Xcel-Arc VIPER SYNERGIC MIG165 Page 50 Operating Manual Download

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VIPER MIG 165

OPERATING MANUAL

Spare Parts

Part Number

Description

XA17V

Torch Body with Valve

XA17VFX

Torch Body Flexible with Valve

VS-2

Valve Stem

57Y02

Back Cap Long

98W18

Back Cap O Ring

57Y05

Back Cap Medium

57Y04

Back Cap Short

ERBS

Blank Switch Cover

(

See page 174 for Switch options)

ERSP1

Screw Pack

ERH100

Small Ergo Tig Handle

ERKJ100

Small Knuckle Joint & Lock Nut

ERLC100-08

Leather Cover x 0.8m

Spare Parts

Part Number

Description

ERJK100

Jointing Repair Kit

ERCO100-40

Sheath x 4m c/w Leather Cover

ERCO100-80

Sheath x 8m c/w Leather Cover

SLHD57Y01AOB

Power Cable x 4m Surelok OB Rubber

SLHD57Y03AOB

Power Cable x 8m Surelok OB Rubber

UD1025-38

Dinse Tig Power Cable Connector 10-25

UD3550-38

Dinse Tig Power Cable Connector 35-50

WGCP-1V-58

Gas Hose Assembly x 2m

Recommended TIG Torch Kit

Part Number

Description

XATK4

Tig Torch Package Without Regulator

Torch Model Description

Part Number

XA17V Tig Torch

16-25 Twistlok

End, 2m Gas Hose

XA17V-12NBD25

XA17V-25NBD25

XA17V Tig Torch

35-50 Twistlok

End, 2m Gas Hose

XA17V-12NBD50

XA17V-25NBD50

XA17VFX Flexi Tig Torch

16-25 Twistlok

End, 2m Gas Hose

XA17VFX-12NBD25

XA17VFX-25NBD25

XA17VFX Flexi Tig Torch

35-50 Twistlok

End, 2m Gas Hose

XA17VFX-12NBD50

XA17VFX-25NBD50

Stubby

series

Standa

series

Gas

lens

series

rge

gas

lens

series

Stubby

gas

lens

series

Wear Parts Identification Next Page

14 15

150AMP AIR COOLED

Gas Valve Torch Head

Rating: 150A DC, 105A AC @35% duty cycle.

Suregrip

™

Series

SW Stubby gas lens series

Wear Parts Identification Next Page

19. XA17V TIG Torch (Optional)

Summary of Contents for VIPER SYNERGIC MIG165

Page 1: ...rating Manual XA MIG165V 1 1 YEAR MACHINE WARRANTY 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: ...0 MIG Machine Setup Gas Shielded 18 11 MIG Welding Guide 24 12 MIG Changing Your Torch Liner 29 13 MIG Changing Your Torch Liner Aluminium 31 14 XA15 BINZEL Style MIG Torch 34 14 1 XA15 MIG Torch Cons...

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: ...ts both gas shielded MIG and gasless 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 STI...

Page 8: ...ecifications Parameter Values MIG Welding Current Range 30 165A MIG Duty Cycle 40 C 10 165A 60 68A 100 52A MIG Wire Size Range 0 6 0 9mm MIG Wire Spool Size 1kg 5kg MIG Welding Thickness Range 1 8mm D...

Page 9: ...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 9 Fan 4 3 Interior Layout 10 Wire F...

Page 10: ...tance Knob 6 Control Panel Operation 6 1 Voltage Adjustment Knob Provides digital adjustment of voltage in MIG and MIG Synergic Turn the knob to increase or decrease the desired value displayed on the...

Page 11: ...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...

Page 12: ...65 Drive Rollers 3m XA15 MIG Torch Electrode Holder 3m 300 AMP Earth Clamp Twin Gauge Argon Regulator 10A Plug Fitted XCEL G AS XCEL G AS X C E L G A S XCEL G AS XCEL G AS X C E L G A S 1 x 0 8 0 9mm...

Page 13: ...ity cable to the negative dinse connection twist to lock in place 2 Connect the earth clamp to the positive dinse connection twist to lock in place 3 Connect the MIG torch to the Euro connection and t...

Page 14: ...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 If...

Page 15: ...stment SPOOL GUN STANDARD Burnback Adjustment Burnback Adjustment Burnback Adjustment 9 Unscrew spool retaining nut 10 Place 5kg wire spool onto the spool holder For 1kg spool see step 20 11 Tighten s...

Page 16: ...ce Twist to tighten 14 Remove front end consumables from the MIG torch 15 Hold the torch trigger to feed wire through to the torch If the wire slips or stops you will need to adjust the roller tension...

Page 17: ...s For Standard MIG operation adjust the voltage and wire feed speed according to your material thickness 18 Connect earth clamp to your workpiece 19 Line up the torch with your workpiece then simply p...

Page 18: ...larity cable to the positive dinse connection twist to lock in place 2 Connect the earth clamp to the negative dinse connection twist to lock in place 3 Connect the MIG torch to the Euro connection an...

Page 19: ...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 fit correct roller and repla...

Page 20: ...STANDARD Burnback Adjustment Burnback Adjustment Burnback Adjustment 9 Unscrew spool retaining nut 10 Place 5kg wire spool onto the spool holder 11 Tighten spool retaining nut 12 Feed wire through th...

Page 21: ...Twist to tighten 14 Remove front end consumables from the MIG torch 15 Hold the torch trigger to feed wire through to the torch If the wire slips or stops you will need to adjust the roller tension kn...

Page 22: ...A S XCEL G AS XCEL G AS X C E L G A S ON OFF GAS IN 17 Place twin gauge argon regulator into your gas outlet 18 Tighten securely with wrench 19 Connect gas hose to the regulator outlet and crimp in pl...

Page 23: ...to your material thickness For Standard MIG operation adjust the voltage and wire feed speed according to your material thickness 23 Connect earth clamp to your workpiece 24 Line up the torch with you...

Page 24: ...e 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 sec...

Page 25: ...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 26: ...c lack of penetration lack of fusion and increase spatter MIG Welding Guide 5 15 Travel Direction Normal Stick Out Too Short Too long Correct Angle Not enough angle Too Much Angle check check times ti...

Page 27: ...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 11 7 2 Travel Speed Too Slow A too...

Page 28: ...Welding Guide Argon CO CO T D Manual MIG Setup Guide Synergic MIG Setup Guide T Material Type Wire Type Wire Size Drive Roller Polarity Shielding Gas Gas Flow Rate Material Thickness 1mm 2mm 3mm 4mm...

Page 29: ...MIG torch front end parts 2 Remove the liner retaining nut 3 Carefully pull out and completely remove the existing liner Ensure MIG torch is completely unravelled until setup is complete 4 Carefully f...

Page 30: ...own 6 Snip the excess liner off about the length of the where tip holder sits past the end of the torch neck 7 Replace the front end parts 8 Fully screw down the liner retaining nut and nip it up tigh...

Page 31: ...l out and completely remove the existing liner Ensure MIG torch is completely unravelled until setup is complete 4 Fit the neck spring to the front end of the aluminium liner 5 Feed liner and neck spr...

Page 32: ...uminium 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 diameter wire being used 10 Fee...

Page 33: ...IG Changing Your Torch Liner Aluminium 11 Take the extended polymide liner all the way up and over the drive roller 12 Cut the extended Polymide liner with a sharp knife just in front of the drive rol...

Page 34: ...Pins 20 XA1524 Gun Plug O Ring 21 XA1525 Liner Nut Spare Parts Part Number Description 1 XA1504 Nozzle Spring 2 XA1501 Swan Neck Assembly 3 XA1515 Ergo Handle Location Body 4 XA1521 Cable Terminal 5 X...

Page 35: ...XA1535 40B Insulated Liner 0 6 0 9mm wire x 4 4m Blue XA1535 50B Insulated Liner 0 6 0 9mm wire x 5 4m Blue XA2513 30B Teflon Liner 1 0 1 2mm x 3 4m for Soft wire Red XA2513 40B Teflon Liner 1 0 1 2m...

Page 36: ...electrodes connect earth clamp to the negative dinse connection and electrode holder to the positive dinse connection 2 For DC electrodes connect earth clamp to the positive dinse connection and elec...

Page 37: ...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 electrode 8 Adjust amperage to...

Page 38: ...PERATING 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 workpie...

Page 39: ...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 40: ...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 16 3 Electrode Angle The angle that the elect...

Page 41: ...nnect the TIG torch to the negative dinse connection 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 poi...

Page 42: ...TIG Machine Setup XCEL GAS XCEL GAS XCEL GAS XCEL GAS 5 Place argon flowmeter regulator into your gas outlet 6 Tighten securely with wrench 7 Connect gas hose to the flowmeter outlet and crimp in pla...

Page 43: ...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 handle 12 Lay the outside edge of the gas cup on the work...

Page 44: ...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 45: ...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 46: ...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 47: ...onger overall lifetime Tests have shown that ignition delay with E3 Tungsten Electrodes actually improves over time while 2 thoriated tungsten starts to deteriorate after only 25 starts At equivalent...

Page 48: ...nformation is intended to act as a guide only individual results may vary depending on technique skill and material 18 5 TIG Tungsten Selection Guide 18 6 Tungsten Electrodes Rating for Welding Curren...

Page 49: ...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 50: ...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 51: ...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 52: ...e softer wire Softer wires also require less tension from the top pressure roller to avoid deforming the shape of the wire too much tension will push the wire out of shape and cause it to catch in the...

Page 53: ...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 54: ...ad too long Small diameter wires and soft wires like aluminium don t feed well through long torch leads replace the torch with a lesser length torch MIG torch lead kinked or too sharp angle being held...

Page 55: ...filler wire into the leading edge of the weld pool in front of the tungsten 22 3 Porosity Poor weld appearance and colour Wrong gas poor gas flow gas leaks Use pure argon Gas is connected check hoses...

Page 56: ...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 22 7...

Page 57: ...or seek assistance for the correct technique 23 5 Lack of penetration Insufficient heat input Increase the amperage or choose a larger electrode Poor welding technique Use the correct welding techniqu...

Page 58: ...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...

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