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VIPER 182 Mk II

U14001K | Operating Manual

Summary of Contents for U11002K

Page 1: ...VIPER 182 Mk II U14001K Operating Manual ...

Page 2: ...2 ...

Page 3: ...TUP FOR MIG GAS SHIELDED 18 MIG WELDING GUIDE 25 SETUP FOR SPOOL GUN 30 CHANGING THE MIG TORCH LINER 38 CHANGING THE MIG TORCH LINER ALUMINIUM 40 SETUP FOR STICK MMA WELDING 44 MMA STICK WELDING GUIDE 47 TORCH BREAKDOWN SPARES 49 MIG DRIVE ROLLERS 51 MACHINE PARTS BREAKDOWN 52 FAQ TROUBLESHOOTING 53 3 ...

Page 4: ...on or ventilation to remove welding cutting fumes and gases In confined or heavy fume environments always wear an approved air supplied respirator Welding cutting 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 cut in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react wit...

Page 5: ...r 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 electrode or earth clamp to to...

Page 6: ... to bring down the temperature inside the equipment The machine will be ready for use again when the internal temperature reaches a safe level iii 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 In case th...

Page 7: ...as 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 point 6 Tighten clamps o...

Page 8: ...RANGE 30 180A MIG DUTY CYCLE 40 C 10 180A MIG WIRE SIZE RANGE 0 6 0 9mm MIG WIRE SPOOL SIZE 1kg 5kg MIG WELDING THICKNESS RANGE 1 10mm DRIVE ROLLER SIZE 30 22 STICK SPECIFICATIONS STICK WELDING CURRENT RANGE 10 160A STICK DUTY CYCLE 40 C 10 160A STICK ELECTRODE RANGE 2 5 4 0mm STICK WELDING THICKNESS RANGE 2 10mm SIZE WEIGHT DIMENSIONS mm 553x214x388mm WEIGHT kg 12 0kg MACHINE FEATURES WIRE DRIVE ...

Page 9: ...4 Amperage control knob in MMA 5 Thermal Overload LED 6 Power LED 7 VRD LED 8 MIG MMA switch 9 Wire feed speed control in MIG 10 Voltage control knob in MIG 11 Polarity cable 12 Socket for Spool Gun Rear Panel Layout 13 Fan 14 Gas inlet 15 Input power cord 16 On off Switch 17 Warning mark 18 Data plate MACHINE LAYOUT 9 ...

Page 10: ...N STANDARD Burnback Adjustment 19 20 21 22 23 Interior Layout 19 Wire feeding spool holder 20 Burn back control knob 21 Manual wire feeding button 22 Spool Gun selecting switch 23 Wire feeder MACHINE LAYOUT 10 ...

Page 11: ...5 MIG Torch Twin Gauge Argon Regulator Operating Manual 3m Electrode Holder Drive Rollers VIPER 182 Mk II Includes 1 x 0 8mm Contact Tip 1 x Tip Holder 1 x Gas Nozzle Includes 1 x 0 8 0 9mm V GROOVE 30 22 1 x 0 8 0 9mm F GROOVE 30 22 1 x 0 9 1 0mm U GROOVE 30 22 WHAT S IN THE BOX 11 ...

Page 12: ...ection twist to lock in place Connect the earth clamp to the positive dinse connection twist to lock in place Connect the MIG torch to the Euro connection and twist end to secure in place Connect the plug into a 10 AMP socket then switch the machine ON SETUP FOR MIG GASLESS 12 ...

Page 13: ...D Burnback Adjustment Select MIG on the MIG MMA selector 6 Select Standard on the Standard Spool Gun selector 7 Pull down the roller tension knob to release the wire drive 8 Unscrew the roller cap SETUP FOR MIG GASLESS 13 ...

Page 14: ...ARD Burnback Adjustment Burnback Adjustment Ensure you have an Knurled F Groove drive roller installed If not fit correct roller and replace the roller cover Unscrew spool retaining nut Place 5kg wire spool onto the spool holder For 1kg spool see step 18 Tighten spool retaining nut SETUP FOR MIG GASLESS 14 ...

Page 15: ...ube Ensure that the wire passes through the roller 14 Lift roller tension knob to lock wire in place Twist to tighten 15 Remove front end consumables from the MIG torch 16 Hold the Wire Inch button to feed wire through to the torch If the wire slips or stops you will need to adjust the roller tension knob SETUP FOR MIG GASLESS 15 ...

Page 16: ...e MIG torch Adjust voltage and wire speed according to your material and thickness 19 20 Adjust the burn back control to prevent the wire sticking in the weld pool Burn back control is located above the wire feed motor Connect earth clamp to your workpiece SETUP FOR MIG GASLESS 16 ...

Page 17: ...lace 1kg spool housing inside the square hole where the spool housing is removed from The 1kg housing is found on the inside of the main spool holder housing For 1kg spool After removing spool holder nut unscrew the 1kg spool bolt located inside the spool holder housing For 1kg spool Place 1kg spool over 1kg spool housing then tighten and secure with 1kg spool bolt and nut Burnback Adjustment Burn...

Page 18: ...ion twist to lock in place Connect the earth clamp to the negative dinse connection twist to lock in place Connect the MIG torch to the Euro connection and twist end to secure in place Connect the plug into a 10 AMP socket then switch the machine ON SETUP FOR MIG GAS SHIELDED 18 ...

Page 19: ...urnback Adjustment Select MIG on the MIG MMA selector 6 Select Standard on the Standard Spool Gun selector 7 Pull down the roller tension knob to release the wire drive 8 Unscrew the roller cap SETUP FOR MIG GAS SHIELDED 19 ...

Page 20: ...DARD Burnback Adjustment Burnback Adjustment Ensure you have an V Groove drive roller installed If not fit correct roller and replace the roller cover Unscrew spool retaining nut Place 5kg wire spool onto the spool holder For 1kg spool see step 27 Tighten spool retaining nut SETUP FOR MIG GAS SHIELDED 20 ...

Page 21: ...e Ensure that the wire passes through the roller 14 Lift roller tension knob to lock wire in place Twist to tighten 15 Remove front end consumables from the MIG torch 16 Hold the Wire Inch button to feed wire through to the torch If the wire slips or stops you will need to adjust the roller tension knob SETUP FOR MIG GAS SHIELDED 21 ...

Page 22: ...ront end consumables on the MIG torch Place twin gauge argon regulator into your gas outlet 19 20 Tighten securely with wrench Connect gas hose the the regulator outlet and crimp in place SETUP FOR MIG GAS SHIELDED 22 ...

Page 23: ...ect gas hose to the gas inlet on the rear of the machine 23 24 Adjust voltage and wire speed according to your material and thickness Adjust the burn back control to prevent the wire sticking in the weld pool Burn back control is located above the wire feed motor SETUP FOR MIG GAS SHIELDED 23 ...

Page 24: ...th clamp to your workpiece For 1kg spool After removing spool holder nut unscrew the 1kg spool bolt located inside the spool holder housing Burnback Adjustment For 1kg spool Remove spool holder housing and spring Place 1kg spool housing inside the square hole where the spool housing is removed from The 1kg housing is found on the inside of the main spool holder housing Burnback Adjustment SETUP FO...

Page 25: ...29 For 1kg spool Place 1kg spool over 1kg spool housing then tighten and secure with 1kg spool bolt and nut Burnback Adjustment SETUP FOR MIG GAS SHIELDED 25 ...

Page 26: ...nsfer is the most commonly used method whereby the wire electrode is fed continuously down the welding torch through to and exiting the contact tip The wire touches the workpiece and causes a short circuit the 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...

Page 27: ...le and degree of weld penetration Push Technique The wire is located at the leading edge of the weld pool and pushed towards the un melted work surface This technique offers a better view of the weld joint and direction of the wire into the weld joint Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration usef...

Page 28: ...f welding A travel angle of 5 15 is ideal and produces the right level of control over the weld pool A travel angle higher than 20 will give an unstable arc condition with poor weld metal transfer less penetration high levels of spatter weak gas shield and poor quality finished weld Angle to Work The work angle is the forward back angle of the gun relative to the workpiece The correct work angle p...

Page 29: ...led 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 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 wider weld bead with more deposited...

Page 30: ...V 13 14 5 16 18 20 Wire Speed m min 7 8 9 10 14 Aluminium 5356 1 0mm U Groove DCEP Ar 8 12L min Voltage V 11 12 13 17 18 Wire Speed m min 9 10 11 14 16 Argon CO CO Gas selection The purpose of the gas in the MIG process is to protect shield the wire the arc and the molten weld metal from the atmosphere Most metals when heated to a molten state will react with the air in the atmosphere without the ...

Page 31: ...ce Connect the earth clamp to the negative dinse connection twist to lock in place Connect the Spool Gun to the Euro connection and twist end to secure in place Inset the spool gun control cable into the 9 pin socket Connect the plug into a 10 AMP socket then switch the machine ON SETUP FOR SPOOL GUN 31 ...

Page 32: ...Burnback Adjustment Select MIG on the MIG MMA selector 6 Select Spool Gun on the Standard Spool Gun selector 7 Unscrew spool holder 8 Push back the spool guides and place wire spool onto the spool nut SETUP FOR SPOOL GUN 32 ...

Page 33: ...9 10 11 12 Feed wire through the inlet guide tube Open cover and loosen roller lock Open the wire drive Unscrew roller nut SETUP FOR SPOOL GUN 33 ...

Page 34: ...r for the wire size you are using If not replace with correct size 14 Replace roller nut and tighten 15 Feed wire through roller and through the outlet guide tube 16 Close wire drive and tighten roller tension knob SETUP FOR SPOOL GUN 34 ...

Page 35: ...17 18 Remove front end consumables Push trigger to feed wire out the torch nozzle 19 20 Replace front end consumables Replace spool cover and tighten SETUP FOR SPOOL GUN 35 ...

Page 36: ...21 Adjust gas glow to 8 10L min Place twin gauge argon regulator into your gas outlet 22 23 Tighten securely with wrench Connect gas hose the the regulator outlet and crimp in place SETUP FOR SPOOL GUN 36 ...

Page 37: ...n the rear of the machine 26 27 SPOOL GUN STANDARD Burnback Adjustment Adjust voltage and wire speed according to your material and thickness Adjust the burn back control to prevent the wire sticking in the weld pool Burn back control is located above the wire feed motor SETUP FOR SPOOL GUN 37 ...

Page 38: ...29 Line up the torch with your workpiece then simply pull the trigger to initiate the weld Release trigger to end the weld SETUP FOR SPOOL GUN 38 ...

Page 39: ...ll the way to exit the torch neck Remove MIG torch front end parts 2 3 Remove the liner retaining nut Carefully pull out and completely remove the existing liner Ensure MIG torch is completely unravelled until setup is complete CHANGING THE MIG TORCH LINER 39 ...

Page 40: ...e torch cable assembly preventing it moving during use and ensures good wire feed Fit the liner retaining nut and screw only 1 2 way down 6 7 Snip the excess liner off about the length of the where tip holder sits past the end of the torch neck Replace the front end parts CHANGING THE MIG TORCH LINER 40 ...

Page 41: ...luminium liner Remove MIG torch front end parts 2 3 Remove the liner retaining nut Carefully pull out and completely remove the existing liner Ensure MIG torch is completely unravelled until setup is complete CHANGING THE MIG TORCH LINER ALUMINIUM 41 ...

Page 42: ...ner and neck spring through the torch then fit liner collet liner O ring and liner retaining nut 6 7 Push the liner firmly into the torch lead and tighten the liner retaining nut Loosen the inlet guide tube retaining screw CHANGING THE MIG TORCH LINER ALUMINIUM 42 ...

Page 43: ... roller Install a U groove drive roller of the correct size for the diameter wire being used 10 11 Feed liner through euro connection and connect and tighten the torch Take the extended polymide liner all the way up and over the drive roller CHANGING THE MIG TORCH LINER ALUMINIUM 43 ...

Page 44: ...13 Replace the front end parts CHANGING THE MIG TORCH LINER ALUMINIUM 44 ...

Page 45: ... to the negative dinse connection and electrode holder to the positive dinse connection For DC electrodes connect earth clamp to the positive dinse connection and electrode holder to the negative dinse connection Connect the plug into a 10 AMP socket then switch the machine ON Select MMA from the MIG MMA selector SETUP FOR STICK MMA WELDING 45 ...

Page 46: ... 8 Twist electrode holder to loosen grip Place electrode into electrode holder Twist electrode holder to tighten and securely grip electrode Adjust amperage to desired setting SETUP FOR STICK MMA WELDING 46 ...

Page 47: ...1 Connect earth clamp to your workpiece Strike electrode against workpiece to initiate arc Drag along workpiece to weld Pull the electrode away from the workpiece to finish weld SETUP FOR STICK MMA WELDING 47 ...

Page 48: ...transferred across 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 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 serie...

Page 49: ...0 4 0mm 130 165 5 0mm 165 260 Arc Length To strike the arc the electrode should be gently scraped on the work until the arc is established There is a simple rule for the proper arc length it should be the shortest arc that gives a good surface to the weld An arc too long reduces penetration produces spatter and gives a rough surface finish to the weld An excessively short arc will cause sticking o...

Page 50: ...t C W Ball Joint 4 UG2514 Ergo Handle Kit C W Lock Nut 5 UB2517 Hanger Hook 6 UB1518 Gun Plug Housing C W Nut 7 UC1528 Hybrid Gun Plug Body C W Spring Pins 8 UB1524 Gun Plug O Ring 9 UB1525 Liner Nut TECHNICAL DATA COOLING METHOD Air Cooled DUTY CYCLE CO2 60 180A DUTY CYCLE MIXED GAS 60 150A WIRE SIZE 0 6 1 0mm LENGTHS m 3 4 5 STANDARD EN60974 7 SB15 BINZEL Style MIG Torch TORCH BREAKDOWN SPARES 5...

Page 51: ... PGN15CON GAS NOZZLE Conical 2 PGN15CYL GAS NOZZLE Cylindrical 2 PGN15SPOT GAS NOZZLE Spot 2 PGN15TAP GAS NOZZLE Tapered 2 SKU Description Wire Size SLB3M Blue Steel Liner 3 Metre 0 6 0 8mm SLB4M Blue Steel Liner 4 Metre 0 6 0 8mm SLB5M Blue Steel Liner 5 Metre 0 6 0 8mm SLR3M Red Steel Liner 3 Metre 0 9 1 2mm SLR4M Red Steel Liner 4 Metre 0 9 1 2mm SLR5M Red Steel Liner 5 Metre 0 9 1 2mm TLB3M Bl...

Page 52: ...pe 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 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 t...

Page 53: ...tch 12 Median Septum 13 10054475 Wire Feeding Spool 14 10068410 Wire Feeding 15 10041716 Fixed Cover For Wire Feeder MACHINE SPARES 16 10068307 Base Board 17 10070464 Vrd Board 18 10062441 Rocker Switch 19 10054623 Inverter 20 10070471 Main Board 21 10054164 Long Column 22 10054163 Short Column 23 10045432 Quick Socket 24 10068848 Front Panel 25 10068218 Aviation Socket 26 10068359 Hand Line 27 Fr...

Page 54: ...re 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 Check and replace the O ring 3 Wire stubbing during welding Holding the torch too far away Bring the torch closer to the work and m...

Page 55: ...st 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 Liner worn or clogged the most common cau...

Page 56: ...orrect technique 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 up 6 Excessive penetration Burn th...

Page 57: ...NOTES 57 ...

Page 58: ...NOTES 58 ...

Page 59: ...NOTES 59 ...

Page 60: ...CE 180 Kerry Rd Archerfield QLD 4108 PH 07 3333 2855 FAX 07 3274 5829 EMAIL qld unimig com au VIC OFFICE 91 Yellowbox Drive Craigieburn VIC 3064 PH 03 8682 9911 FAX 03 9333 7867 EMAIL vicsales unimig com au WA OFFICE Unit 2 29 Biscayne Way Jandakot WA 6164 PH 08 6363 5111 FAX 08 9417 4781 EMAIL wasales unimig com au ...

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