Xcel-Arc VIPER SYNERGIC MIG135 Operating Manual
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Xcel-Arc VIPER SYNERGIC MIG135 Operating Manual

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1
1
YEAR
M ACH I N E
WARRANTY
10 AMP
MIG135
SYNERGIC
DC INVERTER WELDER
Operating Manual | XA-MIG135V
Please read and understand this instruction manual carefully
MIG
TIG
before the installation and operation of this equipment.
MMA
© Xcel-Arc 2022

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Summary of Contents for Xcel-Arc VIPER SYNERGIC MIG135

  • Page 1 YEAR M ACH I N E WARRANTY 10 AMP MIG135 SYNERGIC DC INVERTER WELDER Operating Manual | XA-MIG135V 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 135 OPERATING MANUAL 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. Package Contents 6. MIG: Machine Setup (Gasless) 7. MIG: Machine Setup (Gas-Shielded) 8. MIG: Welding Guide 9. MMA: Machine Setup 10. MMA: Welding Guide...

  • Page 3: Safety

    VIPER MIG 135 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 135 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 135 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 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. • 1 Year from date of purchase.

  • Page 7: Machine Features

    VIPER MIG 135 OPERATING MANUAL 2. Machine Features VIPER Synergic MIG 135 10 AMP Synergic MIG Control 10A Plug The clever Synergic MIG control takes the guesswork out A 10 AMP power plug can be used on any domestic outlet. of your settings. Simply select your wire size and adjust It’s perfect for the DIY home handyman or the professional the Synergic power knob to the thickness of your material.

  • Page 8: Machine Specifications

    VIPER MIG 135 OPERATING MANUAL 3. Machine Specifications VIPER Synergic MIG 135 3.1 Technical Data 3.3 TIG Specifications Parameter Values Parameter Values XA-MIG135V TIG Function Type DC Lift Arc Primary Input Voltage 230V Single Phase TIG Welding Current Range 20-120A Supply Plug 10 AMP TIG Duty Cycle @ 40°C 15% @ 120A 60% @ 60A...

  • Page 9: Machine Layout

    VIPER MIG 135 OPERATING MANUAL 4. Machine Layout 4.1 Front Panel Layout 1. Power LED 2. Thermal Overload LED 3. Weld Mode Selector 4. Synergic MIG Programs 5. Synergic Control Knob 6. Positive Output (+) 7. Polarity Cable 8. Negative Output (-) 9.

  • Page 10: Package Contents

    VIPER MIG 135 OPERATING MANUAL 5. Package Contents VIPER Synergic MIG 135 2m Direct Connect MIG Torch 2m Earth Clamp & Lead 1 x 0.6-0.8mm “V GROOVE” 25/7 - SOLID WIRE 1 x 0.8-0.9mm “F GROOVE” 25/7 - GASLESS WIRE Drive Rollers Electrode Holder 10A Plug (Fitted)

  • Page 11: Mig: Machine Setup (Gasless)

    VIPER MIG 135 OPERATING MANUAL 6. 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. 3.
  • Page 12 VIPER MIG 135 OPERATING MANUAL MIG: Machine Setup (Gasless) 7. Unscrew spool retaining nut and remove tension 8. Place 1kg wire spool onto the spool holder. spring and spool holder bracket. 9. Replace tension spring and spool holder bracket, then 10.
  • Page 13 VIPER MIG 135 OPERATING MANUAL MIG: Machine Setup (Gasless) 15. Replace front end consumables on the MIG torch. 16. Select wire size according to the wire spool installed. 17. Adjust synergic power knob according to material 18. Connect earth clamp to your workpiece. thickness.

  • Page 14: Mig: Machine Setup (Gas-Shielded)

    VIPER MIG 135 OPERATING MANUAL 7. 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. 3.
  • Page 15 VIPER MIG 135 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 7. Unscrew spool retaining nut and remove tension 8. Place 1kg wire spool onto the spool holder. spring and spool holder bracket. 9. Replace tension spring and spool holder bracket, then 10.
  • Page 16 VIPER MIG 135 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 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.
  • Page 17 VIPER MIG 135 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 17. Tighten securely with wrench. 18. Connect gas hose to the regulator outlet, and crimp in place. C E L - C E L - 19. Connect gas hose to the gas inlet on the rear of the 20.
  • Page 18 VIPER MIG 135 OPERATING MANUAL MIG: Machine Setup (Gas-Shielded) 21. Select wire size according to the wire spool installed. 22. Adjust synergic power knob according to material thickness. Use a higher value for thicker material, and a lower value for thinner material. 23.

  • Page 19: Mig: Welding Guide

    VIPER MIG 135 OPERATING MANUAL 8. MIG: Welding Guide 8.1 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 20 VIPER MIG 135 OPERATING MANUAL MIG: Welding Guide 8.3 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 21 VIPER MIG 135 OPERATING MANUAL MIG: Welding Guide 8.4 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 22 VIPER MIG 135 OPERATING MANUAL MIG: Welding Guide 8.7 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 23 VIPER MIG 135 OPERATING MANUAL MIG: Welding Guide 8.8 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. VIPER MULTI 135 Using poor quality milled wire can result in poor performance and appearance.

  • Page 24: Mma: Machine Setup

    VIPER MIG 135 OPERATING MANUAL 9. 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 25 VIPER MIG 135 OPERATING MANUAL MMA: Machine Setup 7. Release 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. Pull the electrode away from the workpiece to finish weld.

  • Page 26: Mma: Welding Guide

    VIPER MIG 135 OPERATING MANUAL 10. 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 27 VIPER MIG 135 OPERATING MANUAL MMA: Welding Guide 10.1 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 metals, there is a choice of several electrodes, each of which has particular properties to suit specific classes of work.

  • Page 28: Tig: Machine Setup

    VIPER MIG 135 OPERATING MANUAL 11. 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. 3.
  • Page 29 VIPER MIG 135 OPERATING MANUAL TIG: Machine Setup 7. Connect gas hose to the flowmeter outlet, and crimp in 8. Adjust gas flow to 6-12L/min. place. XCEL-GAS XCEL-GAS 9. Set the welding current using the amperage control 10. Connect earth clamp to your workpiece. dial.
  • Page 30 VIPER MIG 135 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 31: Tig: Welding Guide

    VIPER MIG 135 OPERATING MANUAL 12. TIG: Welding Guide 12.1 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 32 VIPER MIG 135 OPERATING MANUAL TIG: Welding Guide 12.3 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 33 VIPER MIG 135 OPERATING MANUAL TIG: Welding Guide TIG TUNGSTEN SELECTION GUIDE 12.5 TIG Tungsten Selection Guide LANTHANATED ZIRCONIATED THORIATED CERIATED (GOLD) (WHITE) (RED) (TURQUOISE) (GREY)     AC CURRENT     DC CURRENT    ...
  • Page 34 VIPER MIG 135 OPERATING MANUAL TIG: Welding Guide 12.7 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 35: Drive Roller Selection

    VIPER MIG 135 OPERATING MANUAL 13. 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 36: Mig Torch Consumables

    VIPER MIG 135 OPERATING MANUAL 14. MIG Torch Consumables FRONT END CONSUMABLES VIPER 135 SYNERGIC CONTACT TIPS Description Material XA1527-06 Contact Tip 0.6mm D6 M6 x 25mm QTY10 XA1527-08 Contact Tip 0.8mm D6 M6 x 25mm QTY10 XA1527-09 Contact Tip 0.9mm D6 M6 x 25mm QTY10 XA1527-10 Contact Tip 1.0mm D6 M6 x 25mm...

  • Page 37: Mig Troubleshooting

    VIPER MIG 135 OPERATING MANUAL 15. MIG Troubleshooting 15.1 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 38 VIPER MIG 135 OPERATING MANUAL MIG Troubleshooting 15.6 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 39: Tig Troubleshooting

    VIPER MIG 135 OPERATING MANUAL 16. TIG Troubleshooting 16.1 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 40 VIPER MIG 135 OPERATING MANUAL TIG Troubleshooting 16.6 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 41: Mma (Stick) Troubleshooting

    VIPER MIG 135 OPERATING MANUAL 17. MMA (STICK) Troubleshooting 17.1 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. 17.2 Porosity - Small cavities or holes resulting from gas pockets in weld metal •...

  • Page 42: Xa17V Tig Torch (Optional)

    VIPER MIG 135 OPERATING MANUAL 18. XA17V TIG Torch (Optional) Suregrip Suregrip™ ™ Series Series 150AMP AIR COOLED Gas Valve Torch Head Rating: 150A DC, 105A AC @35% duty cycle. Wear Parts Identification Next Page Wear Parts Identification Next Page Torch Model Description Part Number XA17V Tig Torch 16-25 Twistlok End, 2m Gas Hose XA17V-12NBD25...

  • Page 43: Xa17V Tig Torch Consumables

    VIPER MIG 135 OPERATING MANUAL 18.1 XA17V TIG Torch Consumables 18CG 10N22 Collet 1.0mm 10N30 Collet Body 1.0mm 10N50 Alumina Nozzle Ø 6mm 10N49L Long Alumina Nozzle Ø 8mm Cup Gasket 10N23 Collet 1.6mm 10N31 Collet Body 1.6mm 10N49 Alumina Nozzle Ø 8mm 10N48L Long Alumina Nozzle Ø...
  • Page 44 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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