SweissTek Viper User manual

VIPER MC WELDING TORCH
Manual
The publisher does not assume and hereby disclaims any liabilities to any party for any loss or damage caused by any error or
omission in this manual, whether such error results from negligence, accident, or any other cause.

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SCOPE OF THIS MANUAL
This Instruction Manual provides set-up, operating instructions and basic maintenance
procedures for the Viper MC Plasma Welding Torches. Unqualified and / or untrained
personnel are severely cautioned against attempting repairs or adjustments not covered in
this Manual. Failure to heed these warnings may result in damage and possible personal injury.
A full understanding of the capabilities, functions and safety procedures associated with the
equipment described herein should assure the safe and reliable operation for which it is
designed. It is therefore essential that this Instruction Manual is read and understood
thoroughly.
CONTENTS
Page.
Health and Safety Information 2
Warnings and Precautions. 4
1.0 – Technical Specification 6
2.0 - Maintenance Procedure (Steps 1 – 10) 7
Appendix 1 – Viper Series Torch – Machine Torch 10

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Health and Safety Information
1. Before undertaking any maintenance and / or diagnostic procedures with the welding
torches described herein it is essential to have read and fully understood the appropriate
manuals supplied with the Plasma Welding system. Be especially aware of the warnings
and precautions outlined therein and ensure that appropriate steps are taken to follow the
safe practices recommended.
2. Never undertake maintenance on any plasma torch assembly unless the main disconnect
is in the OFF position and securely tagged to prevent accidental connection of the supply
during the maintenance process.
3. Do not reconnect the main disconnect unless all the welding torch consumables have
been inspected to assure their condition and that the parts are correctly fitted as outlined
in this manual.
4. Never attempt to start the pilot arc circuit of the machine unless the power source and
weld controller are fully operational and in particular that the plasma gas flow rate,
indicated on the flowmeter on the front panel of the power source or console indicates
that the gas flow is set to the appropriate flowrate. FAILURE TO COMPLY WITH THE
ABOVE CONDITIONS MAY SERIOUSLY DAMAGE OR DESTROY THE TORCH AND /
OR THE PILOT ARC POWER SUPPLY MODULE.
5. Never attempt to start the pilot arc or undertake welding operations without the welding
torch being securely fitted to its mounting bracket.

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THE OPERATION AND MAINTENANCE OF ANY PLASMA ARC EQUIPMENT INVOLVES
POTENTIAL HAZARDS.
PERSONNEL SHOULD BE ALERTED TO THE FOLLOWING HAZARDS AND PRECAUTIONS
TAKEN TO PREVENT POSSIBLE INJURY.
SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly installed, used and maintained. Misuse of this equipment and other
unsafe practices can be hazardous. The operator, supervisor and helper must read and understand the following safety warnings and instructions before
installing or using any welding or cutting equipment.
The welding /cutting process is used in many potentially dangerous environments such as elevated heights, areas of limited ventilation, close quarters,
around water, in hostile environments etc., and it is important that the operators are aware of the dangers associated in working in these types of
conditions. Be certain that the operator s) are trained in safe practices for environments in which they are expected to work and under competent
supervision.
It is essential that the operator, supervisor and others in the work place are aware of the dangers of the welding or cutting process. Training and proper
supervision are important for a safe work place. Keep these instructions for future use. Additional recommended safety and operating information is
referenced in each section.
ELECTRIC SHOCK CAN CAUSE INJURY AND DEATH.
Install and maintain equipment in accordance with the National Electric Code NFPA70 and local codes. Do not service or repair equipment with power on. Do
not operate equipment with protective insulators or covers removed. Service or repair to equipment must be done by qualified and/or trained personnel
only.
Do not contact electrically live parts. Do not touch electrode with bare skin and electrical ground at the same time. Always wear dry welding gloves in good
condition. Aluminized protective clothing can become part of the electrical path. Keep oxygen cylinders, chains, wire ropes, cranes, hoists and elevators
away from any part of the electrical path. All ground connections must be checked periodically to determine that they are mechanically strong and
electrically adequate for the required current.
When engaged in alternating current welding/cutting under wet conditions or warm surroundings where perspiration is a factor, the use of reliable
automatic controls for reducing no load voltage is recommended to reduce shock hazard. When the welding/cutting process requires values of open circuit
voltages in alternating current machines higher than 80 volts and direct current machines higher than 100 volts, means must be provided to prevent the
operator from making accidental contact with the high voltage by adequate insulation or other means.
When welding is to be suspended for any substantial period of time, such as during lunch or overnight, all electrodes should be removed from the electrode
holder and the holder carefully located so that accidental contact cannot occur. The holder must be disconnected from the power source when not in use.
Never immerse MIG-torchs, electrode holders, TIG torches, Plasma torches or electrodes in water.
See safety and operating references 1,2 and 7.
SMOKE, GASES AND FUMES CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.
Keep smoke, fumes and gases from the breathing area. Fumes from welding or cutting processes are of various types and strengths, depending on the kind
of base metal being worked on. To ensure safety, do not breathe these fumes. Ventilation must be adequate to remove smoke, fumes and gases during the
operation to protect operators and others in the area.
Vapours of chlorinated solvents can form the toxic gas "Phosgene" when exposed to ultraviolet radiation from an electric arc. All solvents, degreasers and
potential sources of these vapours must be removed from the operating area.
Fumes produced by welding or cutting particularly in confined places can cause discomfort and physical harm if inhaled over an extended period of time.
Provide adequate ventilation in the welding/cutting area. Use air-supplied respirators if ventilation is not adequate to remove all fumes and gases. Never
ventilate with oxygen, because oxygen supports and vigorously accelerates fire.
See safety and operating references 1,2,3, and 4.
ARC RAYS, HOT SLAG AND SPARKS CAN INJURE EYES AND BURN SKIN.
The welding/cutting processes produce extreme localised heat and strong ultraviolet rays, never attempt to weld/cut without the proper lens that complies
with federal guidelines. A number 11 to 14 shade filter provides the best protection against arc radiation. When in a confined area, prevent the reflective arc
rays from entering around the helmet.
READ
THESE
WARNINGS
WARNINGS
PROTECT
YOURSELF
AND OTHERS

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Make sure others are protected from arc rays and sparks. Approved shielding curtains and appropriate goggles should be used to provide protection to
others in the surrounding work area and operators of nearby equipment.
Skin should always be protected from rays, heat and molten metal. Always wear protective gloves and clothing which will not allow skin to become exposed.
All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings etc should be worn for out of position welding/cutting or for heavy
operations using large electrodes. High top work shoes provide adequate protection from foot burns. For added protection use leather spats. Flammable hair
preparations should not be used when welding/cutting. Wear ear-plugs to protect ears from sparks. Where the work permits the operator should be
enclosed in an individual booth painted with a finish of low reflectivity, such as zinc oxide, an important factor for absorbing ultraviolet radiation and lamp
black or shall be enclosed with non-combustible screens similarly painted.
See safety and operating references 1,2 and 3.
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS.
Causes of fire and explosion are: combustible materials reached by the arc, flame, flying sparks, hot slag or heated materials. Remove combustible materials
from the work area and/or provide a fire watch. Avoid oily or greasy clothing as a spark can ignite them. Have a fire extinguisher nearby and know how to
use it.
Be alert to danger from heat conduction or radiation, for example: if welding/cutting is to be done on a wall, partition, ceiling or roof precautions must be
taken to prevent ignition of combustible materials on the other side. Do not weld/cut containers that have held combustible substances. All hollow spaces,
cavities and containers should be vented prior to welding/cutting to permit escape of air/gases. Purging with inert gas is recommended.
NEVER USE OXYGEN IN ANY ARC WELDING TORCH. Use only inert gas mixtures as required by the process. Use of a combustible compressed gases cause
explosions resulting in personal injury or death. Arcing against any compressed gas cylinder can cause damage or explosion.
See safety and operating references 1,2,5,6 and 7.
SEE SAFETY AND OPERATING REFERENCES.
1. Code of Federal regulations OSHA)
Section 29 part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254, and 1000. U.S Government printing Office, Washington DC
20402.
2. ANSI Z49.1 "Safety in Welding & Cutting".
3. ANSI Z87.1 "Practice for Occupational and Educational Eye & Face Protection.
4. ANSI Z88.2 Standard Practice for Respiratory Protection.
5. AWS F4.1 "Recommended safe practices for Welding and Cutting Containers". The American Welding Society, 550 Lejeune Rd., P.O Box
351040, Miami PL 33135.
6. NFPA 51B "Fire prevention in Cutting and Welding Processes".
7 NFPA-7 "National Fire protection Association, Battery Park, Quincy MA 02269
8 CSA Standard W117.2 “Safety in Welding, Cutting and Allied Processes”
Canadian Standards Association, 178 Rexdale, Ontario, Canada M9W 1RE

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1.0 – Technical Specifications
Welding Current Rating:
DC – 100% Duty Cycle 300 Amps
AC – 100% Duty Cycle 300 Amps
Coolant Requirements
NOTE – Any interruption of cooling water flow can irreparably
damage the torch
Flow Rate 5 l/min
Maximum Coolant Temperature 45°C

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2.0 – Maintenance Procedure for Viper MC Plasma WeldingTorch
STEP 1 STEP 2
STEP 3 STEP 4
Set-up before maintenance.
Check parts for damage and for build
up of spatter material within torch
end. If replacement is needed follow
onto step two.
Note in this case the shield cup is
severely eroded and will need
replacement.
Using 15mm wrench loosen tip and
unscrew by hand.
Check for damage – burning of
material around orifice, build up of
spatter material, ovalling or erosion
of aperture. Replace if required.
The electrode can now be clearly
seen and inspected for wear.
In this instance the point of the
electrode is eroded. Excessive
“bluing” of the electrode indicates
possible plasma gas contamination
or incorrect shut down procedure for
the pilot arc.
Carefully remove shield cup – note
O-Ring located at lower end of screw
thread.
Check for damage – chips, cracks,
melting and replace if these are
evident. Check condition of ‘O’ ring
and replace if necessary.

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STEP 5 STEP 6
STEP 7 STEP 8
To remove the electrode slide
electrode tool over the electrode by
hand turning clockwise – use the end
marked “OUT”.
Rotate counterclockwise to unscrew
the electrode
The torch front end as stripped – the “o”-
ring can be seen in place as can the white
insulating insert. This insert should not be
removed – it cannot be removed without
damaging it, requiring replacement of the
part.
USING TORCH WITHOUT INSERT OR
WITH DAMAGED INSERT CAN CAUSE
IRREPAIRABLE DAMAGE TO THE
WELDING TORCH. INSPECT PART FOR
CHIPS, CRACKS OR SIGNS OF
EXCESSIVE SOOTING AND REPLACE
AS NEEDED
Insert new electrode into the end of
the electrode tool marked “IN”.
Firmly screw the electrode fully home
using hand force only. Do not
overtighten by using grips or a
wrench as this can damage the torch
head.
The new electrode is shown fitted
into the torch. As can be seen the o-
ring and insulating insert are fitted
and the electrode is accurately
centered with the torch body.
Ensure no debris is present on the
screw threads of the torch.

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STEP 9 STEP 10
IF COOLANT LEAKS ARE APPARENT THEIR SOURCE MUST BE DIAGNOSED AND
CORRECTIVE MEASURES TAKEN BEFORE ATTEMPTING TO USE THE WELD TORCH
ASSEMBLY. STARTING THE PILOT ARC OR WELDING PROCESS WITH ANY MOISTURE
PRESENT MAY DESTROY THE WELD TORCH HEAD AND MAY CAUSE SERIOUS
DAMAGE TO THE PLASMA ARC POWER SOURCE
Fit new tip into the end of the torch
by hand until tight. Firmly nip the tip
into place using a 15mm wrench –
do not use excessive force as this
can damage the torch.
Fit new shield cup by screwing on
firmly by hand only. Make sure that
the shield cup seats properly against
the o-ring to avoid shielding gas
leaks.
If sintered bronze gas lens has
separated from the shield cup refit
this with chamfer towards torch to
allow shield cup to locate properly.

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Appendix 1 – Viper Series Torch – Machine Torch
Item Part No Description Pack Size
1 061015-L Shield Cup including Gas Diffuser 10
3 220001 O Ring (Shield Cup to Body) 5
4 021101-3.0C Nozzle 3.0mm Special AM 5
5 022102-1.4C Electrode 1.4mm SB DC Special 10
6 025009 Ceramic Insulator 5
7 070010 Viper Machine Torch Head Only 1
NS T-991 Electrode Tool 1
NS 4-2525 Leadset – 12.5 ft 1
4-2544 Leadset – 25 ft 1