Viper Xcel-Arc, Operating Manual

Page 1: ...and understand this instruction manual carefully before the installation and operation of this equipment Xcel Arc 2020 VIPER 120 SYNERGIC Operating Manual XA MIG120V YEAR MACHINE WARRANTY 1 1 YEAR MACHINE WARRANTY ...

Page 2: ...ed repair agent as appointed by this company Warranty does not cover abuse misuse accident theft general wear and tear New product will not be supplied unless ESSETI New Zealand Limited has inspected product returned for warranty and agrees 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 XcelAr...

Page 3: ...ER 120 SYNERGIC FEATURES DATA 7 MACHINE PARTS LAYOUT 8 GASLESS MIG INSTALLATION 9 MIG WITH GAS INSTALLATION 11 WIRE INSTALLATION SET UP GUIDE 13 MIG WELDING GUIDE 14 XA15 MIG TORCH SPARES 20 MIG WELDING TROUBLE SHOOTING 21 MIG WIRE FEED TROUBLE SHOOTING 22 GAS FLOW REGULATORS SHEILDING GASES GAS FLOW RATES 23 WARRANTY TERMS 24 VIPER 120 SYNERGIC MIG Welder 3 CONTENTS ...

Page 4: ...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 ...

Page 5: ...se gas cylinders are normally 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 Insure cylinders are held secure and upright to prevent tipping or falling over Never allow the welding cutting electrode or earth clamp to touch the gas cylind...

Page 6: ...re inside the equipment The machine will be ready for use again when the internal temperature reaches safe level iii 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 that the voltage of input power supp...

Page 7: ...he machine allows welding with both Gas Shielded and Gasless wires and set up is easy with the synergic program and simple interface providing quick and simple weld parameter adjustments even for the novice welder The VIPER Synergic MIG120 is an exceptional machine for the price and is suitable for a wide range of applications including light fabrication body repair farming and whatever else a Kiw...

Page 8: ...ntrol Knob 4 Positive Output 5 Polarity Cable 6 Negative Output 7 Direct Connect MIG Torch 8 Power Cable 9 Power Switch 10 Gas Inlet 11 Wire Spool Holder 12 Wire Feed Assembly 1 7 9 10 11 12 2 3 4 6 8 5 8 VIPER 120 SYNERGIC MIG Welder Manual MACHINE PARTS LAYOUT ...

Page 9: ...ugh the inlet guide tube into the drive roller 5 Feed wire over the drive roller into the outlet guide tube Push the wire through approx 150mm 1 2 1 Insert the earth cable plug into the required polarity and tighten positive for flux cored wires 2 The weld power cable goes into the opposing negative socket VIPER 120 SYNERGIC MIG Welder 9 GASLESS MIG INSTALLATION ...

Page 10: ... the drive roller 9 Fit the correct size contact tip over the wire and fasten tightly into the tip holder 7 Remove the gas nozzle and contact tip from the front end of the MIG torch 10 Fit the gas nozzle to the torch head 8 Press and hold the Torch Trigger to feed the wire down the torch cable through to the torch head 10 VIPER 120 SYNERGIC MIG Welder Manual GASLESS MIG INSTALLATION ...

Page 11: ...ollers V Groove for Hard Wires Knurled for Flux Cored 5 Place wire onto spool holder spool retaining nut is left hand thread Feed the wire through the inlet guide tube into the drive roller NOTE VIPER MIG 120 is not suitable to weld Aluminium as it is a Synergic Welding Machine programmed for Solid Mild Steel wire and Flux Cored Gasless wires only 6 Feed wire over the drive roller into the outlet ...

Page 12: ...ze contact tip over the wire and fasten tightly into the tip holder 8 Remove the gas nozzle and contact tip from the front end of the MIG torch 11 Fit the gas nozzle to the torch head 9 Press and hold the Torch Trigger to feed the wire down the torch cable through to the torch head 12 Carefully open the valve of the gas cylinder set the flow to 8 10 L min 12 VIPER 120 SYNERGIC MIG Welder Manual MI...

Page 13: ...gh to the torch head 2 Note the tension spring adjuster and spool locating pin 5 Feed the wire through the drive roller and into the outlet guide tube of the wire feeder 8 A simple check for the correct drive tension is to bend the end of the wire over hold it about 100mm from your hand and let it run into your hand it should coil round in your hand without stopping and slipping at the drive rolle...

Page 14: ... transfer and pulsed spray each of which has distinct properties and corresponding advantages and limitations To perform MIG welding the basic necessary equipment is a welding gun a wire feed unit a welding power supply an electrode wire and a shielding gas supply Short circuit transfer is the most common used method whereby the wire electrode is fed continuously down the welding torch through to ...

Page 15: ...tens out the droplet into the weld pool The heat of the arc melts the end of the wire slightly as it feeds towards the base metal The wire feed speed overcomes the heat of the arc and the wire again approaches the work to short circuit and repeat the cycle Droplet separates Arc flattens the droplet Cycle repeats MIG Metal Inert Gas Welding Short Circuit Transfer Short circuit transfer is the most ...

Page 16: ...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 Perpendicular Technique The wire is fed directly into the weld this technique is used primarily for automated situations or when conditions make it necessary The weld profile is generally higher an...

Page 17: ...s a good level of control over the weld pool A travel angle greater that 20 will give an unstable arc condition with poor weld metal transfer less penetration high levels of spatter poor gas shield and poor quality finished weld Angle to Work The work angle is the forward back angle of the gun relative to the work piece The correct work angle provides good bead shape prevents undercut uneven penet...

Page 18: ... of poor quality 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 welders skill and is limited to the welders ability to control the weld pool Push technique allows faster travel speeds than Drag technique Gas flow must also correspond with the travel speed increasing wit...

Page 19: ...ck of fusion and slag inclusions Additionally some of the gas becomes ionised electrically charged and helps the current flow smoothly The correct gas flow is also very important in protecting 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 contamin...

Page 20: ...IC GAS NOZZLE Part No Description Type Bore Ø Material QTY XA1529 XA15 Gas Nozzle Cylindrical 16 0mm Copper QTY2 XA1530 XA15 Gas Nozzle Conical 12 0mm Copper QTY2 XA1531 XA15 Gas Nozzle Tapered 10 5mm Copper QTY2 XA1532 XA15 Gas Nozzle Bottle 12 8mm Copper QTY2 XA1533 XA15 Gas Nozzle Spot Weld 16 0mm Copper QTY2 VIPER 120 SYNERGIC NOZZLE SPRING Part No Description QTY XA1504 XA15 Nozzle Spring QTY...

Page 21: ...oo far away Bring the torch closer to the work and maintain stick out of 5 10mm Welding voltage set too low Adjust SYNERGIC Control Knob Wire Speed set too high Adjust SYNERGIC Control Knob 4 Lack of Fusion failure of weld metal to fuse completely with base metal or a proceeding weld bead Possible Reason Suggested Remedy Contaminated base metal Remove materials like paint grease oil and dirt inclu...

Page 22: ...oove Locate the wire into the groove of the drive roller Incorrect drive roller size Fit the correct size drive roller e g 0 8mm wire requires 0 8mm drive roller Wrong type of drive roller selected Fit the correct type roller e g knurled rollers needed for flux cored wires Worn drive rollers Replace the drive rollers Drive roller pressure too high Can flatten the wire electrode causing it to lodge...

Page 23: ...resulting in fusion defects also porosity and embrittlement of the weld metal Selecting the right type of shielding gas depends on the welding process being used and type of material being welded The MIG process is typically a mixture of Argon and Co2 AR90 Co2 10 or pure Co2 for steel welding applications other specialised mixtures of Argon Co2 and Oxygen are available for stainless steel welding ...

Page 24: ...llowing Warranty Periods effective from the date of purchase XCEL ARC Inverter MIG SWF MTS MMA TIG TIG ACDC Plasma Power Source Only 2 Years RAZORWELD Inverter MIG SWF MTS MMA TIG TIG ACDC Power Source Only 3 Years RAZORCUT Inverter Plasma Power Source Only 3 Years VIPER MIG185 Viper TIG180ACDC Power Source Only 2 Years VIPER ARC140 VIPER ARC160 VIPER CUT30 Power Source Only 1 Year VIPER TIG200P V...

Page 25: ...t and therefore also entitled to at the consumer s discretion either a refund of the purchase price of the goods or repair of the goods or replacement of the goods Returns will only be accepted provided that a You have complied with the provisions outlined above and b where the goods are unable to be repaired the goods are returned at your cost within thirty 30 days of the delivery date and c Esse...

Page 26: ...TIG Welding Torch Consumables such as Tungsten Electrodes Collet Collet Body Alumina Nozzle Torch Head Torch Head water Cooled Torch Head Flexible Back Caps Gas Lens Torch Handle Cup Gasket Torch Body Gas Valve O ring All XCEL ARC TIG Welding Rods All XCEL ARC Magmaweld Electrodes Arc Leads Welding Cable Electrode Holder Earth Clamps PLASMA Cutting Torches Consumables such as All Cutting Tips All ...

Page 27: ... VIPER 120 SYNERGIC MIG Welder 27 NOTES ...

Page 28: ...Esseti New Zealand Limited PO Box 4189 Palmerston North 4442 Phone 06 355 1103 Fax 06 354 2437 Email sales esseti co nz www esseti co nz www xcelarc nz Xcel Arc Esseti NZ LTD 2020 New Zealand Limited ...