operating manual

operating manual

OPERATING MANUAL

MIG-TIG-STICK BUILT-IN

KUMJR250SWF

KUMJR350SWF

MIG-TIG-STICK BUILT-IN

KUMJR500SWF

TECHNOLOGY

ADVANTAGE

TECHNOLOGY

TECHNOLOGY

MIG-TIG-STICK

TECHNOLOGY

MIG-TIG-STICK

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

before the installation and operation of this equipment.

©

Welding Guns Of Australia PTY LTD 2012

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 guaranteeing you electrical safety and performance.

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• 3 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

CONTENTS PAGE

Warranty 2

Safety

Caution, Maintenance and Trouble Shooting

Technical Data, Product Information

Machine Layout Pictogram

Machine Assembly

MMA (Stick) Welding)

Installation & Operation for MIG Welding

Wire Feed Drive Rollers

Wire Installation and Wire Feeder Set Up

MIG Torch Liner Installation

Torch and Wire Feeder Setup for Aluminium Wire

MIG Welding Guide

DC TIG Welding

TIG Welding Guide

MIG Torch Parts Breakdown

TIG Torch Parts Breakdown

Spare Parts Breakdown

Trouble Shooting Guide

Warranty terms

18

19

20-21

22-27

28-29

30--33

34-39

40-41

8

9

4-5

6-7

10

11-13

14-16

17

42-47

48-52

53-55

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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.

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.

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• 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 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 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.

ATTENTION! - CHECK FOR GAS LEAKAGE

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.

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MIG/TIG/MMA DC Welding Machines

Separate Wire Feeder System

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

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KUMJR250/350/500SWF

Features

• Latest IGBT Inverter Technology

• MIG/Mag with Gas and Gasless wire function

• Stick Electrode (MMA) Function

• DC TIG welding with scratch start

• Voltage & Wire Feed Controls at Wire Feeder

• Variable Inductance & Burn Back Controls

• Adjustable Crater Current Control

• Gas Check / Inch Wire

• 2T/4T Trigger Function

• Separate 4 Roll Geared Wire Feeder

• LED Digital Display

• Euro MIG torch connection

• 10m Interconnecting Cables

• Excellent arc stability for MIG/TIG/MMA welding

Technical Data

Power Supply / Phases (V-Ph)

Duty [email protected]°c to AS/NZ60974

Output Current Range MIG

Output Current Range MMA

Rated Power MIG

I Max MIG

MMA

I ieff MIG

MMA

Wire Feeder Type

Protection Class

Insulation Class

Dimensions Power Source (LxWxH)

Weight Power Source

Dimensions Wire Feeder (LxWxH)

Weight Wire Feeder

Length of Interconnecting Cable

Warranty

MIG500SWF

AC415V±15%~50/60Hz

60% @ 500 Amps MIG

60% @ 500 Amps MMA

50A/16.5V - 500A/39.0V

20A/20.8V - 500A/40.0V

24.7 KVA

34.0 Amps

35.0 Amps

26.0 Amps

27.0Amps

Gear Driven 4 Roll

IP 21S

F

595x280x440mm

40.6 Kg

630x235x420mm

14 Kg

10 m

3 years on machine

MIG350SWF

415V 3 Phase

60% @ 350 Amps MIG

60% @ 350 Amps MIG

50A/16.5V - 350A/31.5V

20A/20.8V - 350A/34.0V

11.9 KVA

31.0 Amps

34.0 Amps

24.0 Amps

26.0Amps

Gear Driven 4 Roll

IP 21S

F

595x280x440mm

38 Kg

630x235x420mm

14 Kg

10 m

3 years on machine

MIG250SWF

240V 1 Phase

35% @ 250Amps MIG

35% @ 225Amps MMA

30A/15.5V - 250/26.5V

10A/20.4V - 250/30.0V

10.8 KVA

45.0 Amps

51.0 Amps

26.6 Amps

28.0 Amps

Gear Driven 4 Roll

IP 21S

F

595x280x440mm

38 Kg

630x235x420mm

14 Kg

10 m

3 years on machine

Overview

The MIG Separate Wire Feeder range are inverter-based MIG welding machines with added MMA and TIG function. These are industrial machine equiped with a separate 4 roll gear driven wire feeder and 10m interconnecting cables. The MIG function allows you to weld with Solid wires, Fluxcored Gas and Gasless wires. Adjustment of Voltage & Wire Feed at the wire feeder make for easy setting of welding parameters and give the convenience of remote adjustment from the power source. The Crater Current setting delivers perfect finishing of the weld, the electronic inductance offers fine adjustment of the arc characteristic and burn back adjustment leaves the wire stick out ready for the next weld. Wire inch and Gas Check provides set up of the wire feed and gas setting with wastage of wire or gas. Added MMA welding capability delivers easy and high quality welding using electrodes, including cast Iron, stainless and low hydrogen. Connection of the 17V or 26V TIG torch provides quality DC TIG (scratch start) welding of steel, stainless steel and copper. Ideal for heavy and structural welding applications through to general engineers, maintenance workshops, light engineering, rural workshops and home workshops. Designed and built to our specification. Certified to - AS/NZ60974.1

MACHINE PACKAGE: KUMJR250SWF

UNI-MIG 250SWF Multifunction Welding Inverter / SB24 4M Sure Grip MIG torch with Euro connector, 10M ARC lead set

35-50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator 2M Gas Hose Complete with fittings,

10M Inter connection Cables, Trolley.

MACHINE PACKAGE: KUMJR350SWF

UNI-MIG 350SWF Multifunction Welding Inverter / SB36 4M Sure Grip MIG torch with Euro connector, 10M ARC lead set

35-50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator 2M Gas Hose Complete with fittings,

10M Inter connection Cables, Trolley.

MACHINE PACKAGE: KUMJR500SWF

UNI-MIG 500SWF Multifunction Welding Inverter / TWC5-15FTE Sure Grip MIG torch with Euro connector, 10 ARC lead set

35-50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator 2M Gas Hose Complete with fittings,

10M Inter connection Cables, Trolley.

Machine Layout Description

Power Source Front Panel Layout

1. Amperage Meter

2. Mains Power LED

3. Thermal Overload LED

4. Over Current LED

5. Voltage Meter

6. 2T - 4T Trigger Switch

7. Gas Check Switch

8. MIG/MMA/TIG Mode Selector Switch

9. Crater Current Control

10. Crater Voltage Control

11. Inductance Control

12. Amperage Control (MMA/TIG)

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Power Source Rear Panel Layout

13. Primary Power Switch

14. Wire Feeder Control Cable Receptacle

15. Wire Feeder Weld Power Cable Receptacle

16. Burn Back Control

17. Primary Input Cable

18. Data Plate

19. Fan

WIRE FEEDER LAYOUT

20. Voltage Control

21. Wire Speed Control

22. Inch Wire Feed Button

23. Euro Torch Connector

24. Gas Connection

25. Torch Holder

26. Control Cable Receptacle

27. Weld Power Cable Receptacle

28. Interface Cable Assembly Clamp

29. Spool Cover

30. Wire Drive Unit

31. Carry Handle

22

21

25 24

1

2 3 4

5

16

17

18

9 10 11 12

13

14

19

15

20

31

8

26

27 28

23

29

30

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MACHINE ASSEMBLY

Please install the machine according to the following steps.

(1) Unpack the trolley and locate the assembly parts inside the trolley drawer

(2) Connect and fasten down the retaining side panels onto the trolley using the screws provided.

(3) Mount power source to the trolley, lock in place by fastening to the mounting brackets front and back.Assemble the handle and wire feeder mounting assembly.

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(4) Place the wire feeder by locating the mounting hole on the wire feeder base over the locating pin on the wire feeder mounting bracket.

(5) Connect the control cable assembly and fasten firmly in place with the cable retaining bracket.

(6) Connect the other end of the control cable assembly to the rear of the power source.

Installation set up for MMA (Stick) Welding with MIG250/350/500 SWF Welder

(1) Select the MMA function with the TIG/MMA/MIG selector switch.

(2) Connection of Output Cables

Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DC+ polarity. However various electrodes require a different polarity for optimum results and careful attention should be paid to the polarity, refer to the electrode manufacturers information for the correct polarity.

DC+ Electrode connected to output socket. DC- Electrode connected to output socket.

(3) Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer.

(1) Set TIG/MMA/MIG selector switch to MMA

(2) Connect the electrode lead to

(2) Connect earth lead

to

(3) Set the welding current using the amperage control dial.

(4) Place the electrode into the electrode holder and clamp TIGht.

(5) Strike the electrode against the workpiece to create an arc and hold the electrode steady to 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) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal below.

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MMA (Manual Metal Arc) Welding

One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination. The electrode core itself acts as filler material the residue from the flux that forms a slag covering over the weld metal must be chipped away after welding.

+

Power Source

Core wire

Flux coating

Gas shield from flux melt

Arc with core wire melt

Flux residue forms slag cover

Weld metal

Core wire

Flux coating

Base metal

Protective gas

Arc

Slag

Weld pool

• The arc is initiated by momentarily touching the electrode to the base metal.

• The heat of the arc melts the surface of the base metal to form a molten pool

at the end of the electrode.

• The melted electrode metal is transferred across the arc into the molten pool

and becomes the deposited weld metal.

• The deposit is covered and protected by a slag which comes from the

electrode coating.

• The arc and the immediate area are enveloped by an atmosphere of

protective gas

Manual metal arc ( stick) electrodes have a solid metal wire core and a flux coating. These electrodes are identified by the wire diameter and by a series of letters and numbers. The letters and numbers identify the metal alloy and the intended use of the electrode.

The Metal Wire Core works as conductor of the current that maintains the arc.

The core wire melts and is deposited into the welding pool.

The covering on a shielded metal arc welding electrode is called Flux.

The flux on the electrode performs many different functions.

These include:

● producing a protective gas around the weld area

● providing fluxing elements and deoxidizers

● creating a protective slag coating over the weld as it cools

● establishing arc characteristics

● adding alloying elements.

Covered electrodes serve many purposes in addition to adding filler metal to the molten pool. These additional functions are provided mainly by the covering on the electrode.

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 Maximum Recommended of Material 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 base on using a general purpose type 6013 electrode.

Welding Current (Amperage)

Electrode Size

ø mm

2.5mm

3.2mm

4.0mm

5.0mm

Current Range

(Amps)

60 - 95

100 - 130

130 - 165

165 - 260

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, penetration is poor and beads with a distinct rounded profile will be deposited. Too high current is accompanied by overheating of the electrode resulting 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.

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.

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Installation set up for MIG Welding with MIG250/350/500 SWF Welder

(1) Select the MIG function with the MMA/MIG selector switch.

(2) Insert the earth cable plug into the required polarity and tighten - negative for gas shielded wires

positive for gas less wires. The weld power cable goes into the opposing negative or positive socket.

With Separate Wire Feeder machines the positive MIG socket is located at the rear of the power source

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

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

(5) Fit the correct type and size drive rollers to the wire feed drive unit

(6) Place the Wire Spool onto the Spool Holder

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.

(7) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx 150mm

.

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

(3) Connect MIG torch

(1) Set TIG/MMA/MIG selector switch to MIG

(2) Connect earth lead to the negative output terminal and tighten

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(8) Fit the correct type and size of drive rollers.

V Groove for Hard Wires. Knurled for Flux

Cored. U Groove for Aluminium.

(6) Place wire onto spool holder. Feed the wire through the inlet guide tube into the drive roller.

(7) Feed wire over the drive roller into the outlet guide tube, Push the wire through approx 150mm.

Continued set up of the MIG250/350/500 SWF Welder for MIG Welding

(8) 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 rollers, lock the pressure arm into place. Apply a medium amount of pressure to the drive roller.

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

(10) Press and hold the inch button to feed the wire through to the torch neck, release the inch button when the wire exits the torch neck.

(11) 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.

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

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

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

(15) Set the inductance control to get the desired arc characteristic, Hard for a TIGht narrow arc and soft for a wider softer arc, setting it half way is a good starting point.

(16) Using the Burn Back control set the amount of wire to ‘burn back’ after you release the torch trigger. This prevents the wire becoming stuck in the weld pool when finishing the weld.

(8) Close down the top roller bracket and clip the pressure arm into place. Apply a medium amount of pressure to the drive roller

(9) Remove the gas nozzle and contact tip from the front end of the MIG torch.

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

(11) Fit the correct size contact tip over the wire and fasten TIGhtly into the tip holder.

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

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

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

(15) Set the inductance control on the front panel of the power source to get the desired arc characteristic. Less inductance for a TIGht hard arc and more for a soft wider arc.

(16 Adjust the burn back control to prevent the wire sticking in the weld pool. Burn back control is located on the rear panel of the power source

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16

Continued set up of the MIG250/350/500 SWF Welder for MIG Welding

Crater Current Control Setting:

The purpose of the crater control setting is to be able to reduce of eliminate the crater that is left behind at the end of the weld.

The Crater Current Control only works in 4T Trigger Function. The Crater Current Controls effectively allow you to set an independent setting for wire feed speed and voltage to be used at the end of the weld,

(typically set at lower values than the main welding wire feed and voltage) to allow filling in of the crater at the finishing of the weld. Typically the values are set at around 60% of the main welding current values.

In 4T Mode

The following steps explain how to set the and use the Crater Current Control.

(1) Select 4T on the Trigger Select Mode switch

(2) Set a value using the Crater Current dial on the front panel of the power source.

This dial controls the amount of wire feed speed delivered at the finish of the weld.

(3) Set a value using the Crater Voltage dial on the front panel of the power source.

This dial controls the amount of voltage applied at the finish of the weld.

Test the Crater Current settings by welding.

IMPORTANT: Remember to pay attention to the 4T trigger selection. This means that pulling the torch switch (1T) will start the welding cycle, releasing the trigger switch (2T) will allow you to continue welding without holding down the trigger, pulling the switch (3T) again and holding it down will allow the Crater

Current settings to step in and allow you fill in the weld crater, releasing the trigger (4T) will end the welding. (This completes 4 actions of the trigger and this is why it is referred to as 4T)

If the Crater Current setting is too much, ie too hot and not filling the crater then reduce the setting and test again. If the Crater Current setting is not hot enough and the welding is too cold with stabbing and spatter, then increase the settings and test again.

(1) Select 4T trigger function using the trigger control function switch located on the front panel of the power source.

(2) Set a value using the Crater Current control dial on the front panel of the power source

(3) Set a value using the Crater Voltage dial on the front panel of the power source.

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

22mm

Wire

U Groove Knurled Groove

Wire

V Groove Drive Roller - Steel Wire

Part Number Description

0.6-0.8V30/22

0.8-1.0V30/22

0.9-1.2V30/22

1.0-1.2V30/22

1.2-1.6V30/22

Drive Roll V Groove 0.6-0.8mm

Drive Roll V Groove 0.8-1.0mm

Drive Roll V Groove 0.9-1.2mm

Drive Roll V Groove 1.0-1.2mm

Drive Roll V Groove 1.2-1.6mm

U Groove Drive Roller - Soft Wire

Part Number Description

0.8-1.0U30/22

0.9-1.0U30/22

0.9-1.2U30/22

1.0-1.2U30/22

Drive Roll U Groove 1.0-1.2mm

Drive Roll U Groove 0.9-1.0mm

Drive Roll U Groove 0.9-1.2mm

Drive Roll U Groove 1.0-1.2mm

Knurled Drive Roller - Flux Core Wire

Part Number Description

0.6-0.8F30/22

0.8-0.9F30/22

0.9-1.2F30/22

1.2-1.6F30/22

Drive Roll Knurled 0.6-0.9mm

Drive Roll Knurled 0.8-0.9mm

Drive Roll Knurled 0.9-1.2mm

Drive Roll Knurled 1.2-1.6mm

17

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

18

(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.

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.

19

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

20

(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 U groove drive rollers of the correct size for the diameter wire being used.

Continued Torch & Wire Feed Set Up for Aluminium Wire

(10) Loosen off the inlet guide tube retaining screw Push the inlet guide tube forward with a pair of long nose pliers.

(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

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

(10) Loosen off the inlet guide tube retaining screw Push the inlet guide tube forward with a pair of long nose pliers.

(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) Feed the wire through the drive rollers, apply light pressure on the drive rollers and feed the wire through as shown on Page

14-15

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

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

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

MATERIAL

THICKNESS

0.6mm

MIG SOLID WIRE

0.8mm

0.9mm

1.0mm

GASLESS FLUX CORED WIRE

0.8mm

0.9mm

1.2mm

24 Gauge (.60mm)

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

Installation and set up for DC TIG welding for MIG250/350/500 SWF Welder

(1) Switch on the machine, select the MMA function with the MMA/MIG 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.

(5) Carefully open the valve of the gas cylinder, set the flow to 6-10 l/min

(6)

Set the welding current using the amperage control dial

(1) Set MMA/MIG selector switch to MMA

(2) Connect the TIG torch cable connector to

(3) Connect earth lead

to

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

(5) Carefully open the valve of the gas cylinder, set the flow to 6-10 l/min

(6) Set the welding current using the amperage control dial

28

Caution:

Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding voltage is present and can cause arcing or flash.

LIFT ARC DC TIG Operation for MIG250/350/500 SWF Welder

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.

(5) 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.

(6) Turn on the Gas Valve located on the TIG torch handle.

(7) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from the

work piece.

(8) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work

piece.

(9) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc.

5) Assemble front end parts of the TIG torch, fitting a sharpened tungsten suitable for DC welding.

(6) Turn on the Gas Valve (7) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from the work piece.

(8) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work piece.

(9) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to create the arc.

Caution:

Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding voltage is present and can cause arcing or flash.

29

DC TIG Welding

30%

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 ).

70% power source argon gas 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. low current

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

(amps) are necessary to melt the material.

high 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.

30

gas flow tungsten off the work tungsten touches the work arc ignition

Lay the nozzle on the job without the tungsten touching the work

Rock the torch sideways so that the tungsten touches the work & hold momentarily

Rock the torch back in the opposite direction, the arc will ignite as the tungsten lifts off the work 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.

Travel direction

Form a weld pool

Retract the filler wire

Angle torch

75° gas shield

Move the torch forward to the front of the weld pool

15°

Add TIG filler wire

Repeat the process

31

32

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

1.0mm

1.6mm

2.4mm

3.2mm

4.0mm

15 - 80

70 -150

150- 250

250 - 400

400 - 500

AC Current Amps

Un-Balanced Wave

0.8% Zirconiated

15 - 80

70 - 150

140 - 235

225 - 325

300 - 400

AC Current Amps

Balanced Wave

0.8% Zirconiated

20 - 60

60 - 120

100 - 180

160 - 250

200 - 320

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 whee l

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 flat tip pointed 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

• Have better weld penetration

• Have a narrower arc shape

• Can handle more amperage without eroding. flat spot diameter

Sharper electrodes with smaller included angle provide:

• Offer less arc weld

• Have a wider arc

• Have a more consistent arc included angle

The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration increases and bead width decreases.

Tungsten

Diameter

1.0mm

1.6mm

1.6mm

2.4mm

2.4mm

3.2mm

3.2mm

Diameter at the Tip - mm

.250

.500

.800

.800

1.100

1.100

1.500

Constant Included

Angle - Degrees

20

25

30

35

45

60

90

Current Range

Amps

05 - 30

08 - 50

10 - 70

12 - 90

15 - 150

20 - 200

25 - 250

Current Range

Pulsed Amps

05 - 60

05 - 100

10 - 140

12 - 180

15 - 250

20 - 300

25 - 350

33

Suregrip Series

SB24 MIG TORCH

SUIT - KUMJR250SWF

250A AIR COOLED MIG WELDING TORCH

Rating:250A CO² 220A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires

34

Torch Model

Description

SB Suregrip Ergo Torch Package

Part Number

3 Mt

SB24-3M

4 Mt

SB24-4M

5 Mt

SB24-5M

5

6

7

1

2

3

4

8

9

Spare Parts

Part Number

SNK24

UG1515

UB1505

UG8015

UB1521

UB1521-C

UB2603-30

UB2603-40

UB2603-50

UG2514

UG2516

Description

Swan Neck Assembly

Ergo Handle Location Body

Lock Nut

Part Number

10 UB2517

11

12

UB1522

UPA2041

Handle Cable Support C/W Ball Joint 13 UB1518

Cable Terminal

Cable Terminal Cover

Hyperflex Cable Assembly x 3mt

Hyperflex Cable Assembly x 4mt

Hyperflex Cable Assembly x 5mt

Ergo Handle Kit C/W Lock Nut

Medium / Large Ergo Trigger

14 UB1541

15 UB1519/S

16 UB1523

17 UC1528

18 UB1524

19 UB1525

Description

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

SB24 MIG TORCH

28.0

Suregrip Series

Front end consumables

SB24 Contact Tips

Part Number Description

PCT0009-06

PCT0009-08

PCT0009-09

PCT0009-10

PCT0009-12

PCT0009-16

PCTZR009-09

PCTZR009-12

PCTAL0009-09

PCTAL0009-10

PCTAL0009-12

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 Steel (1.2mm)

Contact Tip Steel (1.6mm)

Contact Tip Steel Long Life (0.9mm) QTY10

Contact Tip Steel Long Life (1.2mm) QTY10

Contact Tip Aluminium (0.9mm)

Contact Tip Aluminium (1.0mm)

QTY10

QTY10

QTY10

QTY10

Contact Tip Aluminium (1.2mm) QTY10

SB24 Tip Holder

Part Number

PCTH24

Description

Contact Tip Holder

QTY2

26.0

SB24 Gas Diffuser

Part Number

Description

PCGD24 Gas Diffuser (Ceramic)

QTY2

25.0

Liners

63.5

SB24 Gas Nozzle

Part Number Description

PGN24CYL

PGN24CON

PGN24TAP

PGN24SPOT

Cylindrical Nozzle

Conical Nozzle

Tapered Nozzle

Spot Nozzle

QTY2

QTY2

QTY2

QTY2

SB24 Liners

Part Number

SLB3M

SLB4M

SLB5M

SLR3M

SLR4M

SLR5M

TLB3M

TLB4M

TLR3M

TLR4M

TLY3M

TLY4M

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

}

0.6 - 0.9mm

1.0 - 1.2mm

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

}

Yellow Aluminium Liner 3 Metre

Yellow Aluminium Liner 4 Metre

}

0.6 - 0.9mm

1.0 - 1.2mm

1.2 - 1.6mm

Neck Spring for Aluminium

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

35

Suregrip Series

SB36 MIG TORCH

SUIT - KUMJR350SWF

300A AIR COOLED MIG WELDING TORCH

Rating:300A CO² 270A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires

1

36

Torch Model

Description

SB36 Suregrip Ergo Torch Package

Part Number

3 Mt

SB36-3M

4 Mt

SB36-4M

5 Mt

SB36-5M

5

6

7

1

2

3

4

8

Spare Parts

Part Number

SNK36

UG1515

UB1505

UG8016

UB1521

UB1521-C

UB3609-30

UB3609-40

UB3609-50

8UG2514

Description

Swan Neck Assembly

Ergo Handle Location Body

Lock Nut

Handle Cable Support C/W Ball Joint

Cable Terminal

Cable Terminal Cover

Hyperflex Cable Assembly x 3mt

Hyperflex Cable Assembly x 4mt

Hyperflex Cable Assembly x 5mt

Ergo Handle Kit C/W Lock Nut

9

Part Number

UG2516

10 UB2517

11 UB1522

12 UC8026

13 UB1518L

14 UB1526

15 UB1519/S

16 UB1523

17 UB1528

18 UB1524

19 UB1525

Description

Medium / Large Ergo Trigger

Hanger Hook

Cable Terminal Male

Housing Spring

Gun Plug Housing C/W Nut

Gun Plug Screw

Gun Plug Nut

Gun Plug Terminal Female

Gun Plug Body C/W Spring Pins

Gun Plug ‘O’ Ring

Liner Nut

SB36 MIG TORCH

Front end consumables

Liners

28.0

30.0

28.0

32.5

83.2

Suregrip Series

SB36 Contact Tips M6

Part Number

Description

PCT0009-06

PCT0009-08

PCT0009-09

PCT0009-10

PCT0009-12

PCT0009-16

PCTZR009-09

PCTZR009-12

PCTAL0009-09

PCTAL0009-10

PCTAL0009-12

PCT0005-08

PCT0005-09

PCT0005-10

PCT0005-12

PCT0005-16

PCTAL0005-08

PCTAL0005-09

PCTAL0005-10

PCTAL0005-12

PCTAL0005-16

Contact Tip Steel (0.6mm)

Contact Tip Steel (0.8mm)

Contact Tip Steel (0.9mm)

Contact Tip Steel (1.0mm)

Contact Tip Steel (1.2mm)

Contact Tip Steel (1.6mm)

Contact Tip Steel Long Life (0.9mm)

Contact Tip Steel Long Life (1.2mm)

Contact Tip Aluminium (0.9mm)

Contact Tip Aluminium (1.0mm)

Contact Tip Aluminium (1.2mm)

Contact Tip Steel M8 (0.8mm)

Contact Tip Steel M8 (0.9mm)

Contact Tip Steel M8 (1.0mm)

Contact Tip Steel M8 (1.2mm)

Contact Tip Steel M8 (1.6mm)

Contact Tip Aluminium M8 (0.8mm)

Contact Tip Aluminium M8 (0.9mm)

Contact Tip Aluminium M8 (1.0mm)

Contact Tip Aluminium M8 (1.2mm)

Contact Tip Aluminium M8 (1.6mm)

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

QTY10

SB36 Tip Holder M8

Part Number Description

PCTH36M6S Contact Tip Holder M6 (Short)

PCTH36M8S Contact Tip Holder M8 (Short)

SB36 Tip Holder M6

Part Number Description

PCTH36M6L

PCTH36M8L

Contact Tip Holder M6 (Long)

Contact Tip Holder M8 (Long)

QTY2

QTY2

QTY2

QTY2

SB36 Gas Diffuser

Part Number Description

PCGD36 Gas Diffuser QTY2

SB36 Gas Nozzle

Part Number

PGN36CYL

PGN36CON

PGN36TAP

Description

Cylindrical Nozzle

Conical Nozzle

Tapered Nozzle

SB36 Liners

Part Number

SLB3M

SLB4M

SLB5M

SLR3M

SLR4M

SLR5M

SLY3M

SLY4M

SLY5M

TLB3M

TLB4M

TLR3M

TLR4M

TLY3M

TLY4M

NKSTL

Description

Blue Steel Liner 3 Metre

Blue Steel Liner 4 Metre

}

0.6 - 0.9mm

Blue Steel Liner 5 Metre

Red Steel Liner 3 Metre

Red Steel Liner 4 Metre

Red Steel Liner 5 Metre

}

Yellow Steel Liner 3 Metre

Yellow Steel Liner 4 Metre

}

1.0 - 1.2mm

1.2 - 1.6mm

QTY2

QTY2

QTY2

Yellow Steel Liner 5 Metre

Blue Aluminium Liner 3 Metre

Blue Aluminium Liner 4 Metre

Red Aluminium Liner 3 Metre

Red Aluminium Liner 4 Metre

Yellow Aluminium Liner 3 Metre

Neck Spring for Aluminium

}

}

Yellow Aluminium Liner 4 Metre

}

0.6 - 0.9mm

1.0 - 1.2mm

1.2 - 1.6mm

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

37

Suregrip Series

TWC5 STYLE MIG TORCH

SUIT - KUMJR500SWF

TWC5 Air Cooled MIG Welding Torch

Rating: 500A CO2 4000A mixed gas, EN60974-7 @ 60% duty cycle. 0.9 to 2.8mm wires

5 4

2

1

21

3

7

10

6

9

11

9

13 14

15 16

18

12

20

19

17

38

Torch Model

Description

Welding Torch c/w Euro Fitting

5

6

2

3

4

1

Spare Parts

Part Number Description

WGA65J60

WGA65A45

WGA65J45

WGA65A60

WGA65J60

U104

U244T

U134-14

UBE8018

U500-10E

U500-12E

U500-15E

U500-10

U500-12

U500-15

Metal Jacket Neck Assembly

Swan Neck 45 Degree

Heavy Duty Swan Neck 45 Degree

Swan Neck 60 Degree

Heavy Duty Swan Neck 60 Degree

Connection Block C/W Spacer

Control Wire Terminals

Cable Hose Clamp

Spring Cable Support & Ball Joint

Hyperflex C/Assy X 10ft Euro

Hyperflex C/Assy X 12ft Euro

Hyperflex C/Assy X 15ft Euro

Hyperflex C/Assy X 10ft

Hyperflex C/Assy X 12ft

Hyperflex C/Assy X 15ft

Part Number

12ft

TWC5-12FTE

15ft

TWC5-15FTE

17ft

TWC5-17FTE

7

8

9

Part Number

Description

UP85

U94R

U154

10 U122FMS

Handle With Hook & Screw

Grey Trigger Switch

Hanger Hook

Screw Kit

11 UB1522

12 UXL1542

13 UC8026

14 UB1518L

15 UB1526

16 UB1519/S

17 UB1523

18 U174EX-1

19 UB1524

20 UXL1826

21 WGA65N

Cable Terminal Male

Cable End Lock Nut (M12 X 1.0)

Spring Cable Support

Gun Plug Housing C/W Nut

Gun Plug Screw

Gun Plug Nut

Gun Plug Terminal Female

TWC Euro Gun Plug Body

Gun Plug ‘O’ Ring

Liner Retaining Nut

Nipple

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

TWC5 STYLE MIG TORCH

Suregrip Series

Front end consumables

TWC5 Contact Tips H/D

Part Number

PWGA15H-35

PWGA15H-40

PWGA15H-45

PWGA15H-52

PWGA15H-116

PWGA15H-564

PWGA15-AH45

PWGA15-AH116

Description

Contact Heavy Duty Tip 0.9mm

Contact Heavy Duty Tip 1.0mm

Contact Heavy Duty Tip 1.2mm

Contact Heavy Duty Tip 1.3mm

QTY10

QTY10

QTY10

QTY10

Contact Heavy Duty Tip 1.6mm

Contact Heavy Duty Tip 2.0mm

QTY10

QTY10

Contact Heavy Duty Tip 1.2mm Aluminium QTY10

Contact Heavy Duty Tip 1.6mm Aluminiumm QTY10

TWC5 Contact Tips Holder

Part Number

PWGA55

PWGA55-SW

PWGA55-H

Description

Contact Tip Holder 1.6-2.0mm

Contact Tip Holder 0.9-1.2mm

Contact Tip Holder 2.4-2.8mm

QTY2

QTY2

QTY2

Liners

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

TWC5 Insulator

Part Number

PWGA35CT

Description

Insulator

TWC5 Torch Nozzle Fixed

Part Number

Description

PWGA25CT62

PWGA25CT75

Standard 16mm fixed

Standard 20mm fixed

TWC5 Liners

Part Number

WGA44-3545-15

WGA44-116-15

WGA44-564-15

WGA44N-3545-15

WGA44N-116-15

Description

Liner 15 ft 0.9-1.2mm

Liner 15ft 1.6mm

Liner 15ft -2.0mm

Liner 15 ft 0.9-1.2mm Alloy

Liner 15 ft 1.6mm Alloy

QTY2

QTY2

QTY2

39

Suregrip Series

7

5

4

3

2

26V TIG TORCH

200A AIR COOLED TIG WELDING TORCH

Rating:200A DC, 140A AC @35% ducy cycle.

6

8

Stubby

series

Standa rd

series

G as

L en s s eri es

La rge

Gas

Lens

series

Stubby

Gas

Lens

series

9

10

11

12

15 14

16

13

6

17

40

4

5

6

7

1

2

3

8

9

10

18

Torch Model

Description

26V TIG Torch Package c/w 2m Gas Hose

Part Number

4m

26V-4MCP50

8m

26V-8MCP50

26V-8MCP25

Spare Parts

Part Number

WP26V

WP26VF

57Y02

57Y03

57Y04

UERBS

UERSP1

UERH200

UERKJ200

UERLC200-08

UERJK200

Description

Torch head

Torch head flexible

Back cap long

Meduim back cap

Short back cap

Blank Kit

Screw Pack

Large Ergo TIG Handle

Large Knuckle Joint

Leather Cover X 0.8mt

Jointing Repair Kit

13

14

15

16

11

12

17

18

Part Number

UERNCL-32

UERNCL-72

UERCO200-40

UERCO200-80

USLH26-S

USLH26-H

USLH26-C

USL46V28AR

USL46V30AR

USL3550

USL-1-GS4

Description

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 Large

“Surelok “ Housing Large

“Surelok “ Housing Cover

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.

26V TIG TORCH

Part # Description

18CG Cup Gasket

Part # Description

10N30 Collet Body 1.0mm

10N31 Collet Body 1.6mm

10N32 Collet Body 2.4mm

10N28 Collet Body 3.2mm

Suregrip Series

Standard Front End Parts

Part # Description

10N49L Long Alumina Nozzle Ø

8mm #5L

53N48L Long Alumina Nozzle Ø

10mm #6L

53N47L Long Alumina Nozzle Ø

11mm #7L

Part # Description

10N22 Collet 1.0mm

10N23 Collet 1.6mm

10N24 Collet 2.4mm

10N25 Collet 3.2mm

Part # Description

10N50

Alumina Nozzle Ø 6mm #4

10N49

Alumina Nozzle Ø 8mm #5

10N48

Alumina Nozzle Ø 10mm #6

10N47

Alumina Nozzle Ø 11mm #7

10N46

Alumina Nozzle Ø 13mm #8

10N45

Alumina Nozzle Ø 16mm #10

10N44

Alumina Nozzle 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 # Description

54N14 Gas lens ceramic 8.0mm

54N15 Gas lens ceramic 7.0mm

54N17 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

1/16 x 7” (1.6mm x 175mm)

3/32 x 7” (2.4mm x 175mm)

1/8 x 7” (3.2mm x 175mm)

Part #

TR0004-10

TR0004-16

TR0004-24

TR0004-32

Description

1.0mm x 175mm thoriated tungsten electrode 2%

1.6mm x 175mm thoriated tungsten electrode 2%

2.4mm x 175mm thoriated tungsten electrode 2%

3.2mm x 175mm thoriated tungsten electrode 2%

©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.

41

42

SPARE PARTS IDENTIFICATION - KUMJR250SWF

Description

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

31

32

33

4

5

6

7

1

2

3

POWER SUPPLY AND WIRE FEED PCB

CONTROL PCB

IGBT PCB

EMC BOARD

OUTPUT DIODES PCB

FILTER BOARD PCB

MAIN TRANSFORMER

8 CHOKE

9 SHUNT

10

11

12

13

14

ON/OFF SWITCH

PEAK CURRENT SONSOR PCB

FRONT PANEL

REAR PANEL

BASE PLATE

POT FOR CURRENT ADJUSTMENT 4.7K 2W

POT FOR VOLTAGE ADJUSTMENT 4.7K 2W

MIG/MMA/TIG SELECTOR SWITCH

MIG/MMA SELECTOR SWITCH

DIGITAL METER ( VOLT AND AMP)

KNOB BLACK

FAN MOTOR

POWER SUUPLY CABLE

AUXILARY TRANSFORMER T2-1

AUXILARY TRANSFORMER T2-2

POT FOR CRATER VOLTAGE ADJUSTMENT

POT FOR CRATER CURRENT ADJUSTMENT

POT FOR BURN BACK ADJUSTMENT

INOUT BRIDGE RECTIFIER MBS-100

6 PIN PANEL FEMALE SOCKET

35/50 PANEL DINSE CONNECTOER FEMALE

2T/4T SELECTOR SWITCH

WELD/GAS CHECK SELECTOR SWITCH

MIG/MMA CHECK SELECTOR SWITCH

Part Number

10003592

10003593

10006797

10004906

10007325

10001471

10006030

10006045

10006506

10006506

10006508

10006625

10004686

CX0031

10004944

10004944

10004944

10000816

10000519

10000889

10000930

10000321

10000460

10006064

10006559

10016424

10004926

10000871

10011728

10013239

10011309

10001209

10001209

16

24

10

26

12

27

22

23

11

15

14

25

13

9

8

1

7

20

19

3

18

2 21

4

5

13

43

44

SPARE PARTS IDENTIFICATION - KUMJR350SWF

Description

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

25

26

27

28

29

30

4

5

6

7

1

2

3

POWER SUPPLY AND WIRE FEED PCB

CONTROL PCB

IGBT PCB

EMC BOARD

OUTPUT DIODES PCB

CAPACITOR 1250V DC 40µF

MAIN TRANSFORMER

8 SHUNT

ON/OFF SWITCH

PEAK CURRENT SONSOR PCB

FRONT PANEL

REAR PANEL

BASE PLATE

POT FOR CURRENT ADJUSTMENT 4.7K 2W

POT FOR VOLTAGE ADJUSTMENT 4.7K 2W

DIGITAL METER ( VOLT AND AMP)

KNOB BLACK

FAN MOTOR

POWER SUPPLY CABLE

AUXILARY TRANSFORMER T2-1

AUXILARY TRANSFORMER T2-2

POT FOR CRATER VOLTAGE ADJUSTMENT

POT FOR CRATER CURRENT ADJUSTMENT

POT FOR BURN BACK ADJUSTMENT

INPUT BRIDGE RECTIFIER MBS-100

6 PIN PANEL FEMALE SOCKET

35/50 PANEL DINSE CONNECTOER FEMALE

2T/4T SELECTOR SWITCH

WELD/GAS CHECK SELECTOR SWITCH

MIG/MMA CHECK SELECTOR SWITCH

Part Number

10004906

10007306

10001429

10006032

10006045

10006506

10006506

10006508

10006635

10004686

CX0031

10004944

10004944

10004944

10000865

10000558

10001940

10000844

10000332

10005913

10006120

10016424

10004925

10000836

10026518

10013230

10014243

10001209

10001209

10006797

16

24

10

26

12

27

22

23

11

15

14

25

13

9

8

1

7

20

19

3

18

2 21

4

5

13

45

46

SPARE PARTS IDENTIFICATION - KUMJR500SWF

Description

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

4

5

6

7

1

2

3

POWER SUPPLY AND WIRE FEED PCB

CONTROL PCB

IGBT PCB

EMC BOARD

OUTPUT DIODES PCB

CAPACITOR 1250V DC 40µF

MAIN TRANSFORMER

8 CHOKE

9 SHUNT

10

11

12

13

14

ON/OFF SWITCH

FRONT PANEL

REAR PANEL

BASE PLATE

POT FOR CURRENT ADJUSTMENT 4.7K 2W

POT FOR INDUCTANCE ADJUSTMENT 4.7K 2W

DIGITAL METER ( VOLT AND AMP)

KNOB BLACK

FAN MOTOR

POWER SUPPLY CABLE

AUXILARY TRANSFORMER T2-1

AUXILARY TRANSFORMER T2-2

POT FOR CRATER VOLTAGE ADJUSTMENT

POT FOR CRATER CURRENT ADJUSTMENT

POT FOR BURN BACK ADJUSTMENT

INOUT BRIDGE RECTIFIER MBS-100

6 PIN PANEL FEMALE SOCKET

35/50 PANEL DINSE CONNECTOER FEMALE

2T/4T SELECTOR SWITCH

WELD/GAS CHECK SELECTOR SWITCH

MIG/MMA CHECK SELECTOR SWITCH

Part Number

10004906

10007306

10001429

10006032

10006045

10006506

10006506

10006508

10006623

10004686

CX0031

10004944

10004944

10004944

10000573

10000527

10001948

10000844

10000345

10005913

10006068

10002010

10016425

10004925

10014783

10013316

10014251

10001209

10001209

10006797

16

24

10

26

12

27

22

23

11

15

14

25

13

9

8

1

7

20

19

3

18

2 21

4

5

13

47

48

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 10-15 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 Suggested Remedy

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

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

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

Improper welding technique 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

Not enough heat input

Contaminated base metal

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

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

Wrong type of drive roller selected

Worn drive rollers

Drive roller pressure too high

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

49

50

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

Wrong mode selected

No power supply

Check earth lead is connected. Check all cable connections.

Check the MMA selector switch is selected

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

Work piece dirty, contaminated or moisture

Damp electrodes

3: Excessive Spatter

Possible Reason

Shorten the arc length

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

Use only dry electrodes

Amperage too high

Arc length too long

3: Weld sits on top, lack of fusion

Decrease the amperage or choose a larger electrode

Shorten the arc length

Possible Reason Suggested Remedy

Insufficient heat input

Work piece dirty, contaminated or moisture

Poor welding technique

4: Lack of penetration

Possible Reason

Suggested Remedy

Increase the amperage or choose a larger electrode

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

Use the correct welding technique or seek assistance for the correct technique

Suggested Remedy

Insufficient heat input

Poor welding technique

Increase the amperage or choose a larger electrode

Use the correct welding technique or seek assistance for the correct technique

Poor joint preparation Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit up

5: Excessive penetration - burn through

Possible Reason Suggested Remedy

Excessive heat input

Incorrect travel speed

6: Uneven weld appearance

Possible Reason

Reduce the amperage or use a smaller electrode

Try increasing the weld travl speed

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

Poor welding technique

Poor joint preparation and or joint design

Reduce the amperage or use a smaller electrode

Use the correct welding technique or seek assistance for the correct technique

Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit 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

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

No gas

Inadequate gas flow

Back cap not fitted correctly

Torch connected to DC +

Incorrect tungsten being used

Tungsten being oxidised after weld is finished

2: Contaminated tungsten

Possible Reason

Check that pure Argon is being used

Check the gas cylinder contains gas and is connected and the torch gas valve is open

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 12 - 15 l/min flow rate

Make sure the torch back cap is fitted so that the o-ring is inside the torch body

Connect the torch to the DC- output terminal

Check and change the tungsten type if necessary

Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10 amps of weld current.

Suggested Remedy

Touching tungsten into the weld pool

Touching the filler wire to the tungsten

Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work piece 2 - 5mm

Keep the filler wire from touching the tungsten during welding, feed the filler 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

Inadequate gas flow / gas leaks

Moisture on the base metal

Contaminated base metal

Contaminated filler wire

Incorrect filler wire

Check that pure Argon is being used

Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the gas flow between 6 - 10 l/min flow rate. Check hoses and fittings for holes, leaks etc.,

Remove all moisture from base metal before welding

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

Remove all grease, oil, or moisture from filler metal.

Check the filler wire and change if necessary

4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten

Possible Reason Suggested Remedy

Incorrect Gas

Inadequate gas flow

Use pure Argon gas

Set the gas flow between 6 - 10 l/min flow rate

Alumina gas nozzle too small for size of tungsten being used

Increase the size of the alumina gas nozzle

5: Unstable Arc during DC welding

Possible Reason Suggested Remedy

Torch connected to DC +

Contaminated base metal

Tungsten is contaminated

Arc length too long

7: Arc wanders during DC welding

Connect the torch to the DC- output terminal

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

Remove 10mm of contaminated tungsten and re grind the tungsten

Lower torch so that the tungsten is off of the work piece 2 - 5mm

Possible Reason Suggested Remedy

Poor gas flow

Incorrect arc length

Tungsten incorrect or in poor condition

Poorly prepared tungsten

Check and set the gas flow between 6 - 10 l/min flow rate

Lower torch so that the tungsten is off of the work piece 2 - 5mm

Check that correct type of tungsten is being used. Remove 10mm from the weld end of the tungsten and re sharpen the tungsten

Grind marks should run lengthwise with tungsten, not circular. Use proper grinding method and wheel.

Contaminated base metal

Contaminated filler wire

Incorrect filler wire

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

Remove all grease, oil, or moisture from filler metal.

Check the filler wire and change if necessary

51

continued- TIG WELDING TROUBLE SHOOTING

8: Arc difficult to start or will not start DC welding

Possible Reason Suggested Remedy

Incorrect machine set up

No gas, incorrect gas flow

Tungsten is contaminated

Incorrect tungsten size and or tungsten being used

Loose connection

Earth clamp not connected to work

Check machine set up is correct

Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted. Set the gas flow between 10 - 15 l/min flow rate

Remove 10mm of contaminated tungsten and re grind the tungsten

Check and change the size and or the tungsten if required

Check all connectors and tighten

Connect the earth clamp directly to the work piece wherever possible

52

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 6-10 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 6-10 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.

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)

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

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 3)

(Clause 3)

3 Years

1 Year

2 Year

2 Year

(Clause 3)

(Clause 3)

(Clause 3)

(Clause 3)

3 Years

2 Years

(Clause 3)

(Clause 3)

1 Year (Clause 3)

3 Months (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.

53

54

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.

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 on 02 9870 4200 or Mail PO Box 3033 Lansvale NSW 2166.

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.

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

.

55

©

Welding Guns Of Australia PTY LTD 2012

56

Welding Guns Of Australia PTY LTD Pty Ltd

ABN: 14 001 804 422

PO Box 3033, Lansvale NSW 2166, AUSTRALIA

112 Christina Rd, Villawood, NSW 2163

Phone: (02) 9780 4200

Fax: (02) 9780 4244

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

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