operating manual

operating manual
OPERATING MANUAL
KUMJRRW205SSMIG
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Welding Mode
KF4-20130829
3YEARS Warranty
(Power Source)
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
1
© Welding Guns Of Australia PTY LTD 2016
2
Thank you for your purchase of your UNI-MIG welding machine.
We are proud of our range of welding equipment that has a proven track record of innovation, performance and
reliability. Our product range represents the latest developments in Inverter technology put together by our
professional team of highly skilled engineers. The expertise gained from our long involvement with inverter technology
has proven to be invaluable towards the evolution and future development of our equipment range. This experience
gives us the inside knowledge on what the arc characteristics, performance and interface between man and machine
should be. Within our team are specialist welders that have a proven history of welding knowledge and
expertise, giving vital input towards ensuring that our machines deliver control and performance to the utmost
professional level. We employ an expert team of professional sales, marketing and technical personnel that provide
us with market trends, market feedback and customer comments and requirements. Secondly they provide a
customer support service that is second to none, thus ensuring our customers have confidence that they will be well
satisfied both now and in the future.
UNI-MIG welders are manufactured and compliant with - AS/NZ60974.1 2006 - AS60974-6:2006 guaranteeing you
electrical safety and performance.
• 3 Years from date of purchase.
WARRANTY
• Welding Guns Of Australia PTY LTD Ltd warranties all goods as specified by the manufacturer of those goods.
• This Warranty does not cover freight or goods that have been interfered with.
• All goods in question must be repaired by an authorised repair agent as appointed by this company.
• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.
• New product will not be supplied unless Welding Guns Of Australia PTY LTD has inspected product returned for warranty and agree’s to replace product.
• Product will only be replaced if repair is not possible
• Please view full Warranty term and conditions supplied with machine or at www.unimig.com.au/warranty.asp or at the back of this manual.
ATTENTION! - CHECK FOR GAS LEAKS
At initial set up and at regular intervals we recommend to check for gas leakage.
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 8-10 l/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the
regulator, if the needle drops away towards zero there is a gas leak.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator
and line for an extended time period. In this situation it is recommended to open the cylinder valve, set
the flow rate to 8-10 l/min, close the cylinder valve and check after a minimum of 15 minutes.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing orspraying
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 Pty Ltd will not be liable or responsible for the loss of any gas.
3
CONTENTSPAGE
4
Introduction - Warranty
3
Safety - Cautions
5-7
Technical Data, Product Information
8
Machine Layout Description
9
Front Panel Functions & Descriptions
10
Installation & Operation for MMA (stick) Welding
11
MMA (Stick) Welding Information
12-13
Installation & Operation for MIG Welding - Gas Shielded
14-15
Wire Feed Drive Roller Selection
16
Wire Installation Set up Guide
17
Installation & Operation for MIG Welding - Gasless Wire
18-19
MIG Torch Liner Installation
20
MIG Torch Liner Types and Information
21
MIG Torch and Wire Feeder Set Up Guide for Aluminium 22-23
Installation & Operation for MIG Welding with Spool Gun
24-25
MIG (Metal Inert Gas) Welding
26-27
Basic MIG Welding Guide
28-31
Installation & Operation for DC TIG Welding
32-33
Basic DC TIG Welding Guide
34-35
Tungsten Electrode information 36-37
SB25 MIG Torch Parts Guide / Breakdown
38-39
240 Spool Gun Torch Parts Guide / Breakdown
40-41
SRE26 TIG Torch Parts Guide / Breakdown
42-43
MIG Welding Trouble Shooting Guide
44-45
DC TIG Welding Trouble Shooting Guide
46
MMA Welding Trouble Shooting Guide
47
Gas Flow Regulators - Sheilding Gases - Gas Flow Rates
48
Gas Leak Check - Procedure
49
Warranty
50
Machine Spare Parts
54
Electrical Schematic Diagram
55
SAFETY
Welding and cutting equipment can be dangerous to both the operator and people in or near the
surrounding working area, if the equipment is not correctly operated. Equipment must only be
used under the strict and comprehensive observance of all relevant safety regulations.
Read and understand this instruction manual carefully before the installation and operation of this
equipment.
Machine Operating Safety
•Do not switch the function modes while the machine is operating. Switching of the function modes during
welding can damage the machine. Damage caused in this manner will not be covered under warranty.
•Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing
should the electrode be in contact with the work piece.
•Operators should be trained and or qualified.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe
burns. The electrode and work circuit is electrically live whenever the output is on. The input
power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding,
the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment is dangerous.
•Connect the primary input cable according to Australian and New Zealand standards and regulations.
•Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.
The operator must wear dry welding gloves while he/she performs the welding task.
•The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.
•Do not use damaged, under sized, or badly joined cables.
•Do not drape cables over your body.
Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can
be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health. •Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
•Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
•In confined or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
•Do not weld in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.
•Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic
fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding process produce
intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
•Always wear a welding helmet with correct shade of filter lens and suitable protective clothing including
welding gloves whilst the welding operation is performed.
•Measures should be taken to protect people in or near the surrounding working area. Use protective
screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
5
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.
6
CAUTION
1. Working Environment.
1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive
chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity.
1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;
the temperature of working environment should be maintained within -10°C to +40°C.
1.3 Keep this equipment 30cm distant from the wall.
1.4 Ensure the working environment is well ventilated.
2. Safety Tips.
2.1 Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is
of critical importance for the normal performance and service life of this equipment.
2.2
Thermal Overload protection.
2.3
Over-Voltage Supply
Should the machine be used to an excessive level, or in high temperature environment, poorly
ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the
machine will cease to operate. Under this circumstance, leave the machine switched on to keep the
built-in fan working to bring down the temperature inside the equipment. The machine will be ready for
use again when the internal temperature reaches safe level.
Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.
This equipment is of automatic voltage compensation, which enables the maintaining of the voltage
range within the given range. In case that the voltage of input power supply amperage exceeds the
stipulated value, it is possible to cause damage to the components of this equipment. Please ensure
your primary power supply is correct.
2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock
may possibly occur.
MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to prevent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and
dry compressed air of required pressure.
Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of
this welding equipment will be void if the machine has been modified, attempt to take apart the machine or
open the factory-made sealing of the machine without the consent of an authorized representative of the
manufacturer.
TROUBLE SHOOTING
Caution: Only qualified technicians are authorized to undertake the repair of this welding equipment.
For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.
7
RAZOR MIG 205 SMART SET
MIG/TIG/MMA - 205 Amp DC Inverter Welder
Welds: Steels, Stainless, Cast Iron, Bronze, Aluminium, Copper
Razorweld
™
™
Features
• New 40 KHz IGBT inverter technology
• MIG/MAG with Gas and Gasless wire function
- Smart Set Synergic programs for 0.8 / 0.9 Mild Steel
- Soft Start - Self Adaptive Crater Fill
- Wire Inch
• MMA function (Stick electrode)
- VRD (Voltage Reduction Device)
- Hot start (improves electrode starting)
- Adjustable Arc Force
• DC TIG
- Lift Arc ignition (prevents tungsten sticking during arc ignition)
- 2T 4T Trigger Control
- Adjustable Downslope
• Internal wire feeder, gear driven for up to 200mm Ø spool
• Euro style MIG & TIG torch connection
• IP21S rating for environmental/safety protection
• Tolerant to variable power supply
• Spool Gun Connection
Technical Data
Power Supply / Phases (V-Ph) Duty Cycle @ 40°c as per AS/NZ60974 Output Current Range MIG Output Current Range TIG Output Current Range MMA Rated Power MMA I Max
I ieff Power factor Protection Class Insulation Class Dimensions Power Source (LxWxH) Weight Power Source Warranty
240v - 1 +/- 15%
20% @ 200 Amps MIG 35% @ 200 Amps TIG
15% @ 200 Amps MMA
30A/15.5V - 200A/24.0V
10A/10.4V - 200A/18.0V
10A/20.4V - 200A/28.0V
9.4 KVA
MIG 33.6 Amps
TIG 25.2 Amps
MMA 39.0 Amps
MIG/TIG/MMA 15.0 Amps
0.70
P 21S
F
470x190x380mm
12.5 Kg
3 years on power source
RAZOR MIG205SS OPTIONS
240A SpoolGun
Part No.
PLSP240A-24-P1-60ER
SRE26 Euro Connect
TIG Torch
Part No. SRE26-4M
RAZOR BAG
Part No.
RAZOR MIG200 BAG-1
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Package includes: MIG205SS Welding Machine, SB25 MIG Torch x 4m, Argon Regulator,
Earth Lead & Arc Lead 25mm x 4m, Gas hose with quick connect fitting.
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The Razorweld Series MIG205-SS is a new inverter-based portable MIG/MMA/TIG Welding machine with Synergic Programs for
0.8mm and 0.9mm solid welding wires. The MIG function allows you to weld with both Gas Shielded and Gasless wire applications
giving excellent, professional welding results. Easy step-less adjustment of voltage and wire feed coupled with integrated digital
meters allows easy setting of welding parameters. The MIG 205SS features Smart set welding with four Synergic Mild Steel
welding programs designed for ease of use with your selected gas mixture. The operator selects the gas mixture and wire diameter
they are using then simply start welding. Once this is done the operator can make fine adjustments to the voltage for even greater
control of the weld pool. The added Lift-Arc DC TIG capability delivers perfect arc ignition every time and a remarkably smooth
stable arc produces high quality TIG welds. TIG functionality includes adjustable Down Slope & Post Gas as well as being gas
solenoid-valve equipped. The stick welding (MMA) capability delivers easy electrode welding with high quality results, including
cast Iron, stainless and low hydrogen. An additional feature is the Spool gun ready function that allows the simple connection of the
SPGRW200II Spool Gun for the use of thin or softer wires that don’t have the column strength to feed through standard MIG
torches, such as aluminum wire. This is an industrial quality machine that is extremely lightweight and portable. Being 240v single
phase gives great versatility. Ideal for general engineers, maintenance workshop, rural workshop, panel beaters and home
workshop. Designed and built to our specification. Certified to - AS/NZ60974.1
IG W R R A N
A
Razor2O5-SS MIG-TIG-MMA
Machine Layout Description
FRONT PANEL LAYOUT
1. Digital Amperage & Wire Speed Display
2. Digital Volt Meter/ Arc Force / Downslope Display
3. VRD LED
4. Wire Speed / Ampearge Adjustment Knob
5. Voltage /Arc Force / Downslope Adjustment Knob
6. “-” Output terminal
7. Euro Mig & TIG Torch Connector
8. “+” Output terminal
9. Weld Power Lead
10. 2T/4T Selector Switch 7.
11.MIG/TIG/MMA/ SMART SET Selector Knob
12.SpoolGun Power Supply Connection
1
2
10
11
3
4
5
6
7
8
12
9
BACK PANEL LAYOUT
14. Power switch
15. Gas Inlet
16. Fan
17. Input power cable
18. Data Plate
14
15
17
16
18
20
21 22
INTERNAL PANEL LAYOUT
20. Spoolgun/Standard selector switch
21. Inch wire feed button
22. Gas check button
23. Spool holder assembly
24. Wire feed assembly
23
24
9
Front Panel Functions and Descriptions
Razor2O5-SS MIG-TIG-MMA
MMA Function - Front Panel Description
Arc Force Display
Amperage Display
Amperage Control
Arc Force Control
MMA Function Select
1
Amperage
Voltage
L1
Argon 90% C
02
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Welding Mode
KF4-20130829
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TIG Function - Front Panel Description
2
Downslope Time Display
Amperage Display
Amperage Set
Down Slope Time Set
TIG Function Select
2T/4T Trigger Select
1
Amperage
Voltage
L1
6
Argon 90% C
02
10
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Welding Mode
KF4-20130829
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MIG Function - Front Panel Description
Voltage Display
Wire Feed / Amperage Display
Wire Speed Set
Voltage Set
MIG Function Select
2T/4T Trigger Select
1
Amperage
Voltage
L1
6
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SMART SET MIG Function - Front Panel Description
Voltage Display
Wire Feed / Amperage Display
Wire Speed Set
Voltage Set
SMART SET Program Function Select
2T/4T Trigger Select
1
Amperage
Voltage
L1
MMA
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Welding Mode
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Set up installation for MMA (Stick) Welding
Razor2O5-SS MIG-TIG-MMA
(1) Turn the power source on and 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 MIG/TIG/MMA selector
switch to MMA
(2) Connect the earth
lead to
(2) Connect the
electrode lead to
3) Set the Amperage and Arc Force using
the Control Knobs
4) Place the electrode into the electrode
holder and clamp tight.
5) Strike the electrode against the work
piece to create and arc and hold the
electrode steady to maintain the arc
11
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.
Core wire
+
Flux coating
Gas shield from flux melt
Power Source
Arc with core wire melt
Flux residue forms slag cover
Weld metal
▬
• The arc is initiated by momentarily touching the electrode to the base metal.
Core wire
Flux coating
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
Protective gas
Arc
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.
Slag
Weld pool
12
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
of Material
Maximum Recommended The size of the electrode generally depends on the
Electrode Diameter
thickness of the section being welded, and the thicker the
1.0 - 2.0mm
2.0 - 5.0mm
5.0 - 8.0mm
8.0 - > mm
2.5mm
3.2mm
4.0mm
5.0mm
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)
Correct current selection for a particular job is an
important factor in arc welding. With the current set too
low, difficulty is experienced in striking and maintaining a
stable arc. The electrode tends to stick to the work,
2.5mm
60 - 95
penetration is poor and beads with a distinct rounded
3.2mm
100 - 130
profile will be deposited. Too high current is accompanied
4.0mm
130 - 165
by overheating of the electrode resulting undercut and
5.0mm
165 - 260
burning through of the base metal and producing
excessive spatter. Normal current for a particular job may be considered as the maximum, which can be
used without burning through the work, over-heating the electrode or producing a rough spattered surface.
The table shows current ranges generally recommended for a general purpose type 6013 electrode.
Electrode Size
ø mm
Current Range
(Amps)
Arc Length
To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a
simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An
arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld.
An excessively short arc will cause sticking of the electrode and result in poor quality welds. General rule of
thumb for down hand welding is to have an arc length no greater than the diameter of the core wire.
Electrode Angle
The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal.
When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5
and 15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should
be between 80 and 90 degrees to the work piece.
Travel Speed
The electrode should be moved along in the direction of the joint being welded at a speed that will give the
size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all
times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel
will frequently lead to arc instability,slag inclusions and poor mechanical properties.
Material and Joint Preparation
The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or
any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend
on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases
edges should be clean and free of any contaminates. The type of joint will be determined by the chosen
application.
13
Set up installation for MIG - Gas shielded wire
Razor2O5-SS MIG-TIG-MMA
(1) Select Standard using the Standard/Spool Gun selector switch.
(2) Insert the earth cable plug into the negative socket on the front of the machine and tighten it.
(3) Plug the welding torch into the Euro MIG torch connection socket on the front panel, and tighten it.
IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can
result in the connector arcing and damaging the machine and gun connector.
This damage is not covered under warranty.
(4) Connect Weld Power Lead to the Positive terminal
(5) Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator. Check for Leaks!
(6) Connect the gas line to the machine via the quick push lock connector located on the rear panel. Check for Leaks!
(7) 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.
(8) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into the torch
receptacle. Check that the drive roller size is compatible with the wire diameter, replace the roller if necessary.
(5) Connect the gas regulator to the gas
cylinder and tigthen. Connect the gas
line to the gas regulator.
(1) Set Standard/Spoolgun
selector switch inside door
to Standard
(2) Connect the earth
lead to the
terminal
(3) Connect MIG torch
IMPORTANT : When connecting the
(6) Connect the gas line to the machine
inlet gas connector via the quick push
lock connector located on the rear panel
torch be sure to tighten the connection.
IMPORTANT
Select the correct polarity. Connect the weld
power lead to
output terminal.
Caution:
(7) Place wire onto spool holder - (spool retaining
nut is left hand thread ) Feed the wire through the
inlet guide tube on to the drive roller.
(4) Connect the Weld Power lead
to the
terminal
(8) Feed wire over the drive roller into
the outlet guide tube, Push the wire
through approx 150mm.
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.
14
Continued: set up installation for MIG - Gas shielded wire
Razor2O5-SS MIG-TIG-MMA
(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in the
groove of the bottom drive roller, lock the pressure arm into place. Apply a medium amount of pressure to the
drive roller
(10) Remove the gas nozzle and contact tip from the torch neck,
(11) 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.
(12) 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.
(13) Fit the gas nozzle to the torch head.
(14) Carefully open the gas cylinder valve and set the flow rate to between 8-12 l/min.
(15) Select 2 or 4 time trigger function.
(16) Select the MIG Smart Set program to suit the wire diameter and gas type being used.
(17) Select the wire feed speed required to suit the material thickness being welded, it will show on the digital meter
as m/min. Increasing the wire feed speed increases the welding amperage output - Smart Set will adjust the
Voltage to suit automatically, always providing a smooth arc. Smart Set permits fine tuning of the voltage
allowing you to personally customise your setting.
(9) Close down the top roller bracket and clip
the pressure arm into place with a medium
amount of pressure applied.
(12) Fit the correct size contact tip over
the wire and fasten tightly into the tip
holder.
(15) Select torch switch mode 2T or 4T
(10) Remove the gas nozzle and contact tip
from the front end of the mig torch.
(13) Fit the gas nozzle to the torch head.
(16) Select your preferred Smart Set
program selection
(11) Press and hold the inch wire button to
feed the wire down the torch cable through
to the torch head.
(14) Carefully open the valve of the gas
cylinder, set the flow to 10 l/min
(17) Set welding amperage using the wire feed
knob, increasing the wire feed increase the
amperage. Fine tune if required using the voltage
knob.
15
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.
Wire
16
Top Pressure Roller
Top Pressure Roller
V Groove
U Groove
Wire
Top Pressure Roller
Knurled Groove
Wire
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.
(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.
(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.
(2) Note the tension spring adjuster
and spool locating pin.
(5) Feed the wire through the drive roller and
into the outlet guide tube of the wire feeder.
(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.
(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
(6) Lock down the top pressure roller and
apply a medium amount of pressure using the tension adjustment knob
(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.
17
Set up installation for MIG - Gasless wire
Razor2O5-SS MIG-TIG-MMA
(1) Select Standard using the Standard/Spool Gun selector switch.
(2) Insert the earth cable plug into the Positive socket on the front of the machine and tighten it.
(3) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.
IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can
result in the connector arcing and damaging the machine and gun connector.
This damage is not covered under warranty.
(4) Connect Weld Power Lead to the Negative terminal
(5) Fit the correct size Knurled drive roller for Gas Less Flux Core wire.
(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) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into
the torch receptacle. Check that the drive roller size is compatible with the wire diameter, replace the roller
if necessary.
(1) Set Standard/Spoolgun
selector switch inside door
to Standard
(2) Connect the Weld Power
lead to the
terminal
(3) Connect Mig torch
IMPORTANT : When connecting the
torch be sure to tighten the connection.
IMPORTANT
Select the correct polarity. Connect the weld
power lead to
output terminal.
Caution:
(5) Fit the correct sized Knurled Drive roller for
Gas Less Flux Cored wire
(4) Connect the Earth lead
to the
terminal
(6) Place wire onto spool holder. Feed the wire
through the inlet guide tube on to the drive roller.
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.
18
Continued: set up installation for MIG - Gasless wire
Razor2O5-SS MIG-TIG-MMA
(8) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into
the torch receptacle. Check that the correct drive roller is being used.
(9) Align the wire into the groove of the drive roller and close down the top roller making sure the wire is in
the groove of the bottom drive roller, lock the pressure arm into place.
(10) Apply a light amount of pressure to the drive roller. Too much pressure will crush the cored wire.
(11) Remove the gas nozzle and contact tip from the torch neck,
(12) 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.
(13) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of
the torch head and nip it up tightly.
(14) Fit the nozzle to the torch head.
(15) Select MIG on the front panel.
(16) Set the welding parameters using the wire feed and voltage control knobs.
(8) Feed wire over the drive roller into
the outlet guide tube, Push the wire
through approx 150mm. Use a Knurled
Drive Roller of the correct size
(11) Remove the gas nozzle and contact tip
from the front end of the mig torch.
(14) Fit the nozzle to the torch head.
(9) Close down the top roller bracket and clip
the pressure arm into place.
(12) Press and hold the inch wire button to
feed the wire down the torch cable through
to the torch head.
(16) Select MIG function.
Important: Smart Set programs are for
gas sheilded solid wire only.
(10) Apply a light amount of
pressure to the drive roller
(13) Fit the correct size contact tip over
the wire and fasten tightly into the tip
holder.
(16) Set welding parameters using the
wire feed and voltage knobs.
19
MIG Torch Liner Installation
(1)
(2) (3) (4) (5) (6) (7) (8) (9) 20
Lay the torch out straight on the ground and remove the front end parts
Remove the liner retaining nut.
Carefully pull the liner out of the torch cable assembly
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.
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.
Fit the liner retaining nut and screw down only 1/2 way
Leaving the torch straight snip the liner approximately 3mm past the end of the torch neck
Place the tip holder over the end of the liner and screw into the torch neck nipping it up tight.
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.
MIG Torch Liner Types and Information
MIG Torch Liners
The liner is both one of the simplest and most important components of a MIG gun. Its sole purpose is to guide the
welding wire from the wire feeder, through the gun cable and up to the contact tip.
Steel Liners
Most MIG gun liners are made from coiled steel wire also known as piano wire, which provides the liner with good
rigidity and flexibility and allows it to guide the welding wire smoothly through the welding cable as it bends and flexs
during operational use. Steel liners are primarily used for feeding of solid steel wires, other wires such as Aluminium,
Silicon Bronze etc will perform better using a teflon or Polyamide liner. The internal diameter of the liner is important
and releative to the wire diameter being used and will assit in smooth feeding and prevention of the wire kinking and
birdnesting at the drive rollers. Also bending the cable too tightly during welding increases the friction between the liner
and the welding wire making it more difficult to push the wire through the liner resulting in poor wire feeding, premature
liner wear and birdnesting. Dust, grime and metal particles can accumalate inside the liner over time and cause friction
and blockages, it is recommended to periodically blow out the liner with compressed air.
Small diameter welding wires, 0.6mm through 1.0mm have relatively low columnar strength, and if matched with
an oversized liner, can cause the wire to wander or drift within the liner. This in turn leads to poor wire feeding and
premature liner failure due to excessive wear. By contrast, larger diameter welding wires, 1.2mm through 2.4mm have
much higher columnar strength but it is important to make sure the liner has enough internal diameter clearance. Most
manufacturers will produce liners sized to match wire diameters and length of welding torch cable and most are colour
coded to suit.
Blue - 0.6mm - 0.8mm
Steel Liners
Red - 0.9mm - 1.2mm
Yellow - 1.6mm
Green - 2.0mm - 2.4mm
Teflon and Polyamide (PA) Liners
Teflon liners are well suited for feeding soft wires with poor column strength like aluminium wires. The interiors of these
liners are smooth and provide stable feedability, especially on small diameter welding wire Teflon can be good for
higher heat applications that utilize water-cooled torches and brass neck liners. Teflon has good abrasion resistance
characteristics and can be used with a variety of wire types such as silicon bronze, stainless steel as well as
aluminium. A note of caution to careful inspect the end of the welding wire prior to feeding it down the liner. Sharp
edges and burrs can score the inside of the liner and lead to blockages and accelerated wear.
Polyamide Liners (PA) are made of carbon infused nylon and are ideal for softer aluminum, copper alloy welding wires
and push pull torch applications. These liners are generally fitted with a floating collet to allow the liner to be inserted
all the way to the feed rollers.
Blue - 0.6mm - 0.8mm
Teflon Liners
Red - 0.9mm - 1.2mm
Yellow - 1.6mm
Black - 1.0mm - 1.6mm
PA Liner
Copper - Brass Neck Liners
For high heat applications fitting brass or copper wound jumper or neck liner on the end of the liner at the neck end
will increase the working temperature of the liner as well as improve the electrical conductivity of the welding power
transfer to the wire.
Neck Liner
21
Torch & Wire Feed Set Up for Aluminium Wire
(1)
(2) (3) (4) (5) (5) (8) (9) 22
Lay the torch out straight on the ground and remove the front end parts
Remove the liner retaining nut.
Carefully pull the liner out of the torch cable assembly
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.
Leave the liner extending out the end of the torch neck end by 3mm.
Fit the liner retaining nuttogether with the liner o-ring.
Push the liner firmly into the torch lead and tighten the liner retaining nut.
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
(7) Fit the liner collet, liner O-ring and
liner retaining nut.
(8) Push the liner firmly into the torch lead
and tighten the liner retaining nut
(9) Install a U groove drive roller of the
correct size for the diameter wire being
used.
Continued Torch & Wire Feed Set Up for Aluminium Wire
(10) Loosen off the inlet guide tube retaining screw
(11) Remove the inlet guide tube from the front end machine euro connector using long nose pliers.
(12) Carefully feed the extended PA liner section into the inlet guide tube hole of the machine euro
connector
(13) Feed the extended PA liner all the way up and over the drive roller
(14) Tighten the torch euro connection to the machine euro connector
(15) Cut the extended liner with a sharp Stanley knife just in front of the drive roller
(16) Fit an Aluminium contact tip of the correct size to match the diameter of the wire being used
(17) Fit the remaining front end parts to the torch neck ready for welding
(10)Connect the torch to the machine tighten
and secure the torch euro connector to the
machine euro connection.
(11) Install a U groove drive roller of the
correct size for the diameter wire being
used.
(7) Place aluminium wire onto spool holder.
Feed the wire through the inlet guide tube
on to the drive roller.
(12) Press and hold the inch wire button to
feed the wire down the torch cable through
to the torch head.
(16) Fit an Aluminium contact tip of the
correct size to match the wire diameter
being used
(17) Fit the remaining front end parts to the
torch neck ready for welding.
23
Razor2O5-SS MIG-TIG-MMA
Set up installation for Spool Gun
(1) (2) (3) (4) (5) (6) (7) (9) (10)
Select Spool Gun using the Standard/Spool Gun selector switch.
Connect the Spool Gun to the Euro Mig torch connection socket on the front panel, and tighten it.
IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can
result in the connector arcing and damaging the machine and gun connector.
This damage is not covered under warranty.
Insert the weld power cable plug into the Positive socket on the front of the machine and tighten it.
Connect the Spool Gun control cable to the multipin receptacle located on the lower front panel.
Insert the earth cable plug into the Negative socket on the front of the machine and tighten it.
Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator.
Connect the gas line to the machine via the quick push lock connector located on the rear panel.
Take the Spool Gun and remove the spool cover.
Place the Wire Spool onto the Spool Holder - Hold and snip the wire from the spool being sure to hold
the wire to prevent rapid uncoiling.
(6) Connect the gas regulator to the gas
cylinder and tigthen. Connect the gas
line to the gas regulator.
(1) Set Standard/Spoolgun selector
switch inside door to Spool Gun
(2) Connect the Spool Gun
IMPORTANT : When connecting the
torch be sure to tighten the connection.
(7) Connect the gas line to the machine
inlet gas connector via the quick push
lock connector located on the rear panel
(5) Connect the earth
lead to the
terminal
(4) Connect the Spool Gun
control cable
(3) Connect the Weld Power
lead to the
terminal
IMPORTANT
Select the correct polarity. Connect the weld
power lead to
output terminal.
Caution:
(9) Remove the spool cover by unscrewing the retaining nut and lifting off the
cover
(10) Place a spool of wire onto the Spool
holder.
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.
24
continued: Set up installation for Spool Gun
Razor2O5-SS MIG-TIG-MMA
(11) Unclip and swing open the wire feed housing cover to expose the wire feed mechanism.
(12) Unclip and swing back the wire tension swing arm. Check the that the correct drive roller is installed.
(13) Carefully feed the wire through the drive roller into the inlet guide tube. Swing back and clip down the
wire tension swing arm.
(13) Remove the gas nozzle and contact tip from the torch neck, Pull the trigger to drive the wire through
the neck until it exits the contact tip holder.
(14) Check the drive roll pressure is enough to drive the wire smoothly and djust the drive roll pressure if
required by using the adjustment grub screw. Screw clockwise to increase the tension using an Allen
Key tool.
(14) Fit the correct sized contact tip and gas nozzle. Close the wire feed housing cover, fit the spool
cover,ready for welding.
(17) Carefully open the gas cylinder valve and set the flow rate to between 8-12 l/min.
(19) Select MIG function and 2 or 4T Trigger function on the front panel.
(18) Set the welding parameters using the wire feed and voltage control knobs.
(11) Unclip and open the wire feed housing
cover
(12) Unclip and swing back the wire tension
swing arm. Check the that the correct drive
roller is installed.
(13) Feed the wire through the drive roller
into the inlet guide tube. Swing back and clip
down the wire tension swing arm.
(14) Remove the gas nozzle and contact tip.
Pull the trigger to drive the wire through the
neck until it exits the contact tip holder
(15) Adjust the drive roll pressure if required
by using the adjustment grub screw. Screw
clockwise to increase the tension using an
Allen Key tool.
(16) Fit the contact tip and gas nozzle, close
the wire feed housing cover, fit the spool
cover,ready for welding.
(17) Carefully open the valve of the gas
cylinder, set the flow to 10 l/min
(18) Select MIG function and 2Tor 4T trigger
Important: Smart Set programs are for solid
steel wire only.
(19) Set welding parameters using the
wire feed and voltage knobs.
25
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
26
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
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.
droplet
separates
The pinch causes the forming
droplet to separate and fall
towards the now creating weld
pool.
wire heating
The wire cannot support all the
current flow, resistance builds
up and the wire becomes hot
and weak and begins to melt
arc flattens
the droplet
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
magnetic
field pinches
wire
The current flow creates a
magnetic field that begins to pinch
the melting wire forming it into droplet
cycle
repeats
The wire feed speed overcomes
the heat of the arc and the wire
again approaches the work to
short circuit and repeat the cycle.
27
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 primarly 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
(B) Gun Perpendicular
(C) Drag Technique
10°
10°
travel direction
travel direction
wire pointed ahead of bead
flat even weld profile
light penetration
28
travel direction
wire pointed back into bead
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.
Not enough angle
Angle 5°- 15°
good level of control over the
weld pool, even flat weld
Angle more than 20°
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.
Not enough angle
Correct angle
good level of control over the
weld pool, even flat weld
less control over the weld pool
more spatter
Too much angle
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
29
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
porosity
undercut
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.
Too Slow Travel Speed
large wide bead
porosity
lack of fusion
cold lap
lack of joint penetration
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.
Correct Travel Speed
even shaped bead
good side wall fusion
30
good toe 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
MIG SOLID WIRE
0.6mm
0.8mm
0.9mm
GASLESS FLUX CORED WIRE
1.0mm
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
31
Installation and set up for DC TIG Welding with XA-MIG205SS
(1) Connect the TIG torch to the Euro connection on the front of the machine and tighten it.
IMPORTANT : When connecting the torch be sure to tighten the connection
(2) Insert the earth cable plug into the Positive socket on the front of the machine and tighten it.
(3) Insert the weld power cable plug into the Negative 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) Connect the gas line to the machine via the quick push lock connector located on the rear panel.
(6) Open the gas valve cylinder slowly and set the flow rate for 12 l/min.
(7) Select TIG functionon the front panel.
Set torch operation 2T / 4T.
• When 2T operation is selected press trigger Gas starts, touch and lift arc start, release trigger Gas and Arc stops.
• When 4T operation is selected press and release trigger Gas starts, touch and lift arc start, press and release
trigger Gas and Arc stops.
(4) Connect the gas line to the regulator
and connect to the gas cylinder
(5) Connect the gas line to the machine
inlet gas connector via the quick push
lock connector located on the rear panel
(1) Connect the TIG torch
IMPORTANT : When connecting the
torch be sure to tighten the connection.
(3) Connect the Weld Power lead
to the
terminal
(2) Connect earth lead
to the
IMPORTANT
Select the correct polarity. Connect the weld
power lead to
output terminal.
32
(6) Carefully open the valve of the gas
cylinder, set the flow to 6-10 l/min
terminal
(7) Select TIG function, 2T, 4T Trigger as
required
LIFT ARC DC TIG Operation
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.
(8) Select amperage as required on the front panel. The selected amperage will show on the digital meter.
(9) Assemble front end parts of the TIG torch making sure they 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.
(10) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from the
work piece. Press and hold the torch switch to activate to gas flow and welding power.
(11) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the work
piece.
(12) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece to
create the arc.
(13) Release the trigger to stop the welding.
(8) Select the required Amperage and
Downslope Time using the control knobs.
(11) With a small movement rotate the
Gas Cup forward so that the Tungsten
Electrode touches the work piece.
(9) Assemble front end parts of the TIG torch,
fitting a sharpened tungsten suitable for DC
welding.
(10) Lay the outside edge of the Gas Cup
on the work piece with the Tungsten Electrode 1- 2mm from the work piece. Press
and hold the trigger button on TIG torch to
start the gas flow.
(12) Now rotate the Gas Cup in the reverse
direction to lift the Tungsten electrode from
the work piece to create the arc.
(13) Release the trigger to stop the welding
IMPORTANT! - We strongly recommend that you check for gas leaks 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, And authorised representatives or
agents of Welding Guns Of Australia Pty Ltd will not be liable or
responsible for the loss of any gas.
33
DC TIG Welding
The DC power source uses what is known as DC (direct current) in which the main
electrical component known as electrons flow in only one direction from the negative pole
(terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical
principle at work which should always be taken into account when using any DC circuit.
With a DC circuit 70% of the energy (heat) is always on the positive side. This needs to
be understood because it determines what terminal the TIG torch will be connected to
(this rule applies to all the other forms of DC welding as well ).
30%
70%
argon gas
power source
nozzle
DC TIG welding is a process in which an arc is struck between a
TUNGSTEN electrode and the metal work piece. The weld area
is shielded by an inert gas flow to prevent contamination of the
tungsten, molten pool and weld area.
When the TIG arc is struck the inert gas is ionized and
superheated changing it’s molecular structure which converts it into
a plasma stream. This plasma stream flowing between the tungsten
and the work piece is the TIG arc and can be as hot as 19,000°C.
It is a very pure and concentrated arc which provides the controlled
melting of most metals into a weld pool. TIG welding offers the user
the greatest amount of flexibility to weld the widest range of material
and thickness and types. DC TIG welding is also the cleanest weld
with no sparks or spatter.
The intensity of the arc is proportional to the current that flows from the
tungsten. The welder regulates the welding current to adjust the power
of the arc. Typically thin material requires a less powerful arc with less
heat to melt the material so less current (amps) is required, thicker
material requires a more powerful arc with more heat so more current high
current
(amps) are necessary to melt the material.
low
current
LIFT ARC IGNITION for TIG (tungsten inert gas) Welding
Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts, with
a current limit of one or two amps (well below the limit that causes metal to transfer and contamination of the
weld or electrode). When the machine detects that the tungsten has left the surface and a spark is present,
it immediately (within microseconds) increases power, converting the spark to a full arc. It is a simple, safe
lower cost alternative arc ignition process to HF (high frequency) and a superior arc start process to scratch
start.
gas flow
tungsten off the
work
Lay the nozzle on the job
without the tungsten touching the work
34
tungsten touches
the work
Rock the torch sideways so
that the tungsten touches
the work & hold momentarily
arc ignition
Rock the torch back in the
opposite direction, the arc
will ignite as the tungsten
lifts off the work
established
TIG arc
Lift the torch to maintain
the arc
TIG Welding Fusion Technique
Manual TIG welding is often considered the most difficult of all the welding
processes. Because the welder must maintain a short arc length, great care and skill are
required to prevent contact between the electrode and the workpiece. Similar to Oxygen
Acetylene torch welding, Tig welding normally requires two hands and in most
instances requires the welder to manually feed a filler wire into the weld pool with one
hand while manipulating the welding torch in the other. However, some welds combining
thin materials can be accomplished without filler metal like edge, corner, and butt joints.
This is known as Fusion welding where the edges of the metal pieces are melted together using only the
heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until
a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired
size. Once the weld pool is established tilt the torch at about a 75° angle and move smoothly and evenly
along the joint while fusing the materials together.
75°
Travel direction
Form a weld pool
Angle torch
Move the torch slowly
and evenly forward
TIG Welding with Filler Wire Technique
It is necessary in many situations with TIG welding to add a filler wire into the weld
pool to build up weld reinforcement and create a strong weld. Once the arc is started
the torch tungsten is held in place until a weld pool is created, a circular movement
of the tungsten will assist is creating a weld pool of the desired size. Once the weld
pool is established tilt the torch at about a 75° angle and move smoothly and
evenly along the joint. The filler metal is introduced to the leading edge of the
weld pool. The filler wire is usually held at about a 15° angle and fed into the
leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is
moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the
wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly
and evenly forward. It is important during the welding to keep the molten end of the filler wire inside
the gas shield as this protects the end of the wire from being oxidised and contaminating the weld
pool.
75°
Travel direction
Form a weld pool
15°
Angle torch
Add Tig filler wire
gas
shield
Retract the filler wire
Move the torch forward to
the front of the weld pool
Repeat the process
35
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, 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 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. 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.
E3 (Color Code: Purple)
E3 tungsten electrodes (AWS classification EWG) contain a minimum of 98% percent tungsten and up to 1.5 percent
Lanthanum and small percentages of Zirconium and Yttrium they are called E3 Tungsten. E3 Tungsten Electrodes provide
conductivity similar to that of thoriated electrodes. Typically, this means that E3 Tungsten Electrodes are exchangeable with
thoriated electrodes without requiring significant welding process changes. E3 deliver superior arc starting, electrode lifetime,
and overall cost-effectivenes. When E3 Tungsten Electrodes are compared with 2% thoriated tungsten, E3 requires fewer
re-grinds and provides a longer overall lifetime. Tests have shown that ignition delay with E3 Tungsten Electrodes actually
improves over time, while 2% thoriated tungsten starts to deteriorate after only 25 starts. At equivalent energy output, E3
Tungsten Electrodes run cooler than 2% thoriated tungsten, thereby extending overall tip lifetime. E3 Tungsten Electrodes
work well on AC or DC. They can be used DC electrode positive or negative with a pointed end, or balled for use with AC
power sources.
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
36
Tungsten
Diameter
mm
DC Current Amps
Torch Negative
2% Thoriated
AC Current Amps
Un-Balanced Wave
0.8% Zirconiated
AC Current Amps
Balanced Wave
0.8% Zirconiated
1.0mm
1.6mm
2.4mm
3.2mm
4.0mm
15 - 80
70 -150
150- 250
250 - 400
400 - 500
15 - 80
70 - 150
140 - 235
225 - 325
300 - 400
20 - 60
60 - 120
100 - 180
160 - 250
200 - 320
Tungsten Preparation
Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a
diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium
oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will
contribute to weld inconsistency and weld defects.
Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel. Tungsten electrodes are
manufactured with the molecular structure of the grain running lengthwise and thus grinding crosswise is “grinding
against the grain.” If electrodes are ground crosswise, the electrons have to jump across the grinding marks and the
arc can start before the tip and wander. Grinding longitudinally with the grain, the electrons flow steadily and easily to
the end of the tungsten tip. The arc starts straight and remains narrow, concentrated, and stable.
grind longitudinal on the
grinding wheel
don’t grind across
the grinding wheel
Electrode Tip/Flat
The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection
of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur
and the more difficult it will be to arc start. However, increasing the flat to the maximum level that still allows arc start
and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders still grind
electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from
melting at the tip and the possibility of the point falling off into the weld pool.
2.5 times tungsten diameter
pointed tip
flat tip
Electrode Included Angle/Taper - DC Welding
Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a
specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and
offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide
the following benefits:
• Last Longer
flat spot diameter
• Have better weld penetration
• Have a narrower arc shape
• Can handle more amperage without eroding.
included angle
Sharper electrodes with smaller included angle provide:
• Offer less arc weld
• Have a wider arc
• Have a more consistent arc
The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration
increases and bead width decreases.
Tungsten
Diameter
Diameter at
the Tip - mm
Constant Included
Angle - Degrees
Current Range
Amps
Current Range
Pulsed Amps
1.0mm
1.6mm
1.6mm
2.4mm
2.4mm
3.2mm
3.2mm
.250
.500
.800
.800
1.100
1.100
1.500
20
25
30
35
45
60
90
05 - 30
08 - 50
10 - 70
12 - 90
15 - 150
20 - 200
25 - 250
05 - 60
05 - 100
10 - 140
12 - 180
15 - 250
20 - 300
25 - 350
37
Suregrip Series
SB25 MIG TORCH
250A AIR COOLED MIG WELDING TORCH
Rating:230A CO² 200A mixed gas EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires
*
Wear parts next page
*
Wear parts next page
Torch Model
Description
SB25 Suregrip Ergo Torch Package
Part Number
3 Mt
4 Mt
5 Mt
SB25-3M
SB25-4M
SB25-5M
Spare Parts
1
2
3
4
5
6
7
8
9
38
128
Part Number
GNS25
SNK25
SNKF
UG1515
UB1505
UG8015
UB1521
UB1521-C
UB2503-30
UB2503-40
UB2503-50
UG2514
Description
Shroud Spring
Swan Neck Assembly
Swan Neck Flexiable 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
10
11
12
13
14
15
16
17
18
19
20
Part Number
UG2516
UB2517
UB1522
UPA2041
UB1518
UB1541
UB1519/S
UB1523
UC1528
UB1524
UB1525
Description
Medium / Large Ergo Trigger
Hanger Hook
Cable Terminal Male
Cable Support
Gun Plug Housing C/W Nut
Gun Plug Screw
Gun Plug Nut
Gun Plug Terminal Female
Hybrid Gun Plug Body C/W Spring Pins
Gun Plug ‘O’ Ring
Liner Nut
Suregrip Series
SB25 MIG TORCH
Front end consumables
SB25 Contact Tips
Ø 8.0
M6 x 1.0
Part Number
PCT0009-06
PCT0009-08
PCT0009-09
PCT0009-10
PCT0009-12
PCT0009-16
PCTZR009-09
PCTZR009-12
PCTAL0009-09
PCTAL0009-10
PCTAL0009-12
M6 x 1.0
M8 x 1.25
28.0
Description
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)
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
Description
Contact Tip Holder
Shroud Spring
QTY2
QTY2
Description
Cylindrical Nozzle
Conical Nozzle
Tapered Nozzle
Spot Nozzle
QTY2
QTY2
QTY2
QTY2
SB25 Tip Holder
Part Number
PCTH25
PGNS25
35.0
Ø 15
Bore
Ø 21.5
SB25 Gas Nozzle
57.5
Liners
Part Number
PGN25CYL
PGN25CON
PGN25TAP
PGN25SPOT
SB25 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
0.6
Blue Steel Liner 5 Metre
Red Steel Liner 3 Metre
Red Steel Liner 4 Metre
0.9
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
Neck Spring for Aluminium
- 0.8mm
- 1.2mm
} 0.6 - 0.8mm
} 0.9 - 1.2mm
} 1.2 - 1.6mm
These parts are manufactured in China and are offered as
replacement parts suitable for “BINZEL®” style torches.
129
39
Suregrip Series
240AMP SPOOL GUN
240A Air-Cooled MIG Welding Torch
Rating: 240A CO2 220A mixed gas, EN60974-7 @ 60% duty cycle. 0.8 to 1.2mm wires
20
21
22
23
* page next page
Wear parts
24
36
41
37
39
35
38
40
25
26
28
32
29
33
34
42
27
40
30
31
Torch Model
Description
Part Number
6Mt
PLSP240A-24-P1-60ER
240 Spool Gun Suregrip series
Spare Parts
Part Number
Description
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
USP2401 USP1502 UGP36006 UGP36402B UGP36402 UGP36402R USP36001 USP36006 SC2563 MIG8015 PLSP1517-60ER PLSP1517-60DN UKA3X20 USP2515SP-B USP2515SP-C USP2515SP-PT-1K USP2515SP-PT-5K USP2515SP-PT-10K
USP2515SP-PT-25K
UGP2514-C CSP2515-KJ UGP2516 SC2597 UB1521 UGPMS1 UGP8224W-08 UGP8224W-09 UGP8224W-10 Straight Neck Assembly Jump Liner
Jump Liner Nipple
Tension Knob Pressure Arm Assembly Pressure Roll
Motor Body
Wire Guide
Screw Pack
Cable Support
Coax Cable Assembly, Euro Type Coax Cable Assembly, Dinse Type
Handle Screw Pack
Spool Box
Spool Cover
Wire Speed Control 1KΩ
Wire Speed Control 5KΩ
Wire Speed Control 10KΩ
Wire Speed Control 25KΩ
Push Pull Handle Cover
Spool-On Handle
Push Pull Trigger
Circular Cold Press Terminal
Cable Terminal
Motor Screw Pack
Driver Roll For Hard Wire 0.8
Driver Roll For Hard Wire 0.9
Driver Roll For Hard Wire 1.0
23
UGP8224W-08U Driver Roll For Aluminium Wire 0.8
UGP8224W-09U Driver Roll For Aluminium Wire 0.9
UGP8224W-10U Driver Roll For Aluminium Wire 1.0
24
UGP7020-24 Motor 24V DC
UGP7020-42 Motor 42V DC
25
UPA2041 Cable Support
26
UB1505 Lock Nut
27
UB1522 Cable Terminal Male
28
SCSP1-1 Gun Plug Housing Screw
29
UBL1541 Gun Plug Screw
30
SC2578H/L Gun Plug Housing Assembly
31
UB1523 Gun Plug Terminal Female
32
UC1519/S Housing Nut
33
UC1528 Hybrid Gun Plug Body C/W Spring Pins
34
UB1525 Liner Nut
35
USLH26-SM Cable Support Large
36
USLH26-C SurelokTM Housing Cover
37
USLH26-H SurelokTM Housing Large
38
USL-1 Gas Supply Hose
39
USL3550 SurelokTM Body & Support
40
UERSP1 Screw Pack
41
UPA3541 Cable Support
42
UB1525W Washer
*Note: Gas supply hoses are specified by utilizing the part
number and a termination suffix from the gas supply
hose table on page 8.
Example: USL-1-GS1
Gas supply hoses C/W 3/8” BSP fitting.
Denotes torch package drive roll set up
Note: All packages supplied with hard and soft wire drive roll
Part Number
Description
Suregrip Series
240AMP SPOOL GUN
Front end consumables
M6 x 1.0
Ø 8.0
SB24 Contact Tips
M6 x 1.0
M6 x 1.0
28.0
Part Number PCT0009-06 PCT0009-08
PCT0009-09
PCT0009-10
PCT0009-12
PCT0009-16
PCTZR009-09
PCTZR009-12
PCTAL0009-09
PCTAL0009-10
PCTAL0009-12
Description
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)
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
QTY10
Description
Contact Tip Holder
QTY2
SB24 Tip Holder
Part Number PCTH24
26.0
Ø 13.1
Ø 14.5
SB24 Gas Diffuser
Part Number PCGD24
Description
Gas Diffuser
QTY2
Description
Cylindrical Nozzle
Conical Nozzle
Tapered Nozzle
Spot Nozzle
QTY2
QTY2
QTY2
QTY2
Ø 17.2
Bore
Ø 20.0
25.0
63.5
SB24 Gas Nozzle
Part Number PGN24CYL
PGN24CON
PGN24TAP
PGN24SPOT
These parts are manufactured in China and are offered as
replacement parts suitable for “BINZEL®” style torches.
41
Suregrip Series
SR26 ERGO TIG TORCH
180A AIR COOLED TIG WELDING TORCH
5
8
3
Rating:180Amp DC, 125Amp AC @35% duty cycle.
2
4
6
7
G
bby
ens
as L
s
s
erie
serie
ns s
e
as L
s
serie
s
erie
ries
s se
Len
eG
Larg
Gas
by s
dard
Stan
Stub
Stu
9
10
11
13
12
*
Wear Parts Identification Next Page
42
Torch Model
Description
Part Number
4m
SR26 Suregrip TIG Torch Package Euro Connection
SRE26-4M
Spare Parts
Part Number
Description
Part Number
Description
1
2
3
4
5
6
7
8
9
10
11
WP26
WP26F
57Y02
57Y03
57Y04
UER1MS
UERSWL4
UERSWL8
UERSP1
UERH200
UERKJ200
UERLC200-08
UERJK200
Torch head
Torch head flexible
Back cap long
Medium back cap
Short back cap
Momentary Kit
Trigger Lead 12.5ft
Trigger Lead 25ft
Screw Pack
Large Ergo Tig Handle
Large Knuckle Joint
Leather Cover X 0.8mt
Jointing Repair Kit
12
13
UERNCL-32
UERNCL-72
UERCO200-40
UERCO200-80
Neoprene Cover X 3.2mt
Neoprene Cover X 7.2mt
Sheath X 12.5ft Inc Leather Cover
Sheath X 25ft Inc Leather Cover
Suregrip Series
SR26 ERGO TIG TORCH
Standard Front End Parts
Part #
18CG
Description
Cup Gasket
Part #
10N30
10N31
10N32
10N28
Part #
10N22
10N23
10N24
10N25
Description
Collet Body 1.0mm
Collet Body 1.6mm
Collet Body 2.4mm
Collet Body 3.2mm
Description
Collet 1.0mm
Collet 1.6mm
Collet 2.4mm
Collet 3.2mm
Part #
10N49L
53N48L
53N47L
Part #
10N50
10N49
10N48
10N47
10N46
10N45
10N44
Description
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Alumina Nozzle
Description
Long Alumina Nozzle Ø8mm #5L
Long Alumina Nozzle Ø 10mm #6L
Long Alumina Nozzle Ø 11mm #7L
Ø 6mm #4
Ø 8mm #5
Ø 10mm #6
Ø 11mm #7
Ø 13mm #8
Ø 16mm #10
Ø 19mm #12
Compact Gas Lens Front End Parts
Part #
54N01
Description
Gas Lens Gasket
Part #
45V25
45V26
45V27
Description
Gas Lens Body 1.6mm
Gas Lens Body 2.4mm
Gas Lens Body 3.2mm
Part #
54N14
54N15
54N17
Description
Gas lens ceramic 8.0mm
Gas lens ceramic 7.0mm
Gas lens ceramic 5.0mm
TR0004-16
RED
ANSI/AWS A5.12-98
ISO 6848 WT20
2% Thoriated: Best stability
at medium currents, good arc
starts, medium tendency to
spit, medium erosion rate.
Commonly used for steel and
stainless steel applications
Part #
TR0004-10
TR0004-16
TR0004-24
TR0004-32
Description
1.0mm x 175mm
1.6mm x 175mm
2.4mm x 175mm
3.2mm x 175mm
thoriated
thoriated
thoriated
thoriated
tungsten
tungsten
tungsten
tungsten
electrode
electrode
electrode
electrode
2%
2%
2%
2%
1/16 x 7” (1.6mm x 175mm)
3/32 x 7” (2.4mm x 175mm)
1/8 x 7” (3.2mm x 175mm)
TR0006-16
WHITE
ANSI/AWS A5.12 M-98
ISO 6848 WZ8
.8% Zirconiated: Balls well, handles higher current with less spitting,
better arc starts and arc stability
than pure tungsten
Commonly used for
aluminium applications
Part #
TR0006-10
TR0006-16
TR0006-24
TR0006-32
Description
1.0mm x 175mm
1.6mm x 175mm
2.4mm x 175mm
3.2mm x 175mm
zirconiated
zirconiated
zirconiated
zirconiated
tungsten
tungsten
tungsten
tungsten
electrode
electrode
electrode
electrode
1%
1%
1%
1%
1/16 x 7” (1.6mm x 175mm)
3/32 x 7” (2.4mm x 175mm)
1/8 x 7” (3.2mm x 175mm)
©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means,
electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.
43
DC 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
Select a lower voltage setting
Wrong polarity set
select the correct polarity for the wire being used - see machine setup guide
Stick out too long
Bring the torch closer to the work
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Contaminated mig wire
Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc
Inadequate gas flow or too much gas Check the gas is connected, check hoses, gas valve and torch are not restricted. Set
flow
the gas flow between 6-12 l/min flow rate. Check hoses and fittings for holes, leaks etc
Protect the welding zone from wind and drafts
2: Porosity - small cavities or holes resulting from gas pockets in weld metal.
Possible Reason
Suggested Remedy
Wrong gas
Check that the correct gas is being used
Inadequate gas flow or too much gas Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the
flow
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
Moisture on the base metal
Remove all moisture from base metal before welding
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Contaminated mig wire
Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc
Gas nozzle clogged with spatter,
worn or out of shape
Clean or replace the gas nozzle
Missing or damaged gas diffuser
Replace the gas diffuser
Mig torch euro connect o-ring missing or damaged
check and replace the o-ring
4: Wire stubbing during welding
Possible Reason
Suggested Remedy
Holding the torch too far away
Bring the torch closer to the work and maintain stick out of 5-10mm
Welding voltage set too low
Increase the voltage
Wire Speed set too high
Decrease the wire feed speed
Possible Reason
Suggested Remedy
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Not enough heat input
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: Lack of Fusion − failure of weld metal to fuse completely with base metal or a proceeding weld bead.
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
44
Poor in incorrect joint preparation
Material too thick. Joint preparation and design needs to allow access to bottom of
groove while maintaining proper welding wire extension and arc characteristics
Keep the arc at the leading edge of the weld pool and maintain the gun angle at
5 & 15° keeping the stick out between 5-10mm
Not enough heat input
Select a higher voltage range and /or adjust the wire speed to suit
Reduce travel speed
Contaminated base metal
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
Be sure to adjust the WIRE FEED and VOLTAGE dials for MIG welding.
The AMPERAGE dial is for STICK and TIG welding mode
Wrong polarity selected
Select the correct polarity for the wire being used - see machine setup guide
Incorrect wire speed setting
Adjust the wire feed speed
Voltage setting incorrect
Adjust the voltage setting
Mig torch lead too long
Small diameter wires and soft wires like aluminium don’t feed well through long torch
leads - replace the torch with a lesser length torch
Mig torch lead kinked or too sharp
angle being held
Remove the kink, reduce the angle or bend
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)
Try to clear the liner by blowing out with compressed air as a temporary cure,
it is recommended to replace the liner
Wrong size liner
Install the correct size liner
Blocked or worn inlet guide tube
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
Fit the correct type roller (e.g. knurled rollers needed for flux cored wires)
Worn drive rollers
Replace the drive rollers
Drive roller pressure too high
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
45
DC 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 or No Gas
Use pure Argon. Check cylinder has gas, connected, turned on and torch valve is open
Inadequate gas flow
Check the gas is connected, check hoses, gas valve and torch are not restricted.
Back cap not fitted correctly
Make sure the torch back cap is fitted so that the o-ring is inside the torch body
Torch connected to DC +
Connect the torch to the DC- output terminal
Incorrect tungsten being used
Check and change the tungsten type if necessary
Tungsten being oxidised after weld
is finished
Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10
amps of weld current.
Possible Reason
Suggested Remedy
Touching tungsten into the weld
pool
Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of
the work piece 2 - 5mm
Touching the filler wire to the tungsten
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
Possible Reason
Suggested Remedy
2: Contaminated tungsten
3: Porosity - poor weld appearance and colour
Wrong gas / poor gas flow /gas leaks Use pure argon.Gas is connected, check hoses, gas valve and torch are not restricted.
Set the gas flow between 6-12 l/min. Check hoses and fittings for holes, leaks etc.,
Contaminated base metal
Remove moisture and materials like paint, grease, oil, and dirt from base metal
Contaminated filler wire
Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire
Check the filler wire and change if necessary
Possible Reason
Suggested Remedy
Incorrect Gas
Use pure Argon gas
Inadequate gas flow
Set the gas flow between 10 - 15 l/min flow rate
Alumina gas nozzle too small
Increase the size of the alumina gas nozzle
4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten
5: Unstable Arc during DC welding
Possible Reason
Suggested Remedy
Torch connected to DC +
Connect the torch to the DC- output terminal
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long
Lower torch so that the tungsten is off of the work piece 2 - 5mm
Possible Reason
Suggested Remedy
Poor gas flow
Check and set the gas flow between 10 - 15 l/min flow rate
Incorrect arc length
Lower torch so that the tungsten is off of the work piece 2 - 5mm
Tungsten incorrect or in poor condition
Check that correct type of tungsten is being used. Remove 10mm from the weld end of
the tungsten and re sharpen the tungsten
Poorly prepared tungsten
Grind marks should run lengthwise with tungsten, not circular. Use proper grinding
method and wheel.
Contaminated base metal or 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.
7: Arc wanders during DC welding
8: Arc difficult to start or will not start DC welding
46
Possible Reason
Suggested Remedy
Incorrect machine set up
Check machine set up is correct
No gas, incorrect gas flow
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
Incorrect tungsten size or type
Check and change the size and or the tungsten if required
Loose connection
Check all connectors and tighten
Earth clamp not connected to work
Connect the earth clamp directly to the work piece wherever possible
MMA (Stick) WELDING TROUBLE SHOOTING
The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction,
the manufacturer’s recommendations should be strictly adhered to and followed.
1: No arc
Possible Reason
Suggested Remedy
Incomplete welding circuit
Check earth lead is connected. Check all cable connections.
Wrong mode selected
Check the MMA selector switch is selected
No power supply
Check that the machine is switched on and has a power supply
Possible Reason
Suggested Remedy
Arc length too long
Shorten the arc length
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Damp electrodes
Use only dry electrodes
Possible Reason
Suggested Remedy
Amperage too high
Decrease the amperage or choose a larger electrode
Arc length too long
Shorten the arc length
Possible Reason
Suggested Remedy
Insufficient heat input
Increase the amperage or choose a larger electrode
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
2: Porosity − small cavities or holes resulting from gas pockets in weld metal.
3: Excessive Spatter
3: Weld sits on top, lack of fusion
4: Lack of penetration
Possible Reason
Suggested Remedy
Insufficient heat input
Increase the amperage or choose a larger electrode
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation
Check the joint design and 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
Reduce the amperage or use a smaller electrode
Incorrect travel speed
Try increasing the weld travl speed
Possible Reason
Suggested Remedy
Unsteady hand, wavering hand
Use two hands where possible to steady up, practise your technique
Possible Reason
Suggested Remedy
Excessive heat input
Reduce the amperage or use a smaller electrode
Poor welding technique
Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation and or joint
design
Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit up
6: Uneven weld appearance
7: Distortion − movement of base metal during welding
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
47
Gas Flow Regulators - Sheilding Gases - Gas Flow Rates
Gas Flow Regulators
The job of the gas flow regulator is to reduce the bottle pressure gas down to a lower pressure and
deliver it at a constant flow. This constant flow of gas is usually fed through the welding machine where it is
controlled by a solenoid valve, operated when the torch trigger is pulled. Once the gas has passed the
solenoid valve it flows down the torch cable exiting at the gas nozzle to protect the weld pool and
surrounding area. There are two main types of flow regulators commonly used for MIG and TIG welding
applications. Both regulator types perform the same function, but have a different way of setting and
measuring the gas flow. A flow-gauge regulator (Fig.1) has a dial-type pressure gauge to measure the
cylinder contents and a second gauge to measure and deliver the flow rate required.The flow-meter
regulator (Fig.2) has a pressure gauge to measure the cylinder contents and a flow tube assembly to measure and deliver the flow rate required. Some flowmeter regulators will have two flow tube assemblies
Fig.1
Fig.2
Shielding Gases
Shielding gases are almost always necessary for MIG and TIG welding processes to protect the weld zone
from gases that are contained in the surrounding atmosphere, particularly nitrogen and oxygen. If allowed
into the weld zone these gases will contaminate the weld pool resulting in fusion defects also porosity and
embrittlement of the weld metal. Selecting the right type of shielding gas depends on the welding process
being used and type of material being welded.
The MIG process is typically a mixture of Argon and Co2 (AR90% Co2 10%) or pure Co2 for steel welding
applications, other specialised mixtures of Argon, Co2, and Oxygen are available for stainless steel welding
but with welding aluminium pure Argon is almost always used
The TIG welding process almost always requires 100% Argon for welding of all materials, however in some
specialised applications Helium, or a Helium mix are sometimes used.
Today with the multitude of gas mixes available through a number of different suppliers, it is difficult to list
and recommend which gas mix is better for which job. If you are unsure about what gas or gas mix to use
we recommend you discuss with your application local gas suppliers or your Esseti technical representative.
Gas Flow Rates
For MIG applications the ideal gas flow rate will depend on the type of mig wire, wire feed speed and current
being used and also the type metal transfer mode, i.e. Dip Transfer, Spray. Pulse MIG . Long interconnecting
cables between the power source and wire feeder and also long push pull torch cables may require higher
flow rates to compensate for the distance. As a general rule of thumb;
1. Small weld pools use 10 L/min,
2. Medium weld pools up to 15 L/min
3. Large spray, pulse mig weld pools use up to 25 L/min.
It is important to note that too high gas flow can be just as bad as having too low flow rate. The reason being
that if the gas flow exits the gas nozzle a too high rate it can.
1. create a vortex and draw air into the gas flow and the weld zone causing contamination of the weld.
2. produce turbulence at the weld pool resulting in a poor quality weld.
For TIG applications the ideal gas flow required will depend on the welding job being done, the type of
material being welded and the type of filler wire. As a generalguide start with a flow rate of 6 l/min. If porosity
or contamination appears in the weld then increase the flow rate. Also be aware of the welding environment,
if there is wind or a breeze an increase of flow rate will be required to compensate for this.
48
ATTENTION! - CHECK FOR GAS LEAKS
At initial set up and at regular intervals we recommend to check for gas leakage.
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 8-10 l/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the
regulator, if the needle drops away towards zero there is a gas leak.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the regulator
and line for an extended time period. In this situation it is recommended to open the cylinder valve, set
the flow rate to 8-10 l/min, close the cylinder valve and check after a minimum of 15 minutes.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing orspraying
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 leaks 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, and authorised representatives or agents of
Welding Guns Of Australia Pty Ltd will not be liable or responsible for the loss of any
gas.
49
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 Viper Series (Power Source Only)
UNI-MIG DIY Series (Power Source Only)
RAZORWELD Series (Power Source Only)
UNI-MIG Procraft Series (Power Source Only)
UNI-MIG Trade Series (Power Source Only)
UNI-MIG Trade Series SWF (Power Source / Seperate Wire Feeder Only)
UNI-MIG Workshop Series (Power Source Only)
UNI-MIG Workshop Series SWF (Power Source / Separate Wire Feeder Only)
UNI-MIG Jasic Inverter MIG (Power Source Only)
UNI-MIG Jasic Inverter MIG SWF (Power Source / Separate Wire Feeder Only)
UNI-TIG Jasic Inverter TIG (Power Source Only)
UNI-MIG Water Cooler
T&R Pulse MIG (Power Source Only)
T&R Pulse MIG SWF (Power Source / Separate Wire Feeder Only)
UNI-PLAS (Power Source Only)
UNI-PLAS Jasic Series (Power Source Only)
UNI-PLAS Site Cut Series (Power Source Only)
UNI-FLAME Gas Cutting and Welding Kits
UNI-FLAME Straight Line & Gas Cutting Machines (Power Source Only)
UNI-FLAME Regulators Argon/ Acetylene / Oxygen / LPG / Bobbin Flowmeter
UNI-FLAME Automatic Welding Helmet
UNI-MIG Automatic Welding Helmets
TECNA (Power Source Only)
HIT-8SS Automatic Carriage (Power Source Only)
ROTA 102 Rotating table
HOTBOX ElectrodeOven
SPOTCAR 3500
TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,
INTERCONNECTING CABLES, GAS HOSE
1 Year
2 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
3 Years
1 Year
2 Year
2 Year 3 Years
2 Years
1 Year
3 Months 1 Year 1 Year
2 Years
2 Years
1 Year 1 Year
1 Year
1 Year
1 Year
(Clause 1&3)
(Clause 3)
(Clause 1&3)
(Clause 1&3)
(Clause 1&3)
(Clause 1&3))
(Clause 1&3)
(Clause 1&3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 2&3)
(Clause 3)
(Clause 3)
(Clause 3)
(Clause 3)
3 Months (Clause 3)
(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB, and all other
components, .
(Clause 2) Gas Hose, Flashbacks are subject to and covered by the Manufacture’s Individual Warranty, Contact
the manufacturer for details
(Clause 3) This only Covers Manufactures defaults on all accesories for the first three months after date of purchase.
50
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.
51
MAKING A CLAIM
If you wish to make a claim under this Warranty, you should:
• Return the product to the point of purchase either in person or on a prepaid courier; or
• Contact Us by Telephone
Sydney Head Office:
Queensland:
Victoria:
Western Australia:
02 9780 4200 or Mail PO Box 3033 Lansvale NSW 2166.
07 3333 2855
03 8682 9911
08 6363 5111
When returned, the product must be accompanied with the original invoice including the purchase price and
disclosing the purchase date
All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the
Customer.
To the extent permitted by law, our total liability for loss or damage of every kind related to the product in any way
whatsoever is limited to the amount paid to the retailer by you for the product or the value of the product.
No responsibility will be taken for products lost, damaged or mislaid whilst in transit.
WARRANTY EXCLUSIONS
This Warranty covers Material and Faulty Workmanship defects only.
This Warranty does not cover damage caused by:
•
•
•
•
• •
•
•
•
•
Normal wear and tear due to usage
Misuse or abusive use of the UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA, instructions supplied with the product.
Failure to clean or improper cleaning of the product
Failure to maintain the equipment such as regular services etc
Incorrect voltage or non-authorised electrical connections
Improper installation
Use of non-authorised/non-standard parts
Abnormal product performance caused by any ancillary equipment interference or other external factors
Failure or any breakage caused by overload, dropping or abusive treatment or use by the customer
Repair, modifications or other work carried out on the product other than by an Authorised UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA Service Dealer
Unless it is a manufacturing fault, this Warranty does not cover the following parts:
MIG Welding Torches and Consumables to suit, such as:
Gas Nozzels, Gas Diffusers, Contact Tip holder, Contact tip, Swan Necks, Trigger, Handle, Liners,
Wire Guide, Drive Roller, Gas Nozzle Spring. Neck Spring, Connector Block, Insulator, Gas Nipple, Cap, Euro Block,
Head Assembly, Gas Block, Trigger Spring, Spring Cable Support, Neck Insulator, Shroud Spring,
Gun Plug Cover, Lock Nut, Snap On Head, Spring Cap, Ball, Motor 42 Volt, Pot 10K standard, Knob, Drive Roll Seat,
Washer, Bow, Ball Bearing, Wire Condue Nipple, Central Plug, Printed Circuit Board, Gun Plug House, Cable
Support, Gas Connector, Handle To Suit PP36 with Knobs, All Xcel-Arc/ Magmaweld Mig Welding Wires &
Electrodes, Arc Leads, Welding Cable, Electrode Holder, Eatch Clamps
.
TIG Welding Torches and Consumables to suit, such as:
Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled,
Torch Head Flexible,Back Caps, Gas Lens, Torch Handle, Cup Gasket, Torch Body Gas Valve, O-ring,
All UNI-MIG TIG Welding Rods, All Xcel-Arc/ Magmaweld Electrodes, Arc Leads, Welding Cable, Electrode Holder,
Eatch Clamps.
52
PLASMA Cutting Torches and Consumables to suit, such as:
All Cutting Tips, All Diffuser/Swirl Ring, All Electrode, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps,
All Air and Power Cables, All Switches, All O-rings, All Springs, All Circle Guides and Cutting Kits, Torch Bodies, Air
Filter Regulator, Arc Leads, Welding Cable, Electrode Holder, Eatch Clamps
STRAIGHT LINE CUTTING MACHINES and Consumables to suit, such as:
Hoses, Fittings, Track, Cutting Nozzles.
HIT-8SS Welding Carriage Consumables to suit, such as:
Input Cord, Inter-connecting Cord, Triggering Cable.
This Warranty does not cover products purchased:
• From a non-authorised UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA,T&R, HIT-8SS & ROTA Dealer
(such as purchases from unauthorised retailers and purchases over the Internet from unauthorised
local/international sellers or sites such as EBay)
• At an auction;
• From a private seller
Unless it is a manufacturing fault, this Warranty does not apply to any products sold to Hire Companies.
These conditions may only be varied with the written approval of the Directors of Welding Guns Of Australia PTY LTD
REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE
Notes
53
Spare Parts Identification - MIG205SS
1
14
17
15
16
2
3
4
5
6
8
7
20
18
19
9
21
22
23
10
13
11
12
24
#
Part Number Description Part Number
1
2
3
4
5
6
7
8
9
10
11
54
10043478
10043403
30000129
30000103
10041426
10041419
10037151
10041416
10043404
10004949
10041723
Handle
Front panel
Knob pointer
Knob pointer
Quick-connect 35-50
Central adaptor
Polarity lead
9 pin female socket
Rear panel
Power switch
Gas inlet
#
Part Number Description
12
10041446
13
10042876
14
10045879
15
10040667
16
10037485
17 10054346 18
10049264
19
10045881
2010054860
21
10054475
22
10041284
23
10046137
24
10049264
Fan DC24V
Power cable
Display pcb
Plastic packaged solenoid valve
Silicon bridge plate
Control pcb
Wire feeder motor
Mainboard
Insluation sheet
Spool holder
Selector switch
Wire inch & Gas check button
Wire feeder motor
Electrical Schematic Diagram
Razor2O5-SS MIG-TIG-MMA
55
© Welding Guns Of Australia PTY LTD 2013
Welding Guns Of Australia Pty Ltd
ABN: 14 001 804 422
PO Box 3033, Lansvale NSW 2166, AUSTRALIA
112 Christina Rd, Villawood, NSW 2163
Phone: (02) 9780 4200
Fax: (02) 9780 4244
Email: [email protected] / Web: www.unimig.com.au
56
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