Unimig VIPER User Manual

KUMJRVM185
OPERATING MANUAL
Please read and understand this instruction manual carefully
before the installation and operation of this equipment. © Welding Guns Of Australia PTY LTD 2018
2 YEAR
WARRANTY
(POWER SOURCE)

Unimig VIPER Specifications

General

Welding Current Range	10-200A
Wire Diameter	0.6-1.0mm
Welding Processes	MIG, TIG, MMA
Efficiency	85%
Input Voltage	240V
TIG Start	Lift TIG

Summary

Warranty Information

Safety Guidelines

Machine Operating Safety

Guidelines for safe operation of welding equipment.

Electrical Hazards

Precautions against electric shock during welding operations.

Fumes and Gas Hazards

Risks from welding fumes and gases and necessary precautions.

Arc Ray Hazards

Protection from harmful arc rays to eyes and skin.

Fire and Gas Cylinder Safety

Fire Hazards

Risks of fire from sparks, hot materials, and flammable substances.

Gas Cylinder Safety

Safe handling and storage of gas cylinders to prevent explosions.

Gas Build-up Hazards

Risks associated with gas accumulation in confined spaces.

Magnetic Field and Noise Hazards

Impact of magnetic fields on medical devices and hearing damage from noise.

Hot Part Hazards

Precautions when handling hot welding components.

Safety Precautions and Maintenance

Working Environment Requirements

Conditions for safe and optimal installation and operation.

Operational Safety Tips

Key safety advice including ventilation and thermal protection.

Maintenance Guidelines

Procedures for cleaning and maintaining the welding equipment.

Troubleshooting Caution

Warning for qualified personnel to perform repairs.

Gas Leakage Checks

VIPER MIG 185 Features

Key Features List

List of primary functionalities like MIG, TIG, STICK, and protection ratings.

Machine Package Contents

Details of the components included in the VIPER MIG 185 package.

Technical Data

Technical Specifications

Detailed electrical and mechanical specifications of the welding machine.

MIG Welding Specifications

Parameters for MIG welding, including current, duty cycle, and wire size.

TIG and Stick Welding Specs

Specifications for TIG and Stick welding functions.

Machine Features Summary

Overview of built-in features like wire drive and thermal protection.

Machine Parts Layout

Front Panel Components

Labeling of controls, terminals, and sockets on the front of the unit.

Rear and Side Components

Identification of fan, inlets, and other external parts.

Machine Parts Layout

Wire Feeder Components

Labeling of wire feeding spindle, controls, and feeder unit.

MIG with Gas Installation

Connection Procedures

Instructions for connecting torch, earth, and gas supply.

Wire Feed Roller Setup

Guidance on fitting drive rollers for different wire types.

Wire Spool Loading

Steps for placing and feeding wire from the spool.

MIG with Gas Installation

Drive Roller and Tip Installation

Fitting drive rollers, contact tips, and gas nozzles.

Wire Feeding and Gas Flow

Feeding wire and setting gas flow rate for MIG welding.

Parameter Setting

Adjusting welding parameters and burn-back control.

Gasless MIG Installation

Connection Procedures

Instructions for connecting torch and earth for gasless MIG.

Wire Feed Roller Setup

Fitting knurled drive rollers for gasless flux-cored wire.

Wire Spool Loading

Steps for placing and feeding wire from the spool for gasless welding.

Gasless MIG Installation

Drive Roller and Tip Installation

Fitting drive rollers, contact tips, and gas nozzles.

Wire Feeding and Parameter Setting

Feeding wire and adjusting welding parameters.

Wire Feed Roller Selection

Roller Types and Applications

Explanation of V Groove, U Groove, and Knurled rollers for various wires.

Roller Diameter and Steel Wire

Specifications for V Groove rollers used with steel wire.

Knurled Roller for Flux Core

Specifications for Knurled rollers used with flux-cored wire.

U Groove Roller for Soft Wire

Specifications for U Groove rollers used with soft wires like aluminium.

Wire Installation & Set Up Guide

Spool Installation and Nut

Removing and fitting the spool retaining nut.

Wire Feeding into Drive Roller

Steps for feeding wire through guide tubes and into the drive roller.

Tension Adjustment

Adjusting pressure roller tension for smooth wire feed.

MIG Torch Liner Installation

Liner Removal

Procedure for removing front end parts and the old liner.

New Liner Installation

Feeding and securing the new liner in the torch assembly.

Torch & Wire Feed Set Up for Aluminium Wire

Liner Installation for Aluminium

Replacing the torch liner for aluminium wire.

Drive Roller Installation

Installing the U groove drive roller for aluminium wire.

Torch & Wire Feed Set Up for Aluminium Wire

Inlet Guide Tube and Torch Connection

Managing the inlet guide tube and connecting the torch receptacle.

Contact Tip and Final Assembly

Fitting the correct contact tip and reassembling the torch.

MIG WELDING GUIDE

MIG Welding Definition

Explanation of MIG/GMAW/MAG welding and transfer methods.

MIG Circuit Diagram

Illustration of the basic MIG welding circuit components.

MIG WELDING GUIDE

Short Circuit Transfer Process

Step-by-step breakdown of the short circuit transfer mechanism.

MIG WELDING GUIDE

Gun Position and Work Angle

Guidance on gun angle, travel direction, and work angle for MIG.

Push, Perpendicular, and Drag Techniques

Explanation of different torch manipulation techniques.

MIG WELDING GUIDE

Travel Angle

Optimal travel angles for consistent MIG weld results.

Angle to Work

Correct work angle for achieving desired bead shape and penetration.

Stick Out

Importance of consistent stick out for arc stability and weld quality.

MIG WELDING GUIDE

Travel Speed

How travel speed affects penetration, fusion, and weld appearance.

Too Fast Travel Speed

Consequences of excessive travel speed on weld quality.

Too Slow Travel Speed

Consequences of insufficient travel speed on weld quality.

Correct Travel Speed

Achieving optimal weld quality with correct travel speed.

MIG WELDING GUIDE

Wire Types and Sizes Chart

Recommended wire diameters for various material thicknesses.

Gas Selection

Choosing appropriate shielding gases (Argon, CO2) for MIG welding.

SPOOL GUN SETUP

Spool Gun Connection

Connecting the spool gun to the machine and gas supply.

Wire Spool Loading

Placing and preparing the wire spool for the spool gun.

SPOOL GUN SETUP

Wire Feeding and Tip Installation

Feeding wire through the spool gun and fitting the contact tip.

Parameter and Burn-back Adjustment

Setting welding parameters and burn-back control for the spool gun.

LIFT ARC DC TIG WELDING SETUP

Torch and Earth Connection

Connecting the TIG torch and earth clamp to the machine.

Gas Supply and Parameter Setting

Connecting gas and setting the welding current for TIG.

LIFT ARC DC TIG OPERATION

Torch Assembly and Gas Flow

Assembling TIG torch parts and turning on gas flow.

Lift Arc Ignition Technique

Step-by-step method for initiating the TIG arc using Lift Arc.

DC TIG WELDING GUIDE

DC TIG Welding Process

Understanding direct current in TIG welding and heat distribution.

Arc Intensity and Material Thickness

How current affects arc power for different material thicknesses.

Lift Arc Ignition Explained

Details on the Lift Arc ignition process as an alternative to scratch start.

DC TIG WELDING GUIDE

Fusion Welding Technique

Method for fusing metal without filler wire in TIG welding.

Filler Wire Technique

Adding filler wire during TIG welding for reinforcement.

DC TIG WELDING GUIDE

Tungsten Electrode Selection

Guide to choosing tungsten based on material, amperage, and current type.

Tungsten Electrode Types

Descriptions of Thoriated, E3, Ceriated, Lanthanated, and Zirconiated electrodes.

DC TIG WELDING GUIDE

Tungsten Electrode Ratings

Current ranges for different tungsten diameters and angles.

Tungsten Preparation

Proper methods for grinding tungsten electrodes.

Electrode Tip/Flat

Understanding the effect of tip shape on arc performance.

Included Angle/Taper

How electrode angle affects weld penetration and bead width.

MMA (STICK) WELDING SET UP

Power Source and Cable Connection

Selecting MMA mode and connecting output cables correctly.

Electrode and Arc Initiation

Setting current, inserting electrode, and striking the arc.

Weld Finishing and Cleaning

Techniques for finishing the weld and removing slag.

MMA (STICK) WELDING GUIDE

MMA (Manual Metal Arc) Welding

Definition and process of MMA welding using flux-coated electrodes.

Electrode Core and Flux Functions

Roles of the electrode core wire and flux coating in MMA welding.

MMA (STICK) WELDING GUIDE

Electrode Selection

Choosing the correct electrode based on material thickness and type.

Arc Length

Technique for maintaining the proper arc length for quality welds.

Electrode Angle

Correct electrode angles for different welding positions.

Travel Speed

Adjusting travel speed for optimal weld bead formation.

Material and Joint Preparation

Importance of clean surfaces and proper joint preparation.

SB15 MIG TORCH & SPARES

SB15 Torch Assembly Diagram

Labeled diagram of the SB15 MIG torch components.

Torch Parts List

Detailed list of part numbers for SB15 torch components by length.

SB15 MIG TORCH & SPARES

SB15 Contact Tips

Available contact tips for steel and aluminium wires.

SB15 Tip Holder

Part numbers for tip holders and shroud springs.

SB15 Gas Nozzle

Different types of gas nozzles for the SB15 torch.

SB15 Liners

Available liners for steel and aluminium wire.

MIG WELDING TROUBLE SHOOTING

Excessive Spatter

Reasons for excessive spatter and suggested remedies.

Porosity Issues

Causes of porosity in welds and troubleshooting steps.

Wire Stubbing

Problems with wire feeding into the weld pool and solutions.

Lack of Fusion

Causes and remedies for incomplete fusion in MIG welds.

Excessive Penetration

Troubleshooting excessive heat and penetration issues.

Lack of Penetration

Addressing shallow fusion and insufficient penetration.

MIG WIRE FEED TROUBLE SHOOTING

No Wire Feed

Troubleshooting issues when no wire is feeding.

Inconsistent/Interrupted Wire Feed

Resolving problems with irregular or interrupted wire feeding.

Contaminated MIG Wire

Ensuring clean wire for optimal feed performance.

TIG WELDING TROUBLE SHOOTING

Tungsten Burning Quickly

Causes and remedies for tungsten electrodes burning away.

Contaminated Tungsten

Preventing tungsten contamination during TIG welding.

Porosity and Weld Appearance

Addressing porosity and poor weld appearance in TIG.

Yellowish Residue/Smoke

Troubleshooting discoloration and smoke from the TIG nozzle.

Unstable Arc

Diagnosing and fixing unstable arc conditions in TIG.

Arc Wandering

Causes and solutions for arc wandering in TIG welding.

Arc Difficult to Start

Troubleshooting issues with starting the TIG arc.

MMA (STICK) WELDING TROUBLE SHOOTING

No Arc

Troubleshooting issues when no arc is struck in MMA welding.

Porosity

Causes and remedies for porosity in MMA welds.

Excessive Spatter

Addressing excessive spatter in MMA welding.

Weld Sits on Top / Lack of Fusion

Troubleshooting welds that sit on top and lack fusion.

Lack of Penetration

Causes and remedies for insufficient penetration in MMA.

Excessive Penetration / Burn Through

Addressing excessive heat and burn-through in MMA.

Uneven Weld Appearance

Improving weld appearance and consistency in MMA.

Electrode Arc Characteristics

Troubleshooting unusual arc characteristics with electrodes.

SPARE PARTS IDENTIFICATION

Machine Spare Parts Diagram

Labeled diagram showing the location of various spare parts.

Spare Parts List

Detailed list of part numbers and descriptions for machine components.

WARRANTY TERMS

Warranty Period

Information on standard and extended warranty periods for machinery.

UNIMIG Product Warranty

Specific warranty durations for different UNIMIG machine series.

Other Product Warranties

Warranty details for accessories like torches, helmets, and consumables.

Warranty Clause Explanations

Clarifications for warranty clauses related to transformers, PCB, and accessories.

WARRANTY / RETURNS / EXCHANGES

Australian Consumer Law Rights

Customer entitlements for refunds, replacements, and repairs.

Return Acceptance Conditions

Criteria for accepting product returns and conditions for liability.

Making a Warranty Claim

Procedure for submitting a warranty claim, including contact information.

WARRANTY EXCLUSIONS

General Warranty Exclusions

Conditions like wear and tear, misuse, and improper maintenance.

Non-Warranted Parts

List of parts that are excluded from warranty coverage.

Excluded Product Categories

Categories of products and purchases not covered by warranty.