Viper SYNERGIC MIG165 Operating Manual
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Viper SYNERGIC MIG165 Operating Manual

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DC INVERTER WELDER
Operating Manual | XA-MIG165V
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
© Xcel-Arc 2022
SYNERGIC
MIG165
10 AMP
MIG
1
1
YEAR
M AC H INE
WARRANTY
TIG
MMA

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  • Page 1 SYNERGIC MIG165 DC INVERTER WELDER Operating Manual | XA-MIG165V YEAR M AC H INE WARRANTY 10 AMP Please read and understand this instruction manual carefully before the installation and operation of this equipment. © Xcel-Arc 2022...

  • Page 2: Table Of Contents

    VIPER MIG 165 OPERATING MANUAL Contents 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...

  • Page 3: Safety

    VIPER MIG 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 MIG 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 MIG 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 OPERATING MANUAL Warranty Thank you for your purchase of your Xcel-Arc - VIPER SYNERGIC MIG 165 Welding Machine. We are proud of our range of plasma cutting and welding equipment that has a proven track record of innovation, performance and reliability.

  • Page 7: Machine Features

    Lightweight & Portable Gas & Gasless MIG Weighing just 9.8kg, the VIPER MIG 165 is ready to go This machine supports both gas-shielded MIG and gasless anywhere you need it. MIG wire, meaning you can easily run mild steel, stainless steel &...

  • Page 8: Machine Specifications

    VIPER MIG 165 OPERATING MANUAL 3. Machine Specifications VIPER SYNERGIC MIG 165 3.1 Technical Data 3.3 TIG Specifications Parameter Values Parameter Values XA-MIG165V TIG Function Type DC Lift Arc Primary Input Voltage 230V Single Phase TIG Welding Current Range 20-160A Supply Plug 10 AMP TIG Duty Cycle @ 40°C...

  • Page 9: Machine Layout

    VIPER MIG 165 OPERATING MANUAL 4. Machine Layout 4.1 Front Panel Layout 1. Weld Parameters Panel 2. Euro Connection 3. “+” Output Terminal 4. Polarity Cable 5. “-” Output Terminal 4.2 Rear Panel Layout 6. On/Off Switch 7. Input Power Cord 8. Gas Inlet GAS IN 9.

  • Page 10: Control Panel Layout

    VIPER MIG 165 OPERATING MANUAL 5. Control Panel Layout 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. Voltage Knob 9. Wire Speed / Amperage Knob 10.

  • Page 11: Synergic Settings Operation

    VIPER MIG 165 OPERATING MANUAL 6.3 Inductance Adjustment Knob Inductance is what allows you to change the frequency of your short circuit – how often the wire touches the joint in the circuit’s cycle. The lower your inductance setting, the more frequently your weld will short circuit. Less metal is being added, so the bead is narrower and freezes faster.

  • Page 12: Package Contents

    VIPER MIG 165 OPERATING MANUAL 8. Package Contents VIPER Synergic MIG 165 3m XA15 MIG Torch 3m 300 AMP Earth Clamp C E L - C E L - 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”...

  • Page 13: Mig: Machine Setup (Gasless)

    VIPER MIG 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.
  • Page 14 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gasless) 5. Select MIG from the MIG/TIG/MMA selector. 6. Pull down the roller tension knob to release the wire drive. 7. Unscrew the roller cap. 8. Ensure you have a Knurled (F Groove) drive roller installed.
  • Page 15 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gasless) 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.
  • Page 16 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gasless) 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.
  • Page 17 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gasless) 17. For Synergic MIG operation, select your wire size and 18. Connect earth clamp to your workpiece. type. Adjust the amperage dial up or down according to your material thickness. For Standard MIG operation adjust the voltage and wire feed speed according to your material thickness.

  • Page 18: Mig: Machine Setup (Gas-Shielded)

    VIPER MIG 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.
  • Page 19 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 5. Select MIG from the MIG/TIG/MMA selector. 6. Pull down the roller tension knob to release the wire drive. 7. Unscrew the roller cap. 8. Ensure you have a V Groove drive roller installed. If not,...
  • Page 20 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 9. Unscrew spool retaining nut. 10. Place 5kg wire spool onto the spool holder. 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 21 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 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.
  • Page 22 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 17. Place twin gauge argon regulator into your gas outlet. 18. Tighten securely with wrench. C E L - C E L - 19. Connect gas hose to the regulator outlet, and crimp in 20.
  • Page 23 VIPER MIG 165 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 21. Adjust gas flow to 8-12L/min. 22. For Synergic MIG operation, select your wire size and type. Adjust the amperage dial up or down according to your material thickness. For Standard MIG operation adjust the voltage and wire feed speed according to your material thickness.

  • Page 24: Mig: Welding Guide

    VIPER MIG 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 25 VIPER MIG 165 OPERATING MANUAL MIG: Welding Guide 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 26 VIPER MIG 165 OPERATING MANUAL MIG: Welding Guide 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 27 VIPER MIG 165 OPERATING MANUAL MIG: Welding Guide 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 28 VIPER MIG 165 OPERATING MANUAL MIG: Welding Guide 11.8 Wire Types and Sizes Use the correct wire type for the base metal being welded. Use stainless steel wire for stainless steel, aluminium wires for aluminium and steel wires for steel. Using poor quality milled wire can result in poor performance and appearance. To ensure optimal performance when welding, use standards approved wire.

  • Page 29: Mig: Changing Your Torch Liner

    VIPER MIG 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 30 VIPER MIG 165 OPERATING MANUAL MIG: Changing Your Torch Liner 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.

  • Page 31: Mig: Changing Your Torch Liner (Aluminium)

    VIPER MIG 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 32 VIPER MIG 165 OPERATING MANUAL MIG: Changing Your Torch Liner (Aluminium) 7. Loosen the inlet guide tube retaining screw. 8. Remove the inlet guide tube using long nose pliers. 9. Install a U groove drive roller of the correct size for the 10.
  • Page 33 VIPER MIG 165 OPERATING MANUAL MIG: Changing Your Torch Liner (Aluminium) 11. Take the extended polymide liner all the way up and 12. Cut the extended Polymide liner with a sharp knife just over the drive roller. in front of the drive roller.

  • Page 34: Xa15 Binzel Style Mig Torch

    VIPER MIG 165 OPERATING MANUAL 14. XA15 BINZEL Style MIG Torch XA15 MIG TORCH XA15 MIG TORCH Suregrip Suregrip™ ™ Series Series 180A AIR COOLED MIG WELDING TORCH Rating:180A CO 150A mixed gas EN60974-7 @ 60% duty cycle. 0.6 to 1.0mm wires...

  • Page 35: Xa15 Mig Torch Consumables

    VIPER MIG 165 OPERATING MANUAL 14.1 XA15 MIG Torch Consumables Suregrip Suregrip™ ™ Series Series Front end consumables XA15 Contact Tips Part Number Description Material XA1527-06 Contact Tip 0.6mm D6 M6 x 25mm XA1527-08 Contact Tip 0.8mm D6 M6 x 25mm 25.0...

  • Page 36: Mma: Machine Setup

    VIPER MIG 165 OPERATING MANUAL 15. 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 37 VIPER MIG 165 OPERATING MANUAL MMA: Machine Setup 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.
  • Page 38 VIPER MIG 165 OPERATING MANUAL MMA: Machine Setup 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 39: Mma: Welding Guide

    VIPER MIG 165 OPERATING MANUAL 16. 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 40 VIPER MIG 165 OPERATING MANUAL MMA: Welding Guide 16.1 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...

  • Page 41: Tig: Machine Setup

    VIPER MIG 165 OPERATING MANUAL 17. 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.
  • Page 42 VIPER MIG 165 OPERATING MANUAL TIG: Machine Setup 5. Place argon flowmeter regulator into your gas outlet. 6. Tighten securely with wrench. XCEL-GAS XCEL-GAS 7. Connect gas hose to the flowmeter outlet, and crimp in 8. Adjust gas flow to 6-12L/min.
  • Page 43 VIPER MIG 165 OPERATING MANUAL TIG: Machine Setup 9. Set the welding current using the amperage control 10. Connect earth clamp to your workpiece. dial. 11. Turn on the gas valve located on the TIG torch handle. 12. Lay the outside edge of the gas cup on the workpiece...
  • Page 44 VIPER MIG 165 OPERATING MANUAL TIG: Machine Setup 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 45: Tig: Welding Guide

    VIPER MIG 165 OPERATING MANUAL 18. TIG: Welding Guide 18.1 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 46 VIPER MIG 165 OPERATING MANUAL TIG: Welding Guide 18.3 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 47 VIPER MIG 165 OPERATING MANUAL TIG: Welding Guide Tungsten Electrodes • Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.
  • Page 48 VIPER MIG 165 OPERATING MANUAL TIG: Welding Guide TIG TUNGSTEN SELECTION GUIDE 18.5 TIG Tungsten Selection Guide LANTHANATED ZIRCONIATED THORIATED CERIATED (GOLD) (WHITE) (RED) (TURQUOISE) (GREY)     AC CURRENT     DC CURRENT   ...
  • Page 49 VIPER MIG 165 OPERATING MANUAL TIG: Welding Guide 18.7 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 50: Drive Roller Selection

    VIPER MIG 165 OPERATING MANUAL 19. 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 51: Mig Troubleshooting

    VIPER MIG 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 52 VIPER MIG 165 OPERATING MANUAL MIG Troubleshooting 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 53: Tig Troubleshooting

    VIPER MIG 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 54 VIPER MIG 165 OPERATING MANUAL TIG Troubleshooting 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 55: Mma (Stick) Troubleshooting

    VIPER MIG 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.
  • Page 56 New Zealand Limited Esseti New Zealand Limited PO Box 4189, Palmerston North - 4442 Phone: 06 355 1103 Fax: (06) 354 2437 esseti.co.nz Email: sales@ esseti.co.nz www. Xcel-Arc © Esseti NZ LTD - 2022...

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