Uni-Mig KUMJRRW175MIG User manual

1
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
OPERATING MANUAL
KUMJRRW175MIG
KUMJRRW200MIG
©Welding Guns Of Australia PTY LTD 2013
YEARS Warranty
(Power Source)
3

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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.
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
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 - AS60974-6:2006
guaranteeing you electrical safety and performance.

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CONTENTS PAGE
Warranty 2
Technical Data, Product Information 4
Safety - Cautions 5-7
Machine Layout Pictogram 8
Installation & Operation for MMA (stick) Welding 9
MMA (Stick) Welding Information 10-11
Installation & Operation for MIG Welding with Gas 12-13
Wire Feed Drive Roller Selection 14
Wire Installation Set up Guide 15
Installation & Operation for MIG Welding with No Gas 16-17
Installation Guide for Mig Torch Liner Installation 18
MIG Torch and Wire Feeder Set Up Guide for Aluminium MIG Wire 20-21
Installation & Operation for MIG Welding with Spool Gun 22-23
MIG (Metal Inert Gas) Welding 24-25
Basic MIG Welding Guide 26-29
SB24 / SB25 MIG Torch Parts Breakdown 30-31
SPGRW135 / SPGRW200 Spool Gun Torch Parts Breakdown 32-33
MIG Welding Shooting Guide 34-35
MMA Welding Trouble Shooting Guide 36
SparePartsIdentication 38

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Product Code: KUMJRRW175MIG
Package includes: MIG175 Welding Machine, SB25 MIG Torch x 3m, Earth Lead & Arc Lead 25mm x 4m,
Argon Regulator, Gas hose with quick connect fitting.
Technical Data
Power Supply / Phases (V-Ph) 240v - 1 +/- 15%
Duty Cycle @ 40°c as per AS/NZ60974-1 25% @ 175Amps MIG
25% @ 160Amps MMA
Output Current Range MIG 30A/15.5V - 175A/22.8V
Output Current Range MMA 10A/20.4V - 160A/26.4V
Rated Power MIG 6.7 KVA
I Max MIG 27.9 Amps
MMA 29.6 Amps
I i eff MIG 14.0 Amps
MMA 14.8Amps
Power factor 0.70
Protection Class IP21S
Insulation Class F
Wire Diameter Range (mm) 0.6, 0.8, 0.9, 1.0, 1.2
Dimensions Power Source (LxWxH) 470x190x380mm
Weight Power Source 12.5 Kg
Warranty 3 years on power source
Overview
The RAZORWELD MIG175 is a new inverter-based portable MIG welding machine with added (MMA) Stick function. The MIG
function allows you to weld with both Gas Shielded and Gas-less wire applications. Easy step-less adjustment of voltage and wire
feed make for easy setting of welding parameters giving excellent, professional welding results. Wire Inch gives easy feeding of the
wire during set up without gas wastage and the Burn Back adjustment leaves the wire stick out ready for the next weld. Stick welding
capability delivers easy electrode welding with high quality results, including cast Iron, stainless and low hydrogen. An additional
feature is the Spoolgun ready function that allows the simple connection of the SPGRW135 Spoolgun for the use of thin or softer
wires that don’t have the column strength to feed through standard MIG torches, such as aluminium wire. This is an industrial
machine that is both lightweight and portable. Being 240v single phase gives great versatility. Ideal for general engineers,
maintenance workshop, rural workshop, panel beaters, home workshop. Designed and built to our specification.
Certified to - AS/NZ60974.1
Features
• Latest IGBT inverter technology
• MIG/MAG with Gas and Gasless wire function
• Excellent MIG welding with CO2 gas & mixed gases
• Euro style MIG torch connection
• Internal wire feeder
• 5Kg Spools
• Adjustable Burn Back
• Spool Gun Connection
• Stepless voltage and wire feed control
• Wire Inch
• Stick electrode (MMA) function
• VRD (Voltage Reduction Device)
• Excellent arc stability with all electrode
• Hot Start - Anti Stick
• Industrial rated
• Solid case construction
• IP21S rating for environmental/safety protection
• Tolerant to variable power supply
KUMJRRW175MIG
DC MIG/MMA INVERTER
MIG/STICK - 175Amp DC inverter welderable
Welds: Steels, Stainless, Cast Iron, Bronze & Aluminium
OPTIONAL SPOOL GUN OPTIONAL CARRY BAG
135A SpoolGun
Part No. SPGRW135
RAZOR BAG
Part No. RAZOR MIG200 BAG-1
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Product Code: KUMJRRW200MIG
Package includes: MIG200 Welding Machine, SB24 MIG Torch x 4m, Earth Lead & Arc Lead 25mm x 4m,
Argon Regulator, Razorweld carry bag, Gas hose with quick connect fitting.
Technical Data
Power Supply / Phases (V-Ph) 240v - 1 +/- 15%
Duty Cycle @ 40°c as per AS/NZ60974-1 20% @ 200 Amps MIG
15% @ 200 Amps MMA
Output Current Range MIG 30A/15.5V - 200A/24.0V
Output Current Range MMA 10A/20.4V - 200A/28.0V
Rated Power MIG 9.4 KVA
I Max MIG 33.6 Amps
MMA 39.0 Amps
I i eff MIG 15.0 Amps
MMA 15.0 Amps
Power factor 0.70
Protection Class IP21S
Insulation Class F
Wire Diameter Range (mm)
Dimensions Power Source (LxWxH) 470x190x380mm
Weight Power Source 12.5 Kg
Warranty 3 years on power source
Overview
The RAZORWELD MIG200 is a new inverter-based portable MIG welding machine with added (MMA) Stick function. The MIG
function allows you to weld with both Gas Shielded and Gas-less wire applications. Easy step-less adjustment of voltage and wire
feed make for easy setting of welding parameters giving excellent, professional welding results. Wire Inch gives easy feeding of the
wire during set up without gas wastage and the Burn Back adjustment leaves the wire stick out ready for the next weld. Stick welding
capability delivers easy electrode welding with high quality results, including cast Iron, stainless and low hydrogen. An additional fea-
ture is the Spoolgun ready function that allows the simple connection of the SPGRW200II Spoolgun for the use of thin or softer wires
that don’t have the column strength to feed through standard MIG torches, such as aluminium wire. This is an industrial machine that
is both lightweight and portable. Being 240v single phase gives great versatility. Ideal for general engineers, maintenance workshop,
rural workshop, panel beaters, home workshop. Designed and built to our specification. Certified to - AS/NZ60974.1
Features
• Latest IGBT inverter technology
• MIG/MAG with Gas and Gasless wire function
• Excellent Mig welding with CO2 gas & mixed gases
• Euro style MIG torch connection
• Internal wire feeder, gear driven
• 5Kg Spools
• Adjustable Burn Back
• Spool Gun Connection
Stepless voltage and wire feed control
• Wire Inch
• Stick electrode (MMA) function
• VRD (Voltage Reduction Device)
• Excellent arc stability with all electrode
• Hot Start - Anti Stick
• Industrial rated
• Solid case construction
• IP21S rating for environmental/safety protection
• Tolerant to variable power supply
KUMJRRW200MIG
DC MIG/MMA INVERTER
MIG/STICK - 200Amp DC inverter welder
Welds: Steels, Stainless, Cast Iron, Bronze & Aluminium
OPTIONAL SPOOL GUN
200A SpoolGun
Part No. SPGRW200II
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SAFETY
Welding and cutting equipment can be dangerous to both the operator and people in or near the
surrounding working area, if the equipment is not correctly operated. Equipment must only be
used under the strict and comprehensive observance of all relevant safety regulations.
Read and understand this instruction manual carefully before the installation and operation of this
equipment.
• 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.
• 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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

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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
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&spattermaycausere,thereforeremoveanyammablematerialswellawayfrom
 theworkingarea.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.

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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,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.
TROUBLE SHOOTING
Caution:Onlyqualied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.
Note:
Minimum Motor Generator Power Suggested:- 7.1KVA for MIG165 - 9.4KVA for MIG200

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FRONT PANEL LAYOUT
1. Mains Power LED
2. VRD LED
3. Thermal Overload LED
4. Wire Feed Adjustment Knob (MIG/MAG)
5. Voltage Adjustment Knob (MIG/MAG)
6. MIG/MMA Selector Switch
7. Amperage Adjustment Knob (MMA)
8. “-” Output terminal
9. Euro Mig Torch Connector (MIG/MAG)
10. “+” Output terminal
11. SpoolGun Power Supply Connection
1 2 3 4
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BACK PANEL LAYOUT
12. Power switch
13. Gas Inlet
14. Fan
15. Input power cable
16. Data Plate
15
13
16
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INTERNAL PANEL LAYOUT
17. Burn back control
18. Spoolgun/Standard selector switch
19. Inch wire feed button
20. Spool holder assembly
21. Wire feed assembly
NOTE: MIG 165 not geared
18
21
20
6
7
8
9
10 11
14
19
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(2) Connect the
electrode lead to
(1) Set MIG/MMA selector
switch to MMA
(2) Connect the earth
lead to
Installation set up for MMA (Stick) Welding with RAZOR 175-200 MIG
(1) Turn the power source on and select the MMA function with the MIG/MMA selector switch.
(2) Connection of Output Cables
Two sockets are available on this welding machine. For MMA welding the electrode holder is shown
be connected to the negative socket, while the earth lead (work piece) is connected to the positive
socket, this is known as DC- polarity. However various electrodes require a different polarity for
optimum results and careful attention should be paid to the polarity, refer to the electrode
manufacturers information for the correct polarity.
DC+ Electrode connected to output socket.
DC- Electrode connected to output socket.
(3) Set the welding current relevant to the electrode type and size being used as recommended by the
electrode manufacturer.
(3) Set the welding current using the amperage
control dial.
(6) Hold the electrode slightly above the work
maintaining the arc while travelling at an even
speed.
(4) Place the electrode into the electrode holder
and clamp tight.
(7) Tonishtheweld,breakthearcbyquickly
snapping the electrode away from the work
piece.
(5) Strike the electrode against the workpiece to
create an arc and hold the electrode steady to
maintain the arc.
(8) Wait for the weld to cool and carefully chip
away the slag to reveal the weld metal below.