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RED-D-ARC
VIPER
For use with machines having Code Numbers:
OPERATOR'S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America's Largest Fleet of Welding Equipment
10597, 10635
11017 and 11018
IM639-B
March, 2004
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Table of Contents
Related Manuals for Lincoln Electric RED-D-ARC VIPER
Summary of Contents for Lincoln Electric RED-D-ARC VIPER
- Page 1 OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
- Page 2 SAFETY WARNING PLASMA CUTTING or GOUGING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information it is strongly recommended that you pur- chase a copy of “Safety in Welding &...
- Page 3 SAFETY 4.g. Sparks and spatter are thrown from the plasma arc. Wear PLASMA ARC can injure. safety glasses, ear protection and oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when cutting or gouging out of position or in confined places.
- Page 4 NOTES VIPER...
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
- Page 6 for selecting a QUALITY product. We want you to take pride in Thank You operating this product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation........................Section A Technical Specifications .......................A-1 Safety Precautions .......................A-2 Select Proper Location ......................A-2 Stacking..........................A-2 Lifting and Moving ........................A-2 Tilting ............................A-2 High Frequency Interference Protection................A-2 Input Electrical Connections ....................A-3 Power Input Connection .......................A-3 Input Power Cord Connector Installation................A-3 Cord Removal .......................A-3 Cord Installation ......................A-3 Frame Grounding .........................A-4... - Page 8 TABLE OF CONTENTS Page Maintenance ....................Section D Safety Precautions ....................D-1 Input Filter Capacitor Discharge Procedure ............D-1 Routine Maintenance.....................D-2 Periodic Maintenance ....................D-2 Troubleshooting ....................Section E Safety Precautions....................E-1 How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide ..................E-2 Wiring Diagrams ....................Section F Wiring Diagrams..................F-1 thru F-4 Dimension Print......................F-5 Parts Lists ...................P336 Series &...
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Page 9: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - VIPER INPUT THREE PHASE SINGLE PHASE Standard Input Current Standard Input Current Voltage at Rated Output Model Voltage at Rated Output Model 208/230/460 31/28/17 50/60 Hz 208/230/460 60/55/30 50/60Hz 460/575 17/14 50/60 Hz RATED OUTPUT Duty Cycle AMPS VOLTS 50% Duty Cycle... -
Page 10: Safety Precautions
INSTALLATION Read entire Installation Section before installing the LIFTING AND MOVING VIPER. Either the front or rear handles or both may be used to lift or move the machine. SAFETY PRECAUTIONS DO NOT use the pull handle on the optional undercar- WARNING riage, if installed, to lift the machine. -
Page 11: Input Electrical Connections
INSTALLATION INPUT ELECTRICAL 5. Angle the line switch so the screws on the near side of the switch can be loosened. CONNECTIONS 6. Loosen the screws and remove the existing cord Before installing the machine, check that input supply from the switch. voltage, phase, and frequency are the same as the machine's voltage, phase, and frequency as specified on the machine's rating plate. -
Page 12: Frame Grounding
INSTALLATION USE ON ENGINE DRIVEN POWER SUPPLIES FRAME GROUNDING The VIPER can be used on engine driven power sup- The frame of the VIPER must be properly grounded. plies. However, the following AC Wave Form Voltage A ground terminal marked is mounted on the case and Input Power Restrictions do apply. -
Page 13: Gas Input Connections
INSTALLATION GAS INPUT CONNECTIONS NOTE: When using nitrogen gas from a cylinder, the cylinder must have a pressure regulator. Supply the VIPER with clean compressed air or nitro- gen. • Maximum psi from nitrogen gas cylinder to • Supply pressure must be between 80 psi VIPER regulator should never and 150 psi. -
Page 14: Operation
OPERATION NOTE: All P.C. boards are protected by a moisture resistant Read and understand this entire section before oper- coating. When the plasma cutter is operated, this coating ating the machine. will "bake off" of certain power resistors that normally oper- ate at high temperatures emitting some smoke and odor for SAFETY PRECAUTIONS a short time. -
Page 15: User Responsibility
OPERATION USER RESPONSIBILITY - Input over voltage protection. - Bright 3.0 second timed pilot arc. Because design, fabrication, erection and cutting vari- ables affect the results obtained in applying this type - Purge momentary push button. of information, the serviceability of a product or struc- ture is the responsibility of the user. -
Page 16: Cutting Capability
OPERATION CUTTING CAPABILITY The VIPER is rated at 55 amps, at 50% duty cycle on a 10 minute basis or 40 amps, at 100% duty cycle. If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal oper- ating temperature. -
Page 17: Limitations
OPERATION 2. GAS PRESSURE SETTINGS. LIMITATIONS • Push-in and hold the Purge button to check or set the gas pressure. Pull the pressure regulator cap Do not exceed output current and duty cycle rating of out and turn it to set the pressure. - Adjust the gas regulator for 70 PSI for 25’... - Page 18 OPERATION ANGLE OF APPROACH • Hold the nozzle standoff 1/8” (3.2mm) to 3/16” (4.7mm) above the workpiece during cutting. Do not let the torch nozzle touch the work or carry a long arc. TORCH HELD AT ANGLE THROUGHOUT GOUGE • Keep moving while cutting. Cut at a steady speed without pausing.
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Page 19: Pilot Arc Discussion
OPERATION PILOT ARC DISCUSSION Thick Sections of Metal The VIPER has a smooth, continuous pilot arc. The Torch Standoff Machine Output Setting pilot arc is only a means of transferring the arc to the workpiece for cutting. Repeated pilot arc starts, in rapid succession, is not recommended as these starts will generally reduce consumable life. -
Page 20: Suggestions For Extra Utility From The Viper System
OPERATION Suggestions for Extra Utility from the h. Set air pressure to recommended setting. A higher or lower pressure will cause turbulence VIPER System: in the plasma arc, eroding the orifice of the nozzle tip. WARNING ELECTRIC SHOCK CAN KILL. i. -
Page 21: Accessories
VORTECH™ NOZZLES The following options/accessories are available for your VIPER from your local Lincoln Distributor. • Only Genuine Lincoln Electric consumables yield the best cutting performance for the VIPER. K1600-1 Undercarriage - A valet style undercarriage with pull-out handle for machine only. Provides Torch •... -
Page 22: Maintenance
MAINTENANCE 4. Obtain a high resistance and high wattage resistor WARNING (25-1000 ohms and 25 watts minimum). This resis- ELECTRIC SHOCK can kill. tor is not supplied with machine. NEVER USE A • Have an electrician install and service SHORTING STRAP FOR THIS PROCEDURE. this equipment. -
Page 23: Routine Maintenance
MAINTENANCE ROUTINE MAINTENANCE PERIODIC MAINTENANCE WARNING 1. Keep the cutting or gouging area and the area around the machine clean and free of combustible ELECTRIC SHOCK CAN KILL. materials. No debris should be allowed to collect • Turn off machine at the disconnect which could obstruct air flow to the machine. -
Page 24: Troubleshooting
TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 25 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION No Status indicators light and the fan 1. Check the input power to be sure does not operate 5 seconds after the it is on.
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Page 26: Wiring Diagrams
TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION The VIPER powers up properly but 1. Press Purge button on the front of there is no response when the trig- the VIPER. - Page 27 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION When the trigger is pulled air begins 1. Check the torch consumables to be to flow, but there is no pilot arc after sure they are not dirty or greasy, at least 3 seconds.
- Page 28 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION Pilot arc starts but will not transfer 1. Check work lead connection for when brought near work. clean, secure connection. 2. Plasma will only cut conductive material.
- Page 29 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual STATUS BOARD INDICATORS SYMPTOM CHECK Machine is unresponsive immediately after 1. There is a 4 second soft start period for pre-charging the input fil- power-up. ter capacitors. Wait until that time is up. The Power LED will light when ready.
- Page 30 DIAGRAMS xxxxxxx ELEC VIPER...
- Page 31 DIAGRAMS xxxxxxx ELEC VIPER...
- Page 32 Enhanced Diagram DIAGRAMS xxxxxxx ELEC VIPER...
- Page 33 Enhanced Diagram DIAGRAMS xxxxxxx ELEC VIPER...
- Page 34 DIAGRAMS VIPER...
- Page 35 NOTES VIPER...
- Page 36 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 37 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
- Page 38 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...