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 identiedby 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 Insufcient 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 Insufcient 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 difcult 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
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project
Related manuals
Download PDF
advertisement