OPERATING MANUAL

KUMJRRW200

KUMJRRW160

Please read and understand this instruction manual carefully

3

YEARS Warranty

(Power Source)

©

Welding Guns Of Australia PTY LTD 2015

3

CONTENTS PAGE

Warranty 2

Safety

Technical Data, Product Information

Machine Layout Descriptions

Installation & Operation for MMA (stick) Welding

MMA General Description

Installation & Operation for DC TIG Welding with Lift Arc

DC TIG General Description

26V TIG Torch Parts Breakdown

MMA (Stick) Welding Trouble Shooting

TIG Welding Trouble Shooting

Sapre Part Identification

Warranty terms

7

8

4-5

6

9-11

12-13

14-16

18-19

20

21-22

23

24-27

Thank you for your purchase of your UNI-MIG welding machine.

We are proud of our range of welding equipment that has a proven track record of innovation, performance and reliability.

Our product range represents the latest developments in Inverter technology put together by our professional team of highly skilled engineers. The expertise gained from our long involvement with inverter technology has proven to be invaluable towards the evolution and future development of our equipment range. This experience gives us the inside knowledge on what the arc characteristics, performance and interface between man and machine should be.

Within our team are specialist welders that have a proven history of welding knowledge and expertise, giving vital input towards ensuring that our machines deliver control and performance to the utmost professional level.

We employ an expert team of professional sales, marketing and technical personnel that provide us with market trends, market feedback and customer comments and requirements. Secondly they provide a customer support service that is second to none, thus ensuring our customers have confidence that they will be well satisfied both now and in the future.

UNI-MIG welders are manufactured and compliant with - AS/NZ60974.1 2006 - AS60974-6:2006 guaranteeing you electrical safety and performance.

WARRANTY

• 3 Years from date of purchase.

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

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

• Product will only be replaced if repair is not possible

3

SAFETY

Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations.

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

MACHINE OPERATING SAFETY

• Do not switch the function modes while the machine is operating. Switching of the function modes during

welding can damage the machine. Damage caused in this manner will not be covered under warranty.

• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing

should the electrode be in contact with the work piece.

• Operators should be trained and or qualified.

Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding, the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is dangerous.

• Connect the primary input cable according to Australian and New Zealand standards and regulations.

• Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.

The operator must wear dry welding gloves while he/she performs the welding task.

• The operator should keep the work piece insulated from himself/herself.

• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,

bare wiring is dangerous and can kill.

• Do not use damaged, under sized, or badly joined cables.

• Do not drape cables over your body.

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

Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes

• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and

gases.

• In confined or heavy fume environments always wear an approved air-supplied respirator.

Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the

breathing air is safe.

• Do not weld in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc

can react with vapours to form highly toxic and irritating gases.

• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic

fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing

an air supplied respirator.

Arc rays: harmful to people’s eyes and skin. Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.

• Always wear a welding helmet with correct shade of filter lens and suitable protective clothing including

welding gloves whilst the welding operation is performed.

• Measures should be taken to protect people in or near the surrounding working area. Use protective

screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

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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 cutting sparks may cause fire, therefore remove any flammable materials well away from the working

area. Cover flammable materials and containers with approved covers if unable to be moved from the

welding area.

• Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared

according to the required Safety Standards to insure that flammable or toxic vapors and substances are

totally removed, these can cause an explosion even though the vessel has been “cleaned”.

Vent hollow castings or containers before heating, cutting or welding. They may explode.

• Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)

• Have a fire extinguisher nearby and know how to use it. Be alert that welding sparks and hot materials

from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding

on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged.

• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames,

sparks, and arcs.

• Insure cylinders are held secure and upright to prevent tipping or falling over.

• Never allow the welding electrode or earth clamp to touch the gas cylinder, do not drape welding cables

over the cylinder.

• Never weld on a pressurised gas cylinder, it will explode and kill you.

• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.

Gas build up. The build up of gas can causes a toxic environment, deplete the oxygen content in the air resulting in death or injury. Many gases used in welding are invisible and odourless.

• Shut off shielding gas supply when not in use.

• Always ventilate confined spaces or use approved air-supplied respirator.

Electronic magnetic fields. MAGNETIC FIELDS can affect Implanted Medical Devices.

• Wearers of Pacemakers and other Implanted Medical Devices should keep away.

• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going

near any electric welding, cutting or heating operation.

Noise can damage hearing. Noise from some processes or equipment can damage hearing.

Wear approved hearing protection if noise level is high.

Hot parts. Items being welded generate and hold high heat and can cause severe burns.

Do not touch hot parts with bare hands. Allow a cooling period before working on the welding gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

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CAUTION

1. Working Environment.

1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive

chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity.

1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;

the temperature of working environment should be maintained within -10°C to +40°C.

1.3 Keep this equipment 30cm distant from the wall.

1.4 Ensure the working environment is well ventilated.

2. Safety Tips.

2.1 Ventilation

This equipment is small-sized, compact in structure, and of excellent performance in amperage output.

The fan is used to dissipate heat generated by this equipment during the welding operation.

Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is of critical importance for the normal performance and service life of this equipment.

2.2

Thermal Overload protection.

Should the machine be used to an excessive level, or in high temperature environment, poorly ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the machine will cease to operate. Under this circumstance, leave the machine switched on to keep the built-in fan working to bring down the temperature inside the equipment. The machine will be ready for use again when the internal temperature reaches safe level.

2.3

Over-Voltage Supply

Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.

This equipment is of automatic voltage compensation, which enables the maintaining of the voltage range within the given range. In case that the voltage of input power supply amperage exceeds the stipulated value, it is possible to cause damage to the components of this equipment. Please ensure your primary power supply is correct.

2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock may possibly occur.

MAINTENANCE

Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to prevent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry compressed air of required pressure.

Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of this welding equipment will be void if the machine has been modified, attempt to take apart the machine or open the factory-made sealing of the machine without the consent of an authorized representative of the manufacturer.

TROUBLE SHOOTING

Note:

Minimum Motor Generator Power Suggested:- 7KVA

EMC DECLARATION

I EC 60974-10:2007

Arc Welding equipment - Part 10: Electromagnetic compatibility (EMC) requirements (Classification of ISM

Equipment - According to IEC 60974-10:2007 and CISPR 11: 2033+A1:2004 Clause 4.1 and 4.2. The EUT

Belongs to Apparatus Group2 Class A)

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™

Razorweld

™

RAZORWELD ARC 160

MMA/TIG - 160 Amp DC Inverter Welder

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

™

Razor

weld

™

Industrial Rated

240V Single Phase 160 Amp DC Welder

Small, Lightweight and Portable

Features

• 10 Amp Plug

• Selectable VRD on/off (Voltage Reduction Device)

• Single PCB construction

• MMA

• PFC ( Power Factor Correction) for maximum electrical efficiency

- Hot start (improves electrode starting)

- Arc Force (boosts current to prevent electrode extinguishing)

- Excellent arc stability with all electrodes

• DC TIG

- Lift Arc ignition (prevents tungsten sticking during arc ignition)

- Ultra smooth DC TIG welding current

• Thermal overload protection

• IP21S rating for environmental/safety protection

• Generator compatible (recommend 7.5 KVA minimum)

• Auto-compensation for voltage fluctuation

• Minimal harmonic feedback to power grid

Selectable VRD on/off

(Voltage Reduction Device)

10 AMP

Technical Data

Power Supply / Phases (V-Ph)

Rated Input Power (KVA)

Ieff

Rated Output

Welding Current Range

No-Load Voltage (V)

240V - 1 ±15%

7.1

10A

160A/26.4V MMA

160A/16.4V TIG

10~160A

9

Duty Cycle @ 40ºC as per AS/NZ60974-1 20%@160Amps MMA

45%@160Amps TIG

Power Factor

Protection Class

Insulation Class

Size (mm)

Weight (kg)

Warranty

0.99

IP21S

F

365 x 227 x 135

6.5

3 years on power source

RAZOR160CA RAZOR160CT

Standard Package TIG Option

Overview

The ARC160 is an inverter-based welding machine produced using the latest in IGBT technology. This machine is reliable, robust and stacked with features that you can expect from a quality welder. The DC MMA welding capability delivers a smooth and incredibly stable arc allowing easy welding with electrodes producing high quality welds including cast Iron, stainless and low hydrogen. The

ARC160 is equipped with DC Lift Arc function, connection of the 26V TIG torch allows quality DC TIG welding of steel, stainless steel, bronze and copper. The Lift Arc function is superb and delivers perfect arc ignition every time without any sticking of the tungsten electrode to the work piece, a remarkably smooth stable arc produces high quality TIG welds. The ARC160 is an exceptional machine that is suitable for a wide range of industrial applications including, site welding, farming, along with repair and maintenance applications. ARC160 is packaged in a Razorweld carry bag with your choice of MMA option accessories or MMA/TIG option accessories. The ARC160 gives you the best of both worlds great portability, with the power to get the job done.

Built to our specification and manufactured in compliance to AS/NZ60974-1

Product Code: KUMJRRW160CA

MMA option includes: ARC160 Machine, Earth Lead & Arc Lead 25mm x 4m, Razorweld Carry Bag

Product Code: KUMJRRW160CT

TIG option includes: ARC160 Machine, Earth Lead & Arc Lead 25mm x 4m, 26V x 4m TIG Torch,

UNI-FLAME Argon Flowmeter Regulator and Razorweld carry bag

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Razorweld

™

RAZORWELD ARC 200

MMA/TIG - 200 Amp DC Inverter Welder

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

Industrial Rated

240V Single Phase 200 Amp DC Welder

Small, Lightweight and Portable

Features

• Single PCB construction

• MMA

• PFC ( Power Factor Correction) for maximum electrical efficiency

• VRD (Voltage Reduction Device)

- Hot start (improves electrode starting)

- Arc Force (boosts current to prevent electrode extinguishing)

- Excellent arc stability with all electrodes

• DC TIG

- Lift Arc ignition (prevents tungsten sticking during arc ignition)

- Ultra smooth DC TIG welding current

• Thermal overload protection

• IP21S rating for environmental/safety protection

• Generator compatible (recommend 9.0 KVA minimum)

• Auto-compensation for voltage fluctuation

• Minimal harmonic feedback to power grid

™

Razor

weld

™

15 AMP

Technical Data

Power Supply / Phases (V-Ph)

Rated Input Power (KVA)

Ieff

Rated Output

Welding Current Range

No-Load Voltage (V) MMA

240V - 1 ±15%

9.0

15A

200A/28V MMA

200A/18V TIG

10~200A

9 VRD ON

69 VRD OFF

Duty Cycle @ 40ºC as per AS/NZ60974-1 30%@200Amps MMA

Protection Class

Insulation Class

Size (mm)

Weight (kg)

Warranty

45%@200Amps TIG

IP21S

F

365 x 227 x 135

6.5

3 years on power source

RAZOR200CA RAZOR200CT

Standard Package TIG Option

Overview

The ARC200 is an inverter-based welding machine produced using the latest in IGBT technology. This machine is reliable, robust and stacked with features that you can expect from a quality welder. The DC MMA welding capability delivers a smooth and incredibly stable arc allowing easy welding with electrodes producing high quality welds including cast Iron, stainless and low hydrogen. The

ARC200 is equipped with DC Lift Arc function, connection of the 26V TIG torch allows quality DC TIG welding of steel, stainless steel, bronze and copper. The Lift Arc function is superb and delivers perfect arc ignition every time without any sticking of the tungsten electrode to the work piece, a remarkably smooth stable arc produces high quality TIG welds. The ARC2000 is an exceptional machine that is suitable for a wide range of industrial applications including, site welding, farming, along with repair and maintenance applications. ARC200 is packaged in a Razorweld carry bag with your choice of MMA option accessories or MMA/TIG option accessories. The ARC200 gives you the best of both worlds great portability, with the power to get the job done.

Built to our specification and manufactured in compliance to AS/NZ60974-1

Product Code: KUMJRRW200CA

MMA option includes: ARC200 Machine, Earth Lead & Arc Lead 25mm x 4m, Razorweld Carry Bag

Product Code: KUMJRRW200CT

TIG option includes: ARC200 Machine, Earth Lead & Arc Lead 25mm x 4m, 26V x 4m TIG Torch,

UNI-FLAME Argon Flowmeter Regulator and Razorweld carry bag

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FRONT MACHINE LAYOUT DESCRIPTION

Primary Power LED

VRD LED

Voltage Reduction Device

MMA /TIG Selector

Switch

Positive Output

Terminal

Thermal Alarm LED

Amperage Control

Dial

Negative Output

Terminal

Rear Machine Layout Description

On /Off Power Switch

Primary Input

Power Lead

VRD (Safe Function) Description - Note 160PFC Only

VRD reduces the welding power source’s open circuit voltage (OCV).

OCV is the voltage measured across the terminals when not welding.

The VRD unit will turn on welding power when the resistance between the electrode and work is less than 200 Ohms (typically metal to metal contact).

The Safe Function (VRD) allows the reduction of the no load voltage in the power source to a very safe level Uo<24V.

This function can be started up with the safe key indicated in the picture

When the Safe function is active, the green led on the front panel of the power source is ON

.

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INSTALLATION SET UP FOR MMA (STICK) WELDING WITH MMA-TIG160/200PFC

Please install the machine strictly according to the following steps.

The protection class of this machine is IP21, so avoid using it in rain.

Connection of Input Cables

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

(1) Turn the power source on and select the MMA function with the TIG/MMA selector switch.

(2) Connection of Output Cables: Various electrodes require a different polarity for optimum results refer

to the electrode manufacturers information for the correct polarity. Most GP electrodes are Electrode

connected to output socket, Earth Connected to the output socket

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

electrode manufacturer.

(4) Place the electrode into the electrode holder and clamp tight

(5) Strike the electrode on the work to create the arc and hold the electrode steady to maintain the arc

(6) Hold the electrode slightly above the work piece to maintain the arc while travelling at an even speed

to create and even weld deposition

(7) To finish the weld, break the arc by quickly snapping the electrode away from the work piece.

(8) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal underneath.

(1) Set TIG/MMA selector switch to MMA

(2) Connect the electrode lead to

(2) Connect earth lead to

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

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

(5) Strike the electrode against the workpiece to create and arc and hold the electrode steady to maintain the arc.

(6) Hold the electrode slightly above the work maintaining the arc while travelling at an even speed.

(7) To finish the weld, break the arc by quickly snapping the electrode away from the work piece.

10

(8) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal below.

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MMA (Manual Metal Arc) Welding

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

Core wire

Core wire

Flux coating

+

+

Power Source

Power Source

▬

▬ Weld 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

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

protective gas

Protective gas

Protective gas

Arc

Arc

Slag

Slag

Weld pool

Weld pool

Manual metal arc ( stick) electrodes have a solid metal wire core and a  ux

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 core wire melts and is deposited into the welding pool.

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

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

The  ux on the electrode performs many different functions.

These include:

● producing a protective gas atmosphere around the weld area.

● providing  uxing 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  ller metal to the molten pool. These additional functions are provided mainly by the covering on the electrode.

Flux.

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.

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MMA (Stick) Welding Fundamentals

Electrode Selection

As a general rule, the selection of an electrode is straight forward,in that it is only a matter of selecting an electrode of similar composition to the parent metal. However, for some metals there is a choice of several electrodes, each of which has particular properties to suit specific classes of work. It is recommend to consult your welding supplier for the correct selection of electrode.

Electrode Size

Average Thickness Maximum Recommended of Material Electrode Diameter

1.0 - 2.0mm

2.0 - 5.0mm

5.0 - 8.0mm

8.0 - > mm

2.5mm

3.2mm

4.0mm

5.0mm

The size of the electrode generally depends on the thickness of the section being welded, and the thicker the section the larger the electrode required. The table gives the maximum size of electrodes that maybe used for various thicknesses of section based on using a general purpose type 6013 electrode.

Welding Current (Amperage)

Electrode Size

ø mm

2.5mm

3.2mm

4.0mm

5.0mm

Current Range

(Amps)

60 - 100

100 - 130

130 - 165

165 - 260

Correct current selection for a particular job is an important factor in arc welding. With the current set too low, difficulty is experienced in striking and maintaining a stable arc. The electrode tends to stick to the work, penetration is poor and beads with a distinct rounded profile will be deposited. Too high current is accompanied by overheating of the electrode resulting undercut and burning through of the base metal and producing excessive spatter. Normal current for a particular job may be considered as the maximum, which can be used without burning through the work, over-heating the electrode or producing a rough spattered surface.The table shows current ranges generally recommended for a general purpose type 6013 electrode.

Arc Length

To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld.

An excessively short arc will cause sticking of the electrode and result in poor quality welds. General rule of thumb for down hand welding is to have an arc length no greater than the diameter of the core wire.

Electrode Angle

The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal.

When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should be between 80 and 90 degrees to the work piece.

Travel Speed

The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel will frequently lead to arc instability,slag inclusions and poor mechanical properties.

Material and Joint Preparation

The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases edges should be clean and free of any contaminates. The type of joint will be determined by the chosen application.

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RECOMMENDED

ELECTRODE CLASSIFICATION & SELECTION CHART

APPLICATION DIAMETER PACKAGE PART No

ESR11

General-purpose electrode for structural steelwork, workshop and maintenance welding. Easily operated in positional welding, including vertically-down. Good gap-bridging. Possible to use equally well both with AC and DC. Smooth arc, well suited for tack-welding due to it’s easy arc striking and restriking properties. Welds are smooth, slightly concave and blending into base metal without undercutting. Slag is self-releasing in most cases. Suitable for welding on galvanized, primer painted and slightly rusted components.

2.5 / 3.2mm HANDYPACK ESR-11-BLISTER

2.5mm

2.5mm

3.2mm

3.2mm

4.0mm

2.5KG PACK ESR-11-2.5mm-2.5kg

5.0KG PACK ESR-11-2.5mm-5kg

2.5KG PACK ESR-11-3.2mm-2.5kg

5.0KG PACK ESR-11-3.2mm-5kg

5.0mKG PACK ESR-11-4.0mm-5kg

ESB-44

Multi-purpose electrode suitable for structural steelwork, workshop and maintenance welding. Smooth and clean welds, blending into base metal without undercuts. Excellent gap bridging properties. The double covering of this electrode produces a stable, concentrated and directed arc, thus being ideally suited for root pass and positional welding. Welds are of

X-ray quality.

EI 316L

Electrode for welding austenitic stainless Cr-Ni-Mo steels or cast steels, having an extra low carbon content. For operating temperatures of up to +400˚C. Especially suitable for welding of stainless steel chemical tanks and pipes in chemical, textile, paint, paper industries. Possible to use equally well both with

AC and DC. Easy arc striking and restriking. Fine metal droplet transfer, good fusion of joint faces, finely rippled bead surface, easily removable slag.

2.5 / 3.2mm HANDYPACK ESB-44-BLISTER

2.5mm

3.2mm

5.0KG PACK

2.5KG PACK

ESB-44-2.5mm-5kg

ESB-44-3.2mm-2.5kg

3.2mm

4.0mm

5.0KG PACK ESB-44-3.2mm-5kg

6.5KG PACK ESB-44-4.0mm-6.5kg

2.5 / 3.2mm HANDYPACK EI316L-BLISTER

2.5mm

3.2mm

4.0mm

1.75KG PACK EI316L-2.5mm-1.75kg

2.0KG PACK

2.0KG PACK

EI316L-3.2mm-2.0kg

EI316L-4.0mm-2kg

EH531

Heavy coated, high recovery (235%) hardfacing electrode, depositing evenly distributed Cr, B carbides in austenitic stainless steel matrix. Suitable for hardfacing of parts subjected to heavy abrasion with moderate impact. Required hardness and abrasion resistance can be obtained in the first layer even on low alloy steels. The hardfacing layers have a very smooth surface and machinable only by grinding. Suitable to use in excavator teeth, leading edges of excavator buckets, mixer blades, gravel pumps, conveyor worn-screws, conveyor belts.

Possible to use with both DC and AC.

ENI-416

Electrode having a nickel-iron core wire for welding cast iron with or without preheating. The weld metal features a low coefficient of thermal expansion and as a result , little shrinkage.

It has higher strength properties than pure nickel weld metal and is therefore preferable used for welding nodular cast iron, white and black heart malleable cast iron, as well as austenitic nodular cast iron or joining these metals to components made of steel, copper or nickel materials. Easy arc striking and restriking, stable arc, smooth bead. Weld metal is machinable. Weld short beads.

3.2mm

3.2mm

4.0mm

5.0mm

HANDYPACK EH-531-BLISTER

5.0KG PACK EH-531-3.2mm-5kg

5.0KG PACK EH-531-4.0mm-5kg

5.0KG PACK EH-531-5.0mm-5kg

2.5 / 3.2mm HANDYPACK ENI-416-BLISTER

2.5mm

3.2mm

4.0mm

1.75KG PACK ENI-416-2.5mm-1.75kg

1.75KG PACK ENI-416-3.2mm-1.75kg

2.25KG PACK ENI-416-4.0mm-2.25kg

EI 312

Electrode for joining dissimilar steels and depositing claddings on ferritic steels. The ferritic-austenitic Cr-Ni weld metal contains approximately 50% of delta-ferrite and is non-scaling up to

+1100˚C. It features high resistance to cracking and is therefore suited for joining difficult to weld steels and depositing stress-relaxing buffer layers on crack sensitive base metals.

Suitable for welding galvanized steel plates. Possible to use equally well both with AC and DC. Easy arc striking and restriking. Fine metal droplet transfer, good fusion of joint faces, finely rippled bead surface, easy slag removal.

2.5 / 3.2mm HANDYPACK EI-312-BLISTER

2.5mm

3.2mm

4.0mm

1.75KG PACK EI-312-2.5mm-1.75kg

1.75KG PACK EI-312-3.2mm-1.75kg

2.0KG PACK EI-312-4.0mm-2kg

For a full range of recommended MAGMAWELD welding electrodes please visit our website @ WWW.UNIMIG.COM.AU

The above chart is a reference only and are not included in this kit.

13

INSTALLATION AND SET UP FOR DC TIG WELDING FOR MMA-TIG160/200PFC

(1) Switch on the machine, select the TIG function with the TIG/MMA selector switch.

(2) Insert the power cable plug of the TIG torch into the Negative socket on the front of the machine and

tighten it.

(3) Insert the earth cable plug into the Positive socket on the front of the machine and tighten it.

(5) Connect the gas line of the TIG torch to regulator and connect the regulator to the gas cylinder.

Carefully open the gas cylinder valve and set the flow rate to between 8 -10 l/min.

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

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

(1) Set TIG/MMA selector switch to TIG

(3) Connect earth lead to

(2) Connect the TIG torch cable connector to

(4) Carefully open the valve of the gas cylinder, set the flow to 8-10 l/min

Note: Photos show TIG torch with Suregrip option

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

14 15

LIFT ARC DC TIG OPERATION FOR MMA-TIG160/200PFC

Lift Arc ignition allows the arc to be started easily in DC TIG by simply touching the tungsten to the work piece and lifting it up to start the arc. This prevents the tungsten tip sticking to the work piece and breaking the tip from the tungsten electrode. There is a particular technique called “rocking the cup” used in the Lift Arc process that provides easy use of the Lift Arc function.

(6) Make sure the front end parts of the TIG torch are correctly assembled, use the correct size and type of tungsten electrode for the job, the tungsten electrode requires a sharpened point for DC welding.

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

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

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

piece.

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

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

(7) Turn on the Gas Valve (8) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from the work piece.

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

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

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.

15

DC TIG Welding

30%

The DC power source uses what is known as DC (direct current) in which the main electrical component known as electrons flow in only one direction from the negative pole

(terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical principle at work which should always be taken into account when using any DC circuit.

With a DC circuit 70% of the energy (heat) is always on the positive side. This needs to be understood because it determines what terminal the TIG torch will be connected to

(this rule applies to all the other forms of DC welding as well ).

70% power source argon gas nozzle

DC TIG welding is a process in which an arc is struck between a

TUNGSTEN electrode and the metal work piece. The weld area is shielded by an inert gas flow to prevent contamination of the tungsten, molten pool and weld area.

When the TIG arc is struck the inert gas is ionized and superheated changing it’s molecular structure which converts it into a plasma stream. This plasma stream flowing between the tungsten and the work piece is the TIG arc and can be as hot as 19,000°C. It is a very pure and concentrated arc which provides the controlled melting of most metals into a weld pool. TIG welding offers the user the greatest amount of flexibility to weld the widest range of material and thickness and types. DC TIG welding is also the cleanest weld with no sparks or spatter. low current

The intensity of the arc is proportional to the current that flows from the tungsten. The welder regulates the welding current to adjust the power of the arc. Typically thin material requires a less powerful arc with less heat to melt the material so less current (amps) is required, thicker material requires a more powerful arc with more heat so more current

(amps) are necessary to melt the material.

high current

LIFT ARC IGNITION for TIG (tungsten inert gas) Welding

Lift Arc is a form of arc ignition where the machines has low voltage on the electrode to only a few volts, with a current limit of one or two amps (well below the limit that causes metal to transfer and contamination of the weld or electrode). When the machine detects that the tungsten has left the surface and a spark is present, it immediately (within microseconds) increases power, converting the spark to a full arc. It is a simple, safe lower cost alternative arc ignition process to HF (high frequency) and a superior arc start process to scratch start.

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

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

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

16

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

17

TIG Welding Fusion Technique

Manual TIG welding is often considered the most difficult of all the welding processes.

Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the workpiece. Similar to Oxygen Acetylene torch welding, TIG welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other. However, some welds combining thin materials can be accomplished without filler metal like edge, corner, and butt joints.

This is known as Fusion welding where the edges of the metal pieces are melted together using only the heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size. Once the weld pool is established tilt the torch at about a 75 ° angle and move smoothly and evenly along the joint while fusing the materials together.

75°

Travel direction

Form a weld pool Angle torch Move the torch slowly and evenly forward

TIG Welding with Filler Wire Technique

It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size. Once the weld pool is established tilt the torch at about a 75 ° angle and move smoothly and evenly along the joint. The filler metal is introduced to the leading edge of the weld pool. The filler wire is usually held at about a 15° angle and fed into the leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward. It is important during the welding to keep the molten end of the filler wire inside the gas shield as this protects the end of the wire from being oxidised and contaminating the weld pool.

Travel direction

Form a weld pool

Retract the filler wire

Angle torch

75° gas shield

Move the torch forward to the front of the weld pool

17

15°

Add TIG filler wire

Repeat the process

Tungsten Electrodes

Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.

Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare earth elements. Choosing the correct tungsten depends on the material being welded, the amount of amps required and whether you are using AC or DC welding current.

Tungsten electrodes are colour-coded at the end for easy identification.

Below are the most commonly used tungsten electrodes found in the New Zealand and Australian market.

Thoriated

Thoriated tungsten electrodes (AWS classification EWTh-2) contain a minimum of 97.30 percent tungsten and 1.70 to 2.20 percent thorium and are called 2 percent thoriated. They are the most commonly used electrodes today and are preferred for their longevity and ease of use. Thorium increases the electron emission qualities of the electrode, which improves arc starts and allows for a higher current-carrying capacity. This electrode operates far below its melting temperature, which results in a considerably lower rate of consumption and eliminates arc wandering for greater stability. Compared with other electrodes, thoriated electrodes deposit less tungsten into the weld puddle, so they cause less weld contamination.

Thorium however is a low-level radioactive hazard and many users have switched to other alternatives. Regarding the radioactivity, thorium is an alpha emitter but when it is enclosed in a tungsten matrix the risks are negligible.

Thus holding a stick of Thoriated tungsten in your hand should not pose a great threat unless a welder has open cuts on their skin. Thoriated tungsten should not get in contact with open cuts or wounds. The more significant danger to welders can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours during welding or from ingestion of material/dust in the grinding of the tungsten. Follow the manufacturer’s warnings, instructions, and the Material Safety Data Sheet (MSDS) for its use.

Ceriated (Color Code: Orange)

Ceriated tungsten electrodes (AWS classification EWCe-2) contain a minimum of 97.30 percent tungsten and 1.80 to

2.20 percent cerium and are referred to as 2 percent ceriated. Ceriated tungstens perform best in DC welding at low current settings. They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding, thin sheet metal work. They are best used to weld carbon steel, stainless steel, nickel alloys, and titanium, and in some cases it can replace 2 percent thoriated electrodes. Ceriated tungsten is best suited for lower amperages it should last longer than Thoriated tungsten higher amperage applications are best left to Thoriated or

Lanthanated tungsten.

Lanthanated (Color Code: Gold)

Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of 97.80 percent tungsten and

1.30 percent to 1.70 percent lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent arc starting, a low burn off rate, good arc stability, and excellent re-ignition characteristics. Lanthanated tungstens also share the conductivity characteristics of 2 percent thoriated tungsten. Lanthanated tungsten electrodes are ideal if you want to optimise your welding capabilities. They work well on AC or DC electrode negative with a pointed end, or they can be balled for use with AC sine wave power sources. Lanthanated tungsten maintains a sharpened point well, which is an advantage for welding steel and stainless steel on DC or AC from square wave power sources.

Zirconiated (Color Code: White)

Zirconiated tungsten electrodes (AWS classification EWZr-1) contain a minimum of 99.10 percent tungsten and 0.15 to 0.40 percent zirconium. Most commonly used for AC welding Zirconiated tungsten produces a very stable arc and is resistant to tungsten spitting. It is ideal for AC welding because it retains a balled tip and has a high resistance to contamination. Its current-carrying capacity is equal to or greater than that of thoriated tungsten. Zirconiated tungsten is not recommended for DC welding.

Tungsten Electrodes Rating for Welding Currents

Tungsten

Diameter mm

DC Current Amps

Torch Negative

2% Thoriated

1.0mm

1.6mm

2.4mm

3.2mm

4.0mm

15 - 80

70 -150

150- 250

250 - 400

400 - 500

AC Current Amps

Un-Balanced Wave

0.8% Zirconiated

15 - 80

70 - 150

140 - 235

225 - 325

300 - 400

AC Current Amps

Balanced Wave

0.8% Zirconiated

20 - 60

60 - 120

100 - 180

160 - 250

200 - 320

18 19

Tungsten Preparation

Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects.

Always ensure to grind the tungsten in a longitudinal direction on the grinding wheel. Tungsten electrodes are manufactured with the molecular structure of the grain running lengthwise and thus grinding crosswise is “grinding against the grain.” If electrodes are ground crosswise, the electrons have to jump across the grinding marks and the arc can start before the tip and wander. Grinding longitudinally with the grain, the electrons flow steadily and easily to the end of the tungsten tip. The arc starts straight and remains narrow, concentrated, and stable. grind longitudinal on the grinding wheel don’t grind across the grinding whee l

Electrode Tip/Flat

The shape of the tungsten electrode tip is an important process variable in precision arc welding. A good selection of tip/flat size will balance the need for several advantages. The bigger the flat, the more likely arc wander will occur and the more difficult it will be to arc start. However, increasing the flat to the maximum level that still allows arc start and eliminates arc wonder will improve the weld penetration and increase the electrode life. Some welders still grind electrodes to a sharp point, which makes arc starting easier. However, they risk decreased welding performance from melting at the tip and the possibility of the point falling off into the weld pool.

2.5 times tungsten diameter flat tip pointed tip

Electrode Included Angle/Taper - DC Welding

Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and offer different weld penetration capabilities. In general, blunter electrodes that have a larger included angle provide the following benefits:

• Last Longer

• Have better weld penetration

• Have a narrower arc shape

• Can handle more amperage without eroding. flat spot diameter

Sharper electrodes with smaller included angle provide:

• Offer less arc weld

• Have a wider arc

• Have a more consistent arc included angle

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

Tungsten

Diameter

1.0mm

1.6mm

1.6mm

2.4mm

2.4mm

3.2mm

3.2mm

Diameter at the Tip - mm

.250

.500

.800

.800

1.100

1.100

1.500

Constant Included

Angle - Degrees

20

25

30

35

45

60

90

19

Current Range

Amps

05 - 30

08 - 50

10 - 70

12 - 90

15 - 150

20 - 200

25 - 250

Current Range

Pulsed Amps

05 - 60

05 - 100

10 - 140

12 - 180

15 - 250

20 - 300

25 - 350

Suregrip Series

17V TIG TORCH

2

150A AIR COOLED TIG WELDING TORCH

Rating: 150Amp DC, 105Amp AC @35% duty cycle.

For use with non gas solenoid machines

7

6

5

9

10

8

12

4

3

Stubby

series

Standa rd

series

Gas

lens

series

La rge

gas

lens

series

Stubby

gas

lens

series

11

*

Wear Parts Identification Next Page

13

14 15

6

16

1

5

6

7

8

2

3

4

9

10

Torch Model

Description

17V Suregrip Tig Torch Package c/w 2m Gas Hose

17

Spare Parts

Part Number

WP17V

WP17VF

57Y02

57Y03

57Y04

UERBS

UERSP1

UERH100

UERKJ100

UERLC200-08

UERJK100

Description

Torch head

Torch head flexible

Back cap long

Meduim back cap

Short back cap

Blank Kitt

Screw Pack

Small Ergo Tig Handle

Small Knuckle Joint

Leather Cover X 0.8mt

Jointing Repair Kit

Part Number

4m

17V-4MCP25

8m

17V-8MCP25

11

14

15

16

17

12

13

Part Number

UERNCL-32

UERNCL-72

UERCO100-40

UERCO100-80

USLH917-S

USLH917-H

USL57Y01AR

USL57Y03AR

USL3550

USL-1-GS4

Description

Neoprene Cover X 3.2mt

Neoprene Cover X 7.2mt

Sheath X 12.5ft Inc Leather Cover

Sheath X 25ft Inc Leather Cover

Cable Support Small

“Surelok “ Housing Small

“Power Cable X 12.5ft “Surelok “ Rubber

Power Cable X 25ft “Surelok “ Rubber

“Surelok “ Body & Support

Gas Supply Hose

20 21

Suregrip Series

17V TIG TORCH

Standard Front End Parts

Part # Description

18CG Cup Gasket

Part # Description

10N30 Collet Body 1.0mm

10N31 Collet Body 1.6mm

10N32 Collet Body 2.4mm

10N28 Collet Body 3.2mm

Part # Description

10N49L Long Alumina Nozzle Ø 8mm #5L

53N48L Long Alumina Nozzle Ø 10mm #6L

53N47L Long Alumina Nozzle Ø 11mm #7L

Part # Description

10N22 Collet 1.0mm

10N23 Collet 1.6mm

10N24 Collet 2.4mm

10N25 Collet 3.2mm

Part # Description

10N50 Alumina Nozzle Ø 6mm #4

10N49 Alumina Nozzle Ø 8mm #5

10N48 Alumina Nozzle Ø 10mm #6

10N47 Alumina Nozzle Ø 11mm #7

10N46 Alumina Nozzle Ø 13mm #8

10N45 Alumina Nozzle Ø 16mm #10

10N44 Alumina Nozzle Ø 19mm #12

Compact Gas Lens Front End Parts

Part #

54N01

Description

Gas Lens Gasket

Part #

45V25

45V26

45V27

Description

Gas Lens Body 1.6mm

Gas Lens Body 2.4mm

Gas Lens Body 3.2mm

Part # Description

54N14 Gas lens ceramic 8.0mm

54N15 Gas lens ceramic 7.0mm

54N17 Gas lens ceramic 5.0mm

TR0004-16

RED

ANSI/AWS A5.12-98

ISO 6848 WT20

2% Thoriated: Best stability at medium currents, good arc starts, medium tendency to spit, medium erosion rate.

Commonly used for steel and stainless steel applications

1/16 x 7” (1.6mm x 175mm)

3/32 x 7” (2.4mm x 175mm)

1/8 x 7” (3.2mm x 175mm)

Part #

TR0004-10

TR0004-16

TR0004-24

TR0004-32

Description

1.0mm x 175mm thoriated tungsten electrode 2%

1.6mm x 175mm thoriated tungsten electrode 2%

2.4mm x 175mm thoriated tungsten electrode 2%

3.2mm x 175mm thoriated tungsten electrode 2%

©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means, electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.

21

Suregrip Series

26V TIG TORCH

7 5

4

3

2

200A AIR COOLED TIG WELDING TORCH

Rating:180Amp DC, 125Amp AC @35% duty cycle.

6

8

Stubby

series

Standa rd

series

G as

L en s s eri es

La rge

Gas

Lens

series

Stubby

Gas

Lens

series

9

10

11

12

13

6

4

5

6

7

1

2

3

8

9

10

Torch Model

Description

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

Spare Parts

Part Number

WP26V

WP26VF

57Y02

57Y03

57Y04

UERBS

UERSP1

UERH200

UERKJ200

UERLC200-08

UERJK200

Description

Torch head

Torch head flexible

Back cap long

Meduim back cap

Short back cap

Blank Kit

Screw Pack

Large Ergo Tig Handle

Large Knuckle Joint

Leather Cover X 0.8mt

Jointing Repair Kit

15 14

16

17

18

Part Number

4m

26V-4MCP50

13

14

15

16

11

12

17

18

Part Number

UERNCL-32

UERNCL-72

UERCO200-40

UERCO200-80

USLH26-S

USLH26-H

USLH26-C

USL46V28AR

USL46V30AR

USL3550

USL-1-GS4

8m

26V-8MCP25

26V-8MCP50

Description

Neoprene Cover X 3.2mt

Neoprene Cover X 7.2mt

Sheath X 12.5ft Inc Leather Cover

Sheath X 25ft Inc Leather Cover

Cable Support Large

“Surelok “ Housing Large

“Surelok “ Housing Cover

Power Cable X 12.5ft “Surelok “ Rubber

Power Cable X 25ft “Surelok “ Rubber

“Surelok “ Body & Support

Gas Supply Hose

22 23

Suregrip Series

26V TIG TORCH

Standard Front End Parts

Part # Description

18CG Cup Gasket

Part # Description

10N30 Collet Body 1.0mm

10N31 Collet Body 1.6mm

10N32 Collet Body 2.4mm

10N28 Collet Body 3.2mm

Part # Description

10N49L Long Alumina Nozzle Ø 8mm #5L

53N48L Long Alumina Nozzle Ø 10mm #6L

53N47L Long Alumina Nozzle Ø 11mm #7L

Part # Description

10N22 Collet 1.0mm

10N23 Collet 1.6mm

10N24 Collet 2.4mm

10N25 Collet 3.2mm

Part # Description

10N50 Alumina Nozzle Ø 6mm #4

10N49 Alumina Nozzle Ø 8mm #5

10N48 Alumina Nozzle Ø 10mm #6

10N47 Alumina Nozzle Ø 11mm #7

10N46 Alumina Nozzle Ø 13mm #8

10N45 Alumina Nozzle Ø 16mm #10

10N44 Alumina Nozzle Ø 19mm #12

Compact Gas Lens Front End Parts

Part #

54N01

Description

Gas Lens Gasket

Part #

45V25

45V26

45V27

Description

Gas Lens Body 1.6mm

Gas Lens Body 2.4mm

Gas Lens Body 3.2mm

Part # Description

54N14 Gas lens ceramic 8.0mm

54N15 Gas lens ceramic 7.0mm

54N17 Gas lens ceramic 5.0mm

TR0004-16

RED

ANSI/AWS A5.12-98

ISO 6848 WT20

2% Thoriated: Best stability at medium currents, good arc starts, medium tendency to spit, medium erosion rate.

Commonly used for steel and stainless steel applications

1/16 x 7” (1.6mm x 175mm)

3/32 x 7” (2.4mm x 175mm)

1/8 x 7” (3.2mm x 175mm)

Part #

TR0004-10

TR0004-16

TR0004-24

TR0004-32

Description

1.0mm x 175mm thoriated tungsten electrode 2%

1.6mm x 175mm thoriated tungsten electrode 2%

2.4mm x 175mm thoriated tungsten electrode 2%

3.2mm x 175mm thoriated tungsten electrode 2%

©All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means, electronic, mechanical, photocopying or otherwise without the prior permission of ©Uniarc® the copyright holder.

23

MMA (Stick) WELDING TROUBLE SHOOTING

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

1: No arc

Possible Reason Suggested Remedy

Incomplete welding circuit

Wrong mode selected

Check earth lead is connected. Check all cable connections.

Check the MMA selector switch is selected

No power supply Check that the machine is switched on and has a power supply

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

Possible Reason Suggested Remedy

Arc length too long

Work piece dirty, contaminated or moisture

Check that pure Argon is being used

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

Use only dry electrodes Damp electrodes

3: Excessive Spatter

Possible Reason

Amperage too high

Arc length too long

Suggested Remedy

Decrease the amperage or choose a larger electrode

Shorten the arc length

Tungsten melting into the weld pool Check that correct type of tungsten is being used. Too much current for the tungsten size so reduce the amps or change to a larger tungsten

3: Weld sits on top, lack of fusion

Possible Reason Suggested Remedy

Insuf cient heat input

Work piece dirty, contaminated or moisture

Poor welding technique

4: Lack of penetration

Possible Reason

Increase the amperage or choose a larger electrode

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

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

Suggested Remedy

Insuf cient heat input

Poor welding technique

Increase the amperage or choose a larger electrode

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

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

5: Excessive penetration - burn through

Possible Reason Suggested Remedy

Excessive heat input Reduce the amperage or use a smaller electrode

Try increasing the weld trav el speed Incorrect travel speed

6: Uneven weld appearance

Possible Reason Suggested Remedy

Unsteady hand, wavering hand Use two hands where possible to steady up, practise your technique

7: Distortion − movement of base metal during welding

Possible Reason Suggested Remedy

Excessive heat input

Poor welding technique

Reduce the amperage or use a smaller electrode

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

Poor joint preparation and or joint design

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

7: Electrode welds with different or unusual arc characteristic

Possible Reason Suggested Remedy

Incorrect polarity Change the polarity, check the electrode manufacturer for correct polarity

TIG WELDING TROUBLE SHOOTING

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

1: Tungsten burning away quickly

Possible Reason Suggested Remedy

Incorrect Gas

No gas

Inadequate gas  ow

Back cap not  tted correctly

Torch connected to DC +

Incorrect tungsten being used

Tungsten being oxidised after weld is  nished

2: Contaminated tungsten

Possible Reason

Check that pure Argon is being used

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

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

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

Connect the torch to the DC- output terminal

Check and change the tungsten type if necessary

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

Suggested Remedy

Touching tungsten into the weld pool

Touching the  ller wire to the tungsten

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

Keep the  ller wire from touching the tungsten during welding, feed the  ller wire into the leading edge of the weld pool in front of the tungsten

Tungsten melting into the weld pool Check that correct type of tungsten is being used. Too much current for the tungsten size so reduce the amps or change to a larger tungsten

3: Porosity - poor weld appearance and colour

Possible Reason Suggested Remedy

Incorrect Gas

Inadequate gas  ow / gas leaks

Moisture on the base metal

Contaminated base metal

Contaminated  ller wire

Check that pure Argon is being used

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

Remove all moisture from base metal before welding

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

Remove all grease, oil, or moisture from  ller metal.

Incorrect  ller wire Check the  ller wire and change if necessary

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

Possible Reason Suggested Remedy

Incorrect Gas

Inadequate gas  ow

Use pure Argon gas

Set the gas  ow between 10 - 15 l/min  ow rate

Alumina gas nozzle too small for size of tungsten being used

Increase the size of the alumina gas nozzle

5: Unstable Arc during DC welding

Possible Reason Suggested Remedy

Torch connected to DC +

Contaminated base metal

Tungsten is contaminated

Connect the torch to the DC- output terminal

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

Remove 10mm of contaminated tungsten and re grind the tungsten

Arc length too long Lower torch so that the tungsten is off of the work piece 2 - 5mm

7: Arc wanders during DC welding

Possible Reason Suggested Remedy

Poor gas  ow

Incorrect arc length

Tungsten incorrect or in poor condition

Poorly prepared tungsten

Check and set the gas  ow between 10 - 15 l/min  ow rate

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

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

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

Contaminated base metal

Contaminated  ller wire

Incorrect  ller wire

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

Remove all grease, oil, or moisture from  ller metal.

Check the  ller wire and change if necessary

8: Arc dif cult to start or will not start DC welding

Possible Reason Suggested Remedy

Incorrect machine set up

No gas, incorrect gas  ow

Tungsten is contaminated

Incorrect tungsten size and or tungsten being used

Loose connection

Earth clamp not connected to work

Check machine set up is correct

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

Remove 10mm of contaminated tungsten and re grind the tungsten

Check and change the size and or the tungsten if required

Check all connectors and tighten

Connect the earth clamp directly to the work piece wherever possible

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:

ATTENTION! - CHECK FOR GAS LEAKAGE

At initial set up and at regular intervals we recommend to check for gas leakage.

Recommended procedure is as follows:

1. Connect the regulator and gas hose assembly and Tighten all connectors and clamps.

2. Slowly open the cylinder valve.

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

4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure

gauge on the regulator, if the needle drops away towards zero there is a gas leak.

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

regulator and line for an extended time period. In this situation it is recommended to open the

Important:

We strongly recommend that you check for gas leakage prior to operation of your

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

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

27

SPARE PARTS IDENTIFICATION - ARC160PFC

2

3

1

5

6

7

8

9

14

4

10 11 12

14 17

Part Number

1. 10045765

2. 10043476

3. 10004966

4. 10004636

5 10052313

6. 30000103

7. 10052306

8. 10052508

9. 10004949

Description

front plastic panel carry strap / handle

TIG/MMA selector switch panel socket 35-50

front panel adhesive sticker

Amperage knob cable support assembly rear plastic panel

ON/OFF switch

13 16

27

Part Number

10. 10006650

11. 10043327

12. 10052250

13. 10037766

14. 10052310

15. 10044009

16. 10042320

17. 10043959

Description

Single-phase rectifier bridge main PCB control PCB thermal switch cover fan-24V DC base plate

Insulation Sheet

SPARE PARTS IDENTIFICATION - ARC200PFC

2

3

1

5

6

7

8

9

14

4

10 11 12

14 17

Part Number

1. 10045765

2. 10043476

3. 10004966

4 10004636

5 10048359

6. 30000103

7. 10042876

8. 10045764

9. 10004949

Description front plastic panel carry strap / handle

TIG/MMA selector switch panel socket 35-50 front panel adhesive sticker

Amperage knob cable support assembly rear plastic panel

ON/OFF switch

13 16

28

Part Number Description

10. 10037345

11. 10046842

12. 10046844

13. 10037766

14. 10048366

15. 10047583

16. 10042320

17. 10043959

Single-phase rectifier bridge main PCB control PCB thermal switch cover fan-24V DC base plate

Insulation Sheet

28

Part Number Description

10. 10037345

11. 10046842

12. 10046844

13. 10037766

14. 10048366

15. 10047583

16. 10042320

17. 10043959

Single-phase rectifier bridge main PCB control PCB thermal switch cover fan-24V DC base plate

Insulation Sheet

PO Box 3033, Lansvale NSW 2166, AUSTRALIA

112 Christina Rd, Villawood, NSW 2163

Phone: (02) 9780 4200

Fax: (02) 9780 4244

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

Welding Guns Of Australia Pty Ltd

ABN: 14 001 804 422

Welding Guns Of Australia Pty Ltd (‘Us’, ‘We’) warrants that the following products under UNI-MIG, UNI-TIG,

UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA, supplied by Us and purchased by you from an Authorised

UNI-MIG, UNI-TIG, UNI-PLAS, UNI-FLAME, TECNA, T&R, HIT-8SS & ROTA Dealer throughout Australia are free of

Material and Faulty Workmanship defects except for those products listed under ‘Warranty Exclusions’.

These terms and conditions supersede and exclude all former and other representations and arrangements relating to any warranties on these products.

WARRANTY PERIOD

We offer the following ‘Warranty Periods’ from ‘date of purchase’:

An Extended Warranty Period of 6 months total shall apply only to Machinery where offered and warranty is registered online.

UNI-MIG WELDING MACHINES

UNI-MIG DIY Series (Power Source Only)

RAZORWELD Series (Power Source Only)

UNI-MIG Procraft Series (Power Source Only)

UNI-MIG Trade Series (Power Source Only)

UNI-MIG Trade Series SWF (Power Source / Seperate Wire Feeder Only)

UNI-MIG Workshop Series (Power Source Only)

UNI-MIG Workshop Series SWF (Power Source / Separate Wire Feeder Only)

UNI-MIG Jasic Inverter MIG (Power Source Only)

UNI-MIG Jasic Inverter MIG SWF (Power Source / Separate Wire Feeder Only)

UNI-TIG Jasic Inverter TIG (Power Source Only)

UNI-MIG Water Cooler

T&R Pulse MIG (Power Source Only)

T&R Pulse MIG SWF (Power Source / Separate Wire Feeder Only)

UNI-PLAS (Power Source Only)

UNI-PLAS Jasic Series (Power Source Only)

UNI-PLAS Site Cut Series (Power Source Only)

UNI-FLAME Gas Cutting and Welding Kits

UNI-FLAME Straight Line & Gas Cutting Machines (Power Source Only)

UNI-FLAME Regulators Argon/ Acetylene / Oxygen / LPG / Bobbin Flowmeter

UNI-FLAME Automatic Welding Helmet

UNI-MIG Automatic Welding Helmets

TECNA (Power Source Only)

HIT-8SS Automatic Carriage (Power Source Only)

ROTA 102 Rotating table

HOTBOX ElectrodeOven

SPOTCAR 3500

TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,

INTERCONNECTING CABLES, GAS HOSE

2 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

3 Years

1 Year

2 Year

2 Year

3 Years

2 Years

1 Year

(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)

3 Months (Clause 2&3)

1 Year (Clause 3)

1 Year

2 Years

2 Years

1 Year (Clause 3)

(Clause 3) 1 Year

1 Year

1 Year

1 Year (Clause 3)

3 Months (Clause 3)

(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB, and all other components, .

(Clause 2) Gas Hose, Flashbacks are subject to and covered by the Manufacture’s Individual Warranty, Contact the manufacturer for details

(Clause 3) This only Covers Manufactures defaults on all accesories for the first three months after date of purchase.

WARRANTY / RETURNS / EXCHANGES

We understand that sometimes you may need to return a product you have purchased from Welding Guns Of

Australia PTY LTD Authorised Dealer Network, to assist you, we have set out below the Welding Guns Of Australia

PTY LTD Returns Policy that you should know.

Our Returns Policy includes the rights you have under the Australian Consumer Law and other relevant laws.

Your Rights under the Australian Consumer Law - Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

• You shall inspect the Goods on delivery and shall within seven (7) days of delivery (time being of the essence) notify Welding Guns Of Australia PTY LTD of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.

• You shall also afford Welding Guns Of Australia PTY LTD the opportunity to inspect the Goods within a reasonable time following delivery if you believe the Goods are defective in any way.

• If you shall fail to comply with these provisions the Goods shall be presumed to be free from any defect or damage.

For defective Goods, which Welding Guns Of Australia PTY LTD has agreed in writing that you are entitled to reject,

Welding Guns Of Australia PTY LTD liability is limited to either (at the Welding Guns Of Australia PTY LTD discretion) replacing the Goods or repairing the Goods except where you have acquired Goods as a consumer within the meaning of the Trade Practices Act 1974 or the Fair Trading Acts of the relevant state or territories of Australia, and is therefore also entitled to, at the consumer’s discretion either a refund of the purchase price of the Goods, or repair of the Goods, or replacement of the Goods.

Returns will only be accepted provided that:

(a) You have complied with the provisions outlined above, and

(b) where the Goods are unable to be repaired, the Goods are returned at your cost within thirty (30) days of the delivery date, and

(c) Welding Guns Of Australia PTY LTD will not be liable for Goods which have not been stored or used in a proper manner, and

(d) the Goods are returned in the condition in which they were delivered and with all packaging material, brochures and instruction material in as new condition as is reasonably possible in the circumstances.

• Welding Guns Of Australia PTY LTD Accepts no responsibility for products lost, damaged or mislaid whilst in transit

• Welding Guns Of Australia PTY LTD may (at their sole discretion) accept the return of Goods for credit but this may incur a handling fee of up to fifteen percent (15%) of the value of the returned Goods plus any freight costs.

• Where a failure does not amount to a major failure, Welding Guns Of Australia PTY LTD is entitled to choose between providing you with a repair, replacement or other suitable remedy.

• Your rights under the Australian Consumer Law are not limited by a defined time. However, the Australian

Consumer Law does recognise that the relevant time period can vary from product to product, depending on factors such as the nature of the product and the price. Welding Guns Of Australia PTY LTD adopts the same approach. As you can appreciate, the type of remedy we can offer you may also vary depending on how long it takes you to return the product to us.

30 31

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

Queensland:

Victoria:

Western Australia:

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,

Failure to follow 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.

31

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

32 33

33

34 35

35

©

Welding Guns Of Australia PTY LTD 2015

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