Xcel-Arc VIPER SYNERGIC MIG135, Operating Manual

Page 1: ...rating Manual XA MIG135V YEAR MACHINE WARRANTY 1 1 10 AMP TIG MIG MMA Please read and understand this instruction manual carefully before the installation and operation of this equipment Xcel Arc 2022...

Page 2: ...Rear Panel Layout 9 4 3 Interior Layout 9 5 Package Contents 10 6 MIG Machine Setup Gasless 11 7 MIG Machine Setup Gas Shielded 14 8 MIG Welding Guide 19 9 MMA Machine Setup 24 10 MMA Welding Guide 26...

Page 3: ...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...

Page 4: ...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 exce...

Page 5: ...n 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 supp...

Page 6: ...ents 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...

Page 7: ...ess 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 The...

Page 8: ...MIG Specifications Parameter Values MIG Welding Current Range 40 135A MIG Duty Cycle 40 C 15 135A 60 65A 100 50A MIG Wire Size Range 0 6 0 9mm MIG Wire Spool Size 1kg MIG Welding Thickness Range 1 6mm...

Page 9: ...ode Selector 4 Synergic MIG Programs 5 Synergic Control Knob 6 Positive Output 7 Polarity Cable 8 Negative Output 9 Direct Connect MIG Torch 4 2 Rear Panel Layout 10 Power Cable 11 Power Switch 12 Gas...

Page 10: ...G MANUAL 5 Package Contents VIPER Synergic MIG 135 Drive Rollers 2m Direct Connect MIG Torch Electrode Holder 2m Earth Clamp Lead 10A Plug Fitted 1 x 0 6 0 8mm V GROOVE 25 7 SOLID WIRE 1 x 0 8 0 9mm F...

Page 11: ...place 2 Connect the earth clamp to the positive dinse connection twist to lock in place 3 Connect the plug into a 10 AMP socket then switch the machine ON 4 Pull up the roller tension knob to release...

Page 12: ...tighten spool retaining nut 10 Feed wire through the inlet guide tube to the outlet guide tube Ensure that the wire passes through the roller 11 Pull down tension knob to lock wire in place Twist to...

Page 13: ...djust synergic power knob according to material thickness Use a higher value for thicker material and a lower value for thinner material 18 Connect earth clamp to your workpiece 19 Line up the torch w...

Page 14: ...in place 2 Connect the earth clamp to the negative dinse connection twist to lock in place 3 Connect the plug into a 10 AMP power point then switch the machine ON 4 Pull up the roller tension knob to...

Page 15: ...Place 1kg wire spool onto the spool holder 9 Replace tension spring and spool holder bracket then tighten spool retaining nut 10 Feed wire through the inlet guide tube to the outlet guide tube Ensure...

Page 16: ...13 Remove front end consumables from the MIG torch 14 Hold down 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 15 Repla...

Page 17: ...S X C E L G A S ON OFF GAS IN XCEL G AS XCEL G AS X C E L G A S XCEL G AS XCEL G AS XCEL GAS 17 Tighten securely with wrench 18 Connect gas hose to the regulator outlet and crimp in place 19 Connect g...

Page 18: ...according to material thickness Use a higher value for thicker material and a lower value for thinner material 23 Connect earth clamp to your workpiece 24 Line up the torch with your workpiece then s...

Page 19: ...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 secon...

Page 20: ...h 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 f...

Page 21: ...ick 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 pe...

Page 22: ...cur 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 8 7 2 Travel Speed Too Slow A too s...

Page 23: ...cting the welding zone from the atmosphere Too low a flow will give inadequate coverage and result in weld defects and unstable arc conditions Too high a flow can cause air to be drawn into the gas co...

Page 24: ...e 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...

Page 25: ...ase handle to securely grip electrode 8 Adjust amperage to desired setting 9 Connect earth clamp to your workpiece 10 Strike electrode against workpiece to initiate arc 11 Drag along workpiece to weld...

Page 26: ...t 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 sol...

Page 27: ...de 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 10 3 Electrode Angle The angle that the elect...

Page 28: ...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...

Page 29: ...nd crimp in place 8 Adjust gas flow to 6 12L min 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 ha...

Page 30: ...e reverse direction to lift the tungsten electrode from the workpiece to create the arc IMPORTANT We strongly recommend that you check for gas leaks prior to operation of your machine We recommend tha...

Page 31: ...e 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...

Page 32: ...nique 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...

Page 33: ...8 35 12 90 12 180 2 4mm 1 1 45 15 150 15 250 3 2mm 1 1 60 20 200 20 300 3 2mm 1 5 90 25 250 25 350 LANTHANATED GOLD ZIRCONIATED WHITE THORIATED RED E3 TURQUOISE CERIATED GREY AC CURRENT DC CURRENT AL...

Page 34: ...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 we...

Page 35: ...nal column strength They are stiffer and don t bend so easily 13 2 Flux Cored Gasless Wire Knurled F Groove These wires are made up of a thin metal sheath that has fluxing and metal compounds layered...

Page 36: ...Tip Thread Material QTY XA1507SLH XA15 Tip Holder Short L H Thread 34 0mm M6 Brass QTY2 VIPER 135 SYNERGIC GAS NOZZLE SKU Description Bore Type QTY XA1529 XA15 GAS NOZZLE Cylindrical 16 0mm Copper QTY...

Page 37: ...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 greas...

Page 38: ...ge 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 leng...

Page 39: ...filler wire into the leading edge of the weld pool in front of the tungsten 16 3 Porosity Poor weld appearance and colour Wrong gas poor gas flow gas leaks Use pure argon Gas is connected check hoses...

Page 40: ...heel 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 16 7...

Page 41: ...or seek assistance for the correct technique 17 5 Lack of penetration Insufficient heat input Increase the amperage or choose a larger electrode Poor welding technique Use the correct welding techniqu...

Page 42: ...nector 10 25 UD3550 38 Dinse Tig Power Cable Connector 35 50 15 WGCP 1V 58 Gas Hose Assembly x 2m Torch Model Description Part Number 4m 8m XA17V Tig Torch 16 25 Twistlok End 2m Gas Hose XA17V 12NBD25...

Page 43: ...et Body 3 2mm Gas Lens Front End Parts 18CG Cup Gasket 54N01 Gas Lens Gasket USTB80300236 Gas Lens Gasket 10N22S Stubby Collet 1 0mm 10N23S Stubby Collet 1 6mm 10N24S Stubby Collet 2 4mm 10N25S Stubby...

Page 44: ...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 Xcel Arc Esseti NZ LTD 2022 New Zealand Limited...