Kemppi 220 User manual

Minarc 220
Operating manual • English
Käyttöohje • Suomi
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OPERATING MANUAL
English
Minarc 220 / © Kemppi Oy / 1117

EN
CONTENTS
1. PREFACE.................................................................................................................3
1.1 General..........................................................................................................................3
1.2 Machine properties................................................................................................3
1.3 About welding..........................................................................................................3
2. MACHINE USE..................................................................................................4
2.1 Before commissioning the machine ............................................................4
2.2 General view of the machine ...........................................................................5
2.3 Distribution network.............................................................................................5
2.4 Cable connections..................................................................................................6
2.5 Welding power selection and electrodes..................................................6
2.6 Function controls and indicator lights........................................................8
2.6.1 Welding current regulation and remote control................................9
2.6.2 MMA welding settings.................................................................................9
2.6.3 TIG welding function....................................................................................9
2.6.4 The VRD feature..............................................................................................9
3. MAINTENANCE............................................................................................10
3.1 Daily maintenance...............................................................................................10
3.2 Disposal .....................................................................................................................10
4. ORDERING NUMBERS.........................................................................11
5. TROUBLESHOOTING............................................................................12
6. TECHNICAL DATA.....................................................................................12
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1. PREFACE
1.1 GENERAL
Congratulations on choosing the Minarc 220 equipment. Used correctly,
Kemppi 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 Kemppi product. The technical specications
of the equipment can be found at the end of the manual.
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 Kemppi products, contact Kemppi Oy, consult an
authorised Kemppi dealer, or visit the Kemppi web site at www.kemppi.com.
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 their instructions.
1.2 MACHINE PROPERTIES
The Minarc 220 is intended for use in a three-phase electric network. It is
designed to be a compact and ecient direct current MMA/TIG machine.
Extremely light in weight for its high 220 A output power, the machine is easy
to carry to the work place with either the inbuilt moulded carry handle or the
shoulder strap provided.
1.3 ABOUT WELDING
Minarc 220 provides high quality welding results time after time provided
the correct operational procedures are followed. Welding quality is not only
inuenced by the machine itself. Personal expertise, ancilliary equipment and
consumables also play an essential role, as does the correct, fused supply power.
Welding is carried out when an electric arc is established between the
welding electrode and work piece. Welding is not possible unless the
equipment is correctly set-up, including the earthing cable attached to the
work piece. This cable creates the welding circuit that allows the welding
current to ow. Please check the earthing clamp is on the work piece to be
welded, and that the area of the clamps contact is clean and free from paint.
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Minarc 220 / © Kemppi Oy / 1117

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MMA Welding
The MMA is a simple welding process. A coated MMA electrode is short
circuited to the work piece and the resulting electric arc creates a molten
pool into which the electrode wire melts. The coating around the electrode
burns to create a protective gaseous atmosphere and slag, which directly
protects the molten weld pool from atmospheric contamination. The slag
oats on the molten weld pool and solidies on the surface of the resulting
weld bead, protecting the cooling weld.
The electrode is moved slowly along the weld seam. The travel speed
is directly proportional to the size of the electrode and welding current
selected. The slag is nally removed with a chipping hammer to reveal the
weld (always use eye protection).
TIG Welding
In TIG welding, the welding arc is formed between a non-consumable
tungsten electrode and the work piece. The resulting high temperature arc
melts the work piece to form a molten pool, into which ller wire of a similar
alloy composition is slowly melted. The molten weld pool and ller wire are
protected from the harmful eects of atmospheric contamination by an inert
shielding gas that ows out from the TIG welding torch’s ceramic nozzle at a
rate of approximately 8–15 litres per minute. (Gas regulator, ow meter and
pure argon shielding gas are not provided in this package.)
2. MACHINE USE
2.1 BEFORE COMMISSIONING THE MACHINE
Minarc 220 is packed in sturdy, custom-made packaging. However, always
ensure that the equipment has not been damaged in transportation. Even so,
make sure that all in-transport damage is reported to the machine supplier.
Do not unpack the machine under these circumstances. In addition, before
commissioning, check that you have received all of the items you ordered
along with their operating instructions.
Transportation
The machine should be transported in an upright position.
Environment
The machine is suitable for both indoor and outdoor use. In outdoor use,
protect it from heavy rain and sunshine. Store the machine in a dry and clean
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Minarc 220 / © Kemppi Oy / 1117

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environment and protect it from sand and dust during use and storage.
The recommended operating temperature range is -20 to +40 degrees
centigrade. Site the machine so that it does not come into contact with hot
surfaces, sparks and welding spatter. Make sure the airow to and from the
machine is unrestricted.
2.2 GENERAL VIEW OF THE MACHINE
1.2.
3.
4.
1. MMA welding cable
2. Earthing cable and earthing clamp
3. Main switch
4. Mains cable
2.3 DISTRIBUTION NETWORK
All regular electrical devices without special circuits generate harmonic
currents into distribution network. High rates of harmonic current may cause
losses and disturbance to some equipment.
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Minarc 220:
This equipment complies with IEC 61000-3-12 provided that the short-circuit
power Ssc is greater than or equal to 1.6 MVA at the interface point between
the user's supply and the public supply network. It is the responsibility of
the installer or user of the equipment to ensure, by consultation with the
distribution network operator if necessary, that the equipment is connected
only to a supply with a short-circuit power Ssc greater than or equal to
1.6 MVA.
2.4 CABLE CONNECTIONS
Connection to mains
Minarc 220 is delivered with a ve-metre mains cable that does not have a plug.
NOTE! Check the fuse size in Technical specications. The plug may be installed
only by electrical contractors and installers authorised to perform such
operations.
If you use an extension power supply cord, its cross sectional area should
be at least as large as the supply voltage cable tted to the machine. The
maximum length for the extension cable is 50 m.
Restrictions on generator type and power may apply in generator use. Fault-
free operation of the machine requires a suciently high-power generator.
The power recommendation is more than 15 kVA.
Earthing cable
Connect the earthing cable to the negative pole in MMA welding, and to the
positive pole in TIG welding.
Before you start welding, clean the work piece surface and x the earth
return clamp to the work piece in order to create a closed and interference
free welding circuit.
Shielding gas
In TIG welding, shielding gas is used to prevent atmospheric contamination of
the molten weld pool and cooling weld. Normally, the shielding gas is argon
(Ar). Normally the gas ow rate is approximately 8–15 litres per minute, but this
can vary according to the welding current used and the size of gas nozzle.
2.5 WELDING POWER SELECTION AND ELECTRODES
MMA welding electrodes
In MMA welding, the welding electrodes must be connected to the correct
pole. Normally, the electrode holder is connected to the positive and the
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earthing cable to the negative connector.
It is also important to properly adjust the welding current so that the ller
material and coating will melt properly and the welding is ecient. The table
below presents the electrode sizes available with the Minarc 220 welding
machine and the corresponding welding current values.
MMA Electrodes and corresponding current settings range
Electrode
diameter
1.6 mm 2.0 mm 2.5 mm 3.25 mm 4.0 mm 5.0 mm
Fe-Rutile 30-60 A 40-80 A 50-110 A 80-150 A 120-210 A 170-220 A
Fe-Basic 30-55 A 50-80 A 80-110 A 110-150 A 140-200 A 200-220 A
TIG welding electrodes and gas nozzles
In DC TIG welding we recommend the use of the WC20 (grey) type electrode,
however other types are available.
The welding electrode size (diameter) is selected depending on the welding
current/power to be used. An electrode with an insucient diameter
compared to the welding current will melt, while excessive electrode size will
make it more dicult to ignite the arc.
Generally speaking, a 1.6 mm tungsten electrode will cover currents up to
150 A, and 2.4 mm tungsten electrode up to 250 A DC current.
Before use, grind the tungsten electrode to a sharp point at approximately
1.5 times the diameter of the electrode.
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2.6 FUNCTION CONTROLS AND INDICATOR LIGHTS
1. 2.
3. 4. 5.
6.
1. Standby indicator. In the VRD version, a VRD safe indicator
(see The VRD feature)
2. Overheating indicator.
3. Welding process selection button (MMA or TIG).
4. Current adjustment selector: panel adjustment or hand-held remote
control.
5. Welding current control knob.
6. Welding value table
Switching the machine on
When you power on the machine, the green standby indicator and the main
switch are lit.
If the machine overheats or the supply voltage is too high or too low, the
welding operation automatically switches o, and the yellow overheating
indicator is illuminated. The light switches o again, when the machine
is ready for operation. Make sure that there is enough space around the
machine to allow the air to freely circulate and ow into and out o the
machine.
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Minarc 220 / © Kemppi Oy / 1117