Table of Contents
Troubleshooting
Related Manuals for Viper Xcel-Arc
Summary of Contents for Viper Xcel-Arc
- Page 1 VIPER 120 SYNERGIC Operating Manual | XA-MIG120V YEAR YEAR M ACH I N E M AC HI NE WARRANTY WARRANTY Please read and understand this instruction manual carefully before the installation and operation of this equipment. © Xcel-Arc 2020...
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Page 2: Warranty
Secondly they provide a customer support service that is second to none, thus ensuring our customers have confidence that they will be well satisfied both now and in the future. Xcel-Arc welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1, guaranteeing you electrical safety and performance. WARRANTY •... -
Page 3: Table Of Contents
CONTENTS WARRANTY SAFETY VIPER 120 SYNERGIC FEATURES & DATA MACHINE PARTS LAYOUT GASLESS MIG INSTALLATION MIG WITH GAS INSTALLATION WIRE INSTALLATION & SET UP GUIDE MIG WELDING GUIDE XA15 MIG TORCH & SPARES MIG WELDING TROUBLE SHOOTING MIG WIRE FEED TROUBLE SHOOTING... -
Page 4: Safety
• Measures should be taken to protect people in or near the surrounding working area. Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc. 4 | VIPER 120 SYNERGIC MIG Welder Manual... - Page 5 Hot parts. Items being welded/cut 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/cutting gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns. VIPER 120 SYNERGIC MIG Welder | 5...
- Page 6 TROUBLE SHOOTING Caution: Only qualified technicians are authorized to undertake the repair of this welding/cutting equipment. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed in this manual. 6 | VIPER 120 SYNERGIC MIG Welder Manual...
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Page 7: Viper 120 Synergic Features & Data
The VIPER Synergic MIG120 is as reliable and robust as you would expect from a machine bearing the Xcel-Arc name. -
Page 8: Machine Parts Layout
3. SYNERGIC Control 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 8 | VIPER 120 SYNERGIC MIG Welder Manual... -
Page 9: Gasless Mig Installation
(5) Feed wire over the drive roller into the outlet guide Flux Core wire. left hand thread ) Feed the wire through the inlet guide tube, Push the wire through approx 150mm. tube into the drive roller. VIPER 120 SYNERGIC MIG Welder | 9... - Page 10 (9) Fit the correct size contact tip over the wire and (10) Fit the gas nozzle to the torch head. (11) Select wire size, then adjust synergic control knob fasten tightly into the tip holder. to suit work piece. 10 | VIPER 120 SYNERGIC MIG Welder Manual...
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Page 11: Mig With Gas Installation
) Feed the wire through the inlet guide tube, Push the wire through approx 150mm. 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. - Page 12 (12) Carefully open the valve of the gas cylinder, set the fasten tightly into the tip holder. flow to 8-10 L/min (13) Select wire size, then adjust synergic control knob to suit work piece. 12 | VIPER 120 SYNERGIC MIG Welder Manual...
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Page 13: Wire Installation & Set Up Guide
MIG welders emanate from poor set up of the wire into the wire feeder. The guide below will assist in the correct setup of your wire feeder. 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. -
Page 14: Mig Welding Guide
100 times per second, making the arc appear constant to the human eye. MIG Circuit Diagram 4. Wire Feeder - 5. Wire Spool - 6. Gas MIG Torch - Work Piece - Power Source - 14 | VIPER 120 SYNERGIC MIG Welder Manual... - Page 15 The heat of the arc melts the end of the wire slightly as it feeds towards the base metal VIPER 120 SYNERGIC MIG Welder | 15...
- Page 16 10° Travel direction Travel direction Travel direction Wire pointed ahead of bead Wire pointed back into bead Flat even weld profile light Narrower weld profile Narrow higher weld profile penetration even penetration more penetration 16 | VIPER 120 SYNERGIC MIG Welder Manual...
- Page 17 Too long stick out will cause an unstable arc, lack of penetration, lack of fusion and increase spatter. Too long Too short Normal stick out 5-10mm Even arc, good penetration Unstable arc, spatter, over Unstable arc, spatter, poor even fusion, good finish heat contact tip penetration and fusion VIPER 120 SYNERGIC MIG Welder | 17...
- Page 18 The correct travel speed keeps the arc at the leading edge of the weld pool allowing the base metal to melt sufficiently to create good penetration, fusion and wetting out of the weld pool producing a weld deposit of good quality. Correct Travel Speed Even shaped bead Good toe fusion Good side wall fusion Good penetration 18 | VIPER 120 SYNERGIC MIG Welder Manual...
- Page 19 Argon Co2 mixed gas. Argon Co2 mix gas offers better weld ability for thin metals and has a wider range of setting tolerance on the machine. Argon 80% Co2 20% is a good all round mix suitable for most applications. Argon Co2 Penetration Pattern for Steel VIPER 120 SYNERGIC MIG Welder | 19...
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Page 20: Xa15 Mig Torch & Spares
Spot Weld 16.0mm Copper QTY2 53.0 VIPER 120 SYNERGIC NOZZLE SPRING Part-No Description XA1504 XA15 Nozzle Spring QTY2 These parts are manufactured in China and are offered as replacement parts suitable for “BINZEL®” style torches. 20 | VIPER 120 SYNERGIC MIG Welder Manual... -
Page 21: Mig Welding Trouble Shooting
Not enough heat input Select a higher voltage range and /or adjust the wire speed to suit Reduce travel speed Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale from base metal. VIPER 120 SYNERGIC MIG Welder | 21... -
Page 22: Mig Wire Feed Trouble Shooting
Wire crossed over on the spool or tangled Remove the spool untangle the wire or replace the wire Contaminated MIG wire Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc 22 | VIPER 120 SYNERGIC MIG Welder Manual... -
Page 23: Gas Flow Regulators - Sheilding Gases - Gas Flow Rates
1. create a vortex and draw air into the gas flow and the weld zone causing contamination of the weld. 2. produce turbulence at the weld pool resulting in a poor quality weld. VIPER 120 SYNERGIC MIG Welder | 23... -
Page 24: Warranty Terms
ESSETI New Zealand Limited (‘us’, ‘we’) warrants that the products bearing the brand names ESSETI, XCEL-ARC, RAZORWELD, RAZORCUT, JASIC, VIPER, T&R, XCEL-GAS, Otos, Servore, TECNA & HIT-8SS supplied by us and purchased by you from an Authorised ESSETI (NZ) Ltd. Distributor are free of Material and Faulty Workmanship Defects except for those products listed under ‘Warranty Exclusions’... - Page 25 No responsibility will be taken for any products lost, damaged or mislaid whilst in transit. VIPER 120 SYNERGIC MIG Welder | 25...
- Page 26 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 •...
- Page 27 NOTES VIPER 120 SYNERGIC MIG Welder | 27...
- Page 28 New Zealand Limited 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...