Unimig VIPER MULTI 135, Operating Manual

Page 1: ...U11005K Operating Manual ...

Page 2: ...out 9 4 1 Front Panel Layout 9 4 2 Rear Panel Layout 9 4 3 Interior Layout 10 5 Package Contents 11 6 MIG Machine Setup Gasless 12 7 MIG Machine Setup Gas Shielded 17 8 MIG Welding Guide 23 9 MMA Machine Setup 28 10 MMA Welding Guide 31 11 TIG Machine Setup 33 12 TIG Welding Guide 37 13 Drive Roller Selection 41 14 MIG Torch Consumables 42 15 MIG Troubleshooting 43 16 TIG Troubleshooting 45 17 MMA...

Page 3: ...l 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 undersized 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 while weld...

Page 4: ...e If damaged a cylinder can explode Because gas cylinders usually are part of the welding cutting 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 Ensure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding cutting electrod...

Page 5: ... in fan working to bring down the temperature inside the equipment The machine will be ready for use again when the internal temperature reaches a safe level Over Voltage Supply Regarding the power supply voltage range of the machine please refer to the Main parameter table This equipment is of automatic voltage compensation which enables the maintaining of the voltage range within the given range...

Page 6: ... require leaving the gas pressure in the regulator and line for an extended time period In this situation it is recommended to open the cylinder valve set the flow rate to 8 10 L min close the cylinder valve and check after a minimum of 15 minutes 5 If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying with soapy water bubbles will appear at the leakage po...

Page 7: ...IG wire meaning you can easily run mild steel stainless steel flux cored MIG wire Multi Process Welding This three in one machine lets you perform MIG TIG and STICK welding all on one machine There is no need to swap between machines saving you time and setup 10A Plug A 10 AMP power plug can be used on any domestic outlet It s perfect for the DIY home handyman or the professional welder looking fo...

Page 8: ... Specifications Parameter Values MIG Welding Current Range 40 135A MIG Duty Cycle 40 C 15 135A 60 65A 100 50A MIG Wire Size Range 0 6 0 9mm MIG Wire Spool Size 1kg MIG Welding Thickness Range 1 6mm 3 3 TIG Specifications Parameter Values TIG Function Type DC Lift Arc TIG Welding Current Range 20 120A TIG Duty Cycle 40 C 15 120A 60 60A 100 45A TIG Welding Thickness Range 1 6mm 3 4 STICK Specificati...

Page 9: ... LED 2 Thermal Overload LED 3 Weld Mode Selector 4 Synergic MIG Programs 5 Synergic Control Knob 6 Positive Output 7 Polarity Cable 8 Negative Output 9 Direct Connect MIG Torch 4 2 Rear Panel Layout 10 Power Cable 11 Power Switch 12 Gas Inlet ON OFF GAS IN 9 5 6 8 10 11 12 7 1 2 3 4 ...

Page 10: ...10 VIPER MULTI 135 OPERATING MANUAL 4 3 Interior Layout 13 Wire Spool Holder 14 Wire Feed Assembly 13 14 ...

Page 11: ...RATING MANUAL 5 Package Contents VIPER MULTI 135 Drive Rollers 2m Direct Connect MIG Torch Electrode Holder 2m Earth Clamp Lead 10A Plug Fitted 1 x 0 6 0 8mm V GROOVE 25 9 SOLID WIRE 1 x 0 8 0 9mm F GROOVE 25 9 GASLESS WIRE ...

Page 12: ...ct the polarity cable to the negative dinse connection twist to lock in place 2 Connect the earth clamp to the positive dinse connection twist to lock in place 3 Connect the plug into a 10 AMP socket then switch the machine ON 4 Pull up the roller tension knob to release the wire drive ...

Page 13: ...roller cap 6 Ensure you have a Knurled F Groove drive roller installed If not fit correct roller and replace the roller cover 7 Unscrew spool retaining nut and remove tension spring and spool holder bracket 8 Place 1kg wire spool onto the spool holder ...

Page 14: ...l holder bracket then tighten spool retaining nut 10 Feed wire through the inlet guide tube to the outlet guide tube Ensure that the wire passes through the roller 11 Pull down tension knob to lock wire in place Twist to tighten 12 Select MIG from the weld mode selector ...

Page 15: ...s from the MIG torch 14 Hold down the torch trigger to feed wire through to the torch If the wire slips or stops you will need to adjust the roller tension knob 15 Replace front end consumables on the MIG torch 16 Select wire size according to the wire spool installed ...

Page 16: ...igher value for thicker material and a lower value for thinner material 18 Connect earth clamp to your workpiece 19 Line up the torch with your workpiece then simply pull the trigger to initiate the weld For gasless MIG the drag method is recommended for optimum weld quality Release trigger to end the weld ...

Page 17: ...ct the polarity cable to the positive dinse connection twist to lock in place 2 Connect the earth clamp to the negative dinse connection twist to lock in place 3 Connect the plug into a 10 AMP power point then switch the machine ON 4 Pull up the roller tension knob to release the wire drive ...

Page 18: ...the roller cap 6 Ensure you have a V Groove drive roller installed If not fit correct roller and replace the roller cover 7 Unscrew spool retaining nut and remove tension spring and spool holder bracket 8 Place 1kg wire spool onto the spool holder ...

Page 19: ...l holder bracket then tighten spool retaining nut 10 Feed wire through the inlet guide tube to the outlet guide tube Ensure that the wire passes through the roller 11 Pull down tension knob to lock wire in place Twist to tighten 12 Select MIG from the weld mode selector ...

Page 20: ...s from the MIG torch 14 Hold down the torch trigger to feed wire through to the torch If the wire slips or stops you will need to adjust the roller tension knob 15 Replace front end consumables on the MIG torch 16 Place twin gauge argon regulator into your gas outlet ...

Page 21: ...OPERATING MANUAL ON OFF GAS IN 17 Tighten securely with wrench 18 Connect gas hose to the regulator outlet and crimp in place 19 Connect gas hose to the gas inlet on the rear of the machine 20 Adjust gas flow to 8 12L min ...

Page 22: ...material thickness Use a higher value for thicker material and a lower value for thinner material 23 Connect earth clamp to your workpiece 24 Line up the torch with your workpiece then simply pull the trigger to initiate the weld For gas shielded MIG the push method is recommended for optimum weld quality Release trigger to end the weld ...

Page 23: ...e wire heats up and begins to form a molten bead the bead separates from the end of the wire and forms a droplet that is transferred into the weld pool This process is repeated about 100 times per second making the arc appear constant to the human eye Short Circuit Droplet separates Wire Heating Arc flattens droplet Magnetic field pinches wire Cycle repeats The wire approaches the workpiece and to...

Page 24: ...d joint Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration useful for welding thin materials The welds are wider and flatter allowing for minimal clean up grinding time 8 3 3 Perpendicular Technique The wire is fed directly into the weld This technique is used primarily for automated situations or when con...

Page 25: ...weld 8 6 Stick Out Stick out is the length of the unmelted wire protruding from the end of the contact tip A constant even stick out of 5 10mm will produce a stable arc and an even current flow providing good penetration and even fusion Too short a stick out will cause an unstable weld pool produce spatter and overheat the contact tip Too long stick out will cause an unstable arc lack of penetrati...

Page 26: ...can also occur and an unfilled groove in the base metal is created when the travel speed is too fast to allow molten metal to flow into the weld crater created by the arc heat 8 7 2 Travel Speed Too Slow A too slow travel speed produces a large weld with a lack of penetration and fusion The energy from the arc dwells on top of the weld pool rather than penetrating the base metal This produces a wi...

Page 27: ... flow is critical in protecting the welding zone from the atmosphere Too low a flow will give inadequate coverage and result in weld defects and unstable arc conditions Too high a flow can cause air to be drawn into the gas column and contaminate the weld zone Use the correct shielding gas CO2 is suitable for steel and offers good penetration characteristics the weld profile is narrower and slight...

Page 28: ...DC electrodes connect earth clamp to the negative dinse connection and electrode holder to the positive dinse connection 2 For DC electrodes connect earth clamp to the positive dinse connection and electrode holder to the negative dinse connection 3 Connect the plug into a 10 AMP power point then switch the machine ON 4 Select MMA from the MIG TIG MMA selector ...

Page 29: ...VIPER MULTI 135 OPERATING MANUAL 5 Push down handle to open up electrode holder grip 6 Place electrode into electrode holder 7 Release handle to securely grip electrode 8 Adjust amperage to desired setting ...

Page 30: ...MULTI 135 OPERATING MANUAL 9 Connect earth clamp to your workpiece 10 Strike electrode against workpiece to initiate arc 11 Drag along workpiece to weld Pull the electrode away from the workpiece to finish weld ...

Page 31: ...he deposit is covered and protected by a slag which comes from the electrode coating The arc and the immediate area are enveloped by an atmosphere of protective gas 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 inte...

Page 32: ...he electrode and result in poor quality welds The general rule of thumb for down hand welding is to have an arc length no greater than the diameter of the core wire 10 3 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 ...

Page 33: ...Connect the TIG torch to the negative dinse connection twist to lock in place 2 Connect the earth clamp to the positive dinse connection twist to lock in place 3 Connect the plug into a 10 AMP power point then switch the machine ON 4 Select TIG from the MIG TIG MMA selector ...

Page 34: ...ER MULTI 135 OPERATING MANUAL 5 Place argon flowmeter regulator into your gas outlet 6 Tighten securely with wrench 7 Connect gas hose to the flowmeter outlet and crimp in place 8 Adjust gas flow to 6 12L min ...

Page 35: ...ding current using the amperage control dial 10 Connect earth clamp to your workpiece 11 Turn on the gas valve located on the TIG torch handle 12 Lay the outside edge of the gas cup on the workpiece with the tungsten electrode 1 2mm from the workpiece ...

Page 36: ...the tungsten electrode from the workpiece 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 ga...

Page 37: ...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 12 2 Lift Arc Ignition for TIG Tungsten Inert Ga...

Page 38: ...r Wire Technique It is necessary for 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 in creating a weld pool of the desired size Once the weld pool is established tilt the torch at a...

Page 39: ...N GUIDE This information is intended to act as a guide only individual results may vary depending on technique skill and material 12 5 TIG Tungsten Selection Guide 12 6 Tungsten Electrodes Rating for Welding Currents Tungsten Diameter mm Diameter at the Tip mm Constant Included Angle Current Range Amps Current Range Pulsed Amps 1 0mm 0 25 20 5 30 5 60 1 6mm 0 5 25 8 50 5 100 1 6mm 0 8 30 10 70 10 ...

Page 40: ...at 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 starts and eliminates arc wander 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 melt...

Page 41: ...onal column strength They are stiffer and don t bend so easily 13 2 Flux Cored Gasless Wire Knurled F Groove These wires are made up of a thin metal sheath that has fluxing and metal compounds layered onto it and then rolled into a cylinder to form the finished wire The wire cannot take too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied A Knurle...

Page 42: ...NS15 NOZZLE SPRING 2 SKU Description QTY PCT0008 06 CONTACT TIPS Steel 0 6mm 10 PCT0008 08 CONTACT TIPS Steel 0 8mm 10 PCT0008 09 CONTACT TIPS Steel 0 9mm 10 SKU Description QTY PGN15CON GAS NOZZLE Conical 2 PGN15CYL GAS NOZZLE Cylindrical 2 PGN15SPOT GAS NOZZLE Spot 2 PGN15TAP GAS NOZZLE Tapered 2 PGN15GLN GASLESS NOZZLE 2 ...

Page 43: ...g Contaminated base metal Remove materials like paint grease oil and dirt including mill scale from base metal Contaminated MIG wire Use clean dry rust free wire Do not lubricate the wire with oil grease etc Gas nozzle clogged with spatter worn or out of shape Clean or replace the gas nozzle Missing or damaged gas diffuser Replace the gas diffuser MIG torch Euro connect O ring missing or damaged C...

Page 44: ... speed Voltage setting incorrect Adjust the voltage setting MIG torch lead too long Small diameter wires and soft wires like aluminium don t feed well through long torch leads replace the torch with a lesser length torch MIG torch lead kinked or too sharp angle being held Remove the kink reduce the angle or bend Contact tip worn wrong size wrong type Replace the tip with correct size and type Line...

Page 45: ...e filler wire into the leading edge of the weld pool in front of the tungsten 16 3 Porosity Poor weld appearance and colour Wrong gas poor gas flow gas leaks Use pure argon Gas is connected check hoses gas valve and torch are not restricted Set the gas flow between 6 12 L min Check hoses and fittings for holes leaks etc Contaminated base metal Remove moisture and materials like paint grease oil an...

Page 46: ...method and wheel Contaminated base metal or filler wire Remove contaminating materials like paint grease oil and dirt including mill scale from base metal Remove all grease oil or moisture from filler metal 16 7 Arc difficult to start or will not start DC welding Incorrect machine set up Check machine set up is correct No gas incorrect gas flow Check the gas is connected and cylinder valve open ch...

Page 47: ...e or seek assistance for the correct technique 17 5 Lack of penetration Insufficient heat input Increase the amperage or choose a larger electrode Poor welding technique Use the correct welding technique or seek assistance for the correct technique Poor joint preparation Check the joint design and fit up make sure the material is not too thick Seek assistance for the correct joint design and fit u...

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