Suitable for welding galvanized steel plates. Possible to use
equally well both with AC and DC. Easy arc striking and
restriking. Fine metal droplet transfer, good fusion of joint faces,
finely rippled bead surface, easy slag removal.
2.5 / 3.2mm HANDYPACK
EI-312-BLISTER
2.5mm
1.75KG PACK EI-312-2.5mm-1.75kg
3.2mm
1.75KG PACK EI-312-3.2mm-1.75kg
4.0mm
2.0KG PACK
EI-312-4.0mm-2kg
For a full range of recommended MAGMAWELD welding electrodes please visit our website @ WWW.UNIMIG.COM.AU
The above chart is a reference only and are not included in this kit.
11
Installation and set up for DC TIG welding for MMA-TIG180
(1) Switch on the machine, select the TIG function with the TIG/MMA 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.
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
(4) Connect the gas line to the regulator
and connect to the gas cylinder
(1) Set TIG/MMA selector
switch to TIG
(2) Connect the TIG torch cable
connector to
(3) Connect earth
lead to
(4) Carefully open the valve of the gas
cylinder, set the flow to 8-10 l/min
Note: Photos show TIG torch with Suregrip option
(5) Set the welding current using the
amperage control dial
12
LIFT ARC DC TIG Operation for MMA-TIG180
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.
(6) Make sure the front end parts of the TIG torch are correctly assembled, use the correct size and type of tungsten electrode for the job, the tungsten electrode requires a sharpened point for DC welding.
(7) Turn on the Gas Valve located on the TIG torch handle.
(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 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.
6) Assemble front end parts of the TIG torch,
fitting a sharpened tungsten suitable for DC
welding.
(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.
(10) Now rotate the Gas Cup in the reverse
direction to lift the Tungsten electrode from the
work piece to create the arc.
(9) With a small movement rotate the Gas Cup
forward so that the Tungsten Electrode touches
the work piece.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to
operation of your machine. We recommend that you close the cylinder valve
when the machine is not in use.
Welding Guns Of Australia PTY LTD, authorised representatives or agents
of Welding Guns Of Australia PTY LTD will not be liable or responsible for
the loss of any gas.
13
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. This needs to
be understood because it determines what terminal the TIG torch will be connected to
(this rule applies to all the other forms of DC welding as well ).
30%
70%
argon gas
power source
nozzle
DC TIG welding is a process in which an arc is struck between a
TUNGSTEN electrode and the metal work piece. The weld area is
shielded by an inert gas flow to prevent contamination of the tungsten, molten pool and weld area.
When the TIG arc is struck the inert gas is ionized and superheated changing it’s molecular structure which converts it into a plasma
stream. This plasma stream flowing between the tungsten and the
work piece is the TIG arc and can be as hot as 19,000°C. It is a very
pure and concentrated arc which provides the controlled melting of
most metals into a weld pool. TIG welding offers 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.
The intensity of the arc is proportional to the current that flows from the
tungsten. The welder regulates the welding current to adjust the power
of the arc. Typically thin material requires a less powerful arc with less
heat to melt the material so less current (amps) is required, thicker
material requires a more powerful arc with more heat so more current high
current
(amps) are necessary to melt the material.
low
current
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 tungsten has left the surface and a spark is present,
it immediately (within microseconds) increases power, converting the spark to a full arc. It is a simple, safe
lower cost alternative arc ignition process to HF (high frequency) and a superior arc start process to scratch
start.
gas flow
tungsten off the
work
Lay the nozzle on the job
without the tungsten touching the work
tungsten touches
the work
Rock the torch sideways so
that the tungsten touches
the work & hold momentarily
arc ignition
Rock the torch back in the
opposite direction, the arc
will ignite as the tungsten
lifts off the work
14
established
TIG arc
Lift the torch to maintain
the arc
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. However, some welds combining thin
materials can be accomplished without filler metal like edge, corner, and butt joints.
This is known as Fusion welding where the edges of the metal pieces are melted together using only the
heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until
a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired
size. Once the weld pool is established tilt the torch at about a 75° angle and move smoothly and evenly
along the joint while fusing the materials together.
75°
Travel direction
Form a weld pool
Angle torch
Move the torch slowly
and evenly forward
TIG Welding with Filler Wire Technique
It is necessary in many situations with TIG welding to add a filler wire into the weld
pool to build up weld reinforcement and create a strong weld. Once the arc is started
the torch tungsten is held in place until a weld pool is created, a circular movement of
the tungsten will assist is creating a weld pool of the desired size. Once the weld pool
is established tilt the torch at about a 75° angle and move smoothly and evenly
along the joint. The filler metal is introduced to the leading edge of the weld
pool. The filler wire is usually held at about a 15° angle and fed into the leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is moved
forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire
is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and
evenly forward. It is important during the welding to keep the molten end of the filler wire inside the
gas shield as this protects the end of the wire from being oxidised and contaminating the weld pool.
75°
Travel direction
Form a weld pool
15°
Angle torch
Add TIG filler wire
gas
shield
Retract the filler wire
Move the torch forward to
the front of the weld pool
15
Repeat the process
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. Choosing the correct tungsten depends on the material being welded,
the amount of amps required and whether you are using AC or DC welding current.
Tungsten electrodes are colour-coded at the end for easy identification.
Below are the most commonly used tungsten electrodes found in the New Zealand and Australian market.
Thoriated
Thoriated tungsten electrodes (AWS classification EWTh-2) contain a minimum of 97.30 percent tungsten and 1.70
to 2.20 percent thorium and are called 2 percent thoriated. They are the most commonly used electrodes today and
are preferred for their longevity and ease of use. Thorium increases the electron emission qualities of the electrode,
which improves arc starts and allows for a higher current-carrying capacity. This electrode operates far below its melting temperature, which results in a considerably lower rate of consumption and eliminates arc wandering for greater
stability. Compared with other electrodes, thoriated electrodes deposit less tungsten into the weld puddle, so they
cause less weld contamination.
Thorium however is a low-level radioactive hazard and many users have switched to other alternatives. Regarding the radioactivity, thorium is an alpha emitter but when it is enclosed in a tungsten matrix the risks are negligible.
Thus holding a stick of Thoriated tungsten in your hand should not pose a great threat unless a welder has open cuts
on their skin. Thoriated tungsten should not get in contact with open cuts or wounds. The more significant danger
to welders can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours during
welding or from ingestion of material/dust in the grinding of the tungsten. Follow the manufacturer’s warnings, instructions, and the Material Safety Data Sheet (MSDS) 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 sheet metal work. They are best used to weld carbon steel, stainless steel, nickel alloys, and
titanium, and in some cases it can replace 2 percent thoriated electrodes. Ceriated tungsten is best suited for lower
amperages it should last longer than Thoriated tungsten higher amperage applications are best left to Thoriated or
Lanthanated tungsten.
Lanthanated (Color Code: Gold)
Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of 97.80 percent tungsten and
1.30 percent to 1.70 percent lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent
arc starting, a low burn off rate, good arc stability, and excellent re-ignition characteristics. Lanthanated tungstens
also share the conductivity characteristics of 2 percent thoriated tungsten. Lanthanated tungsten electrodes are ideal
if you want to optimise your welding capabilities. They work well on AC or DC electrode negative with a pointed end,
or they can be balled for use with AC sine wave power sources. Lanthanated tungsten maintains a sharpened point
well, which is an advantage for welding steel and stainless steel on DC or AC from square wave power sources.
Zirconiated (Color Code: White)
Zirconiated tungsten electrodes (AWS classification EWZr-1) contain a minimum of 99.10 percent tungsten and 0.15
to 0.40 percent zirconium. Most commonly used for AC welding Zirconiated tungsten produces a very stable arc and
is resistant to tungsten spitting. It is ideal for AC welding because it retains a balled tip and has a high resistance to
contamination. Its current-carrying capacity is equal to or greater than that of thoriated tungsten. Zirconiated tungsten
is not recommended for DC welding.
Tungsten Electrodes Rating for Welding Currents
Tungsten
Diameter
mm
DC Current Amps
Torch Negative
2% Thoriated
AC Current Amps
Un-Balanced Wave
0.8% Zirconiated
AC Current Amps
Balanced Wave
0.8% Zirconiated
1.0mm
1.6mm
2.4mm
3.2mm
4.0mm
15 - 80
70 -150
150- 250
250 - 400
400 - 500
15 - 80
70 - 150
140 - 235
225 - 325
300 - 400
20 - 60
60 - 120
100 - 180
160 - 250
200 - 320
16
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. Tungsten electrodes are manufactured with the molecular structure of the grain 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 longitudinal on the
grinding wheel
don’t grind across
the grinding wheel
Electrode Tip/Flat
The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection
of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur
and the more difficult it will be to arc start. However, increasing the flat to the maximum level that still allows arc start
and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders still grind
electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from
melting at the tip and the possibility of the point falling off into the weld pool.
2.5 times tungsten diameter
pointed tip
flat tip
Electrode Included Angle/Taper - DC Welding
Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a
specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and
offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide
the following benefits:
• Last Longer
flat spot diameter
• Have better weld penetration
• Have a narrower arc shape
• Can handle more amperage without eroding.
included angle
Sharper electrodes with smaller included angle provide:
• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration
increases and bead width decreases.
Tungsten
Diameter
Diameter at
the Tip - mm
Constant Included
Angle - Degrees
Current Range
Amps
Current Range
Pulsed Amps
1.0mm
1.6mm
1.6mm
2.4mm
2.4mm
3.2mm
3.2mm
.250
.500
.800
.800
1.100
1.100
1.500
20
25
30
35
45
60
90
05 - 30
08 - 50
10 - 70
12 - 90
15 - 150
20 - 200
25 - 250
05 - 60
05 - 100
10 - 140
12 - 180
15 - 250
20 - 300
25 - 350
17
Suregrip Series
17V TIG TORCH
5
150A AIR COOLED TIG WELDING TORCH
3
Rating: 150Amp DC, 105Amp AC @35% duty cycle.
4
7
2
For use with non gas solenoid machines
6
by g
es
seri
ens
as l
11
b
Stu
es
s
erie
ns s
s le
e ga
Larg
seri
es
12
lens
es
seri
seri
10
dard
Stan
by
Stub
9
Gas
8
*
Wear Parts Identification Next Page
13
14
15
6
16
17
Torch Model
Description
Part Number
4m
8m
17V-4MCP50
17V-8MCP50
17V Suregrip TIG Torch Package c/w 2m Gas Hose
Spare Parts
Part Number
Description
1
2
3
4
5
6
7
8
9
10
WP17V
WP17VF
57Y02
57Y03
57Y04
UERBS UERSP1
UERH100 UERKJ100
UERLC200-08
UERJK100 Torch head
Torch head flexible
Back cap long
Meduim back cap
Short back cap
Blank Kitt
Screw Pack
Small Ergo TIG Handle
Small Knuckle Joint
Leather Cover X 0.8mt
Jointing Repair Kit
Part Number
Description
11
12
13
14
15
16
17
UERNCL-32
UERNCL-72
UERCO100-40
UERCO100-80
USLH917-S USLH917-H
USL57Y01AR
USL57Y03AR
USL3550 USL-1-GS4
Neoprene Cover X 3.2mt
Neoprene Cover X 7.2mt
Sheath X 12.5ft Inc Leather Cover
Sheath X 25ft Inc Leather Cover
Cable Support Small
“Surelok “ Housing Small
“Power Cable X 12.5ft “Surelok “ Rubber
Power Cable X 25ft “Surelok “ Rubber
“Surelok “ Body & Support
Gas Supply Hose
©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means,
electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.
18
Suregrip Series
Standard Front End Parts
17V TIG TORCH
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 3.2mm
Part #
10N49L
53N48L
53N47L
Part #
10N50
10N49
10N48
10N47
10N46
10N45
10N44
Description
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Description
Long Alumina Nozzle Ø 8mm #5L
Long Alumina Nozzle Ø 10mm #6L
Long Alumina Nozzle Ø 11mm #7L
Ø 6mm #4
Ø 8mm #5
Ø 10mm #6
Ø 11mm #7
Ø 13mm #8
Ø 16mm #10
Ø 19mm #12
Compact Gas Lens Front End Parts
Part #
54N01
Description
Gas Lens Gasket
Part #
45V25
45V26
45V27
Description
Gas Lens Body 1.6mm
Gas Lens Body 2.4mm
Gas Lens Body 3.2mm
Part #
54N14
54N15
54N17
Description
Gas lens ceramic 8.0mm
Gas lens ceramic 7.0mm
Gas lens ceramic 5.0mm
TR0004-16
RED
ANSI/AWS A5.12-98
ISO 6848 WT20
2% Thoriated: Best stability
at medium currents, good arc
starts, medium tendency to spit,
medium erosion rate.
Commonly used for steel and
stainless steel applications
Part #
TR0004-10
TR0004-16
TR0004-24
TR0004-32
Description
1.0mm x 175mm
1.6mm x 175mm
2.4mm x 175mm
3.2mm x 175mm
thoriated
thoriated
thoriated
thoriated
tungsten
tungsten
tungsten
tungsten
electrode
electrode
electrode
electrode
1/16 x 7” (1.6mm x 175mm)
3/32 x 7” (2.4mm x 175mm)
1/8 x 7” (3.2mm x 175mm)
©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means,
electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.
19
2%
2%
2%
2%
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.
Wrong mode selected
Check the MMA selector switch is selected
No power supply
Check that the machine is switched on and has a power supply
2: Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Reason
Suggested Remedy
Arc length too long
Check that pure Argon is being used
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Damp electrodes
Use only dry electrodes
3: Excessive Spatter
Possible Reason
Suggested Remedy
Amperage too high
Decrease the amperage or choose a larger electrode
Arc length too long
Shorten the arc length
Tungsten melting into the weld pool
Check that correct type of tungsten is being used. Too much current for the tungsten
size so reduce the amps or change to a larger tungsten
3: Weld sits on top, lack of fusion
Possible Reason
Suggested Remedy
Insufcient heat input
Increase the amperage or choose a larger electrode
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
4: Lack of penetration
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 assistance for the correct joint design and t up
5: Excessive penetration - burn through
Possible Reason
Suggested Remedy
Excessive heat input
Reduce the amperage or use a smaller electrode
Incorrect travel speed
Try increasing the weld travel speed
6: Uneven weld appearance
Possible Reason
Suggested Remedy
Unsteady hand, wavering hand
Use two hands where possible to steady up, practise your technique
7: Distortion − movement of base metal during welding
Possible Reason
Suggested Remedy
Excessive heat input
Reduce the amperage or use a smaller electrode
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation and or joint
design
Check the joint design and t up, make sure the material is not too thick. Seek assistance for the correct joint design and t up
7: Electrode welds with different or unusual arc characteristic
Possible Reason
Suggested Remedy
Incorrect polarity
Change the polarity, check the electrode manufacturer for correct polarity
20
20
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.
1: Tungsten burning away quickly
Possible Reason
Suggested Remedy
Incorrect Gas
Check that pure Argon is being used
No gas
Check the gas cylinder contains gas and is connected and the torch gas valve is open
Inadequate gas ow
Check the gas is connected, check hoses, gas valve and torch are not restricted. Set
the gas ow between 10 - 15 l/min ow rate
Back cap not tted correctly
Make sure the torch back cap is tted so that the o-ring is inside the torch body
Torch connected to DC +
Connect the torch to the DC- output terminal
Incorrect tungsten being used
Check and change the tungsten type if necessary
Tungsten being oxidised after weld
is nished
Keep shielding gas owing 10–15 seconds after arc stoppage. 1 second for each 10
amps of weld current.
2: Contaminated tungsten
Possible Reason
Suggested Remedy
Touching tungsten into the weld
pool
Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of
the work piece 2 - 5mm
Touching the ller wire to the tungsten
Keep the ller wire from touching the tungsten during welding, feed the ller wire into the
leading edge of the weld pool in front of the tungsten
Tungsten melting into the weld pool
Check that correct type of tungsten is being used. Too much current for the tungsten
size so reduce the amps or change to a larger tungsten
3: Porosity - poor weld appearance and colour
Possible Reason
Suggested Remedy
Incorrect Gas
Check that pure Argon is being used
Inadequate gas ow / gas leaks
Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the
gas ow between 10 - 15 l/min ow rate. Check hoses and ttings 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 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 between 10 - 15 l/min ow rate
Alumina gas nozzle too small for size Increase the size of the alumina gas nozzle
of tungsten being used
5: Unstable Arc during DC welding
Possible Reason
Suggested Remedy
Torch connected to DC +
Connect the torch to the DC- output terminal
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long
Lower torch so that the tungsten is off of the work piece 2 - 5mm
7: Arc wanders during DC welding
Possible Reason
Suggested Remedy
Poor gas ow
Check and set the gas ow between 10 - 15 l/min ow rate
Incorrect arc length
Lower torch so that the tungsten is off of the work piece 2 - 5mm
Tungsten incorrect or in poor condition
Check that correct type of tungsten is being used. Remove 10mm from the weld end of
the tungsten and re sharpen the tungsten
Poorly prepared tungsten
Grind marks should run lengthwise with tungsten, not circular. Use proper grinding
method and wheel.
Contaminated base metal
Remove contaminating 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
21
21
8: Arc difcult 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 ow
Check the gas is connected and cylinder valve open, check hoses, gas valve and torch
are not restricted. Set the gas ow between 10 - 15 l/min ow rate
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Incorrect tungsten size and or tungsten 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
ATTENTION! - CHECK FOR GAS LEAKS
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 hose assembly and tighten all connectors and clamps.
ATTENTION!
- CHECK
2. Slowly open the cylinder
valve. FOR GAS LEAKAGE
3. Set the ow rate on the regulator to approximately 8-10 l/min.
At initial set up and at regular intervals we recommend to check for gas leakage.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure
gauge on the regulator, if the needle drops away towards zero there is a gas leak.
Recommended procedure is as follows:
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the
1. Connect the regulator and gas hose assembly and Tighten all connectors and clamps.
regulator and line for an extended time period. In this situation it is recommended to open the
2. Slowly open the cylinder valve.
cylinder valve, set the ow rate to 8-10 l/min, close the cylinder valve and check after a
3. Set the flow rate on the regulator to approximately 8-10 l/min.
minimum of 15 minutes.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying
gauge on the regulator, if the needle drops away towards zero there is a gas leak.
with soapy water, bubbles will appear at the leakage point.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the
6. Tighten clamps or ttings to eliminate gas leakage.
regulator 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
Important:
minimum ofWe
15 strongly
minutes. recommend that you check for gas leakage prior to operation of your
machine.
recommend
that you
close the cylinder
valve
theby
machine
not in use.
5.If
there isWe
a gas
loss then check
all connectors
and clamps
forwhen
leakage
brushingisorspraying
with soapy water, bubbles will appear at the leakage point.
Esseti
NZclamps
Ltd, authorised
or agents of Esseti NZ Ltd will not be liable or
6.
Tighten
or fittings torepresentatives
eliminate gas leakage.
responsible for the loss of any gas.
22
22
Spare Parts IdentiFIcation - ARC180DC
15
2
1
8
5
7
6
3
9
4
10
16
11
12
13
14
17
Part Number
Description
Part Number
1. 10037834 2. 10016485 3. 10004966 4. 10037151 5 30000103 6. 10043028 7. 10042673 8. 10037835 9. 10004957 front plastic panel
carry strap / handle
TIG/MMA selector switch
panel socket 35-50
front panel adhesive sticker
Amperage knob
cable support assembly
rear plastic panel
ON/OFF switch
10. 10006650
11. 10007251
12. 10037435
13. 10043225
14. 10037766
15. 10043024
16. 10037797
17. 10037113
23
Description
Single-phase rectifier bridge
IGBT
main PCB
control PCB
thermal switch
cover
fan-24V DC
base plate
PO Box 3033, Lansvale NSW 2166, AUSTRALIA
112 Christina Rd, Villawood, NSW 2163
Phone: (02) 9780 4200
Fax: (02) 9780 4244
Email: [email protected] / Web: www.unimig.com.au
Welding Guns Of Australia Pty Ltd
ABN: 14 001 804 422
Welding Guns Of Australia Pty Ltd (‘Us’, ‘We’) warrants that the following products under UNI-MIG, UNI-TIG,
UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA, supplied by Us and purchased by you from an Authorised
UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA Dealer throughout Australia are free of
Material and Faulty Workmanship defects except for those products listed under ‘Warranty Exclusions’.
These terms and conditions supersede and exclude all former and other representations and arrangements relating
to any warranties on these products.
WARRANTY PERIOD
We offer the following ‘Warranty Periods’ from ‘date of purchase’:
An Extended Warranty Period of 6 months total shall apply only to Machinery where offered and warranty
is registered online.
UNI-MIG WELDING MACHINES
UNI-MIG DIY Series (Power Source Only)
RAZORWELD Series (Power Source Only)
UNI-MIG Procraft Series (Power Source Only)
UNI-MIG Trade Series (Power Source Only)
UNI-MIG Trade Series SWF (Power Source / Seperate Wire Feeder Only)
UNI-MIG Workshop Series (Power Source Only)
UNI-MIG Workshop Series SWF (Power Source / Separate Wire Feeder Only)
UNI-MIG Jasic Inverter MIG (Power Source Only)
UNI-MIG Jasic Inverter MIG SWF (Power Source / Separate Wire Feeder Only)
UNI-TIG Jasic Inverter TIG (Power Source Only)
UNI-MIG Water Cooler
T&R Pulse MIG (Power Source Only)
T&R Pulse MIG SWF (Power Source / Separate Wire Feeder Only)
UNI-PLAS (Power Source Only)
UNI-PLAS Jasic Series (Power Source Only)
UNI-PLAS Site Cut Series (Power Source Only)
UNI-FLAME Gas Cutting and Welding Kits
UNI-FLAME Straight Line & Gas Cutting Machines (Power Source Only)
UNI-FLAME Regulators Argon/ Acetylene / Oxygen / LPG / Bobbin Flowmeter
UNI-FLAME Automatic Welding Helmet
UNI-MIG Automatic Welding Helmets
TECNA (Power Source Only)
HIT-8SS Automatic Carriage (Power Source Only)
ROTA 102 Rotating table
HOTBOX ElectrodeOven
SPOTCAR 3500
TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,
INTERCONNECTING CABLES, GAS HOSE
2 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
1 Year
2 Year
2 Year 3 Years
2 Years
1 Year
3 Months 1 Year 1 Year
2 Years
2 Years
1 Year 1 Year
1 Year
1 Year
1 Year
(Clause 3)
(Clause 1&3)
(Clause 1&3)
(Clause 1&3)
(Clause 1&3))
(Clause 1&3)
(Clause 1&3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 2&3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
3 Months (Clause 3)
(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB, and all other
components, .
(Clause 2) Gas Hose, Flashbacks are subject to and covered by the Manufacture’s Individual Warranty, Contact
the manufacturer for details
(Clause 3) This only Covers Manufactures defaults on all accesories for the first three months after date of purchase.
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.
Your Rights under the Australian Consumer Law - Our goods come with guarantees that cannot be excluded under
the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for
any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the
goods fail to be of acceptable quality and the failure does not amount to a major failure.
• You shall inspect the Goods on delivery and shall within seven (7) days of delivery (time being of the essence)
notify Welding Guns Of Australia PTY LTD of any alleged defect, shortage in quantity, damage or failure to comply
with the description or quote.
• You shall also afford Welding Guns Of Australia PTY LTD the opportunity to inspect the Goods within a reasonable
time following delivery if you believe the Goods are defective in any way.
• If you shall fail to comply with these provisions the Goods shall be presumed to be free from any defect or damage.
For defective Goods, which Welding Guns Of Australia PTY LTD has agreed in writing that you are entitled to reject,
Welding Guns Of Australia PTY LTD liability is limited to either (at the Welding Guns Of Australia PTY LTD
discretion) replacing the Goods or repairing the Goods except where 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 the provisions outlined above, and
(b) where the Goods 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 reasonably possible in the circumstances.
• Welding Guns Of Australia PTY LTD Accepts no responsibility for products lost, damaged or mislaid whilst in transit
• Welding Guns Of Australia PTY LTD may (at their sole discretion) accept the return of Goods for credit but this may
incur a handling fee of up to fifteen percent (15%) of the value of the returned Goods plus any freight costs.
• Where a failure does not amount to a major failure, Welding Guns Of Australia PTY LTD is entitled to choose
between providing you with a repair, replacement or other suitable remedy.
• Your rights under the Australian Consumer Law are not limited by a defined time. However, the Australian
Consumer Law does recognise that the relevant time period can vary from product to product, depending on factors
such as the nature of the product and the price. Welding Guns Of Australia PTY LTD adopts the same approach. As
you can appreciate, the type of remedy we can offer you may also vary depending on how long it takes you to return
the product to us.
25
MAKING A CLAIM
If you wish to make a claim under this Warranty, you should:
• Return the product to the point of purchase either in person or on a prepaid courier; or
• Contact Us by Telephone
Sydney Head Office:
Queensland:
Victoria:
Western Australia:
02 9870 4200 or Mail PO Box 3033 Lansvale NSW 2166.
07 3333 2855
03 8682 9911
08 6363 5111
When returned, the product must be accompanied with the original invoice including the purchase price and
disclosing the purchase date
All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the
Customer.
To the extent permitted by law, our total liability for loss or damage of every kind related to the product in any way
whatsoever is limited to the amount paid to the retailer by you for the product or the value of the product.
No responsibility will be taken for products lost, damaged or mislaid whilst in transit.
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.
Failure to clean or improper cleaning of the product
Failure to maintain the equipment such as regular services etc
Incorrect voltage or non-authorised electrical connections
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, HIT-8SS & ROTA Service Dealer
Unless it is a manufacturing fault, this Warranty does not cover the following parts:
MIG Welding Torches and Consumables to suit, such as:
Gas Nozzels, Gas Diffusers, Contact Tip holder, Contact tip, Swan Necks, Trigger, Handle, Liners,
Wire Guide, Drive Roller, Gas Nozzle Spring. Neck Spring, Connector Block, Insulator, Gas Nipple, Cap, Euro Block,
Head Assembly, Gas Block, Trigger Spring, Spring Cable Support, Neck Insulator, Shroud Spring,
Gun Plug Cover, Lock Nut, Snap On Head, Spring Cap, Ball, Motor 42 Volt, Pot 10K standard, Knob, Drive Roll Seat,
Washer, Bow, Ball Bearing, Wire Condue Nipple, Central Plug, 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 Gasket, Torch Body Gas Valve, O-ring,
All UNI-MIG TIG Welding Rods, All Xcel-Arc/ Magmaweld Electrodes, Arc Leads, Welding Cable, Electrode Holder,
Eatch Clamps.
26
PLASMA Cutting Torches and Consumables to suit, such as:
All Cutting Tips, All Diffuser/Swirl Ring, All Electrode, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps,
All Air and Power Cables, All Switches, All O-rings, All Springs, All Circle Guides and Cutting Kits, Torch Bodies, Air
Filter Regulator, Arc Leads, Welding Cable, Electrode Holder, Eatch Clamps
STRAIGHT LINE CUTTING MACHINES and Consumables to suit, such as:
Hoses, Fittings, Track, Cutting Nozzles.
HIT-8SS Welding Carriage 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
Unless it is a manufacturing fault, this Warranty does not apply to any products sold to Hire Companies.
These conditions may only be varied with the written approval of the Directors of Welding Guns Of Australia PTY LTD
REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.
Notes
27
© Welding Guns Of Australia PTY LTD 2012
Welding Guns Of Australia 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: [email protected] / Web: www.unimig.com.au
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