Uni-Mig KUMJR250SWF User manual

1
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
ADVANTAGE
MIG-TIG-STICK BUILT-IN
MIG-TIG-STICK
TECHNOLOGY
ADVANTAGE
TECHNOLOGY
TECHNOLOGY
MIG-TIG-STICK BUILT-IN
TECHNOLOGY
MIG-TIG-STICK
TECHNOLOGY
Please read and understand this instruction manual carefully
before the installation and operation of this equipment. ©Welding Guns Of Australia PTY LTD 2012
Voltage Reduction Device
OPERATING MANUAL
KUMJR250SWF
KUMJR350SWF
KUMJR500SWF

2
Thank you for your purchase of your UNI-MIG welding machine.
We are proud of our range of welding equipment that has a proven track record of innovation, per-
formance 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 characteris-
tics, performance and interface between man and machine should be.
Within our team are specialist welders that have a proven history of welding knowledge and exper-
tise, 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 con-
dence that they will be well satised both now and in the future.
UNI-MIG welders are manufactured and compliant with - AS/NZ60974.1 2006
guaranteeing you electrical safety and performance.
WARRANTY
• 3 Years from date of purchase.
• Welding Guns Of Australia PTY LTD Ltd warranties all goods as specified by the manufacturer
of those goods.
• This Warranty does not cover freight or goods that have been interfered with.
• All goods in question must be repaired by an authorised repair agent as appointed by this
company.
• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.
• New product will not be supplied unless Welding Guns Of Australia PTY LTD has inspected
product returned for warranty and agree’s to replace product.
• Product will only be replaced if repair is not possible
• Please view full Warranty term and conditions supplied with machine or at www.uniMIG.com.au/
warranty.asp or at the back of this manual.

3
CONTENTS PAGE
Warranty 2
Safety 4-5
Caution, Maintenance and Trouble Shooting 6-7
Technical Data, Product Information 8
Machine Layout Pictogram 9
Machine Assembly 10
MMA (Stick) Welding) 11-13
Installation & Operation for MIG Welding 14-16
Wire Feed Drive Rollers 17
Wire Installation and Wire Feeder Set Up 18
MIG Torch Liner Installation 19
Torch and Wire Feeder Setup for Aluminium Wire 20-21
MIG Welding Guide 22-27
DC TIG Welding 28-29
TIG Welding Guide 30--33
MIG Torch Parts Breakdown 34-39
TIG Torch Parts Breakdown 40-41
Spare Parts Breakdown 42-47
Trouble Shooting Guide 48-52
Warranty terms 53-55

4
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.
• 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 qualied.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe
burns. The electrode and work circuit is electrically live whenever the output is on. The input
power circuit and internal machine circuits are also live when power is on. In MIG/Mag welding,
the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment is dangerous.
• Connect the primary input cable according to Australian and New Zealand standards and regulations.
• Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.
The operator must wear dry welding gloves while he/she performs the welding task.
• The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
•Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.
•Do not use damaged, under sized, or badly joined cables.
•Do not drape cables over your body.
Fumes and gases are dangerous. Smoke and gas generated whilst welding or cutting can
be harmful to people’s health. Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health.
•Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
• In conned 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 lter 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 ash,glare and sparks; warn others not to watch the arc.
Machine Operating Safety

5
Fire hazard. Welding on closed containers, such as tanks,drums, or pipes, can cause them
to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause
res and burns. Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or re. Check and be sure the area is safe before doing any welding.
•The welding sparks may cause re, therefore remove any ammable materials away from the working
area, at least 12m from the welding arc. Cover ammable 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 ammable 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 ammable dust, gas, or liquid vapours (such as petrol)
•Have a re 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, oor, bulkhead, or partition can cause re on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylin-
der 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 ames,
sparks, and arcs.
•Insure cylinders are held secure and upright to prevent tipping or falling over.
•Never allow the welding electrode or earth clamp to touch the gas cylinder, do not drape welding cables
over the cylinder.
•Never weld on a pressurised gas cylinder, it will explode and kill you.
•Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.
Gas build up. The build up of gas can causes a toxic environment, deplete the oxygen content
in the air resulting in death or injury. Many gases use in welding are invisible and odourless.
•Shut off shielding gas supply when not in use.
• Always ventilate conned spaces or use approved air-supplied respirator.
Electronic magnetic elds. MAGNETIC FIELDS can affect Implanted Medical Devices.
•Wearers of Pacemakers and other Implanted Medical Devices should keep away.
•Implanted Medical Device wearers should consult their doctor and the device manufacturer before going
near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
Hot parts. Items being welded generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the welding
gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

6
CAUTION
1. Working Environment.
1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive
chemicals, ammable 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 pre-
vent 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 modied, 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.

7
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 ow rate on the regulator to approximately 8-10 l/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure
gauge on the regulator, if the needle drops away towards zero there is a gas leak.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the
regulator and line for an extended time period. In this situation it is recommended to open the
cylinder valve, set the ow rate to 8-10 l/min, close the cylinder valve and check after a
minimum of 15 minutes.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying
with soapy water, bubbles will appear at the leakage point.
6. Tighten clamps or ttings to eliminate gas leakage.
Important: We strongly recommend that you check for gas leakage prior to operation of
your machine. We recommend that you close the cylinder valve when the machine is not in
use. Welding Guns Of Australia PTY LTD, authorised representatives or agents of
Welding Guns Of Australia will not be liable or responsible for the loss of any gas.
ATTENTION! - CHECK FOR GAS LEAKAGE

8
MIG/TIG/MMA DC Welding Machines
Separate Wire Feeder System
Welds: Steels, Stainless, Cast Iron, Bronze, Aluminium, Copper
The MIG Separate Wire Feeder range are inverter-based MIG welding machines with added MMA and TIG function. These are
industrial machine equiped with a separate 4 roll gear driven wire feeder and 10m interconnecting cables. The MIG function allows you
to weld with Solid wires, Fluxcored Gas and Gasless wires. Adjustment of Voltage & Wire Feed at the wire feeder make for easy set-
ting of welding parameters and give the convenience of remote adjustment from the power source. The Crater Current setting delivers
perfect nishing of the weld, the electronic inductance offers ne adjustment of the arc characteristic and burn back adjustment leaves
the wire stick out ready for the next weld. Wire inch and Gas Check provides set up of the wire feed and gas setting with wastage of
wire or gas. Added MMA welding capability delivers easy and high quality welding using electrodes, including cast Iron, stainless and
low hydrogen. Connection of the 17V or 26V TIG torch provides quality DC TIG (scratch start) welding of steel, stainless steel and
copper. Ideal for heavy and structural welding applications through to general engineers, maintenance workshops, light engineering,
rural workshops and home workshops. Designed and built to our specication. Certied to - AS/NZ60974.1
Overview
Features
• Latest IGBT Inverter Technology
• MIG/Mag with Gas and Gasless wire function
• Stick Electrode (MMA) Function
• DC TIG welding with scratch start
• Voltage & Wire Feed Controls at Wire Feeder
• Variable Inductance & Burn Back Controls
• Adjustable Crater Current Control
• Gas Check / Inch Wire
• 2T/4T Trigger Function
• Separate 4 Roll Geared Wire Feeder
• LED Digital Display
• Euro MIG torch connection
• 10m Interconnecting Cables
• Excellent arc stability for MIG/TIG/MMA welding
Technical Data MIG500SWF MIG350SWF MIG250SWF
Power Supply / Phases (V-Ph) AC415V±15%~50/60Hz 415V 3 Phase 240V 1 Phase
Duty Cycle@40°c to AS/NZ60974 60% @ 500 Amps MIG 60% @ 350 Amps MIG 35% @ 250Amps MIG
60% @ 500 Amps MMA 60% @ 350 Amps MIG 35% @ 225Amps MMA
Output Current Range MIG 50A/16.5V - 500A/39.0V 50A/16.5V - 350A/31.5V 30A/15.5V - 250/26.5V
Output Current Range MMA 20A/20.8V - 500A/40.0V 20A/20.8V - 350A/34.0V 10A/20.4V - 250/30.0V
Rated Power MIG 24.7 KVA 11.9 KVA 10.8 KVA
I Max MIG 34.0 Amps 31.0 Amps 45.0 Amps
MMA 35.0 Amps 34.0 Amps 51.0 Amps
I i eff MIG 26.0 Amps 24.0 Amps 26.6 Amps
MMA 27.0Amps 26.0Amps 28.0 Amps
Wire Feeder Type Gear Driven 4 Roll Gear Driven 4 Roll Gear Driven 4 Roll
Protection Class IP 21S IP 21S IP 21S
Insulation Class F F F
Dimensions Power Source (LxWxH) 595x280x440mm 595x280x440mm 595x280x440mm
Weight Power Source 40.6 Kg 38 Kg 38 Kg
Dimensions Wire Feeder (LxWxH) 630x235x420mm 630x235x420mm 630x235x420mm
Weight Wire Feeder 14 Kg 14 Kg 14 Kg
Length of Interconnecting Cable 10 m 10 m 10 m
Warranty 3 years on machine 3 years on machine 3 years on machine
KUMJR250/350/500SWF
MACHINE PACKAGE: KUMJR250SWF
UNI-MIG 250SWF Multifunction Welding Inverter / SB24 4M Sure Grip MIG torch with Euro connector, 10M ARC lead set
35-50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator 2M Gas Hose Complete with fittings,
10M Inter connection Cables, Trolley.
MACHINE PACKAGE: KUMJR350SWF
UNI-MIG 350SWF Multifunction Welding Inverter / SB36 4M Sure Grip MIG torch with Euro connector, 10M ARC lead set
35-50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator 2M Gas Hose Complete with fittings,
10M Inter connection Cables, Trolley.
MACHINE PACKAGE: KUMJR500SWF
UNI-MIG 500SWF Multifunction Welding Inverter / TWC5-15FTE Sure Grip MIG torch with Euro connector, 10 ARC lead set
35-50mm Dinse style connections / UNI-FLAME Twin Gauge Argon Regulator 2M Gas Hose Complete with fittings,
10M Inter connection Cables, Trolley.

9
Power Source Front Panel Layout
1. Amperage Meter
2. Mains Power LED
3. Thermal Overload LED
4. Over Current LED
5. Voltage Meter
6. 2T - 4T Trigger Switch
7. Gas Check Switch
8. MIG/MMA/TIG Mode Selector Switch
9. Crater Current Control
10. Crater Voltage Control
11. Inductance Control
12. Amperage Control (MMA/TIG)
Power Source Rear Panel Layout
13. Primary Power Switch
14. Wire Feeder Control Cable Receptacle
15. Wire Feeder Weld Power Cable Receptacle
16. Burn Back Control
17. Primary Input Cable
18. Data Plate
19. Fan
WIRE FEEDER LAYOUT
20. Voltage Control
21. Wire Speed Control
22. Inch Wire Feed Button
23. Euro Torch Connector
24. Gas Connection
25. Torch Holder
26. Control Cable Receptacle
27. Weld Power Cable Receptacle
28. Interface Cable Assembly Clamp
29. Spool Cover
30. Wire Drive Unit
31. Carry Handle
Machine Layout Description
2
13 4 5
6
7
8
9 10 11 12
13
16
15
14
17
19
18
30
20
21
22
23
29
27 28
26
2425
31

10
MACHINE ASSEMBLY
Please install the machine according to the following steps.
(1) Unpack the trolley and locate the
assembly parts inside the trolley drawer
(2) Connect and fasten down the retaining
side panels onto the trolley using the screws
provided.
(3) Mount power source to the trolley, lock in
place by fastening to the mounting brackets
front and back.Assemble the handle and wire
feeder mounting assembly.
(4) Place the wire feeder by locating the
mounting hole on the wire feeder base over
the locating pin on the wire feeder mounting
bracket.
(5) Connect the control cable assembly and
fasten rmly in place with the cable retaining
bracket.
(6) Connect the other end of the control cable
assembly to the rear of the power source.