Uni-Mig PRO-CRAFT240 MIG Instruction manual

UNI FLAME AUTOLIFT
PRO-CRAFT SERIES
210/240 MIG Manual
240 Volt
Standard
MIG / MAG
UNI FLAME AUTOLIFT
3YEARS Warranty
*
Machine Model
Description
MIG Inverter
Part Number
KPC210 / 240
CONTENTS
PAGE No:
Safety
Main Parameter.
Machine Features
Installation & Operation
Caution
Maintenance
Troubleshooting
3
4
4
4
11
12
12
Machine Model
This welding equipment for industrial and professional use
conforms to IEC 60974 International Safety Standard.
We hereby state that we provide three year of guarantee for this
welding Power Source from the date of purchase.
Refer to Unimig for further details.
Please read and understand this instruction manual carefully before
the installation and operation of this equipment.
The contents of this manual may be revised without prior notice
and without obligation.
This instruction manual is issued on 1st April 2008.
UNIMIG pursue a policy of continuous research and development, and therefore
reserve the right to change the specifications, or design, without prior notice. * 2 year warranty power source.
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. Please
read and understand this instruction manual carefully before the installation and use/operation
of this equipment.
not switch the function modes while the machine is operating.
• Do
Switching of the function modes during welding can damage the machine.
Damage caused in this manner will not be covered under warranty.
the electrode-holder cable from the machine before switching on the
• Disconnect
machine, to avoid arcing should the electrode be in contact with the work piece.
safety switch is necessary to prevent the equipment from electric leakage.
• AWelding
and accessories should be of high quality and in good working order.
• Operatorstools
be trained and or qualified. Electric shock: It can kill.
• Connect theshould
primary
cable according to Australian standard regulation.
• Avoid all contact withinput
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. Smoke and gas generated whilst welding
or cutting can be harmful to people’s health.
Avoid breathing the smoke and gas generated whilst
welding or cutting. Keep the working area well ventilated.
Arc rays are harmful to people’s eyes and skin. Always
wear a welding helmet 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, from all hazards
associated with welding.
Fire hazard
welding sparks may cause fire, therfore remove
• The
flammable material away from the working area.
a fire extinguisher nearby, and have a trained
• Have
person ready to use it.
Noise: possibly harmful to people’s hearing.
Noise is generated while welding/cutting, wear approved
hearing protection when noise levels are high.
Machine fault:
Consult this instruction manual.
Contact your local dealer or supplier for further advice.
•
•
•
*** CAUTION ***
Do not heat, cut or weld tanks, drums or containers
until the proper steps have been taken to insure that
such procedures will not cause flammable or toxic
vapours from substance inside. 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.
UNI FLAME AUTOLIFT
PART NUMBER
PRIMARY INPUT VOLTAGE
Ieff
WELDING CURRENT
VOLTAGE STEPS
DUTY CYCLE 40°C
KPC210
240V 1 Phase
16Amps
30-210 Amps
8
18% @ 210 Amps 24.5V
60% @ 110 Amps 19.5V
100% @ 95 Amps 18.75V
WELDING VOLTAGE RANGE DC 15.5V – 24.5V
WIRE SIZE (mm)
0.6 – 0.9mm Ferrous
0.8 – 0.9mm Stainless Steel
0.8 – 1.0mm Aluminium
0.8 – 1.0mm Flux Cored
DIMENSIONS (mm)
920 x 460 x 820mm
WEIGHT (Kgs)
78 Kgs
KPC240
240V 1 Phase
20Amps
30-240 Amps
8
15% @ 240 Amps 26V
60% @ 150 Amps 21.5V
100% @ 120 Amps 20V
15.5V – 26.5V
0.6 – 0.9mm Ferrous
0.8 – 0.9mm Stainless Steel
0.8 – 1.2mm Aluminium
0.8 – 1.2mm Flux Cored
920 x 460 x 820mm
81 Kgs
1.INTRODUCTION
The MIG welding machines of the UNIMIG series are of advanced technical specification which makes them highly reliable. The
240V single phase series consitis of a generator made of a fan cooled and single-phase transformer with double primary,
The power commutations are made on the primary, which is activated by a contactor.
The DC current is obtained through a multi-diodes fan-cooled rectifier bridge. The machine is protected from overload through
a thermic control on the transformer. The PCBs are protected in order to make up for the lack of the ambient characteristics of
the rooms in which the weldings are carried out.
8 welding current settings (Unimig 210 - 240)
The generator can run eight power regulations through a commutator for the power combinations on the primary.
2. HOW TO PUT THE MACHINE ON
Input cable connectionA.Connect the machine to 240V 1 Phase, ensure that the machine is fitted with a plug that is equal to or larg
than the Ieff. The input cable should be connected well with the corresponding power supply connection plug or socket, to avoid ox
Single-phase machine is preset by the building factory for a single-phase 50/60 hertz 220÷240 V feeding.
To put the machine on, it has to be equipped with the accessories which it is dispatched with and it has to be completed by a
current plug adequate to the electrical system of the workshop. The operations to carry out are:
Opening, lift and wheel assembly - Plug assembly - Trolley assembly - Gas bottle installation - Torch installation - Wire spool
housing
2.1 OPENING, LIFT AND WHEEL ASSEMBLY
Open the box from the up side, take out the accessories from the box, take the screw-hook and scewit on the top of the machine.
Lifting it by manual or mechanical elevator.
The cart is designed for the mounting of two rotating front wheels and for the insertion of an axle for the fastening of the two
fixed rear wheels.
It is supplied with a kit comprising:
Rotating front wheels, axle for the fixed rear wheels, rear wheels, bolts, split pins and cage nuts.
Insert the cage nuts in the apposite slots as illustrated in pic. A and B.
Mount the two front wheels as illustrated in pic. C.
Insert the axle to fasten the rear wheels and block them with the split pins as illustrated in pic. D.
UNI FLAME AUTOLIFT
2.4 GAS BOTTLE INSTALLATION
Put the gas bottle in vertical position on the gas bottle holder plane and position the bottle so that it is lays on the gas bottle
holder and fix it with the chain and the spring clip, like in pic E.
Tightly connect the gas hose, which comes from the back of the machine to the brass nipple of supplied regulator
adjust argon regulator to deliver the required litres per minute.
NOTE. reffer to instruction manual of argon regulator for proper use.
2.5 TORCH ASSEMBLY
To connect the torch, you just have to insert it into the designed EURO adaptor on the front of the machine and then turn the
collar tightly, like in pic.G. This way the electric connection as well as the gas connection is achieved.
2.6 WIRE SPOOL HOUSING
Put the wire spool on the paddle wheel and insert the wire in the wire feeder like in pic.H. The models can all hold either the 5
Kg or the 15 Kg spool. The paddle wheel has a clutch designed to maintain the wire pulled.
2.7 WIRE FEEDER MOTOR
Make sure that the size of the groove in the wire feeding roll corresponds to the size of the welding wire being used.
The machines are arranged with a feed roll for Ø 0,6 and 0, 8 wire. In case you want to use Ø 1 welding wire, ask for the
suitable feeding roll. The feeding roll has the wire diameter stamped on its side.
2.8 HOW TO INSERT THE WELDING WIRE
Cut the first 10 cm of the wire making sure that there are no burrs or distortions at the cut end.
Open the mobile arm of the wire feeder unscrewing the pressure screw of the arm pic. I.
Insert the wire into the wire guide passing it through the feed roll’s groove and then reinsert the wire into the second
alignement guide, like in pic. L. Make sure the wire lies in the feed roll’s groove in a natural line. Drop the pressure arm and
adjust the pressure through the specially designed screw, like in pic M.
The right pressure is the one that allows the even advancing of the wire.
In case the wire should jam, the driving wheel must slip so that the the wire itself doesn’t tangle.
In case the wire tends to unroll, you have to adjust the pressure through the designed screw so that the spool is always
pulled, like in pic N. On the contrary, if the clucth causes an excessive friction and the driving wheel tends to slide, you have to
decrease it until the wire advances evenly.
3. SAFETY RULES
Welding can be dangerous to both operator and bystanders. The following safety rules are strongly recommended.
Personal cautions!
Wear suitable clothing, possibly without protruding pockets and turn up and avoid synthetic materials.
Always wear welding gloves.
Wear heavy duty shoes, high laced with steel caps.
Always use a welding mask fitted with a suitable dark lens, which have also a side protection.
Caution: gas fumes!
Ensure a good ventilation of the work area. If necessary, use an aspiration plant, above all in small working rooms.
Clean away from the work piece any rust, grease or paint to reduce fumes as much as possible.
Caution: short-circuit risk!
Make sure the electric net is provided with adequate earthing and protection against overloads and short circuits.
Make sure that all the main cables, torch, earth are in good conditions and replace if necessary.
Connect the earth cable firmly to the workpiece.
Do not wrap earth or torch cables around the body.
Do not point the torch towards people.
Avoid welding in wet or excessively damp conditions.
Do not operate the machine with its side panels removed.
Do not touch the contact tip on the torch or the workpiece.
Caution: explosion risk!
Do not weld in the proximity of inflammables.
Ensure the welding machine is positioned on a flat, stable level.
Tie the gas bottle to the machine with the chain provided, away from sources of heat.
Make sure you are using the correct gas mixture and the gas reducer is of a proved type and that it works properly.
Don’t use the machine for a tube defrosting activity.
The machine has an IP 21 protection level - it is not to be used or stored in the rain!
4. WELDING
It’s possible to regulate the welding functions selecting the PCB’s electronic card options, located on the generator
Switching the machine to position on, the display on the PCB show the last welding current measured.
UNI FLAME AUTOLIFT
Mod.B
Mod.A
LEGENDA:
LEGENDA:
LED 1 = Thermal protection
LED 2 = Trigger normal – Manual welding
LED 3 = Trigger latch – Automatic welding
LED 4 = Stich welding
LED 5 = Spot welding
S1 = Menù. To select welding parameter on the display
S2 = Mode. To select welding type on the led welding parameter
DISPLAY = Show welding parameter
ENC = Encoder
LED = Thermal protection
4.1 WELDING TYPE
Pushing S2 (mode) it’s possible to select the type of welding
needed on the led 2,3,4 and 5
A) MANUAL (led2):
Pushing the switch on the torch it is possible start to weld,
releasing it shall stop the welding.
B) AUTOMATIC (led3):.
Pushing the switch on the torch it is possible to begin welding
continuously, the switch must be pushed more time in order to
stop the process.
C) STICH WELDING (led4):
Pushing the switch on the torch the machine weld for the
selected time (Time on regulation as in 4.2.5), then will stop for
the selected time (Pause time regulation as in 4.2.6). The
machine will repeat automatically the cycle.
D) SPOT WELDING (led5):
Pushing the switch on the torch the machine weld for the
selected time (Time on regulation as in 4.2.5), after this period it
will stop. It is necessary to re-push the button in order to repeat
the mentioned function.
4.1 WELDING TYPE
4.2 WELDING PARAMETER – Display
Pushing S1 (menù) button it is possible to select the parameter
used during the welding, increasing or decreasing the values
using the knob of the encoder.
LEGENDA:
4.2 WELDING PARAMETER – Display
Pushing S1 (menù) button it is possible to select the parameter
used during the welding, increasing or decreasing the values using
the knob of the encoder
LEGENDA:
Don’t press the “MODE” button while you are welding.
It is possible to reset the PCB’s original parameter (DEFAULT)
following these steps:
Turn off the welding machine, pushing the on/off switch
(position 0). Push S1 and S2 button. Turn on the welding
machine, keeping pushed for three seconds
It is possible to reset the PCB’s original parameter (DEFAULT)
following these steps:
Turn off the welding machine, pushing the on/off switch
(position 0). Push S1 button. Turn on the welding machine,
keeping pushed for three seconds
S1 = Menù. To select welding parameter on the display
DISPLAY = Show welding parameter
ENC = Encoder
A) MANUAL:
Pushing the switch on the torch it is possible start to weld,
releasing it shall stop the welding. (Time ON=0)
D) SPOT WELDING:
Pushing the switch on the torch the machine weld for the
selected time (see 4.2.5 how to regulate it), after this period it will
stop. It is necessary to re-push the button in order to repeat the
mentioned cycle.
Wire speed: It is possible to regulate the wire speed using the knobs of the encoder
2)
Pregas: It is possible to regulate the gas open time using the knob of the encoder before
the arc prime
3)
Ramp up: It is possible to regulate the wire increasing gradually using the knobs of the
encoder in order to have the one selected at point 4.2.1
4)
Burn back: it is possible to regulate, using the knob of the encoder, the wire length came
out at the end of welding process.
5)
Time on: it is possible to regulate, using the knob of the encoder, the welding time for the
welding type 4.1.C and 4.1.D. (Only Mod.B) Regulating it on 0 (zero) value, the welding
is set on manual (4.1.A)
6)
Pause time: it is possible to regulate, using the knob of the encoder, the pause time for
the welding type 4.1.C
7)
Thermal overload: show the thermal overload goes on, it is necessary to wait for
machine cooling. The sign disappear after a few seconds. The thermal overload restoring
is shown when the led 1 switch off.
4.3 GAS PRESSURE
Gas pressure should normally be set to give a reading between 8 / 15 litres per minute. With experience, every operator will
find what suits him the most with his type of work and can make the necessary adjustment.
4.4 GAS-NO GAS WELDING
When you gas with wire, gas is needed for the protection of the melt dip. Usually, the gas to be used is a mix of Argon and CO2,
pure Argon or pure CO2. The argon one is employed for the welding of aluminium while other are used for the welding of ferrous
material.
In case of use with gas, the clip of the torch has to be placed in the positive outlet “+”, while the earth clamp has to be placed in
the negative outlet “-“, like in pic. O.
The use of gas can be avoided if you use flux cored wire. This kind of wire emits gas which creates a protective environment
for the welding. In case you want to weld with flux cored wire, place the torch clip in the negative outlet “-“, and the earth clamp
in the positive outlet “+”, like in pic.P
4.5 DOUBLE INDUCTANCE (Unimig 240)
If you need a lowest inductance to use the machine for a bigger power, put the dinse connector in the
exit
4.6 MIG-MAG WELDING
A) MIG = Metal Inert Gas
B) MAG = Metal Active Gas
The two processes are exactly the same, only gas used changes.
In case A ARGON is the gas employed ( inert gas)
In case B CO2 is the gas employed ( active gas)
To weld alluminium alloys you need use ARGON (100%), to weld steel it is enough a compound of ARGON 80% and CO2
20%.
You can only use pure CO2 in case you want to weld iron.
UNI FLAME AUTOLIFT
1)
UNI FLAME AUTOLIFT
WELDING GUIDE
GENE
G
ENER
EN
NER
N
E
GENERAL
RULE
When welding on the lowest output settings, it is necessary to keep the arc as short as possible.
This should be achieved by holding welding torch as close as possible and at an angle of approximately 60 degrees to the
workpiece. The arc length can be increased when welding on the highest settings, an arc length up to 20 mm can be enough
when welding on maximum settings.
GENERAL WELDING TIPS
From time to time, some faults may be observed in the weld owing to external influences rather due to welding machinès faults.
Here are some that you may come across :
· Porosity
Small holes in the weld, caused by break-down in gas coverage of the weld or sometimes by foreign bodies inclusion. Remedy
is, usually, to grind out the weld.
Remember, check before the gas flux (about 8 liters/minutes), clean well the working place and finally incline the torch while
welding.
· Spatter
Small balls of molten metal which come out of the arc. A little quantity is unavoidable, but it should be kept down to a minimum
by selecting correct settings and having a correct gas flow and by keeping the welding torch clean.
· Narrow heap welding
Can be caused by moving the torch too fast or by an incorrect gas flow.
· Very thick or wide welding
Can be caused by moving the torch too slowly.
· Wire burns back
It can be caused by wire feed slipping, loose or damaged welding tip, poor wire, nozzle held too close to work or voltage too high.
· Poor penetration
It can be caused by moving torch too fast, too low voltage setting or incorrect feed setting, reversed polarity, insufficient blunting
and distance between strips. Take care of operational parameters adjustment and improve the preparation of the workpieces.
· Workpiecès piercing
It may be caused by moving the welding torch too slow, too high welding power or by an invalid wire feeding.
· Heavy spatter and porosity
Can be caused by nozzle too far from work, dirt on work or by low gas flow. You have to the two parameters, remeber that
gas has not to be lower than 7-8 liters/min. and that the current of welding is appropriated to the wire you are using. It is
advisable to have a pressure reducer of input and output. On the manometer you can read the range expressed in liter.
· Welding arc instability
It may be caused by an insufficient welding voltage, irregular wire feed, insufficient protective welding gas.
FAULT FINDING
FAULT
REASON
REMEDY
Wire isn’t conveyed when
feed roll is turning
1) Dirt in liner and/or contact tip
Blow with compressed air,
replace contact tip
Loosen
2) The friction brake in the hub
is too tightened
3) Faulty welding torch
Contact tip defect
Burns in contact tip
Dirt in feed roll groove
Feed roll’s groove worn
Check sheating of torchès
wire guide
Wire feeding in jerk or
erratic way
1)
2)
3)
4)
No arc
1) Bad contact between earth clamp
and workpiece
2) Short-circuit between contact tip
and gas shroud
Tighten earth clamp and
check connections
Clean, replace tip and/or
shroud as necessary
Porous welding seams
1) Failre of gas shield owing
to spatters in gas shro
2) Wrong welding torch distance
and/or inclination from workpiece
4) Humid workpieces
5) Heavily rusted workpieces
Clean gas shroud from
spatters
The lenght of stick out wire
from tip must be 5-10 mm.
Inclination not less than 60
degrees in relation to
workpiece
Increase flux of welding
gas
Dry with heat producer
Clean workpieces from rust
The machine suddenly stops
weldig operations after an
extended and heavy duty
use
1) Welding machine overheated
due to an excessive use in stated
duty cycle
Don’t switch off the machine,
let it cool down for about
20/30 minutes
The machine is switch off even
it is
Fuse blowed on the service transformer
Replace
3) Too small gas flux
Replace
Replace
Clean
Replace
UNI FLAME AUTOLIFT
DESCRIPTION OF GRAPHICS
A
D
B
C
E
F
G
H
I
L
M
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UNI FLAME AUTOLIFT
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UNI FLAME AUTOLIFT
1. Working Environment.
1.1
1.2
1.3
1.4
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.
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.
Keep this equipment 30cm distant from the wall for ventilation.
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.
Should the machine be used to an excessive level, or in high temperature
environment, poorly ventilated area or if the fan malfunctions the Thermal Over
load 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.
2.3 Over-Voltage Supply
Regarding the power supply voltage range of the machine, please refer to “Main
parameter” table. This equipment is of automatic voltage compensation, which
enables the maintaining of the voltage range within the given range. In case that
the voltage of input power 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.
UNI FLAME AUTOLIFT
CAUTION
MAINTENANCE
WARNING:
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.
TROUBLESHOOTING
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.
WARRANTY
• 3 Years from date of purchase.
• Welding Guns of Australia Pty 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 until
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 impossible.
If in doubt please ring.
WELDING GUNS OF AUSTRALIA Pty Ltd
WWW.UNIMIG.COM.AU
Disclaimer:
While the information is provided in good faith, Welding Guns Of Australia does not warrant the accuracy of information
provided nor assume any legal responsibility for it or for any damage which may result from reliance on or use of it or from any
negligence of Welding Guns Of Australia or other person/s with respect to it.
For further information please call Welding Guns of Australia Pty Ltd.
112 Christina Rd, Villawood NSW 2163 - PO Box 3033 Lansvale NSW 2166
UNIMIG pursue a policy of continuous research and development, and therefore
reserve the right to change the specifications, or design, without prior notice. * 3 year warranty power source.