Unimig VIPER MULTI165 Operating Manual
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Unimig VIPER MULTI165 Operating Manual

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  • Page 1 U11006K | Operating Manual...

  • Page 2: Table Of Contents

    VIPER MULTI 165 OPERATING MANUAL 1. Safety 2. Machine Features 3. Machine Specifications 3.1 Technical Data 3.2 MIG Specifications 3.3 TIG Specifications 3.4 STICK Specifications 3.5 Size & Weight 4. Machine Layout 4.1 Front Panel Layout 4.2 Rear Panel Layout 4.3 Interior Layout 5. Control Panel Layout 6. Control Panel Operation 7. Synergic Settings Operation 8. Package Contents 9. MIG: Machine Setup (Gasless) 10. MIG: Machine Setup (Gas-Shielded)

  • Page 3: Safety

    VIPER MULTI 165 OPERATING MANUAL 1. Safety Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations.
  • Page 4 VIPER MULTI 165 OPERATING MANUAL Fire hazard • Welding/cutting on closed containers, such as tanks, drums, or pipes, can cause them to explode. Flying sparks from the welding/cutting arc, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of the electrode to metal objects can cause sparks, explosion, overheating, or fire.
  • Page 5 VIPER MULTI 165 OPERATING MANUAL Caution Working environment • The environment in which this welding/cutting equipment is installed must be free of grinding dust, corrosive chemicals, flammable gas or materials etc., and at no more than a maximum of 80% humidity. •...
  • Page 6 VIPER MULTI 165 OPERATING MANUAL Attention! - Check For Gas Leakage At initial set up and at regular intervals we recommend to check for gas leakage Recommended procedure is as follows: 1. Connect the regulator and gas hose assembly and tighten all connectors and clamps. 2.

  • Page 7: Machine Features

    VIPER MULTI 165 OPERATING MANUAL 2. Machine Features VIPER MULTI 165 Synergic MIG Control 10A Plug The clever Synergic MIG control takes the guesswork out A 10 AMP power plug can be used on any domestic outlet. of your settings. Simply select your wire size and wire type, It’s perfect for the DIY home handyman or the professional and adjust your amperage to suit your work piece.

  • Page 8: Machine Specifications

    VIPER MULTI 165 OPERATING MANUAL 3. Machine Specifications VIPER MULTI 165 3.1 Technical Data 3.3 TIG Specifications Parameter Values Parameter Values U11006K TIG Function Type DC Lift Arc Primary Input Voltage 240V Single Phase TIG Welding Current Range 20-160A Supply Plug 10 AMP TIG Duty Cycle @ 40°C 10% @ 160A 60% @ 65A...

  • Page 9: Machine Layout

    VIPER MULTI 165 OPERATING MANUAL 4. Machine Layout SYNERGIC STEEL FLUX CORED 4.1 Front Panel Layout STAINLESS ALUMINIUM 1. Weld Parameters Panel 2. Euro Connection 3. “+” Output Terminal 4. Polarity Cable 5. “-” Output Terminal 4.2 Rear Panel Layout GAS IN 6. On/Off Switch 7.

  • Page 10: Interior Layout

    VIPER MULTI 165 OPERATING MANUAL 4.3 Interior Layout 10. Wire Feeding Spool Holder 11. Wire Feeder...

  • Page 11: Control Panel Layout

    VIPER MULTI 165 OPERATING MANUAL 5. Control Panel Layout SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM 1. Voltage Display 2. Wire Speed / Amperage Display 3. Synergic Selector 4. MIG/TIG/STICK Selector 5. Torch Mode Selector 6. Wire Size Selector 7. Wire Type Selector 8.

  • Page 12: Control Panel Operation

    SYNERGIC VIPER MULTI 165 OPERATING MANUAL STEEL FLUX CORED 6. Control Panel Operation STAINLESS ALUMINIUM SYNERGIC 6.1 Voltage Adjustment Knob Provides digital adjustment of voltage in MIG and MIG Synergic. • Turn the knob to increase or decrease the desired value displayed on the STEEL LED display.

  • Page 13: Synergic Settings Operation

    VIPER MULTI 165 OPERATING MANUAL 7. Synergic Settings Operation 7.1 Synergic Selector SYNERGIC Activate Synergic mode while MIG is selected. SYNERGIC STEEL FLUX CORED STEEL 7.2 Wire Size Selector STAINLESS FLUX CORED ALUMINIUM Enables selection of MIG wire diameter in Synergic mode. STAINLESS SYNERGIC ALUMINIUM STEEL...

  • Page 14: Package Contents

    VIPER MULTI 165 OPERATING MANUAL 8. Package Contents SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM VIPER MULTI 165 3m SB15 MIG Torch 3m 300 AMP Earth Clamp 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 Drive Rollers Electrode Holder Twin Gauge Argon Regulator...

  • Page 15: Mig: Machine Setup (Gasless)

    VIPER MULTI 165 OPERATING MANUAL 9. MIG: Machine Setup (Gasless) 1. Connect the polarity cable to the negative (-) dinse 2. Connect the earth clamp to the positive (+) dinse connection, twist to lock in place. connection, twist to lock in place. 3.
  • Page 16 VIPER MULTI 165 OPERATING MANUAL 5. Select MIG from the MIG/TIG/MMA selector. 6. Pull down the roller tension knob to release the wire drive. SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM 7. Unscrew the roller cap. 8. Ensure you have a Knurled (F Groove) drive roller installed.
  • Page 17 VIPER MULTI 165 OPERATING MANUAL 9. Unscrew spool retaining nut. 10. Place 5kg wire spool onto the spool holder. For 1kg spool, see step 20. STANDARD SPOOL GUN Burnback Adjustment Burnback Adjustment Burnback Adjustment 11. Tighten spool retaining nut. 12. Feed wire through the inlet guide tube to the outlet guide tube.
  • Page 18 VIPER MULTI 165 OPERATING MANUAL 13. Lift roller tension knob to lock wire in place. Twist to 14. Remove front end consumables from the MIG torch. tighten. 15. Hold the torch trigger to feed wire through to the torch. 16. Replace front end consumables on the MIG torch. If the wire slips or stops you will need to adjust the roller tension knob.
  • Page 19 VIPER MULTI 165 OPERATING MANUAL 17. Adjust voltage and wire speed according to your 18. Connect earth clamp to your workpiece. material and thickness. SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM 19. Line up the torch with your workpiece, then simply 20.
  • Page 20 VIPER MULTI 165 OPERATING MANUAL 21. For 1kg spool: Remove spool holder housing and spring. 22. For 1kg spool: Place 1kg spool over 1kg spool housing, Place 1kg spool housing inside the square hole where the then tighten and secure with 1kg spool bolt and nut. spool housing is removed from.

  • Page 21: Mig: Machine Setup (Gas-Shielded)

    VIPER MULTI 165 OPERATING MANUAL 10. MIG: Machine Setup (Gas-Shielded) 1. Connect the polarity cable to the positive (+) dinse 2. Connect the earth clamp to the negative (-) dinse connection, twist to lock in place. connection, twist to lock in place. 3.
  • Page 22 VIPER MULTI 165 OPERATING MANUAL 5. Select MIG from the MIG/TIG/MMA selector. 6. Pull down the roller tension knob to release the wire drive. SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM 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 VIPER MULTI 165 OPERATING MANUAL 9. Unscrew spool retaining nut. 10. Place 5kg wire spool onto the spool holder. For 1kg spool, see step 25. STANDARD SPOOL GUN Burnback Adjustment Burnback Adjustment Burnback Adjustment 11. Tighten spool retaining nut. 12. Feed wire through the inlet guide tube to the outlet guide tube.
  • Page 24 VIPER MULTI 165 OPERATING MANUAL 13. Lift roller tension knob to lock wire in place. Twist to 14. Remove front end consumables from the MIG torch. tighten. 15. Hold the torch trigger to feed wire through to the torch. 16. Replace front end consumables on the MIG torch. If the wire slips or stops you will need to adjust the roller tension knob.
  • Page 25 VIPER MULTI 165 OPERATING MANUAL 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 20. Connect gas hose to the gas inlet on the rear of the place.
  • Page 26 VIPER MULTI 165 OPERATING MANUAL 21. Adjust gas flow to 8-12L/min. 22. Adjust voltage and wire speed according to your material and thickness. SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM 23. Connect earth clamp to your workpiece. 24. Line up the torch with your workpiece, then simply pull the trigger to initiate the weld.
  • Page 27 VIPER MULTI 165 OPERATING MANUAL 25. For 1kg spool: After removing spool holder nut, 26. For 1kg spool: Remove spool holder housing and spring. unscrew the 1kg spool bolt located inside the spool Place 1kg spool housing inside the square hole where the holder housing.

  • Page 28: Mig: Welding Guide

    VIPER MULTI 165 OPERATING MANUAL 11. MIG: Welding Guide 11.1 MIG (Metal Inert Gas) Welding MIG (Metal Inert Gas) welding, also known as GMAW (Gas Metal Arc Welding) or MAG (Metal Active Gas Welding), is a semi-automatic arc welding process in which a consumable wire electrode and a shielding gas are fed through a welding gun.
  • Page 29 VIPER MULTI 165 OPERATING MANUAL 11.3 Basic MIG Welding Good weld quality and weld profile depend on gun angle, the direction of travel, electrode extension (stick out), travel speed, the thickness of base metal, wire feed speed (amperage) and arc voltage. To follow are some basic guides to assist with your setup.
  • Page 30 VIPER MULTI 165 OPERATING MANUAL 11.4 Travel Angle The travel angle is the right to left, relative to the direction of 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 shielding and a poor quality finished weld.
  • Page 31 VIPER MULTI 165 OPERATING MANUAL 11.7 Travel Speed Travel speed is the rate that the gun is moved along the weld joint and is usually measured in mm per minute. Travel speeds can vary depending on conditions and the welder's skill and is limited to the welder's ability to control the weld pool.
  • Page 32 Using poor quality milled wire can result in poor performance and appearance. To ensure optimal performance when welding, use standards approved wire such as UNIMIG HYPERMIG wire. Welding Setup Guide Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter and larger machine.

  • Page 33: Mig: Changing Your Torch Liner

    VIPER MULTI 165 OPERATING MANUAL 12. MIG: Changing Your Torch Liner 1. Remove MIG torch front end parts. 2. Remove the liner retaining nut. 3. Carefully pull out and completely remove the existing 4. Carefully feed in the new liner down the torch lead all liner.
  • Page 34 VIPER MULTI 165 OPERATING MANUAL 5. Fit the liner retaining nut and screw only 1/2 way down. 6. 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. 8.

  • Page 35: Mig: Changing Your Torch Liner (Aluminium)

    VIPER MULTI 165 OPERATING MANUAL 13. MIG: Changing Your Torch Liner (Aluminium) 1. Remove MIG torch front end parts. 2. Remove the liner retaining nut. 3. Carefully pull out and completely remove the existing 4. Fit the neck spring to the front end of the aluminium liner.
  • Page 36 VIPER MULTI 165 OPERATING MANUAL 5. Feed liner and neck spring through the torch, then fit 6. Push the liner firmly into the torch lead and tighten the liner collet, liner O-ring and liner retaining nut. liner retaining nut. 7. Loosen the inlet guide tube retaining screw. 8.
  • Page 37 VIPER MULTI 165 OPERATING MANUAL 9. Install a U groove drive roller of the correct size for the 10. Feed liner through Euro connection, and connect and diameter wire being used. tighten the torch. 11. Take the extended polymide liner all the way up and 12.
  • Page 38 VIPER MULTI 165 OPERATING MANUAL 13. Replace the front end parts.

  • Page 39: Mma: Machine Setup

    VIPER MULTI 165 OPERATING MANUAL 14. MMA: Machine Setup 1. For DC+ electrodes, connect earth clamp to the 2. For DC- electrodes, connect earth clamp to the negative (-) dinse connection, and electrode holder to positive (+) dinse connection, and electrode holder to the positive (+) dinse connection.
  • Page 40 VIPER MULTI 165 OPERATING MANUAL 5. Twist electrode holder to loosen grip. 6. Place electrode into electrode holder. 7. Twist electrode holder to tighten and securely grip 8. Adjust amperage to desired setting. electrode. SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM...
  • Page 41 VIPER 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: Mma: Welding Guide

    VIPER MULTI 165 OPERATING MANUAL 15. MMA: Welding Guide One of the most common types of arc welding is Manual Metal Arc welding, also known as MMA welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded.
  • Page 43 VIPER MULTI 165 OPERATING MANUAL 15.1 Electrode Selection As a general rule, the selection of an electrode is straight forward, in that it is only a matter of selecting an electrode of similar composition to the parent metal. However, for some metals, there is a choice of several electrodes, each of which has particular properties to suit specific classes of work.

  • Page 44: Tig: Machine Setup

    VIPER MULTI 165 OPERATING MANUAL 16. TIG: Machine Setup 1. Connect the TIG torch to the negative (-) dinse 2. Connect the earth clamp to the positive (+) dinse connection, twist to lock in place. connection, twist to lock in place. 3.
  • Page 45 VIPER 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 8. Adjust gas flow to 6-12L/min. place.
  • Page 46 VIPER MULTI 165 OPERATING MANUAL 9. Set the welding current using the amperage control 10. Connect earth clamp to your workpiece. dial. SYNERGIC STEEL FLUX CORED STAINLESS ALUMINIUM 11. Turn on the gas valve located on the TIG torch handle. 12.
  • Page 47 VIPER MULTI 165 OPERATING MANUAL 13. With a small movement rotate the gas cup forward so 14. Now rotate the gas cup in the reverse direction to lift that the tungsten electrode touches the workpiece. the tungsten electrode from the workpiece to create the arc.

  • Page 48: Tig: Welding Guide

    VIPER MULTI 165 OPERATING MANUAL 17. TIG: Welding Guide 17.1 DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal). In the DC electrical circuit, there is an electrical principle at work which should always be taken into account when using any DC circuit.
  • Page 49 VIPER MULTI 165 OPERATING MANUAL 17.3 TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the workpiece. Similar to Oxygen Acetylene torch welding, TIG welding typically requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other.
  • Page 50 VIPER MULTI 165 OPERATING MANUAL TIG TUNGSTEN SELECTION GUIDE 17.5 TIG Tungsten Selection Guide LANTHANATED ZIRCONIATED THORIATED RARE EARTH CERIATED (GOLD) (WHITE) (RED) (PURPLE) (GREY)     AC CURRENT     DC CURRENT     ALUMINIUM ...
  • Page 51 VIPER MULTI 165 OPERATING MANUAL 17.7 Tungsten Preparation Always use DIAMOND wheels when grinding and cutting. While tungsten is a tough material, the surface of a diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects.

  • Page 52: Drive Roller Selection

    VIPER MULTI 165 OPERATING MANUAL 18. Drive Roller Selection The importance of smooth, consistent wire feeding during MIG welding cannot be emphasised enough. The smoother the wire feed, the better the welding will be. Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.

  • Page 53: Sb15 Binzel Style Mig Torch

    VIPER MULTI 165 OPERATING MANUAL 19. SB15 BINZEL Style MIG Torch Length SB15-3M SB15-4M SB15-5M 19.1 Torch Spares 19.2 Technical Data Machine Spares Parameter Values COOLING METHOD Air Cooled SNK15 Swan Neck Assembly DUTY CYCLE - CO2 60% @ 180A SNKF15 Flexible Swan Neck UG1515 Ergo Handle Location Body DUTY CYCLE - MIXED GAS...

  • Page 54: Sb15 Mig Torch Consumables

    VIPER MULTI 165 OPERATING MANUAL 19.3 SB15 MIG Torch Consumables Description PCTH14 TIP HOLDER Description PGNS15 NOZZLE SPRING Description PCT0008-06 CONTACT TIPS - Steel 0.6mm PCT0008-08 CONTACT TIPS - Steel 0.8mm PCT0008-09 CONTACT TIPS - Steel 0.9mm Description PGN15CON GAS NOZZLE - Conical PGN15CYL GAS NOZZLE - Cylindrical PGN15SPOT...

  • Page 55: Mig Troubleshooting

    VIPER MULTI 165 OPERATING MANUAL 20. MIG Troubleshooting 20.1 Excessive Spatter • Wire feed speed set too high: Select lower wire feed speed. • Voltage too high: Select a lower voltage setting. • Wrong polarity set: Select the correct polarity for the wire being used - see machine setup guide. •...
  • Page 56 VIPER MULTI 165 OPERATING MANUAL 20.6 Lack of penetration - Shallow fusion between weld metal and base metal • Poor or incorrect joint preparation: Material too thick. Joint preparation and design needs to allow access to bottom of groove while maintaining proper welding wire extension and arc characteristics. Keep the arc at the leading edge of the weld pool and maintain the gun angle at 5°...

  • Page 57: Tig Troubleshooting

    VIPER MULTI 165 OPERATING MANUAL 21. TIG Troubleshooting 21.1 Tungsten burning away quickly • Incorrect gas or no gas: Use pure argon. Check cylinder has gas is connected, turned on and torch valve is open. • Inadequate gas flow: Check the gas is connected, check hoses, gas valve and torch are not restricted. •...
  • Page 58 VIPER MULTI 165 OPERATING MANUAL 21.6 Arc wanders during DC welding • Poor gas flow: Check and set the gas flow between 6-12 L/min flow rate. • Amperage too low: Increase the amperage. • Incorrect arc length: Lower torch so that the tungsten is off of the work piece 2-5mm. •...

  • Page 59: Mma (Stick) Troubleshooting

    VIPER MULTI 165 OPERATING MANUAL 22. MMA (STICK) Troubleshooting 22.1 No arc • Incomplete welding circuit: Check earth lead is connected. Check all cable connections. • Wrong mode selected: Check the MMA selector switch is selected. • No power supply: Check that the machine is switched on and has a power supply. 22.2 Porosity - Small cavities or holes resulting from gas pockets in weld metal •...
  • Page 60 PH: (02) 9780 4200 PH: (07) 3333 2855 PH: (03) 8682 9911 PH: (08) 6363 5111 FAX: (02) 9780 4210 FAX: (07) 3274 5829 FAX: (03) 9333 7867 FAX: (08) 9417 4781 EMAIL: sales@unimig.com.au EMAIL: qld@unimig.com.au EMAIL: sales@unimig.com.au EMAIL: wasales@unimig.com.au...

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