NewArc Viper 2500s Quick start guide

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Newcastle UponTyne
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Operational Manual
Newarc Viper 2500S
NA9910308

2VIPER 2500s
WEEE Directive & Product Disposal
At the end of its serviceable life, this product should not be treated as household
or general waste. It should be handed over to the applicable collection point for
the recycling of electrical and electronic equipment, or returned to the supplier for
disposal.
Place and Date
Newcastle upon Tyne, UK
14/06/2016
DECLARATION OF CONFORMITY
The Low voltage Directive 2014/35/EU
The EMC Directive 2004/108/EC, entering into force 20 July 2007
The RoHS Directive 2011/65/EU, entering into force 2 January 2013
Type of Equipment
Compact TIG control unit
Brand name or trade mark
Newarc
Type designation etc.
Viper 2500S
Manufacturer or his authorised representative established within the EEA
Name, address, telephone no
Newarc
Newcastle upon Tyne
Phone: [phone]
The product has been designed to comply with the following harmonised standards:
IEC 60974-1 - Arc welding Equipment Arc striking and stabilizing devices
EN 60974-10 - Arc Welding Equipment Electromagnetic compatibility
Additional information: restrictive use, Class A equipment, intended for use in locations other than residential
We declare that the equipment named above has been designed to comply with the relevant sections of the
above referenced specications. The unit complies with applicable essential requirements of the directives.

Safety Guidelines
These general safety guides cover both arc welding machines and plasma cutting machines unless
otherwise noted. The equipment must only be used for the purpose it was designed for. Using it in any
other way could result in damage or injury and in breach of the safety rules. Only suitably trained and
competent persons should use the equipment. Operators should respect the safety of other persons.
Prevention against electric shock
The equipment should be installed by a qualified person and in accordance with current standards in
operation. It is the user’s responsibility to ensure that the equipment is connected to a suitable power
supply. Consult with your utility supplier if required. If earth grounding of the work piece is required,
ground it directly with a separate cable. Do not use the equipment with the covers removed. Do not
touch live electrical parts or parts which are electrically charged. Turn off all equipment when not in use.
Cables (both primary supply and welding) should be regularly checked for damage and overheating.
Do not use worn, damaged, under sized or poorly jointed cables. Ensure that you wear the correct
protective clothing, gloves, head and eye protection. Insulate yourself from work and ground using
dry insulating mats or covers big enough to prevent any physical contact with the work ground. Never
touch the electrode if you are in contact with the work ground, or another electrode from a different
machine.
Do not wrap cables over your body. Ensure that you take additional safety precautions when you are
welding in electrically hazardous conditions such as damp environments, wearing wet clothing, and
metal structures. Try to avoid welding in cramped or restricted positions. Ensure that the equipment
is well maintained. Repair or replace damaged or defective parts immediately. Carry out any regular
maintenance in accordance with the manufacturer’s instructions.
Safety against fumes and welding gases
Locate the equipment in a well-ventilated position. Keep your head out of the fumes. Do not breathe
the fumes. Ensure the welding zone is in a well-ventilated area. If this is not possible, provision should
be made for suitable fume extraction. If ventilation is poor, wear an approved respirator. Read and
understand the Material Safety Data Sheets (MSDS’s) and the manufacturer’s instructions for metals,
consumable, coatings, cleaners, and de-greasers. Do not weld in locations near any de-greasing,
cleaning, or spraying operations. Be aware that heat and rays of the arc can react with vapours to form
highly toxic and irritating gases. Do not weld on coated metals, unless the coating is removed from the
weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings on many
metals can give off toxic fumes if welded.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Wear an approved welding helmet fitted with a proper shade of filter lens
to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields
under your helmet. Never use broken or faulty welding helmets. Always ensure there are adequate
protective screens or barriers to protect others from flash, glare and sparks from the welding area. Ensure
that there are adequate warnings that welding or cutting is taking place.
3
VIPER 2500s

Wear suitable protective flame resistant clothing. The sparks and spatter from welding, hot work pieces,
and hot equipment can cause fires and burns. Welding on closed containers, such as tanks, drums, or
pipes, can cause them to explode. Accidental contact of electrode to metal objects can cause arcs,
explosion, overheating, or fire. Check and be sure the area is safe and clear of inflammable material
before carrying out any welding.
Protection against noise
Some welding and cutting operations may produce noise. Wear safety ear protection to protect your
hearing.
Protection from moving parts
When the machine is in operation, keep away from moving parts such as motors and fans. Moving
parts, such as the fan, may cut fingers and hands and snag garments. Protections and coverings may
be removed for maintenance and controls only by qualified personnel, after first disconnecting the
power supply cable. Replace the coverings and protections and close all doors when the intervention
is finished, and before starting the equipment. Take care to avoid getting fingers trapped when loading
and feeding wire during set up and operation. When feeding wire be careful to avoid pointing it at other
people or toward your body. Always ensure machine covers and protective devices are in operation.
Precautions against fire and explosion
Avoid causing fires due to sparks and hot waste or molten metal. Ensure that appropriate fire safety
devices are available near the cutting / welding area. Remove all flammable and combustible materials
from the cutting / welding zone and surrounding areas. Do not cut/weld fuel and lubricant containers,
even if empty. These must be carefully cleaned before they can be cut/welded. Always allow the cut/
welded material to cool before touching it or placing it in contact with combustible or flammable
material. Do not work in atmospheres with high concentrations of combustible fumes, flammable gases
and dust. Always check the work area half an hour after cutting to make sure that no fires have begun.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the operation of pacemakers or electronically
controlled medical equipment. Wearers of vital electronic equipment should consult their physician
before beginning any arc welding, cutting, gouging or spot welding operations. Do not go near welding
equipment with any sensitive electronic equipment as the magnetic fields may cause damage.
RF Declaration
Equipment that complies with directive 2004/108/EC concerning electromagnetic compatibility (EMC)
and the technical requirements of EN60974-10 is designed for use in industrial buildings and not those
for domestic use where electricity is provided via the low voltage public distribution system. Difficulties
may arise in assuring class A electromagnetic compatibility for systems installed in domestic locations
due to conducted and radiated emissions. In the case of electromagnetic problems, it is the
responsibility of the user to resolve the situation. It may be necessary to shield the equipment and fit
suitable filters on the mains supply.
4VIPER 2500s

5
LF Declaration
Consult the data plate on the equipment for the power supply requirements. Due to the elevated
absorbency of the primary current from the power supply network, high power systems affect the
quality of power provided by the network. Consequently, connection restrictions or maximum
impedance requirements permitted by the network at the public network connection point must be
applied to these systems. In this case the installer or the user is responsible for ensuring the equipment
can be connected, consulting the electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not contain any toxic or poisonous
materials dangerous to the operator. When the equipment is scrapped, it should be dismantled
separating components according to the type of materials. Do not dispose of the equipment with
normal waste. The European Directive 2002/96/EC on Waste Electrical and Electronic Equipment states
the electrical equipment that has reached its end of life must be collected separately and returned to an
environmentally compatible recycling facility.
Handling of compressed gas cylinders and regulators
All cylinders and pressure regulators used in welding operations should be handled with care.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Always secure the cylinder safely. Never deface or alter any cylinder.
The following signs and explanations are to remind the user of the potential
risks involved and the dangers of misuse or mistreatment of the welding
machine.
!
RUNNING PARTS MAY BE DANGEROUS!
Keep away from running components,
including the fan.
BE AWARE OF SPARKS AND SPATTER
Wear protective clothing, such as leather
gloves, Flame retardant overalls, boots and
eyewear.
DO NOT TOUCH THERMAL COMPONENTS!
Thermal components may cause severe burns
when in contact with unprotected skin.
ELECTRIC SHOCKS CAN KILL!
Never touch electrical parts. Keep the
equipment in good condition, replace
damaged parts, undertake regular
maintenance according to the instructions.
VIPER 2500s

1. Preface 7
1.1 General 7
1.2 Introduction 8
1.3 Technical Specications 9
1.4 Overview of Machine 10
2. Installation 13
3. Operation 14
4. Fault Finding 16
4.1 Welding Problems 17
5. Maintenance 18
6. Warranty 19
7. Parts 20
Contents
6VIPER 2500s

7
1. Preface
Congratulations on choosing your Newarc Viper 2500S.
Used correctly, our products can signicantly increase the productivity of your welding, and provide
years of economical service. This operating manual contains important information on the use,
maintenance and safety of your Newarc product. Please read the manual carefully before using the
equipment for the rst time. For your own safety and that of your working environment, pay particular
attention to the safety instructions in the manual.
For more information on Newarc products, contact an authorised Newarc dealer, or visit the Newarc
website at www.newarc.co.uk. The specications presented in this manual are subject to change without
prior notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and personal harm
are indicated with the ’NOTE!’ notation. Read these sections carefully and follow the instructions.
Disclaimer
While every effort has been made to ensure that the information contained in this guide is accurate and
complete, no liability can be accepted for any errors or omissions. We reserve the right to change the
specication of the product described at any time without prior notice. Do not copy, record, reproduce
or transmit the contents of this guide without prior permission.
WARNING! TO PROTECT THE VIPER 2500S FROM DAMAGE PLEASE ENSURE
THE DEMAND ON THE POWER SOURCE IS TURNED UPTO MAXIMUM
1.1 General
VIPER 2500s

1.2 Introduction
The Viper 2500S is a compact DC TIG Control unit that operates from the open circuit voltage of any DC
power source with an output of 40-100 volts, petrol or diesel generators, rectiers, inverters etc.
This unique machine independently controls the welding current of any DC power source without the
need for auxiliary or control cables. It can be used with one or two piece torches and provides excellent
MMA & TIG welding characteristics.
Features
• Arc ignition
• Variable current control
• Slope up and slope down
• Variable post gas time adjustment
• Torch switch latching
• Argon ow meter
• Digital Display
• Self sealing gas coupler for TIG torch
8VIPER 2500s

1.3 Technical Specications
9
Newarc VIPER 2500s
Input Voltage Range 30 -100 Volts
Maximum Output Current 250 amps
Current control Innitely Variable
Duty Cycle TIG/MMA 100% @ 250amps
Degree of Protection IP23
450 x 190 x 300
16
Gas Flowmeter Yes
Dimensions (L x W x H) (mm)
Weight (kg)
VIPER 2500s

1.4 Overview of Machine
10
Front View
Power source front panel layout
1. Gas ow control
2. Torch switch socket
3. Torch switch socket
4. Post gas time
5. Slope up control
6. Current control
7. Slope down control
8. TIG/MMA switchl
9. TIG2/TIG 4 switch
10. Digital display
11. Power -on indicator
12. Warning Indicator
13. Thermal cut-out Indicator
14. Gas out connector
15. Positive out connector
16. Negative out connector
Viper2500s
VIPER 2500s
Rear View
17. Positive in connector
18. Negative in connector
19. On/Off switch
20. Fuse Holder
21. Gas In connector
22. Remote control socket

11
VIPER 2500s
1. Gas ow control
Adjusts the ow of gas to the welding torch, a ow rate of 15 to 20 lpm is normally used.
2 .Torch switch socket
For connecting the TIG torch control switch lead using a XLR type plug.
3. Torch switch socket
For connecting the TIG torch control switch lead using a DIN type plug.
4. Post gas time
This control sets the post gas delay, This is the period of time that the gas will continue owing after the arc
has extinguished. The length of this period is determined by the position of the control.
5. Slope up control
With slope up control set to minimum the Viper will strike at current set by the current control. With the slope
up control set to anywhere but minimum the Viper will strike at 30A and then gradually increase the current
to the setting on the current control, the time this takes is determined by the position of the slope up control.
6. Current control
Use this on MMA and TIG to set the output current of the Viper.
7. Slope down control
Slope down control set to minimum the current will shut down immediately the torch switch is released.
Slope down control set to anywhere but minimum and torch switch released, the current will gradually
decrease from the setting on the current control to 5 amps, where the current will extinguish, time this takes
is determined by position of slope down control.
8. TIG/MMA switch
This control switches the Viper’s operating mode between MMA and TIG.
9. TIG2/TIG 4 switch
This control switches between 2T and 4T operation (normal and latch). In TIG2 position, when the torch
switch is pressed the arc ignites, when the switch is released the arc goes out. In TIG4 position, when the
torch switch is pressed and released the arc ignites, to extinguish the arc you must press and release the torch
switch again.
10. Digital Display
Gives an accurate indication of the welding current.
11. Power-on indicator
Indicates that the Viper is receiving power from the power source it is connected to.
12. Warning Indicator
Indicates that the Viper is connected in reverse polarity, i.e. the positive lead from the power source is
connected to the
negative in terminal on the rear of the Viper and vice-versa. The set will not operate in this condition.

12 VIPER 2500s
1.4 Overview of Machine
13. Thermal cut-out Indicator
Indicates that the thermal cut-out in the machine has operated. (see paragraph 5.1 in the fault nding and
maintenance section for possible reasons) control to set the desired welding current, the digital display will
indicate the setting.
14. Gas out connector
This is a female quick coupling with an internal shut- off valve. To connect, push the male connection
on the end of the TIG torch adaptor into the coupling until you hear a click. To fully disconnect, push the
knurled ferrule on the connector inwards towards the Viper until it stops. The shut off valve in the connector
automatically closes when the connection is separated.
15. Positive out connector
Main welding power output connector, positive polarity.
16. Negative out connector
Main welding power output connector, negative polarity.
17. Positive in connector
Main power in connector, must be connected by welding cable to the positive terminal of the power source.
18. Negative in connector
Main power in connector, must be connected by welding cable to the negative terminal of the power source.
19. On/O switch
Switches the Viper on and off.
20. Fuse Holder
Holds the main protection fuse for the Viper.
21. Gas In connector
Must be connected to the pressure regulator on the gas cylinder by means of a suitable hose.
22. Remote control socket
For connecting external remote control units, these are the RC300 remote control, the RPC300 pulse unit
and the RFP300 foot pedal. There is no switch for remote operation, plugging an external unit into the socket
automatically selects remote operation and disables the internal current control.

13
VIPER 2500s
2. Installation
Unpacking
Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging
until the installation is complete.
Positioning of the machine
Place the Viper 2500s on a clean dry surface, preferable above ground level.
• Make sure there is at least 20cm clearance at the front and rear of the machine to allow good
circulation of the cooling air.
• Protect the machine from heavy rain and if used in hot climates, against direct sunlight.
• Ensure that the machine is positioned in such a way so that particles created by grinding and cutting
operations do not enter the machine.
Connecting welding cables
Only use copper welding cables with a cross sectional area of 35mm2 or more.
• Connect the negative (-ve) cable from the power source to the‘negative in’connector on the rear of the Viper.
• Connect the positive (+ve) cable from the power source to the‘positive in’connector on the rear of the Viper.
INVERTER POWER SOURCE
Connecting for MMA operation
• Connect the Electrode Holder to the positive out connector on the front of the Viper.
• Connect the Earth return lead to the negative out connector on the front of the Viper.
Note! When using a reverse polarity procedure, always swap the polarity of the output cables.
NEVER swap the polarity of the input cables.
Connecting for TIG operation (As shown above)
• Connect to the power gas adaptor to the negative output connector on the front of the Viper.
• Connect the gas pipe of the power gas adaptor to the quick release connector between the output terminals.
• Connect the TIG torch to the power gas adaptor.
• Connect the Earth return lead to the positive output connector on the front of the Viper.

14 VIPER 2500s
MMA Operation
• Connect the Viper as per paragraphs 3.2 of the Installation section.
• At the power source, turn the power on and the current control to maximum.
• Turn the TIG/MMA switch on the front panel to the MMA setting.
• Press the On/Off switch on the rear panel to the on position, the power on indicator and the digital display
will light and the Viper is ready to use.
• Turn the current control to the setting required for the task in hand.
TIG Operation
• Connect the Viper as per paragraphs 3.2 of the installation section
• At the power source, turn the power on and the current control to maximum.
• Turn the TIG/MMA switch on the front panel to the TIG setting.
• Turn the TIG2/TIG4 switch to the desired mode of operation.
• Press the On/Off switch on the rear panel to the on position, the power on indicator and the digital display
will light and the Viper is ready to use.
• Turn the current control to the setting required for the task in hand.
MMTIG2 mode
NOTE! To be able to initiate a welding arc gas must be present. If a post gas sequence is not still in operation a
pre gas stage will be initialised.
Basic operation of TIG2 mode (Slope up & slope down both set to minimum)
With the slope up control set to minimum the Viper will strike at the current set by the current control knob.
With the slope down control set to minimum the Viper will extinguish the arc immediately the torch button is
released.
Torch button (pressed and held on) = Pre gas —> H.F. —>Arc initiated
Torch button (released) = Arc extinguished.
TIG2 slope up operation.
With the slope up control set to anything but minimum the Viper will strike at 30 Amp and then gradually
increase the current up to the current setting set by the current control knob, the time this takes is
determined by the position of the slope up control knob. The slope up procedure can be halted part way
through by releasing the torch switch. This starts the slope down process or extinguishes the arc if the slope
down knob is set to minimum.
TIG2 slope down operation
With the slope down control set to anything but minimum and the torch switch is released the current
will gradually decrease from the setting set by the current control knob down to 5 Amp, were the arc will
extinguish, the time this takes is determined by the position of the slope down control knob.
The slope down procedure can be halted part way through by pressing the torch switch. This starts the slope
up process or if the slope up knob is set to minimum the current instantly rises to the set level set by the
current control knob.
3. Operation

15
VIPER 2500s
TIG4 mode
TIG4 = Latch mode.
NOTE! To be able to initiate a welding arc Gas must be present. If a post gas sequence is not still in operation
a pre gas stage will be initialised.
Basic operation of TIG4 mode (Slope up & slope down both set to minimum)
In TIG4 mode when the torch switch is pressed and released the arc ignites. To extinguish the arc you must
press and release the torch switch a second time.
Torch button (pressed and held on) = Pre gas
Torch button (released) = H.F. —> Arc initiated
Torch button (pressed and released 2nd time) = Arc extinguished.
TIG4 slope up operation
Torch button (pressed and held on) = Pre gas
Torch button (released) = H.F.—> Arc initiated
If the slope up control is set to anything but minimum the Viper will initiate an arc at 30 Amp and then
gradually increase the current up to the current setting set by the current control knob, the time this takes is
determined by the position of the slope up control knob. The slope up procedure can be halted part way by
pressing and then releasing the torch switch. This starts the slope down process or extinguishes the arc if the
slope down knob is set to minimum.
TIG4 slope down operation.
If the slope down control is set to anything but minimum and the torch switch is pressed and released the
current will gradually decrease from the setting on the current control knob down to 5 Amp, were the arc will
extinguish, the time this takes is determined by the position of the slope down control knob. The slope down
procedure can be halted or paused part way through by pressing the torch switch. If you press and hold the
torch switch down, the slope down procedure can be paused at the displayed current level. Releasing the
torch switch button then starts the slope up process or if the slope up knob is set to minimum
the current instantly rises to the set level set by the current control knob.
Torch button pressed and held on = stop the slope down operation at the present current displayed level and
pause at this level until the button is released.
Torch button released = start the slope up process.
9
Viper2500s
Viper 2500S manual addendum from 30/09/2011
TIG2 & TIG4 mode operation
TIG2 mode
Note: To be able to initiate a welding arc Gas must be present. If a post gas sequence is not still in operation a pre gas stage will be initialised.
Basic operation of TIG2 mode (Slope up & slope down both set to minimum)
With the slope up control set to minimum the Viper will strike at the current set by the current control knob.
With the slope down control set to minimum the Viper will extinguish the arc immediately the torch button is released.
Torch button (pressed and held on) = Pre gas —> H.F. —>Arc initiated
Torch button (released) = Arc extinguished.
TIG2 slope up operation.
With the slope up control set to anything but minimum the Viper will strike at 30 Amp and then gradually increase the current up to the current setting set by the
current control knob, the time this takes is determined by the position of the slope up control knob.
The slope up procedure can be halted part way through by releasing the torch switch. This starts the slope down process or extinguishes the arc if the slope down
knob is set to minimum.
TIG2 slope down operation.
With the slope down control set to anything but minimum and the torch switch is released the current will gradually decrease from the setting set by the current
control knob down to 5 Amp, were the arc will extinguish, the time this takes is determined by the position of the slope down control knob.
The slope down procedure can be halted part way through by pressing the torch switch. This starts the slope up process or if the slope up knob is set to minimum
the current instantly rises to the set level set by the current control knob.
TIG4 mode
TIG4 = Latch mode.
Note: To be able to initiate a welding arc Gas must be present. If a post gas sequence is not still in operation a pre gas stage will be initialised.
Basic operation of TIG4 mode (Slope up & slope down both set to minimum)
In TIG4 mode when the torch switch is pressed and released the arc ignites. To extinguish the arc you must press and release the torch switch a second time.
Torch button (pressed and held on) = Pre gas
Torch button (released) = H.F. —> Arc initiated
Torch button (pressed and released 2
nd
time) = Arc extinguished.
TIG4 slope up operation.
Torch button (pressed and held on) = Pre gas
Torch button (released) = H.F.—> Arc initiated
If the slope up control is set to anything but minimum the Viper will initiate an arc at 30 Amp and then gradually increase the current up to the current setting set
by the current control knob, the time this takes is determined by the position of the slope up control knob.
The slope up procedure can be halted part way by pressing and then releasing the torch switch. This starts the slope down process or extinguishes the arc if the
slope down knob is set to minimum.
TIG4 slope down operation.
If the slope down control is set to anything but minimum and the torch switch is pressed and released the current will gradually decrease from the setting on the
current control knob down to 5 Amp, were the arc will extinguish, the time this takes is determined by the position of the slope down control knob.
The slope down procedure can be halted or paused part way through by pressing the torch switch. If you press and hold the torch switch down, the slope down
procedure can be paused at the displayed current level. Releasing the torch switch button then starts the slope up process or if the slope up knob is set to minimum
the current instantly rises to the set level set by the current control knob.
Torch button pressed and held on = stop the slope down operation at the present current displayed level and pause at this level until the button is released.
Torch button released = start the slope up process.
SECTION 4 — OPERATION AND USE
Current knob set current level
Paused current level
Current knob set current level
Torch button
pressed and
released to start
the slope down
process
This line shows
the normal slope
down level down
to zero.
Torch button
pressed and held
down to pause the
slope down pro-
cedure
Torch button released
to start the slope up
process.

16 VIPER 2500s
Most problems with the Viper 2500S can be overcome by following the procedures below.
Power on Indicator.
Must be on for normal operation. Indicates whether or not the Viper is receiving power from the power
source. If off check that:
• The power source is switched on.
• The leads between the power source and the Viper are connected.
• That the on/off switch on the rear of the Viper is in the on position.
• If all above are satisfactory check the condition of the fuse in the rear panel fuse holder.
Warning Indicator
Must be off for normal operation. If on it indicates that the Viper is connected “reverse polarity” i.e. the
positive in connector is connected to the negative terminal of the power source and vice-versa, swap
the positions of the connectors at either the power source or the rear of the Viper. It is good practice to
mark one of the cables at both ends with red tape and to use this as the positive lead.
Thermal cut-out indicator
Must be off for normal operation. If on it indicates that the Viper has overheated and the power stages of
the Viper has been shut down, so you will have no output current.
In normal climate conditions (below 25°C) the Viper has a 100% duty cycle, so operation of the thermal
cut out is indicative that the inside of the machine is likely choked with dust and therefore not being
cooled properly. In Hot climates (above 25°C) It indicates that you are exceeding the duty cycle of the
Viper, leave switched on for a few minutes without use and the Viper will return to normal operation.
In this circumstance, do not switch the Viper off as this will stop the operation of the cooling fan and
greatly extend the cool down period. Frequent tripping of the thermal cut-out, especially at low
current settings indicates that the inside of the machine is choked with dust.
For information about cleaning the dust out of the Viper please refer to the the three monthly service
Any operating problems not covered above means the Viper must be checked by a trained Newarc
engineer.
4. Fault nding

17
VIPER 2500s
MMA
If problems with the Vipers operation while MMA welding are experienced, rst refer to the information
in the installation section and paragraphs in the operating section and the fault nding procedure
earlier in this section.
• Most problems with MMA welding are the result of not setting the correct welding parameters for the
welding rod being used. All welding rod packets have information on them in symbolic format, giving
suitable current range, polarity and type of weld (normally called ‘position’). If you are in doubt about
what these symbols mean, ask your welding rod supplier to explain them. Choose an initial current
setting towards the middle of the quoted range and if necessary practice on a piece of scrap the same
thickness as the job to be welded.
TIG
If problems with the Vipers operation while TIG welding are experienced rst refer to the information in
the installation section and the operating section.
Please note: If the Viper is damaged as a result of the power source not being turned up to
full, such damage will not be covered by the warranty
The common problems with TIG welding are poor or no striking, porosity and poor appearance of the
weld. If you are experiencing any problems with TIG welding follow the check list below, this will cure
most problems:
• If the Viper does not strike check the operation of the torch switch and the condition of the switch lead
and plug.
• If the Viper is suffering from poor striking, check that all power leads are connected properly, check that
there is sufficient gas ow and that the correct gas is being used, check that the earth clamp is making a
good connection to the work-piece.
• If there is porosity in the weld or the nal weld is of poor appearance, check that there is sufficient
gas ow and that the correct gas is being used, check the condition of the TIG torch, particularly the
gas hose. Make sure that the collet or gas lens in the torch head is not blocked in anyway. Check all
gas connections are tight and that there are no leaks, use a leak detecting spray on all connections if
necessary.
Any welding problems not covered above must be brought to the attention of a qualied Welding
Engineer, if the problem still persists have the Viper checked by a trained maintenance person.
4.1 Welding problems

18 VIPER 2500s
5. Maintenance
Note!
All Electric shocks are potentially fatal, switch off the machine and unplug from the
mains supply before carrying out any maintenance work.
It is very important that the Viper2500S is regularly maintained. The amount of use and the
working environment must be taken into account when scheduling the maintenance periods.
Careful use and regular preventative maintenance will prolong the life of the machine and
ensure trouble free operation.
Weekly
• Clean the exterior of the machine.
• Inspect the machines exterior for obvious signs of damage.
• Check the condition of the welding cable, earth clamp and welding output connectors for damage
and any sign of over-heating
• Check the condition of the mains cable and plug.
Three monthly
As per the weekly schedule, plus:
• Remove the lid from the machine and remove the build up of dust and debris from inside the machine
using, either, compressed air at low pressure or an industrial type vacuum cleaner.
• Remove the grill from the rear of the machine and remove the build up of dust and debris in it using
either, compressed air at low pressure or an industrial type vacuum cleaner.
• Make a thorough visual inspection of the interior of the machine, look particularly for pieces of welding
wire, or stubs of old welding rods that may have got through the cooling air intakes.
• Check the condition of the mains input connector, look for loose terminal block screws and make
sure the sheath of the mains cable is still clamped securely in the combined cable entry/clamp.
Make sure the earth wire is still securely fastened to the earth stud.
• Check the condition of the welding output connectors, look for any signs of discoloration. This could
be an indication of overheating and can be a cause of welding set failure.
Annually
As per the three monthly schedule, plus:
• The machines should be have its calibration checked, if necessary have the machine re-calibrated by
a Newarc trained technician.

19
VIPER 2500s
6. Warranty
Guarantee
Newarc Ltd warrants that its goods and services are guaranteed to meet the specic performance under
the stated conditions of use. Newarc cannot be held responsible for general wear and tear or for failure
occurring due to misuse or abuse arising out of circumstances outside the stated condi-tions of use.
The stated conditions of use are that considered normal industrial practice and are not exhaustive. Each
machine is identied with a unique serial number and accompanied with the guarantee. Newarc reserve
the right to a) Repair. b)Replace. c)Authorise the reasonable cost of repair or replacement at an approved
Newarc service agent. d)Credit for any purchased equip-ment (less reasonable depreciation for actual
use and condition) at its entire discretion. This in no way affects your rights as a consumer. The guarantee
is enclosed with each machine.

20 VIPER 2500s
7. Parts