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VIPER MULTI 165

OPERATING MANUAL

9. MIG: Machine Setup (Gasless)

ON

OFF

GAS IN

1.

Connect 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 MIG torch to the Euro connection, and
twist end to secure in place.

4.

Connect the plug into a 10 AMP socket, then switch the
machine ON.

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Summary of Contents for U11006K

Page 1: ...U11006K Operating Manual ...

Page 2: ... 12 7 Synergic Settings Operation 13 8 Package Contents 14 9 MIG Machine Setup Gasless 15 10 MIG Machine Setup Gas Shielded 21 11 MIG Welding Guide 28 12 MIG Changing Your Torch Liner 33 13 MIG Changing Your Torch Liner Aluminium 35 14 MMA Machine Setup 39 15 MMA Welding Guide 42 16 TIG Machine Setup 44 17 TIG Welding Guide 48 18 Drive Roller Selection 52 19 SB15 BINZEL Style MIG Torch 53 19 1 Tor...

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: ...both gas shielded MIG and gasless MIG 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...

Page 8: ...fications Parameter Values MIG Welding Current Range 30 165A MIG Duty Cycle 40 C 10 165A 60 68A 100 52A MIG Wire Size Range 0 6 0 9mm MIG Wire Spool Size 1kg 5kg MIG Welding Thickness Range 1 8mm Drive Roller SIze 30 10 3 3 TIG Specifications Parameter Values TIG Function Type DC Lift Arc TIG Welding Current Range 20 160A TIG Duty Cycle 40 C 10 160A 60 65A 100 50A TIG Welding Thickness Range 1 6mm...

Page 9: ... Weld Parameters Panel 2 Euro Connection 3 Output Terminal 4 Polarity Cable 5 Output Terminal 4 2 Rear Panel Layout 6 On Off Switch 7 Input Power Cord 8 Gas Inlet 9 Fan STEEL 0 6 2T 4T 0 8 0 9 1 0 SYNERGIC FLUX CORED STAINLESS ALUMINIUM STANDARD ON OFF GAS IN 1 2 3 4 5 7 8 6 9 ...

Page 10: ...10 VIPER MULTI 165 OPERATING MANUAL 4 3 Interior Layout 10 Wire Feeding Spool Holder 11 Wire Feeder 10 11 ...

Page 11: ...eed Amperage Display 3 Synergic Selector 4 MIG TIG STICK Selector 5 Torch Mode Selector 6 Wire Size Selector 7 Wire Type Selector 8 Voltage Knob 9 Wire Speed Amperage Knob 10 Inductance Knob STEEL 0 6 2T 4T 0 8 0 9 1 0 SYNERGIC FLUX CORED STAINLESS ALUMINIUM STANDARD 1 2 3 4 5 6 7 8 9 10 ...

Page 12: ...the torch will continue to weld until you pull it again to turn it off 6 3 Inductance Adjustment Knob Inductance is what allows you to change the frequency of your short circuit how often the wire touches the joint in the circuit s cycle The lower your inductance setting the more frequently your weld will short circuit Less metal is being added so the bead is narrower and freezes faster A low indu...

Page 13: ...ctor Enables selection of MIG wire diameter in Synergic mode 7 3 Wire Type Selector Enables selection of MIG wire type in Synergic mode STEEL 0 6 0 8 0 9 1 0 SYNERGIC FLUX CORED STAINLESS ALUMINIUM TANDARD STEEL 0 6 2T 4T 0 8 0 9 1 0 SYNERGIC FLUX CORED STAINLESS ALUMINIUM STANDARD STEEL 0 6 0 8 0 9 1 0 SYNERGIC FLUX CORED STAINLESS ALUMINIUM STANDARD ...

Page 14: ...ve Rollers 3m SB15 MIG Torch Electrode Holder 3m 300 AMP Earth Clamp Twin Gauge Argon Regulator 10A Plug Fitted STEEL 0 6 2T 4T 0 8 0 9 1 0 SYNERGIC FLUX CORED STAINLESS ALUMINIUM STANDARD 1 x 0 8 0 9mm V GROOVE 30 10 1 x 0 8 0 9mm F GROOVE 30 10 1 x 0 9 1 0mm U GROOVE 30 10 ...

Page 15: ...arity 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 MIG torch to the Euro connection and twist end to secure in place 4 Connect the plug into a 10 AMP socket then switch the machine ON ...

Page 16: ...CORED STAINLESS ALUMINIUM STANDARD 5 Select MIG from the MIG TIG MMA selector 6 Pull down the roller tension knob to release the wire drive 7 Unscrew the roller cap 8 Ensure you have a Knurled F Groove drive roller installed If not fit correct roller and replace the roller cover ...

Page 17: ...L GUN STANDARD Burnback Adjustment Burnback Adjustment Burnback Adjustment 9 Unscrew spool retaining nut 10 Place 5kg wire spool onto the spool holder For 1kg spool see step 20 11 Tighten spool retaining nut 12 Feed wire through the inlet guide tube to the outlet guide tube Ensure that the wire passes through the roller ...

Page 18: ...ock wire in place Twist to tighten 14 Remove front end consumables from the MIG torch 15 Hold 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 16 Replace front end consumables on the MIG torch ...

Page 19: ... your material and thickness 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 20 For 1kg spool After removing spool holder nut unscrew the 1kg spool bolt located inside the spool holder housing ...

Page 20: ...e 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 22 For 1kg spool Place 1kg spool over 1kg spool housing then tighten and secure with 1kg spool bolt and nut ...

Page 21: ...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 MIG torch to the Euro connection and twist end to secure in place 4 Connect the plug into a 10 AMP socket then switch the machine ON ...

Page 22: ...LUX CORED STAINLESS ALUMINIUM STANDARD 5 Select MIG from the MIG TIG MMA selector 6 Pull down the roller tension knob to release the wire drive 7 Unscrew the roller cap 8 Ensure you have a V Groove drive roller installed If not fit correct roller and replace the roller cover ...

Page 23: ...L GUN STANDARD Burnback Adjustment Burnback Adjustment Burnback Adjustment 9 Unscrew spool retaining nut 10 Place 5kg wire spool onto the spool holder For 1kg spool see step 25 11 Tighten spool retaining nut 12 Feed wire through the inlet guide tube to the outlet guide tube Ensure that the wire passes through the roller ...

Page 24: ...ock wire in place Twist to tighten 14 Remove front end consumables from the MIG torch 15 Hold 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 16 Replace front end consumables on the MIG torch ...

Page 25: ...UAL ON OFF GAS IN 17 Place twin gauge argon regulator into your gas outlet 18 Tighten securely with wrench 19 Connect gas hose to the regulator outlet and crimp in place 20 Connect gas hose to the gas inlet on the rear of the machine ...

Page 26: ...ow to 8 12L min 22 Adjust voltage and wire speed according to your material and thickness 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 27: ... bolt located inside the spool holder housing 26 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 27 For 1kg spool Place 1kg spool over 1kg spool housing then tighten and secure with 1kg spool bolt and nut ...

Page 28: ...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 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 ...

Page 29: ...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 11 3 3 Perpendicular Technique The wire is fed directly into the weld This technique is used primarily for automated situations or when co...

Page 30: ... weld 11 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 penetra...

Page 31: ...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 11 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 w...

Page 32: ... for most applications Argon CO CO T D Manual MIG Setup Guide Synergic MIG Setup Guide T Material Type Wire Type Wire Size Drive Roller Polarity Shielding Gas Gas Flow Rate Material Thickness 1mm 2mm 3mm 4mm 6mm 8mm Steel ER70S 6 0 8mm V Groove DCEP Argon 5 2 8 12L min Voltage V 14 4 15 5 17 6 18 4 19 7 21 7 Wire Speed m min 3 9 4 3 6 1 7 1 9 6 11 9 ER70S 6 0 9mm V Groove DCEP Argon 5 2 8 12L min ...

Page 33: ...e MIG torch front end parts 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the existing liner Ensure MIG torch is completely unravelled until setup is complete 4 Carefully feed in the new liner down the torch lead all the way to exit the torch neck ...

Page 34: ...e excess liner off about the length of the where tip holder sits past the end of the torch neck 7 Replace the front end parts 8 Fully screw down the liner retaining nut and nip it up tight This compresses the liner inside the torch cable assembly preventing it moving during use and ensures good wire feed ...

Page 35: ...r Aluminium 1 Remove MIG torch front end parts 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the existing liner Ensure MIG torch is completely unravelled until setup is complete 4 Fit the neck spring to the front end of the aluminium liner ...

Page 36: ...pring through the torch then fit liner collet liner O ring and liner retaining nut 6 Push the liner firmly into the torch lead and tighten the liner retaining nut 7 Loosen the inlet guide tube retaining screw 8 Remove the inlet guide tube using long nose pliers ...

Page 37: ...rrect size for the diameter wire being used 10 Feed liner through Euro connection and connect and tighten the torch 11 Take the extended polymide liner all the way up and over the drive roller 12 Cut the extended Polymide liner with a sharp knife just in front of the drive roller ...

Page 38: ...38 VIPER MULTI 165 OPERATING MANUAL 13 Replace the front end parts ...

Page 39: ...RED STAINLESS ALUMINIUM STANDARD 1 For 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 selecto...

Page 40: ...2T 4T 0 8 0 9 1 0 SYNERGIC FLUX CORED STAINLESS ALUMINIUM STANDARD 5 Twist electrode holder to loosen grip 6 Place electrode into electrode holder 7 Twist electrode holder to tighten and securely grip electrode 8 Adjust amperage to desired setting ...

Page 41: ...MULTI 165 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 42: ...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 43: ...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 15 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 44: ...X CORED STAINLESS ALUMINIUM STANDARD 1 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 45: ...ER MULTI 165 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 46: ...NLESS ALUMINIUM STANDARD 9 Set the welding 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 47: ...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 48: ...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 17 2 Lift Arc Ignition for TIG Tungsten Inert Ga...

Page 49: ...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 50: ...N GUIDE This information is intended to act as a guide only individual results may vary depending on technique skill and material 17 5 TIG Tungsten Selection Guide 17 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 51: ...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 52: ...rface area grip and traction to help feed the softer wire Softer wires also require less tension from the top pressure 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 18 3 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 ...

Page 53: ...n Body 3 UG8015 Handle Cable Support 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 19 2 Technical Data Parameter Values COOLING METHOD Air Cooled DUTY CYCLE CO2 60 180A DUTY CYCLE MIXED GAS 60 150A WIRE SIZE 0 6 1 0mm LENGTHS m 3 04 2005 STANDARD E...

Page 54: ...ription 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 19 3 SB15 MIG Torch Consumables ...

Page 55: ...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 56: ... 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 57: ...e filler wire into the leading edge of the weld pool in front of the tungsten 21 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 58: ...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 21 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 59: ...e or seek assistance for the correct technique 22 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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