Uni-Mig KUMJR200AC/DC User manual

AC/DC TIG/MMA200
Manual
UNI FLAME AUTOLIFT

Machine Model
Description Part Number
AC/DC TIG/MMA 200 KUMJR200AC/DC
CONTENTS PAGE No:
Safety 2
General Description 4
Curcuit Diagram 5
Main Parameter 6
Pre-operation Check 7
Installation & Operation 8
Pre-Caution 14
Machine Parts 15
Maintenance 16
Troubleshooting 16
Machine Model
UNI FLAME AUTOLIFT
UNIMIG pursue a policy of continuous research and development, and therefore
reserve the right to change the specifications, or design, without prior notice. *2 year warranty power source.
YEARS Warranty*
2
This welding equipment for industrial and professional use
conforms to IEC 60974 International Safety Standard.
We hereby state that we provide two years of guarantee for
this welding equipment from the date of purchase.
Please read and understand this instruction manual
carefully before the installation and operation of this
equipment.
The contents of this manual may be revised without prior
notice and without obligation.
This instruction manual is issued on 1st Mar 2007.

•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.
•Asafety switch is necessary to prevent the equipment from electric leakage.
•Welding tools and accessories should be of high quality and in good working order.
•Operators should be trained and or qualified. Electric shock: It can kill.
•Connect the primary input cable according toAustralian standard regulation.
•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. Smoke and gas generated whilst welding
or cutting can be harmful to people’s health.
•Avoid breathing the smoke and gas generated whilst
welding or cutting. Keep the working area well ventilated.
•Arc rays are harmful to people’s eyes and skin. Always
wear a welding helmet and suitable protective
clothing including welding gloves whilst the welding
operation is performed.
•Measures should be taken to protect people in or near
the surrounding working area, from all hazards
associated with welding.
Fire hazard
•The welding sparks may cause fire, therfore remove
flammable material away from the working area.
•Have a fire extinguisher nearby, and have a trained
person ready to use it.
Noise: possibly harmful to people’s hearing.
•Noise is generated while welding/cutting, wear approved
hearing protection when noise levels are high.
Machine fault:
•Consult this instruction manual.
•Contact your local dealer or supplier for further advice.
SAFETY
Welding and cutting equipment can be dangerous to both the operator and people in or near the
surrounding working area, if the equipment is not correctly operated. Equipment must only be
used under the strict and comprehensive observance of all relevant safety regulations. Please
read and understand this instruction manual carefully before the installation and use/operation
of this equipment.
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*** CAUTION ***
Do not heat, cut or weld tanks, drums or containers
until the proper steps have been taken to insure that
such procedures will not cause flammable or toxic
vapours from substance inside. These can cause
an explosion even though the vessel has been
“cleaned”.Vent hollow castings or containers before
heating, cutting or welding. They may explode.

UNI FLAME AUTOLIFT
These are a newly developed TIGAC/DC P range ofAC/DC and Pulse Welding
Machines. DC function allows the welding of stainless steel, alloy steel and carbon steel
and other nonferrous metals. AC function allows the welding aluminum and aluminum
alloys.
The machine is equipped with Pulse function, selection of the pulse function provides
adjustable pulsation of the welding current. Therefore providing better control of the
welding and control of the heat input to the work piece during some applications.
The power exchange rates of this welding equipment are over 85, and it is
energy-saving.
The model type available is TIG 200PAC/DC.
The development of Inverter technology of welding machines has many benefits.
The invention of high power switching components enables these TIG welding
machines to function with HF of 100KHz, thus reducing the volume and weight of the
main components (transformers and electric reactor). The application of PWM (Pulse
Width Modulation) technology enables the concentration and stability of the welding
current and much more precision of the current adjustment. The unique structuring
design enables ease in the disassembly and maintenance of this welding equipment
and maximizes the EMI.
Exclusive HF Inverter technology, TIG ACDC P series provides many advantages
in comparison to the traditional welding equipment. Smaller in size, lighter in weight,
higher power efficiency rate and more energy saving.The most outstanding feature is
the application of Twin Square Wave Inverter Technology.
This provides pure AC square wave output, which increases the arc stability and
provides stronger arc energy, better reverse cleaning capability, wider cleaning width,
and superior arc sustainability. The excellent welding characteristics of this welding
equipment provide a new dimension to welding of aluminum and aluminum alloys.
A remote foot control pedal is available to provide easy adjustment of the output cur-
rent range. Use of the foot control pedal allows the operator variable control over the
output current range during welding. Using the remote foot control can improve welding
efficiency and welding performance.
A range of necessary welding accessories such as welding torch, earth lead, arc lead,
gas lead, gas regulator, and other accessory items are available for this Inverter TIG
AC/DC welding equipment. Please contact your supplier / agent for advice and
recommendation of accessory items.
GENERAL DESCRIPTION & SAFEGUARDS

UNI FLAME AUTOLIFT
CIRCUIT DIAGRAM
Three Phase Input

Machine Model
Description Part Number
TIG200PAC/DC KUMJR200AC/DC
Tecnical Specification
MAIN PARAMETER
Power voltage AC240V±15%
Input Frequency (Hz) 50/60
Rated Maximium Supply current MMAI1max 24A
Maximum Effective Supply current MMAI1eff 17A
Rated Maximium Supply current TIGI1max 20.7A
Maximum Effective Supply current TIGI1eff 14.6A
Power rating 5.8 KVA
Rated output current 185A
Range of output current 10-185A
Arc force % 0-100
No-load voltage 56V
Working voltage TIG 10.4 - 17.4V
Pre-flow % 0-2
AC Balance/Clean width % 20-80
Slope-down time 0-10
Post-flow time 0-10
Base current % 10-90
Pulse frequency Hz 0.5-300
Pulse duty cycle % 10-90
Remote control Yes
Arc Ignition HF ignition
Efficiency % 85
Load duty cycle TIG % 185A-20% (40oC)
Power factor 0.93
Insulation class F
Protection class IP21S
Weight (Kgs) 26.5
Size (mm) 500 L×320 W×365 D
UNI FLAME AUTOLIFT

UNI FLAME AUTOLIFT
Pre-Operative Check List
1) The welding machine has automatic compensation for primary input voltage
fluctuation. The welding machine will still operate within +/- 15% of the required
primary voltage input. Please check the primary input voltage supply before
connecting the machine. Connection to incorrect primary voltage supply may
damage the machine. Warning ! : Connection to incorrect primary voltage supply
will void warranty.
2) The cross sectional area of the primary lead is important. It is necessary to provide
the correct cross sectional area of cable when using long extension leads.
To avoid any machine operational faults when using long extension leads please
ensure the recommended length and across sectional area of cable are optimal.
3) Check that you have adequate Argon gas supply. Connect the machine to the gas
supply and check for leaks.
4) Connect input and output cable as following drawing.
5) The welding operation is obtainable only if the above procedures are completed.

1.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.
2.Connection of Output Cables
2a.Connect the three connectors of the Tig Torch cable assembly as follows: 2 Pin Plug
of trigger switch cable into the receptacle. Connect the gas lead fitting to the
”GAS” connection, then connect the power cable twist lock connector to negative “-”
terminal socket on the front panel of the machine and fasten it tightly in a clockwise di-
rection. Ensure all connectors are tight and fastened correctly according to the drawing.
2b. Connect the twist lock connector of the earth cable to positive “+” terminal socket
on the front panel of the machine and fasten it tightly in a clockwise direction. Connect
the earth clamp to the work piece.
2c.Remote Foot Control Option: For connection of the remote foot control pedal,
connect the 2 pin plug to the connector and the 3 pin plug to the connector
on the front panel of the machine.
UNI FLAME AUTOLIFT
INSTALLATION & OPERATION

UNI FLAME AUTOLIFT
INSTALLATION & OPERATION
Selector Switches.
3. Main switch:
The power switch turns the machine on and off.
4. AC/DC Selector Switch.
Select “ARC” for MMA welding
Select “TIG” for Tig welding.
5. AC/DC Selector Switch.
Select “AC” for Aluminum and Aluminum Alloys.
Select “DC” for Stainless Steel, Steel, and Cast Iron etc.
6. 2T / 4T Selector Switch.
Selection of“2T”provides 2 times function of the torch switch.
(1) Pressing the torch switch provides arc ignition and initializes the
welding current.
(2) Releasing the torch switch introduces down slope time to minimum
current level and then terminates the welding current and introduces the
post flow gas.Selection of“4T”provides 4 times function of the torch switch.
(1) Pressing the torch switch provides arc ignition and initializes the
welding current.
(2) Releasing the torch switch continues the welding operation.
(3) Pressing the torch switch introduces down slope and current falls to base
current level.
(4) Releasing the torch switch terminates the welding operation and introduces
the post flow gas.
7. PULSE Selector Switch.
(Available only on “P” Models)
Selection of the Pulse mode switch provides pulsed welding current output.
LED Indicator Lights
8. Thermal Overload Indicator.
To prevent damage of internal components due to overheating and or exceeding
the duty cycle a Thermal Overload will activate causing the LED to light up and
welding to terminate. Do not turn off the machine; the fan will assist it to recover
after 2 or 3 minutes and return it to operational temperature level.
9. Indicator of abnormal operation.
If the machine has an abnormal operation,such as touching the electrode to the
workpiece when welding will result in the LED light, lighting up. Turn off the power
supply and restart the machine to see if it’s normal again; if not, please return
machine for service.
10. Digital meter.
Indicates the welding current output.

UNI FLAME AUTOLIFT
1.Connection of Input Cables
11. Pre-flow Gas Timer:
Provides pre-flow gas to purge tig torch
gas line prior to the initialization of the arc.
Adjustment is 0-2sec.
12. Welding Current Control:
For adjustment and setting of the main
welding current.
13. Base Current Control:
(Available Pulse Model Only) For the
adjustment and setting of the base current
in Pulse mode.
The set value is a percentage of the main
welding current.
14. Down Slope Control:
Approaching the end of the weld time the
welding current can be reduced gradually
until it stops, this prevents craters and pin
holes and is referred to as “down slope”.
This dial is for the adjustment and setting
of the down slope time.
Adjustment is 0-10sec.
Note: When using the remote foot control
set the dial to “0”.
15.Arc Force Control:
(Available Pulse Model Only). Applies
only in MMA mode. This dial adjusts the
characteristic of the welding arc from
forceful arc at maximum to soft arc at
minimum.
16.Pulse Frequency Control:
(Available Pulse Model Only). This dial is
for the adjustment and setting of the pulse
frequency when the machine is set in
Pulse mode.
Adjustment is 0.5-300Hz.
17. Pulse Width:
(Available Pulse Model Only). This dial
is for the adjustment and setting of the
on time of the peak current (pulse width)
when the machine is set in Pulse mode.
Adjustment is 10% – 90%.
18. AC Balance Control:
In AC TIG welding, the current exchanges
between positive and negative directions.
When current flow is from tungsten to
work piece it is in a positive (+) direction,
the arc energy is stronger at the tungsten
and is good for removing the oxidized sur-
face of the work piece. However too much
+ current flow can drive too much energy
to the tungsten causing it to overheat and
melt the tungsten electrode.
When the current flow is from work piece
to
tungsten it is in a negative (-) direction,
the arc energy is greater at the work
piece providing better penetration and the
tungsten heats up less. The arc stability
is good and ideal for most AC welding
situations.
The dial is for adjusting the current flow
time
between positive and negative. When set
at the
middle the proportion is 50%. When set
at the maximum it is 80% and at the mini-
mum it is 20%. Adjusted in a clockwise
direction, the positive
current flow time is longer and negative
flow is less, and vice versa.
19. Post Flow Gas Timer:
This dial provides an after flow of gas
when the welding arc is extinguished.
Post flow gas prevents contamination of
the molten pool and tungsten
electrode during cool down cycle.
Adjustment 0-10sec.
INSTALLATION & OPERATION

UNI FLAME AUTOLIFT

UNI FLAME AUTOLIFT
Instructions for “AC” Tig Welding.
1. Select“AC”mode.
2. Switch on the power source, the machine will energize and the on demand
fan will operate.
3. Set the gas flow at the regulator (refer to Parameter).
4. Set the balance according to the degree of oxidization of work piece or preference
of arc characteristic.
5. Set the main welding current as required.
6. Press the switch of the welding torch, the gas valve will activate and release gas
flow and you will hear the static of the HF points working.
Note: Please press the switch of the welding torch for several seconds to allow the gas
flow to purge the gas line of any impurities.
7. Adjust the time of “pre-gas”,”post-gas” and “down slope time” according to the
application.
8. The machine is now ready for welding in AC standard mode.
The following steps are available only with “Pulse” Models
9. Select “Pulse” option if required. Set main welding current as required,
set “Base” current as required (suggest 40%), Set “Pulse Hz” (suggest 1-2Hz), set
“Pulse Width” (Suggest 50%)
10. Adjust the time of “pre-gas”,”post-gas” and “down slope time” according to the
practical application.
11. The machine is now ready for welding in AC pulse mode.
Notes:
The remote foot control is optional according to the required application.
When connecting the remote foot control set the main weld amperage dial on the front
panel to 0 A. When the remote foot control is connected the weld amperage is adjusted
variably by depressing the foot pedal.
The distance between tungsten and work piece should be maintained strictly in the
range of 2mm to 4mm and a gas flow of between 6 -12 l/min is recommended.
INSTALLATION & OPERATION

UNI FLAME AUTOLIFT
Instructions for DC TIG Welding
1. Select“DC”mode.
2. Switch on the power source, the machine will energize and the on demand
fan will operate.
3. Set the gas flow at the regulator (refer to Parameter).
4. Set the main welding current as required.
5. Press the switch of the welding torch, the gas valve will activate and release gas
flow and you will hear the static of the HF points working.
Note: Please press the switch of the welding torch for several seconds to allow the gas
flow to purge the gas line of any impurities.
6. Adjust the time of “pre-gas”,” post-gas” and “down slope time” according to the
application
7. The machine is now ready for welding in DC standard mode
The following steps are available only with “Pulse” Models
8. Select “Pulse” option if required. Set main welding current as required,
set “Base” current as required (suggest 30%), Set “Pulse Hz” (suggest 10Hz), set
“Pulse Width” (Suggest 50%)
9. Adjust the time of “pre-gas”,” post-gas” and “down slope time” according to the
practical application.
10. The machine is now ready for welding in DC pulse mode.
Notes:
The remote foot control is optional according to the required application.
When connecting the remote foot control set the main weld amperage dial on the front
panel to 0 A. When the remote foot control is connected the weld amperage is adjusted
variably by depressing the foot pedal.
The distance between tungsten and work piece should be maintained strictly in the
range of 2mm to 4mm and a gas flow of between 6 -12 l/min is recommended.
INSTALLATION & OPERATION

UNI FLAME AUTOLIFT
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.
PRE-CAUTIONS

Spare Parts
No Description WGA Part No.
1 Cover J03245
2 Handle J24005
3 Button C14004
4 Function switch C16009
5 Function switch C16012
6 Main switch C16001
7 Front panel J02162
8 Fast-socket J21009
9 Pilot-socket(2 pins) C08146
10 Pilot-socket(3 pins) C04002
11 Rubber foot J24010
12 Coupling socket C02015
13 Panel PCB B04045
14 Control PCB B04046
15 Top PCB(left) B01024
16 Inverter PCB 1 B16007
17 Inverter PCB 2 B16008
18 AC Driver PCB B05003
19 Fan D28005
20 Inductance D16212
21 Heat sink J20031/J20032
22 Input cable C09013
23 Digital meter D20006
24 EMC Filter Board
The layout of the following machines is similar to the above photo,
but some critical parts may be different.
UNI FLAME AUTOLIFT

WELDING GUNS OF AUSTRALIA Pty Ltd
WWW.UNIMIG.COM.AU
Disclaimer:
While the information is provided in good faith, Welding Guns Of Australia does not warrant the accuracy of information
provided nor assume any legal responsibility for it or for any damage which may result from reliance on or use of it or from any
negligence of Welding Guns Of Australia or other person/s with respect to it.
For further information please call Welding Guns of Australia Pty Ltd.
112 Christina Rd, Villawood NSW 2163 - PO Box 3033 Lansvale NSW 2166
MAINTENANCE
TROUBLESHOOTING
Caution:
Only qualified technicians are authorized to undertake the repair of this
welding equipment. For your safety and to avoid Electrical Shock,
please observe all safety notes and precautions detailed in this manual.
UNIMIG pursue a policy of continuous research and development, and therefore
reserve the right to change the specifications, or design, without prior notice. *2 year warranty power source.
WARRANTY
• 2 Years from date of purchase.
• Welding Guns of Australia Pty Ltd warranties all goods as specified by the
manufacturer of those goods. This Warranty does not cover freight or goods that have
been interfered with. All goods in question must be repaired by an authorised repair agent
as appointed by this company. Warranty does not cover abuse, mis-use, accident, theft,
general wear and tear. New product will not be supplied until
Welding Guns of Australia Pty Ltd has inspected product returned for warranty
and agree’s to replace product. Product will only be replaced if repair is impossible.
If in doubt please ring.
WARNING:
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding
machine. In order to prevent any possible failure or fault of this welding
equipment, clean the dust at regular intervals with clean and dry compressed air
of required pressure.
Please note that: lack of maintenance can result in the cancellation of the
guarantee; the guarantee of this welding equipment will be void if the machine
has been modified, attempt to take apart the machine or open the factory-made
sealing of the machine without the consent of an authorized representative of the
manufacturer.