Unimig KUMJRVA160 User Manual

160AMP DC INVERTER ARC WELDER

OPERATING MANUAL

KUMJRVA160

Please read and understand this instruction manual carefully
before the installation and operation of this equipment.

1

©

Welding Guns Of Australia PTY LTD 2015

CONTENTS PAGE

Warranty 2

Safety 3-5

Technical Data, Product Information 6

Machine Layout Descriptions 7

Installation & Operation for MMA (stick) Welding 8

MMA General Description 9-10

Installation & Operation for DC TIG Welding with Scratch Start 11-12

DC TIG General Description 13-16

17V TIG Torch Parts Breakdown 17-18

MMA (Stick) Welding Trouble Shooting 19

TIG Welding Trouble Shooting 20-21

Warranty terms 22-24

Thank you for your purchase of your UNI-MIG welding machine.

We are proud of our range of welding equipment that has a proven track record of innovation,
performance and reliability.
Our product range represents the latest developments in Inverter technology put together by our
professional 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 equipment range. This experience gives us the inside knowledge on what the arc characteris­tics, performance and interface between man and machine should be.
Within our team are specialist welders that have a proven history of welding knowledge and exper­tise, giving vital input towards ensuring that our machines deliver control and performance to the
utmost professional level.
We employ an expert team of professional sales, marketing and technical personnel that provide
us with market trends, market feedback and customer comments and requirements. Secondly they
provide a customer support service that is second to none, thus ensuring our customers have con-

dencethattheywillbewellsatisedbothnowandinthefuture.

UNI-MIG welders are manufactured and compliant with - AS/NZ60974.1 2006 - AS60974-6:2006
guaranteeing you electrical safety and performance.

WARRANTY

• 1 Years from date of purchase.

• Welding Guns Of Australia PTY LTD Ltd warranties all goods as specified by the manufacturer
of those goods.

• This Warranty does not cover freight or goods that have been interfered with.

• All goods in question must be repaired by an authorised repair agent as appointed by this
company.

• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.

• New product will not be supplied unless Welding Guns Of Australia PTY LTD has inspected

 productreturnedforwarrantyandagree’storeplaceproduct.

• Product will only be replaced if repair is not possible

• Please view full Warranty term and conditions supplied with machine or at www.unimig.com.au/
warranty.asp or at the back of this manual.

2 3

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.
Read and understand this instruction manual carefully before the installation and operation of this
equipment.

MACHINE OPERATING SAFETY

• Do not switch the function modes while the machine is operating. Switching of the function modes during
welding can damage the machine. Damage caused in this manner will not be covered under warranty.

• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing
should the electrode be in contact with the work piece.

•Operatorsshouldbetrainedandorqualied.

Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe
burns. The electrode and work circuit is electrically live whenever the output is on. The input
power circuit and internal machine circuits are also live when power is on. In Mig/Mag welding,
the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment is dangerous.

• Connect the primary input cable according to Australian and New Zealand standards and regulations.

• Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands.
The operator must wear dry welding gloves while he/she performs the welding task.

• The operator should keep the work piece insulated from himself/herself.

• Keep cords dry, free of oil and grease, and protected from hot metal 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, 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harmfultopeople’shealth.Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health.

• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes

• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.

• Inconnedorheavyfumeenvironmentsalwayswearanapprovedair-suppliedrespirator.
Welding 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 in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.

• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic
fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.

Arc rays: harmful to people’s eyes and skin. Arc rays from the welding process produce

intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.

• Alwayswearaweldinghelmetwithcorrectshadeoflterlensandsuitableprotectiveclothingincluding
welding gloves whilst the welding operation is performed.

• Measures should be taken to protect people in or near the surrounding working area. Use protective

 screensorbarrierstoprotectothersfromash,glareandsparks;warnothersnottowatchthearc.

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Fire hazard. Welding on closed containers, such as tanks,drums, or pipes, can cause them

to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause

resandburns.Accidentalcontactofelectrodetometalobjectscancausesparks,explosion,
overheating,orre.Checkandbesuretheareaissafebeforedoinganywelding.

• Theweldingsparks&spattermaycausere,therefore removeanyammablematerialswellawayfrom
 theworkingarea.Coverammablematerialsandcontainerswithapprovedcoversifunabletobemoved

from the welding area.

• Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared
according to the required Safety Standards to insurethatammableortoxicvaporsandsubstancesare
totally removed, these can cause an explosion even though the vessel has been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.

•Donotweldwheretheatmospheremaycontainammabledust,gas,orliquidvapours(suchaspetrol)

• Haveareextinguishernearbyandknowhowtouseit.Be alert that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding
 onaceiling,oor,bulkhead,orpartitioncancausereonthehiddenside.

Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylin­der can explode. 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ames,
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 drape welding cables
over the cylinder.

• Never weld on a pressurised gas cylinder, it will explode and kill you.

• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.

Gas build up. The build up of gas can causes a toxic environment, deplete the oxygen content
in the air resulting in death or injury. Many gases used in welding are invisible and odourless.

• Shut off shielding gas supply when not in use.

•Alwaysventilateconnedspacesoruseapprovedair-suppliedrespirator.

Electronic magnetic elds. MAGNETIC FIELDS can affect Implanted Medical Devices.

• Wearers of Pacemakers and other Implanted Medical Devices should keep away.

• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going
near any electric welding, cutting or heating operation.

Noise can damage hearing. Noise from some processes or equipment can damage hearing.
Wear approved hearing protection if noise level is high.

Hot parts. Items being welded generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the welding
gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

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CAUTION

1. Working Environment.

1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive

 chemicals,ammablegasormaterialsetc,andatnomorethanmaximumof80%humidity.

1.2Whenusingthemachineoutdoorsprotectthemachinefromdirectsunlight,rainwaterandsnowetc;

the temperature of working environment should be maintained within -10°C to +40°C.

1.3 Keep this equipment 30cm distant from the wall.

1.4 Ensure the working environment is well ventilated.

2. Safety Tips.

2.1 Ventilation

This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is
of critical importance for the normal performance and service life of this equipment.

Thermal Overload protection.

2.2

Should the machine be used to an excessive level, or in high temperature environment, poorly
ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the
machine will cease to operate. Under this circumstance, leave the machine switched on to keep the
built-in fan working to bring down the temperature inside the equipment. The machine will be ready for
use again when the internal temperature reaches safe level.

Over-Voltage Supply

2.3

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 that the voltage of input power supply amperage exceeds the
stipulated value, it is possible to cause damage to the components of this equipment. Please ensure
your primary power supply is correct.

2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock
may possibly occur.

MAINTENANCE

Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to pre­vent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and
dry compressed air of required pressure.

Please note that:lackofmaintenancecanresultinthecancellationoftheguarantee;theguaranteeof
thisweldingequipmentwillbevoidifthemachinehasbeenmodied,attempttotakeapartthemachineor

open the factory-made sealing of the machine without the consent of an authorized representative of the
manufacturer.

TROUBLE SHOOTING

Caution:Onlyqualiedtechniciansareauthorizedtoundertaketherepairofthisweldingequipment.

For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.

Note:

Minimum Motor Generator Power Suggested:- 6.5KVA - VIPER 160

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KUMJRVA160

1

YEAR Warranty

Approved Domestic Power Supply 10 Amp 240V Single Phase 160 Amp
DC WelderSmall, Lightweight and Portable

Features

• Latest IGBT inverter technology

• MMA (stick electrode)

- Hot start (improves electrode starting)

- Arc Force (boosts current to prevent electrode extinguishing)

- Excellent arc stability with all electrodes

• DC Scratch TIG - Scratch Arc Ignition, basic DC TIG application

• Thermal overload protection

• IP21S rating for environmental/safety protection

• Generator compatible (recommend 6.5 KVA minimum)

• Tolerant to variable power supplies

• Fitted with and approved to use domestic 10 amp plug

(Power Source)

160AMP DC INVERTER ARC WELDER

Technical Data

Supply / Phases (V-Ph) 240V - 1 ±15%
Rated Input Power (KVA) 6.49
ieff (Amps) 10.0A
Rated Input Current (A) 27.4
Rated Output 140A/25.6V
Welding Current Range 20~160A
No-Load Voltage (V) 68
Duty Cycle @ 40ºC as per AS/NZ60974 15%@160Amps MMA
Efficiency (%) 85
Power Factor 0.65
Protection Class IP21S
Insulation Class F
Size (mm) with hande (LxWxH) 295 x 135 x 270
Weight (kg) 3.8
Warranty 12 months machine only
Certification Approval AS/NZ60974-1

Overview

The VIPER 160 is a new generation, low cost welding machine produced using the latest in IGBT inverter technology. Designed to meet
the needs of the price conscious non-commercial user without compromising on quality, this machine is as reliable and robust as you
would expect a machine bearing the UNIMIG name to be. The DC MMA welding function delivers a smooth and incredibly stable arc
allowing easy welding with electrodes producing high quality welds including cast Iron, stainless steel and low hydrogen. The VIPER
160 is also equipped with DC Scratch Start TIG capability and connection of the 17V TIG torch allows DC TIG welding of steel, stainless
steel, bronze and copper. The unique electronic design structure and air channel design in this machine speeds up the heat disapation of
the power device improving the duty cycle of the machine. The unique air channel design also effectively reduces dust ingestion by the
fan, dust build up and absorbtion by the electronic circuits and power device is minmised thereby improving the reliability of the machine.
The VIPER 160 is an exceptional machine for the price and is suitable for a wide range of applications including light fabrication and
farming. The VIPER 160 offers great portability with the power to get the job done and with the convenience of being fitted with a 10 amp
domestic plug. Manufactured in compliance to AS/NZ60974.1.

Product Code: KUMJRVA160

Standard Package includes: VIPER 160 Machine, Earth Lead & Arc Lead 16mm x 2.5m

6 7

FRONT MACHINE LAYOUT DESCRIPTION

140AMP DC INVERTER ARC WELDER

Primary Power LED

Amperage Control
Dial

Positive Output

Terminal

Thermal Alarm LED

Negative Output
Terminal

Rear Machine Layout Description

Primary Input
Power Lead

Cooling Fan

On /Off Power Switch

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INSTALLATION SET UP FOR MMA (STICK) WELDING WITH VIPER 160

Please install the machine strictly according to the following steps.
The protection class of this machine is IP21S, so avoid using it in rain.

(1) Connection of Output Cables: Various electrodes require a different polarity for optimum results refer
to the electrode manufacturers information for the correct polarity. Most GP electrodes are
Electrode connected to output socket, Earth Connected to the output socket
(2) Connect the machine to the power supply and switch on using the on/off switch on the back panel.
(3) Set the welding current relevant to the electrode type and size being used as recommended by the
electrode manufacturer.
(4) Place the electrode into the electrode holder and clamp tight
(5) Strike the electrode on the work to create the arc and hold the electrode steady to maintain the arc
(6) Hold the electrode slightly above the work piece to maintain the arc while travelling at an even speed
to create and even weld deposition
(7) Tonishtheweld,breakthearcbyquicklysnappingtheelectrodeawayfromtheworkpiece.
(8) Wait for the weld to cool and carefully chip away the slag to reveal the weld metal underneath.

(2) Switch on the machine

(1) Connect the electrode
lead to

(3) Set the welding current using the
amperage control dial.

(4) Place the electrode into the electrode
holder and clamp tight.

(1) Connect earth
lead to

(5) Strike the electrode against the
workpiece to create and arc and hold
the electrode steady to maintain the arc.

(6) Hold the electrode slightly above the
work maintaining the arc while travelling
at an even speed.

(7) Tonishtheweld,breakthearcby

quickly snapping the electrode away from
the work piece.

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(8) Wait for the weld to cool and carefully

chip away the slag to reveal the
weld metal below.

MMA (Manual Metal Arc) General Description

One of the most common types of arc welding is manual metal arc welding (MMA) or stick 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 and is covered with a  ux that gives off
gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from
atmospheric contamination. The electrode core itself acts as  ller material the residue from the  ux that forms a slag
covering over the weld metal must be chipped away after welding.

Core wire

+

Flux coating

Power Source

▬

Core wire

Flux coating

Gas shield from  ux melt

Arc with core wire melt

Flux residue forms slag cover

Weld metal

• The arc is initiated by momentarily touching the electrode to the base metal.

• The heat of the arc melts the surface of the base metal to form a molten pool
at the end of the electrode.

• The melted electrode metal is transferred across the arc into the molten pool
and becomes the deposited weld metal.

Base 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

Protective gas

Arc

Slag

Weld pool

Manual metal arc ( stick) electrodes have a solid metal wire core and a  ux
coating. These electrodes are identi ed by the wire diameter and by
a series of letters and numbers. The letters and numbers identify the metal
alloy and the intended use of the electrode.

The Metal Wire Core works as conductor of the current that maintains the arc.
The core wire melts and is deposited into the welding pool.

The covering on a shielded metal arc welding electrode is called Flux.
The  ux on the electrode performs many different functions.
These include:

● producing a protective gas atmosphere around the weld area.

● providing  uxing elements and deoxidizers.

● creating a protective slag coating over the weld as it cools.

● establishing arc characteristics.

● adding alloying elements.

Covered electrodes serve many purposes in addition to adding  ller metal to
the molten pool. These additional functions are provided mainly by the cover­ing on the electrode.

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