Unimig KMM180 Instruction manual

Unimig KMM180 Instruction manual

2

YEARS Warranty

(Power Source)

Lift Arc DC/TIG

15 AMP

240 Volt

Standard

MIG / MAG

OPERATING MANUAL

Please read and understand this instruction manual carefully before the installation and operation of this equipment.

©

Welding Guns Of Australia PTY LTD 2012

2

• 2 Years from date of purchase.

WARRANTY

• This Warranty does not cover freight or goods that have been interfered with.

• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.

• Product will only be replaced if repair is not possible

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 Mig machine design put together by our professional team of highly skilled engineers. The expertise gained from our long involvement with welding machine design 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.The Mini-Mig 180 has been issued electrical approval number ESV110294.

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CONTENTS PAGE

Warranty 2

Technical Data, Product Information

Safety - Cautions

Machine Layout Pictogram

Installation Operation Cautions

Installation & Operation for MMA (stick) Welding

MMA (Stick) Welding Information

Installation & Operation for MIG Welding with Gas

Wire Feed Drive Roller Selection

Wire Installation Set up Guide

Installation & Operation for MIG Welding with No Gas

Installation Guide for Mig Torch Liner Installation

Mig Torch and Wire Feeder Set Up Guide for Aluminium Mig Wire

Installation & Operation for MIG Welding with Spool Gun

MIG (Metal Inert Gas) Welding

Basic MIG Welding Guide

Installation & Operation for DC TIG Welding with Lift Arc

DC TIG Welding

Tungsten Electrodes

24 MIG Torch Parts Breakdown

SP135 Spool Gun Torch Parts Breakdown

17VTIG Torch Parts Breakdown

18

19-20

21

22-23

24-25

26-27

28-31

32-33

5-6

7-9

10

11

12

13-14

15-16

17

34-35

36-37

38-39

40-41

42-43

Mig Welding Shooting Guide

TIG Welding Shooting Guide

MMA Welding Trouble Shooting Guide

Machine Spare Parts Breakdown

44-45

46-47

48

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UNIMIG 180 MINIMIG

180 Amp MIG Welder

Welds: Steels, Stainless, Cast Iron, Bronze, Aluminium, Copper

Features

• Step transformer

• 30-180 Amp

• MIG with Gas and Gasless wire function

• 1Kg to 5Kg Spools

• IP21S rating for environmental/safety protection

• Tolerant to variable power supply

• 6 Step voltage switch

• Euro torch connection

• Spool Gun Connection

• Portable

• Thermal overload protection

• Compliant to AS/NZ60947.1 Standard

15 AMP

Technical Data

Power Supply / Phases (V-Ph) 240v - 1 +/- 15%

Duty Cycle @ 40°c as per AS/NZ60974-1 10% @ 180 Amps MIG

No Load Voltage (V)

Output Current Range MIG

Rated Power MIG

I ieff MIG

Power factor

Protection Class

Insulation Class

Wire Diameter Range (mm)

Dimensions Power Source (LxWxH)

Weight Power Source

Warranty

Certification Approval

21.0

35A/16.0V - 180A/23.0V

4.9 KVA

11.7 Amps

0.72

P 21S

H

0.6, 0.8 Solid Wire

0.8, 0.9 Gasless Wire

480x280x345mm

33 Kg

2 years on power source

AS/NZ60974-1

SPG135

Spool Gun Option

UMJRTROLLEY2

Machine Trolley option

Overview

The UNIMIG 180 is a step transformer portable MIG welding machine. The UNIMIG 180 allows you to MIG weld with both Gas

Shielded and Gasless wire. Easy 6 Step adjustment of voltage and seamless adjustment of the wire feed speed makes for easy setting of welding parameters giving good quality welding results. An additional feature is the Spoolgun ready function that allows the simple connection of the optional SPG135 Spoolgun for use with thin or softer wires that don’t have the column strength required to feed through standard MIG torches, such as aluminium wire. A high quality non-commercial machine, it is compact and portable. An optional trolley provides off the floor operation and better manoeuvrability around the workshop. Being 240v single phase gives great portability, it can be run from any 15 Amp power socket providing more flexible use for site and home workshop locations. Suitable for automotive workshops, light metal fabrication, car repairs, home and hobby use. Designed and built to our specification.

Certified to - AS/NZ60974.1 2006

MACHINE PACKAGE: KMM180

SB15 3M Sure Grip MIG Torch, 3M Direct Connect Earth Lead, UNI-FLAME Twin Gauge Argon Regulator,

2M Gas Hose Complete with fittings, 1 x 0.5Kg Spool Solid Wire plus drive roller ,

1 x 0.45Kg Spool Gasless Wire plus drive roller

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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.

• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to earth.

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.

Fire hazard. Welding on closed containers, such as tanks,drums, or pipes, can cause them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

• The welding sparks & spatter may cause fire, therefore remove any flammable materials well away from

the working area. 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 use 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 ear 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.

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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.

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.

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.

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

Note:

Minimum Motor Generator Power Suggested:- 7KVA for MIG180

FRONT PANEL LAYOUT

1. ON/OFF Power Switch

2. Wire Speed Adjustment Knob

3. Thermal Overload Light

4. Voltage Selecion Knob

5. SpoolGun Power Supply Connection

6. Earth Lead

7. Primary Power Supply Connection

8. Standard Mig/Spool Gun Selector Switch

9. Euro Mig Torch Connector (MIG/MAG)

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BACK PANEL LAYOUT

10. Gas Inlet

11. Fan

12. Data Plate

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1

2

3

4

5

6

7

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INTERNAL PANEL LAYOUT

13. DC Positive output terminal

14. DC Negative output terminal

15. Wire feeder mechanism

16. Spool holder assembly

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INSTALLATION & OPERATION

Please install the machine strictly according to the following steps.

The protection class of this machine is IP21S, so avoid using it in rain.

Connection of Input Cables

Primary input cable is supplied with this welding equipment. Connect the primary input cable with power supply of required input voltage. Refer to data plate on machine for Input voltage, IMAX and IEFF.

Installation set up for MIG with Gas for UNI-MIG MIG180

(1) Plug Primay power supply cable into 15amp power outlet.

(2) Select Standard MIG using the Standard/Spool Gun selector switch.

(3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.

IMPORTANT :

When connecting the torch be sure to tighten the connection. A loose connection can

result in the connector arcing and damaging the machine and gun connector.

This damage is not covered under warranty.

(4) Connect earth lead to the workpiece.

(5) Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder.

(6) Connect the weld power cable plug inside the wire feeder to the output socket GAS, and tighten it.

(7) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread.

Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling. Feed the wire into

the wire feeder inlet guide tube through to the drive roller.

(8) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into

the torch receptacle. Check that the drive roller being used complies with the wire diameter, replace the

roller if necessary.

(5)

Connect the gas line to the regulator and connect to the gas cylinder

(3)

Connect Mig torch

IMPORTANT :

When connecting the torch be sure to tighten the connection.

(4)

Connect earth lead to workpiece

(2)

Set Standard/Spoolgun selector switch to Standard

(1)

Plug Primay power supply cable into 15amp power outlet.

(6) Connect weld power lead to GAS as show in picture inside machine

(7) Place wire onto spool holder - (spool retaining nut is left hand thread ) Feed the wire through the inlet guide tube on to the drive roller.

(8) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx

150mm.

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Continued set up for MIG with Gas for UNI-MIG MIG180

(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller, lock the pressure arm into place.

(10) Apply a medium amount of pressure to the drive roller.

(11) Remove the gas nozzle and contact tip from the torch neck,

(12) Press and hold the trigger on the mig torch until wire is visable at the tip holder

(13) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch head and nip it up tightly.

(14) Fit the gas nozzle to the torch head.

(15) Carefully open the gas cylinder valve and set the flow rate to between 5-10 l/min.

(16) Set the welding parameters using the wire feed and voltage control knobs.

(9) Close down the top roller bracket and clip the pressure arm into place.

(10) Apply a medium amount of pressure to the drive roller

(11) Remove the gas nozzle and contact tip from the front end of the mig torch.

(12) Press and hold the trigger on the mig torch until wire is visable at the tip holder.

(13) Fit the correct size contact tip over the wire and fasten tightly into the tip holder.

(14) Fit the gas nozzle to the torch head.

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(15) Carefully open the valve of the gas cylinder, set the flow to 10 l/min

(16) Set welding parameters using the voltage and wire feed controls.

Wire Feed Roller Selection

The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.

Simply put the smoother the wire feed then the better the welding will be.

Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.

Feed rollers are designed to be used for certain types of welding wire and they have different types of grooves machined in them to accommodate the different types of wire. The wire is held in the groove by the top roller of the wire drive unit and is referred to as the pressure roller, pressure is applied by a tension arm that can be adjusted to increase or decrease the pressure as required. The type of wire will determine how much pressure can be applied and what type of drive roller is best suited to obtain optimum wire feed.

Solid Hard Wire - like Steel, Stainless Steel require a drive roller with a V shape groove for optimum grip and drive capability. Solid wires can have more tension applied to the wire from the top pressure roller that holds the wire in the groove and the V shape groove is more suited for this. Solid wires are more forgiving to feed due to their higher cross sectional column strength, they are stiffer and don’t bend so easy.

Soft Wire - like Aluminium requires a U shape groove. Aluminium wire has a lot less column strength, can bend easily and is therefore more difficult to feed. Soft wires can easily buckle at the wire feeder where the wire is fed into inlet guide tube of the torch. The U-shaped roller offers more surface area grip and traction to help feed the softer wire. Softer wires also require less tension from the top pressure roller to avoid deforming the shape of the wire, too much tension will push the wire out of shape and cause it to catch in the contact tip.

Flux Core / Gasless Wire - these wires are made up of a thin metal sheath that has fluxing and metal compounds layered onto it and then rolled into a cylinder to form the finished wire. The wire cannot take too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied.

A knurled drive roller has been developed and it has small serrations in the groove, the serrations grip the wire and assist to drive it without too much pressure from the top roller. The down side to the knurled wire feed roller on flux cored wire is it will slowly over time bit by bit eat away at the surface of the welding wire, and these small pieces will eventually go down into the liner. This will cause clogging in the liner and added friction that will lead to welding wire feed problems. A U groove wire can also be used for flux core wire without the wire particles coming of the wire surface. However it is considered that the knurled roller will give a more positive feed of flux core wire without any deformation of the wire shape.

Top Pressure Roller Top Pressure Roller Top Pressure Roller

V Groove

Wire

Drive Rollers

10mm

Wire

U Groove Knurled Groove

Wire

V Groove Drive Roller - Steel Wire

Part Number Description

0.6-0.8V30/10

0.8-0.9V30/10

Drive Roll V Groove 0.6-0.8mm

Drive Roll V Groove 0.8-0.9mm

U Groove Drive Roller - Soft Wire

Part Number

0.6-0.8U30/10

0.8-0.9U30/10

Description

Drive Roll U Groove 0.6-0.8mm

Drive Roll U Groove 0.8-0.9mm

Knurled Drive Roller - Flux Core Wire

Part Number

0.6-0.8F30/10

0.8-0.9F30/10

Description

Drive Roll V Groove 0.6-0.8mm

Drive Roll V Groove 0.8-0.9mm

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Wire Installation and Set Up Guide

Again the importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.

The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and consistent wire feed. A high percentage of faults with mig welders emanate from poor set up of the wire into the wire feeder. The guide below will assist in the correct setup of your wire feeder.

(1) Remove the spool retaining nut.

(2) Note the tension spring adjuster and spool locating pin.

(3) Fit the wire spool onto the spool holder fitting the locating pin into the location hole on the spool. Replace the spool retaining nut tightly

(4) Snip the wire carefully, be sure to hold the wire to prevent the spool uncoiling. Carefully feed the wire into the inlet guide tube of the wire feed unit.

(5) Feed the wire through the drive roller and into the outlet guide tube of the wire feeder.

(6) Lock down the top pressure roller and apply a medium amount of pressure using the tension adjustment knob

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(7) Check that the wire passes through the centre of the outlet guide tube without touching the sides. Loosen the locking screw and then loosen the outlet guide tube retaining nut too make adjustment if required. Carefully retighten the locking nut and screw to hold the new position.

(8) A simple check for the correct drive tension is to bend the end of the wire over hold it about

100mm from your hand and let it run into your hand, it should coil round in your hand without stopping and slipping at the drive rollers, increase the tension if it slips.

(8) The weight and speed of the wire spool turning creates an inertia that can cause the spool to run on and the wire loop over the side of the spool and tangle. if this happens increase the pressure on the tension spring inside the spool holder assembly using the tension adjustment screw.

Installation set up for MIG with Gasless wire for UNI-MIG MIG180

(1) Plug Primay power supply cable into 15amp power outlet.

(2) Select Standard MIG using the Standard/Spool Gun selector switch.

(3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.

IMPORTANT :

When connecting the torch be sure to tighten the connection. A loose connection can

result in the connector arcing and damaging the machine and gun connector.

This damage is not covered under warranty.

(4) Connect earth lead to the workpiece.

(5) Connect the weld power cable plug inside the wire feeder to the output socket NO GAS, and tighten it.

(6) Fit the correct sized Knurled Drive roller for Gas Less Flux Cored wire

(7) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread.

Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling. Feed the wire into

the wire feeder inlet guide tube through to the drive roller.

(3)

Connect Mig torch

IMPORTANT :

When connecting the torch be sure to tighten the connection.

(2)

Set Standard/Spoolgun selector switch to Standard

(1)

Plug Primay power supply cable into 15amp power outlet.

(4)

Connect earth lead to workpiece

(5) Connect weld power lead to

NO GAS as show in picture inside machine

(7) Fit the correct sized Knurled

Drive roller for Gas Less Flux

Cored wire

(7) Place wire onto spool holder - (spool retaining nut is left hand thread ) Feed the wire through the inlet guide tube on to the drive roller.

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Continued set up for MIG with Gasless wire for UNI-MIG MIG180

(8) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into the torch receptacle. Check that the drive roller being used complies with the wire diameter, replace the roller if necessary.

(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the groove of the bottom drive roller, lock the pressure arm into place.

(10) Apply a medium amount of pressure to the drive roller.

(11) Remove the gas nozzle and contact tip from the torch neck,

(12) Press and hold the trigger on the mig torch until wire is visable at the tip holder

(13) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch head and nip it up tightly.

(14) Fit the gas nozzle to the torch head.

(15) Set the welding parameters using the wire feed and voltage control knobs.

(8) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx 150mm. Use a Knurled

Drive Roller of the correct size

(9) Close down the top roller bracket and clip the pressure arm into place.

(10) Apply a medium amount of pressure to the drive roller

(11) Remove the gas nozzle and contact tip from the front end of the mig torch.

(12) Press and hold the inch wire button to feed the wire down the torch cable through to the torch head.

(13) Fit the correct size contact tip over the wire and fasten tightly into the tip holder.

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(14) Fit the gas nozzle to the torch head.

(15) Set welding parameters using the voltage and wire feed controls.

Mig Torch Liner Installation

(1) Lay the torch out straight on the ground and remove the front end parts

(2) Remove the liner retaining nut.

(3) Carefully pull the liner out of the torch cable assembly

(4) Select the correct new liner and carefully unravel avoiding putting any kinks in the liner, if you kink the liner it will make it no good and will require replacement.

(5) Carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end. Avoid kinking the liner, kinking liner it will make it no good and require replacement.

(6) Fit the liner retaining nut and screw down only 1/2 way

(7) Leaving the torch straight snip the liner approximately 3mm past the end of the torch neck

(8) Place the tip holder over the end of the liner and screw into the torch neck nipping it up tight.

(9) Screw down the liner nut the remaining 1/2 and nip it up tight. This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed.

(1) Remove mig torch front end parts

(2) Remove the liner retaining nut (3) Carefully pull out and completely remove the liner

(4) Carefully unravel the new liner (5) Carefully feed in the new liner down the torch lead all the way to exit the torch neck.

(6) Fit the liner retaining nut and screw only 1/2 way down

(7) Snip the liner off 3mm past the end of the torch neck.

(8) Replace the front end parts (9) Fully screw down the liner retaining nut and nip it up tight.

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Torch & Wire Feed Set Up for Aluminium Wire

(1) Lay the torch out straight on the ground and remove the front end parts

(2) Remove the liner retaining nut.

(3) Carefully pull the liner out of the torch cable assembly

(4) Select a PA or liner, carefully and slowly feed the liner in short forward movements down the cable assembly all the way through and out the torch neck end. Avoid kinking the liner, kinking the liner will ruin it and require replacement.

(5) Leave the liner extending out the end of the torch neck end by 3mm.

(5) Fit the liner retaining nut together with the liner o-ring.

(8) Push the liner firmly into the torch lead and tighten the liner retaining nut.

(9) Install a U groove drive roller of the correct size to match the wire diameter being used.

(1) Remove mig torch front end parts

(2) Remove the liner retaining nut

(3) Carefully pull out and completely remove the liner

(4) Carefully unravel the new liner (5) Carefully feed in the new liner in short forward movements down the torch lead all the way to exit the torch neck. Be careful not to kink the liner

(6) Replace the front end parts

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(7) Fit the liner collet, liner O-ring and liner retaining nut.

(8) Push the liner firmly into the torch lead and tighten the liner retaining nut

(9) Install a U groove drive roller of the correct size for the diameter wire being used.

Continued Torch & Wire Feed Set Up for Aluminium Wire

(10) Remove circlip from guide tube.

(11) Remove the inlet guide tube from the front end machine euro connector using long nose pliers.

(12) Carefully feed the extended PA liner section into the inlet guide tube hole of the machine euro connector

(13) Feed the extended PA liner all the way up and over the drive roller

(14) Tighten the torch euro connection to the machine euro connector

(15) Cut the extended liner with a sharp Stanley knife just in front of the drive roller

(16) Fit an Aluminium contact tip of the correct size to match the diameter of the wire being used

(17) Fit the remaining front end parts to the torch neck ready for welding

(10) Remove circlip from guide tube. (11 Remove the inlet guide tube using long nose pliers.

(12) Carefully feed the PA liner into the inlet guide tube hole of the torch euro receptacle

(13)Take the extended PA liner all the way up and over the drive roller

(14 Tighten and secure the torch euro connector to the machine euro receptacle

(15) Cut the extended PA liner with a sharp Stanley knife just in front of the drive roller

(16) Fit an Aluminium contact tip of the correct size to match the wire diameter being used

(17) Fit the remaining front end parts to the torch neck ready for welding.

19

Installation set up of the Spool Gun for UNI-MIG MIG180

(1) Plug Primay power supply cable into 15amp power outlet.

(2) Switch on the machine,

(3) Select Spool Gun using the Standard/Spool Gun selector switch.

(4) Connect the Spool Gun to the Euro Mig torch connection socket on the front panel, and tighten it.

Connect the Spool Gun control cable to the receptacle and tighten it.

IMPORTANT :

When connecting the torch be sure to tighten the connection. A loose connection can

result in the connector arcing and damaging the machine and gun connector.

This damage is not covered under warranty.

(5) Connect earth lead to the workpiece.

(6) Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder.

(7) Connect weld power lead to GAS Remove wire from the drive unit as show in picture inside

machine

(8) Take the Spool Gun and remove the spool cover.

(9) Place the Wire Spool onto the Spool Holder - Hold and snip the wire from the spool being sure to

hold the wire to prevent rapid uncoiling.

(4) Connect Spool Gun control cable and gun cable connector

IMPORTANT :

When connecting the torch be sure to tighten the connection.

(6) Connect the gas line to the regulator and connect to the gas cylinder

(2) Switch on the machine

(3) Set Standard/Spoolgun selector switch to Spool Gun

(5) Connect earth lead

to the workpiece

(1)

Plug Primay power supply cable into 15amp power outlet.

20

(7)Connect weld power lead to GAS

Remove wire from the drive unit as show in picture inside machine

(8) Remove the spool cover by unscrewing the retaining nut and lifting off the cover

(9) Place a spool of wire onto the Spool holder.

Continued set up of the Spool Gun for UNI-MIG MIG180

(10) Carefully feed the wire through the red guide tube into meet the drive roller. Push down the tension arm adjustment lever to release the drive roll pressure allowing the wire to be guided through the drive rollers into the gun neck.

(11) Replace the spool cover

(12) Remove the gas nozzle and contact tip from the torch neck, Pull the trigger to drive the wire through the neck until it exits the contact tip holder.

(13) Fit the correct sized contact tip by feeding the wire through it, screw the contact tip into the tip holder of the torch neck and nip it up tightly.

(14) Check the drive roll pressure is enough to drive the wire smoothly and adjust the drive roll pressure if required by using the adjusting screw at the top of the torch body. Do not apply too much pressure.

(15) Fit the gas nozzle to the torch head.

(16) Carefully open the gas cylinder valve and set the flow rate to between 8-12 l/min.

(17) Set the welding parameters using the wire feed and voltage control knobs.

(10) Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube. Push down the tension arm lever to release the pressure of the drive roller allowing the wire to be guided through the drive roller into the gun neck.

(11) Replace the Spool Cover.

(12) Remove the gas nozzle and contact tip.

Pull the trigger to drive the wire through the neck until it exits the contact tip holder

(13) Fit the contact tip over the wire and screw it into the tip holder, nip it up tight.

(14) Adjust the drive roll pressure if required by using the adjusting screw at the top of the torch.

(15) Fit the gas nozzle ready for welding.

(16) Carefully open the valve of the gas cylinder, set the flow to 8-12 l/min

(17) Set welding parameters using the voltage and wire feed controls.

21

22

MIG (Metal Inert Gas) Welding

Definition of MIG Welding

-

MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. A constant voltage, direct current power source is most commonly used with MIG welding.

There are four primary methods of metal transfer in MIG welding, called short circuit (also known as dip transfer) globular transfer, spray transfer and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations. To perform MIG welding, the basic necessary equipment is a welding gun, a wire feed unit, a welding power supply, an electrode wire, and a shielding gas supply. Short circuit transfer is the most common used method whereby the wire electrode is fed continuously down the welding torch through to and exiting the contact tip. The wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool. This process is repeated about 100 times per second, making the arc appear constant to the human eye.

MIG Circuit Diagram

5 6

4

1

2

3

1.

Mig Torch -

2.

Work Piece -

3.

Power Source -

4. Wire Feeder - 5. Wire Spool - 6. Gas

MIG (Metal Inert Gas) Welding

Short Circuit Transfer - Short circuit transfer is the most common used method whereby the wire

electrode is fed continuously down the welding torch through to and exiting the contact tip. The wire touches the work piece and causes a short circuit the wire heats up and begins to form a molten bead, the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool. This process is repeated about 100 times per second, making the arc appear constant to the human eye.

short circuit wire heating magnetic field pinches wire

The wire approaches the work piece and touches the work creating a short circuit between the wire and the base metal, because there is no space between the wire and the base metal there is no arc and current flows through the wire

.

The wire cannot support all the current flow, resistance builds up and the wire becomes hot and weak and begins to melt

The current flow creates a magnetic field that begins to pinch the melting wire forming it into droplet droplet separates arc flattens the droplet cycle repeats

The pinch causes the forming droplet to separate and fall towards the now creating weld pool.

An arc is created at the separation of the droplet and the heat and force of the arc flattens out the droplet into the weld pool. The heat of the arc melts the end of the wire slightly as it feeds towards the base metal

The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short circuit and repeat the cycle.

23

Basic MIG Welding

.

Good weld quality and weld profile depends on gun angle, direction of travel, electrode extension

(stick out), travel speed, thickness of base metal, wire feed speed (amperage) and arc voltage.

To follow are some basic guides to assist with your setup.

Gun Position - Travel Direction, Work Angle

Gun position or technique usually refers to how the wire is directed at the base metal, the angle and travel direction chosen. Travel speed and work angle will determine the characteristic of the weld bead profile and degree of weld penetration.

Push Technique - The wire is located at the leading edge of the weld pool and pushed towards

the un-melted work surface. This technique offers a better view of the weld joint and direction of the wire into the weld joint. Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration - useful for welding thin materials. The welds are wider and flatter allowing for minimal clean up / grinding time.

Perpendicular Technique - The wire is fed directly into the weld, this technique is used prima-

rly for automated situations or when conditions make it necessary. The weld profile is generally higher and a deeper penetration is achieved.

Drag Technique - The gun and wire is dragged away from the weld bead. The arc and heat is

concentrated on the weld pool, the base metal receives more heat, deeper melting, more penetration and the weld profile is higher with more build up.

(A) Push Technique

10

°

(B) Gun Perpendicular (C) Drag Technique

10

° travel direction wire pointed ahead of bead travel direction travel direction wire pointed back into bead

24

flat even weld profile light penetration narrower weld profile even penetration narrow higher weld profile more penetration

Travel Angle - Travel angle is the right to left angle relative to the direction of welding. A travel

angle of 5°- 15° is ideal and produces a good level of control over the weld pool. A travel angle greater that 20° will give an unstable arc condition with poor weld metal transfer, less penetration, high levels of spatter, poor gas shield and poor quality finished weld.

Angle 5

°- 15°

Not enough angle

Angle more than 20

° good level of control over the weld pool, even flat weld less control over the weld pool more spatter poor control, unstable arc, less penetration, lots of spatter

Angle to Work - The work angle is the forward back angle of the gun relative to the work piece.

The correct work angle provides good bead shape, prevents undercut, uneven penetration, poor gas shield and poor quality finished weld.

Correct angle

Not enough angle

Too much angle good level of control over the weld pool, even flat weld less control over the weld pool more spatter poor control, unstable arc, less penetration, lots of spatter

Stick Out- Stick out is the length of the unmelted wire protruding from the end of the contact tip.

A constant even stick out of 5-10mm will produce a stable arc, and an even current flow providing good penetration and even fusion. Too short stick out will cause an unstable weld pool, produce spatter and over heat the contact tip. Too long stick out will cause an unstable arc, lack of penetration, lack of fusion and increase spatter.

Normal stick out

Too short

Too long

5-10mm

Even arc, good penetration even fusion, good finish

Unstable arc, spatter, over heat contact tip

Unstable arc, spatter, poor penetration and fusion

25

Travel Speed - Travel speed is the rate that the gun is moved along the weld joint and is usually

measured in mm per minute. Travel speeds can vary depending on conditions and the welders skill and is limited to the welders ability to control the weld pool. Push technique allows faster travel speeds than Drag technique. Gas flow must also correspond with the travel speed, increasing with faster travel speed and decreasing with slower speed. Travel speed needs to match the amperage and will decrease as the material thickness and amperage increase.

Too Fast Travel Speed - A too fast travel speed produces too little heat per mm of travel resulting

in less penetration and reduced weld fusion, the weld bead solidifies very quickly trapping gases inside the weld metal causing porosity. Undercutting of the base metal can also occur and an unfilled groove in the base metal is created when the travel speed is too fast to allow molten metal to flow into the weld crater created by the arc heat.

high narrow bead

Too Fast Travel Speed

undercut porosity spatter lack of fusion lack of joint penetration

Too Slow Travel Speed - A too slow travel speed produces a large weld with lack of penetration

and fusion. The energy from the arc dwells on top of the weld pool rather than penetrating the base metal. This produces a wider weld bead with more deposited weld metal per mm than is required resulting in a weld deposit of poor quality.

large wide bead

Too Slow Travel Speed

lack of fusion porosity cold lap lack of joint penetration

26

Correct Travel Speed - The correct travel speed keeps the arc at the leading edge of the weld

pool allowing the base metal to melt sufficiently to create good penetration, fusion and wetting out of the weld pool producing a weld deposit of good quality.

even shaped bead

Correct Travel Speed

good toe fusion good side wall fusion good penetration

Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless

steel wire for stainless steel, aluminium wires for aluminium and steel wires for steel.

Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger machine, check the recommended welding capability of you machine.

As a guide refer to the “Welding Wire Thickness Chart” below.

WELDING WIRE DIAMETER CHART

RECOMMENDED WIRE DIAMETERS

MIG SOLID WIRE GASLESS FLUX CORED WIRE

MATERIAL

THICKNESS

24 Gauge (.60mm)

0.6mm

0.8mm

0.9mm

1.0mm

0.8mm

0.9mm

1.2mm

22 Gauge (.75mm)

20 Gauge (.90mm)

18 Gauge (1.0mm)

16 Gauge (1.2mm)

14 Gauge (1.9mm)

3.0mm

5.0mm

6.0mm

8.0mm

10.mm

12.0mm

For material thickness of 5.0mm and greater, multi-pass runs or a beveled joint design may be required depending on the amperage capability of your machine.

Gas selection - The purpose of the gas in the MIG process is to protect / shield the wire, the arc

and the molten weld metal from the atmosphere. Most metals when heated to a molten state will react with the air in the atmosphere, without the protection of the shielding gas the weld produced would contain defects like porosity, lack of fusion and slag inclusions. Additionally some of the gas becomes ionised (electrically charged) and helps the current flow smoothly.

The correct gas flow is also very important in protecting the welding zone from the atmosphere.

Too low flow will give inadequate coverage and result in weld defects and unstable arc conditions.

Too high flow can cause air to be drawn into the gas column and contaminate the weld zone.

Use the correct shielding gas. Co2 is good for steel and offers good penetration characteristics, the weld profile is narrower and slightly more raised than the weld profile obtained from Argon Co2 mixed gas. Argon Co2 mix gas offers better weld ability for thin metals and has a wider range of setting tolerance on the machine. Argon 80% Co2 20% is a good all round mix suitable for most applications.

Argon Co2 Co2

Penetration Pattern for Steel

27

Suregrip Series

SB15 MIG TORCH

180A AIR COOLED MIG WELDING TORCH

Rating:180A CO² 150A mixed gas EN60974-7 @ 60% duty cycle. 0.6 to 1.0mm wires

*

Wear parts next page

28

Torch Model

Description

SB Suregrip Ergo Torch Package

Part Number

3 Mt

SB15-3M

4 Mt

SB15-4M

5 Mt

SB15-5M

4

5

6

7

1

2

3

8

9

10

Spare Parts

Part Number

GNS15

SNK15

SNKF15

UB2501/5

UB2519

UG1515

UB1505

UB1521

UB1521-C

UG8015

UB1517-30

UB1517-40

UB1517-50

Description

Shroud Spring

Swan Neck Assembly

Flexible Swan Neck

End Fitting Ring

Hexagonal Fitting

Ergo Handle Location Body

Lock Nut

Cable Terminal

Cable Terminal Cover

Handle Cable Support C/W Ball Joint

Hyperflex Cable Assembly x 3mt

Hyperflex Cable Assembly x 4mt

Hyperflex Cable Assembly x 5mt

15

16

17

18

11

12

13

14

19

20

21

22

Part Number

UG2514

UG2516

UB2517

UB1522

UPA2041

UB1518

UB1541

UB1519PL

UB1523

UC1528

UB1524

UB1525

Description

Ergo Handle Kit C/W Lock Nut

Medium / Large Ergo Trigger

Hanger Hook

Cable Terminal Male

Cable Support

Gun Plug Housing C/W Nut

Gun Plug Screw

Gun Plug Nut

Gun Plug Terminal Female

Hybrid Gun Plug Body C/W Spring Pins

Gun Plug ‘O’ Ring

Liner Nut

Suregrip Series

SB15 MIG TORCH

25.0

Front end consumables

SB15 Contact Tips

Part Number Description

PCT0008-06

PCT0008-08

PCT0008-09

PCT0008-10

PCTAL0008-09

PCTAL0008-10

Contact Tip Steel (0.6mm)

Contact Tip Steel (0.8mm)

Contact Tip Steel (0.9mm)

Contact Tip Steel (1.0mm)

QTY10

QTY10

QTY10

QTY10

Contact Tip Aluminium (0.9mm) QTY10

Contact Tip Aluminium (1.0mm) QTY10

Liners

42.0

53.0

SB15 Tip Holder

Part Number

PCTH15

PGNS15

Description

Contact Tip Holder (Suit SB15)

Shroud Spring

QTY2

QTY2

SB15 Gas Nozzle

Part Number

PGN15CYL

PGN15CON

PGN15TAP

PGN15SPOT

Description

Cylindrical Nozzle

Conical Nozzle

Tapered Nozzle

Spot Nozzle

QTY2

QTY2

QTY2

QTY2

SB15 Liners

Part Number

SLB3M

SLB4M

SLB5M

SLR3M

SLR4M

SLR5M

TLB3M

TLB4M

TLR3M

TLR4M

NKSTL

Description

Blue Steel Liner 3 Metre

Blue Steel Liner 4 Metre

Blue Steel Liner 5 Metre

Red Steel Liner 3 Metre

Red Steel Liner 4 Metre

}

}

Red Steel Liner 5 Metre

Blue Aluminium Liner 3 Metre

Blue Aluminium Liner 4 Metre

Red Aluminium Liner 3 Metre

Red Aluminium Liner 4 Metre

}

}

0.6 - 0.8mm

0.9 - 1.2mm

0.6 - 0.8mm

0.9 - 1.2mm

Neck Spring for Aluminium

These parts are manufactured in China and are offered as replacement parts suitable for “BINZEL®” style torches.

29

SPG135 AMP SPOOL GUN

30

Description

XcelArc Spool Gun SPG135 x 6m

Spare Parts

Part Number

5

6

7

8

1 LGJ2003

2 LMH2001

3

4

LMT2001

LMT2016

LMT2015

LMT2014

LMT2013

LMT2012

9

10

11

12

LMT2011

LGH2011

LGX2016U

LGX2015

13

14

LGX2014

LGX2012

15 LGX2011

16 LGF2111

17

18

LX1040

LMX2011

Description

Part Number

SPG135

Part Number

Trigger

Handle

Spool Cover Total Assembly

Spool Cover Shell

Spool Shaft

Rubber Resistance Bush

Locating Bush

Adjusting Nut

Locking Screw

Drive Roll Cover

Pressure Roll U Groove 0.8-0.9mm

Bearing

Pressure Arm with Shaft

Pressure Arm Spring

Pressure Arm Bolt

Nut

Gear Box Assembly

Inlet Guide

31

32

33

34

27

28

29

30

23

24

25

26

19 LGX2018

20 LGX2019U

21 LZ3603

22 LYFE1001

SEE PAGE 41

SEE PAGE 41

SEE PAGE 41

LYFE1011

35

36

LW0101

LGK2011

LYH1012

LYH1013

LYL1640

ES2001

EH2201

EP3001

LTU2202

LMV0004

Description

Key

DriveRoll U Groove 0.8-0.9mm

Motor

Gun Neck

Gas Nozzle

Contact Tip

Diffuser Tip Holder with Spring

Gun Neck Body

Gas Hose

Conducting Board

Cable Support

Handle Nut

Cable Assembly 4m

Cable Support Spring

Cable Support Cover

Euro Connector Nut

Euro Connector Plug

4 Pin Plug

SPG135 AMP SPOOL GUN

Duty Cycle 30% @ 135Amp

Front end consumables

25.0

42.0

53.0

SPG135 Contact Tips

Part Number Description

PCT0008-06

PCT0008-08

PCT0008-09

PCT0008-10

PCTAL0008-09

PCTAL0008-10

Contact Tip Steel (0.6mm)

Contact Tip Steel (0.8mm)

Contact Tip Steel (0.9mm)

Contact Tip Steel (1.0mm)

Contact Tip Aluminium (0.9mm)

Contact Tip Aluminium (1.0mm)

SPG135 Tip Holder

Part Number Description

PCTH15 Contact Tip Holder

SPG135 Gas Nozzle

Part Number Description

PGN15CYL

PGN15CON

PGN15TAP

Cylindrical Nozzle

Conical Nozzle

Tapered Nozzle

U Groove Drive Roller - Soft Wire

Part Number Description

LGX2019U DriveRoll U Groove 0.8-0.9mm

31

32

MIG WELDING TROUBLE SHOOTING

The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.

1: Excessive Spatter

Possible Reason Suggested Remedy

Wire feed speed set too high Select lower wire feed speed

Voltage too high

Wrong polarity set

Stick out too long

Contaminated base metal

Contaminated mig wire

Select a lower voltage setting select the correct polarity for the wire being used - see machine setup guide

Bring the torch closer to the work

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal

Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc

Inadequate gas flow or too much gas flow

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 6-12 l/min flow rate. Check hoses and fittings for holes, leaks etc

Protect the welding zone from wind and drafts

2: Porosity - small cavities or holes resulting from gas pockets in weld metal.

Possible Reason

Wrong gas

Inadequate gas flow or too much gas flow

Moisture on the base metal

Contaminated base metal

Contaminated mig wire

Gas nozzle clogged with spatter, worn or out of shape

Missing or damaged gas diffuser

Mig torch euro connect o-ring missing or damaged

Suggested Remedy

Check that the correct gas is being used

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 10 - 15 l/min flow rate. Check hoses and fittings for holes, leaks etc.

Protect the welding zone from wind and drafts

Remove all moisture from base metal before welding

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal

Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc

Clean or replace the gas nozzle

Replace the gas diffuser check and replace the o-ring

4: Wire stubbing during welding

Possible Reason Suggested Remedy

Holding the torch too far away

Welding voltage set too low

Wire Speed set too high

Bring the torch closer to the work and maintain stick out of 5-10mm

Increase the voltage

Decrease the wire feed speed

5: Lack of Fusion − failure of weld metal to fuse completely with base metal or a proceeding weld bead.

Possible Reason Suggested Remedy

Contaminated base metal

Not enough heat input

Improper welding technique

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal

Select a higher voltage range and /or adjust the wire speed to suit

Keep the arc at the leading edge of the weld pool.

Gun angle to work should be between 5 & 15

°

Direct the arc at the weld joint

Adjust work angle or widen groove to access bottom during welding

Momentarily hold arc on side walls if using weaving technique

5: Excessive Penetration − weld metal melting through base metal

Possible Reason Suggested Remedy

Too much heat Select a lower voltage range and /or adjust the wire speed to suit

Increase travel speed

6: Lack of Penetration − shallow fusion between weld metal and base metal

Poor in incorrect joint preparation Material too thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc characteristics

Keep the arc at the leading edge of the weld pool and maintain the gun angle at

5 & 15

° keeping the stick out between 5-10mm

Not enough heat input

Contaminated base metal

Select a higher voltage range and /or adjust the wire speed to suit

Reduce travel speed

Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.

MIG WIRE FEED TROUBLE SHOOTING

The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.

1: No wire feed

Possible Reason Suggested Remedy

Wrong mode selected Check that the TIG/MMA/MIG selector switch set to MIG position

Wrong torch selector switch Check that the STANDARD/SPOOLGUN selector switch is set to STANDARD position for MIG welding and SPOOLGUN when using the Spoolgun

2: Inconsistent / interrupted wire feed

Possible Reason Suggested Remedy

Adjusting wrong dial

Wrong polarity selected

Incorrect wire speed setting

Voltage setting incorrect

Mig torch lead too long

Be sure to adjust the WIRE FEED and VOLTAGE dials for MIG welding.

The AMPERAGE dial is for STICK and TIG welding mode

Select the correct polarity for the wire being used - see machine setup guide

Adjust the wire feed speed

Adjust the voltage setting

Small diameter wires and soft wires like aluminium don’t feed well through long torch leads - replace the torch with a lesser length torch

Remove the kink, reduce the angle or bend Mig torch lead kinked or too sharp angle being held

Contact tip worn, wrong size, wrong type

Replace the tip with correct size and type

Liner worn or clogged (the most common causes of bad feeding)

Wrong size liner

Blocked or worn inlet guide tube

Try to clear the liner by blowing out with compressed air as a temporary cure, it is recommended to replace the liner

Install the correct size liner

Clear or replace the inlet guide tube

Wire misaligned in drive roller groove Locate the wire into the groove of the drive roller

Incorrect drive roller size

Wrong type of drive roller selected

Worn drive rollers

Drive roller pressure too high

Fit the correct size drive roller eg; 0.8mm wire requires 0.8mm drive roller

Fit the correct type roller (e.g. knurled rollers needed for flux cored wires)

Replace the drive rollers

Can flatten the wire electrode causing it to lodge in the contact tip - reduce the drive roller pressure

Too much tension on wire spool hub Reduce the spool hub brake tension

Wire crossed over on the spool or tangled

Remove the spool untangle the wire or replace the wire

Contaminated mig wire Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc

33

34

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.

2. Slowly open the cylinder valve.

3. Set the flow rate on the regulator to approximately 8-10 l/min.

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.

Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the

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

minimum of 15 minutes.

5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying

with soapy water, bubbles will appear at the leakage point.

6. Tighten clamps or fittings to eliminate gas leakage.

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 will not be liable or responsible for the loss of any gas.

©

Welding Guns Of Australia PTY LTD 2012

36

Welding Guns Of Australia PTY LTD Pty Ltd

ABN: 14 001 804 422

PO Box 3033, Lansvale NSW 2166, AUSTRALIA

112 Christina Rd, Villawood, NSW 2163

Phone:

Fax:

(02) 9780 4200

(02) 9780 4244

Email: [email protected] / Web: www.unimig.com.au

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