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Installation set up for MIG with Gasless wire for VIPER 180 MIG ARC

(1) Select the MIG function with the ARC/MIG selector switch.

(2) Connect the weld power cable to the Negative socket and tighten it.

(3) Connect the earth cable plug into the Positive socket and tighten it.

(4) Plug the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.

IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can

result in the connector arcing and damaging the machine and gun connector. This damage is not

covered under warranty.

(5) Check the Weld Power Cable is connected to the Negative terminal.

(6) Fit the correct size Knurled drive roller for Gas Less Flux Core wire.

(7) Place the Wire Spool onto the Spool Holder - Note: the spool retaining nut is Left Hand thread. Snip the

wire from the spool being sure to hold the wire to prevent rapid uncoiling. Feed the wire into the wire

feeder inlet guide tube through to the drive roller.

(1) Set MIG/ARC
selector switch to MIG

(2/5) Connect weld power lead to

negative terminal

Caution:

(6) Fit the correct sized Knurled Drive roller for Gas

(7) Place wire onto spool holder - (spool retaining nut

Less Flux Cored wire

is left hand thread ) Feed the wire through the inlet

NOTE: MIG 180 not geared

guide tube on to the drive roller.

Disconnect the Electrode Holder cable from the machine before using MIG function. If cable is not disconnected welding voltage is present

and can cause arcing or flash.

_________

___________

(3) Connect earth to

(+) Connection

___________

(2)

Power lead (Dongle)

into (-) Connection

_______

(4) Connect MIG torch
IMPORTANT: When connecting the
torch be sure to tighten the
connection ensuring that the spring
pins are nice and secure and lined up.

_____________________

_____

MIG Torch

Summary of Contents for JVM180i

Page 1: ...180i ...

Page 2: ...ts the latest developments in Inverter technology put together by our pro fessional 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 equip ment range This experience gives us the inside knowledge on what the arc characteristics performance and interface between ma...

Page 3: ...n for MIG Welding with Gas Wire Feed Drive Roller Selection Wire Installation Set up Guide Installation Operation for MIG Welding with No Gas Installation Guide for Mig Torch Liner Installation MIG Torch and Wire Feeder Set Up Guide for AluminumMIG Wire SpoolGun Installation and Operation MIG Metal Inert Gas Welding Basic MIG Welding Guide SB15 AND TWC 2 Torch Parts MIG Welding Shooting Guide ARC ...

Page 4: ...79 433in min Welding wire diameter 0 025 0 03 0 035 0 039 in Input 115V X 60 100 Rated input current ARC I1 ft 15A 12 60A 46A l max 20A Output 10A 20 4V 60A 22 4V U2 22 4V 22V Input 115V X 50 60 100 Rated input current MIG I1 ff l5A 12 BOA 73A 57A I max 21A Output 30A 15 5V 80A 18V U2 18V 17 7V 16 SV Efficiency 230Vac 85 115Vac 82 Power factor 230Vac 0 64 llOVac 0 74 Protection class IP21S Insulat...

Page 5: ...ect 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 harm...

Page 6: ...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 flames 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 d...

Page 7: ...orking 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 th...

Page 8: ...RC 7 Output terminal 8 Euro MigTorch Connector MIG MAG 9 Output terminal 10 Spool gun connection BACK PANEL LAYOUT 10 Power switch 11 Gas Inlet 12 Fans 13 Input power cable 14 Data Plate INTERNAL PANEL LAYOUT 15 Burn back control 16 Inch wire feed button 17 Spool holder assembly 18 Wire feed assembly 19 Spool gun selector switch 17 10 11 15 16 5 4 13 14 18 10 __________ 19 __________ ...

Page 9: ...utput 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 1 Set MIG ARC selector switchtoARC ____ 2 Connecttheearth leadto 4 Place the electrode into the electrode ho...

Page 10: ...ss the arc into the molten pool and becomes the deposited weld metal The 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 Core wire Flux coating Base metal Protective gas Arc Slag Weld pool Manual metal arc stick electrodes have a solid metal wire core and a flux coating These electrode...

Page 11: ...welding in down hand fillet horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel When vertical up welding the angle of the electrode should be be tween 80 and 90 degrees to the work piece Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required At...

Page 12: ... Ensure that your spool gun selector is on Standard __ _ 3 Put Power lead Dongle in the Positive connection ...

Page 13: ...H 16 Set the welding parameters using the wire feed and voltage control knobs 17 Using the Burn Back control set the amount of wire to burn back after you release the torch trigger This prevents the wire becoming stuck in the weld pool when finishing the weld 9 Close down the top roller bracket and clip the pressure arm into place 12 Press and hold the inch wire button to feed the wire down the to...

Page 14: ...essure roller to avoid deforming the shape of the wire too much tension will push the wire out of shape and cause it to catch in the contact tip Flux Core Gasless Wire 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 cr...

Page 15: ...locking nut and screw to hold the new position NOTE MIG 180 is not geared 2 Note the tension sp Ing adjuster and spool locating pin SJ Feed the wire through the drive roller and into the outlet guide tube of the wire feeder NOTE MIG 180 not geared 8 A simple check for the correct drive tension is to bend the end of the wire over hold it about 4 from your hand and let it run into your hand it shoul...

Page 16: ...taining nut is Left Hand thread Snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling Feed the wire into the wire feeder inlet guide tube through to the drive roller 1 Set MIG ARC selector switchto MIG 2 5 Connect weld power lead to G negative terminal Caution 6 Fit the correct sized Knurled Drive rollerforGas 7 Place wire onto spool holder spool retaining nut Less Fl...

Page 17: ...elding parameters using the wire feed and voltage control knobs 16 Using the Burn Back control set the amount of wire to burn back after you release the torch trigger This prevents the wire becoming stuck in the weld pool when finishing the weld 8 Feed wire over the drive roller into the outlet guide tube Push the wire through approx 6 Use a Knurled Drive Roller of the correct size NOTE MIG 180 no...

Page 18: ... 2 way 7 Leaving the torch straight snip the liner approximately 3 32 past the end of the torch neck 8 Place the tip holder over the end of the liner and screw into the torch neck nipping it up tight 9 Screw down the liner nut the remaining 1 2 and nip it up tight This method compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed 2 Remove th...

Page 19: ...e torch end 7 Fit the liner retaining nut together with the liner o ring 8 Push the liner firmly into the torch lead and tighten the liner retaining nut 9 Cut the liner flush with the end of liner retaining nut using a sharp box cutter knife 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the liner 4 Carefully unravel the new liner 8 Push the liner firmly into the torch...

Page 20: ...t size to match the diameter of the wire being used 15 Fit the remaining front end parts to the torch neck ready for welding 1O Connect the torch to the machine tighten and secure the torch euro connector to the machine euro connection 13 Press and hold the inch wire button to feed the wire down the torch cable through to the torch head 11 Install a U groove drive roller of the correct size for th...

Page 21: ...r 8 Place the Wire Spool onto the Spool Holder Note the spool retaining nut is Left Hand thread Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling 1 Set Standard Spoolgun selector switch inside door to Spoolgun IMPORTANT When connecting the torch be sure to tighten the connection 5 Connect the gas line to the regulator and connect to the gas cylinder 6 Set...

Page 22: ... and close the wire spool cover 16 Carefully open the gas cylinder valve and set the flow rate to between 20 25cfh 17 Set the welding parameters using the wire feed and voltage control knobs 9 Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube Squeezing the tension arm adjustment knob to release the pressure of the tension arm will allow t...

Page 23: ...has distinct properties andcorresponding advantages and limitations To perform MIGwelding the basicnecessary equipment is a weldinggun a wire feed unit a welding power supply an electrode wire andashieldinggassupply Shortcircuittransferisthemostcommonusedmethod whereby the wire electrode is fedcontinuously down the welding torch through to and exiting thecontact tip The wire touchesthe work piece ...

Page 24: ...tween the wire and the base metal because there is no space between the wire and the base metal there is no arc and current flows through the wire The pinch causes the forming droplet to separate and fall to wards the now creating weld pool 1 I The wire cannot support all the current flow resistance builds up and the wire becomes hot and weak and begins to melt An arc is created at the separation ...

Page 25: ...eld 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 PerpendicularTechnique The wire is fed directly into the weld this technique is used primarly for auto mated situations or when conditio...

Page 26: ...ape prevents undercut uneven penetration poor gas shield and poor quality finished weld Correct angle Not enough angle Too much angle good level of control over the weld pool even flat weld less control over the weld pool more spatter poor control unstable arc less penetration lots of spatter Stick Out Stick out is the length of the unmelted wire protruding from the end of the contact tip A consta...

Page 27: ...ed resulting in a weld deposit of poor quality cold lap lack of fusion lack of joint penetration porosity large wide bead Too Slow Travel Speed Correct Travel Speed The correct travel speed keeps the arc at the leading edge of the weld pool allow ing the base metal to melt sufficiently to create good penetration fusion and wetting out of the weld pool producing a weld deposit of good quality good ...

Page 28: ...rotecting the welding zone from the atmosphere Too low flow will give inadequate coverage and result in weld defects and unstable arc conditions Too high flow can cause air to be drawn into the gas column and contaminate the weld zone Use the correct shielding gas Co2 is good for steel and offers good penetration characteristics the weld profile is narrower and slightly more raised than the weld p...

Page 29: ...NICAL NOZZLE 1 2 X 2 2 15 023 CONTACT TIP 0 023 X5 15 030 CONTACT TIP 0 030 X5 15 035 CONTACT TIP 0 035 X5 15 040 CONTACT TIP 0 040 X5 3 15 NS NOZZLE SPRING X2 4 15 TA TIP ADAPTOR X2 5 A5 SN50 SWAN NECK X1 6 LN2330 10 10 FT STEEL LINER 0 023 0 030 WIRE X1 LN3540 10 10 FT STEEL LINER 0 035 0 040 WIRE X1 5 The sb15 torch is standard on the VIPERMIG 180 Dual process machine however the TWC 2 Style to...

Page 30: ...CODE PRW32 Insulator QTY x 2 0680474943999 TWC2 Torch Nozzle Part Number Description QTY EAN CODE PRW22 50 Nozzle Adjustable 13mm 33 67 QTY x2 0680474943951 PRW22 62 Nozzle Adjustable 16mm 5 8 QTY x2 0680474943968 Torch Model Description Part Number EAN CODE 15 FT Welding Torch Classic Style TWC2 15FTE 0680474943777 10 FT Welding Torch Euro Style Handle TWC2 10FTE 0680474944095 TWC2 Liners Part Nu...

Page 31: ...e stubbing during welding Possible Reason Suggested Remedy Holding the torch too far away Bring the torch closer to the work and maintain stick out of 3 16 3 8 Welding voltage set too low Increase the voltage Wire Speed set too high Decrease the wire feed speed 5 Lack of Fusion failure of weld metal to fuse completely with base metal or a proceeding weld bead Possible Reason Suggested Remedy Conta...

Page 32: ...ged the most com mon causes of bad feeding Try to clear the liner by blowing out with compressed air as a temporary cure it is recommended to replace the liner Wrong size liner Install the correct size liner Blocked or worn inlet guide tube Clear or replace the inlet guide tube Wire misaligned in drive roller groove Locate the wire into the groove of the drive roller Incorrect drive roller size Fi...

Page 33: ...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 up 5 Excessive penetration burn through Possible Reason Suggested Remedy Excessive heat input Reduce the amperage or use a smalle...

Page 34: ...lator 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 point 6 Tighten clamps or fittings to eliminate...

Page 35: ...manufacturer for details Clause 3 This only Covers Manufactures defaults on all accessories for the first three months after date of purchase It does not cover operator abuse or mistreatment of the torch Clause 4 3 years warranty on transformer inductor and Rectifier 1 year on PCB and all other components Does not cover operator abuse or mistreatment of the machine SELLER MAKES NO WARRANTIES EXPRE...

Page 36: ...VIPERMIGTM JASIC Technologies Americ a Inc 25503 74th Ave S Kent Washington 98032 Ph 253 859 6277 253 859 6278 Fax 253 859 6286 e mail sales razorweld com ...

Page 37: ...180i ...

Page 38: ...__ _ 3 ...

Page 39: ...he Wire Spool onto the Spool Holder Note the spool retaining nut is Left Hand thread Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling 1 Set Standard Spoolgun selector switch inside door to Spoolgun IMPORTANT When connecting the torch be sure to tighten the connection 5 Connect the gas line to the regulator and connect to the gas cylinder Set MIG selector...

Page 40: ...e the wire spool cover Carefully open the gas cylinder valve and set the flow rate to between 2 5cfh Set the welding parameters using the wire feed and voltage control knobs 9 Carefully feed the wire through the inlet guide tube onto the drive roller through into the outlet guide tube Squeezing the tension arm adjustment knob to release the pressure of the tension arm will allow the wire to be gui...

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