Kemppi Adaptive 170 User manual

MinarcMig Adaptive 170
Operating manual • English
Käyttöohje • Suomi
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Manuel d’utilisation • Français
Manual de instrucciones • Español
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操作手册 • 中文
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EN
OPERATING MANUAL
English
MinarcMig 170 / © Kemppi Oy / 1117

EN
CONTENTS
1. PREFACE.................................................................................................................3
1.1 General..........................................................................................................................3
1.2 Properties ...................................................................................................................3
2. MACHINE USE .................................................................................................4
2.1 Before implementation ......................................................................................4
2.2 General view of the machine ..........................................................................5
2.3 Distribution network.............................................................................................5
2.4 Cable connections .................................................................................................5
2.5 Filler wire .....................................................................................................................7
2.5.1 Changing the feed roll groove .................................................................7
2.5.2 Threading the ller wire .............................................................................8
2.5.3 Reversing polarity .........................................................................................9
2.6 Controls and indicator lights.........................................................................10
2.6.1 Welding power adjustment ...................................................................11
2.6.2 Arc length trimmer ....................................................................................11
2.7 Threading the shoulder strap .......................................................................12
3. SERVICE ..............................................................................................................12
3.1 Daily maintenance .............................................................................................13
3.2 Maintenance of the wire feed mechanism ...........................................13
4. DISPOSAL..........................................................................................................14
5. TROUBLESHOOTING............................................................................15
6. ORDERING NUMBERS.........................................................................16
7. TECHNICAL DATA.....................................................................................17
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1. PREFACE
1.1 GENERAL
Congratulations on choosing the MinarcMig Adaptive 170 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 PROPERTIES
The welding machine is small, ecient and extremely light. It is easy to
carry with the help of a shoulder strap. The machine is suitable for a range
of dierent purposes and the possibility to use a long extention cord eases
operation in various sites. It is also suitable for generator use on construction
sites.
Welding voltage and wire feed speed are adjusted with one control
according to the thickness of the welded sheet. Thus, selecting the right
parameters is easy. The length of the arc, or welding heat, is trimmed with
another control, and once the right value is found there usually is no need to
change it even when welding a thicker or thinner sheet.
The machine’s welding properties are optimum with a steel wire of
0.8 mm diameter. Also, 0.6 mm, 0.9 mm or 1.0 mm solid wire or cored wire
can be used as ller wire. Note, however, that the machine is designed for
steel wire welding only.
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2. MACHINE USE
The machine is delivered ready for operation without adjustments with
0.8 mm diameter ller wire.
If you use non-recommended ller wire, make sure that the feed roll groove,
welding gun contact tip and machine polarity are suited for the used wire
size and type.
2.1 BEFORE IMPLEMENTATION
The products are packed to durable packages especially designed for them.
However, always make sure before use that the products have not been
damaged during transportation. Check also, that you have received the
products you ordered and the instruction manuals needed. Product packing
material is recyclable.
Transportation
The machine should be transported in an upright position.
NOTE! Always move the welding machine by lifting it from the handle. Never pull
it from the welding gun or other cables.
Environment
The machine is suitable for both indoor and outdoor use, but it should be
protected from heavy rain and sunshine. Store the machine in a dry and clean
environment and protect it from sand and dust during use and storage. The
recommended operating temperature range is -20 °C – +40 °C.
Place the machine in such a way that it does not come in contact with hot
surfaces, sparks and spatters.
Make sure the air ow in the machine is unrestricted.
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2.2 GENERAL VIEW OF THE MACHINE
1. Welding gun
2. Earthing cable
3. Main switch
4. Supply voltage cable
5. Shielding gas hose connector
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.
MinarcMig Adaptive 170:
WARNING: This equipment does not comply with IEC 61000-3-12. If it is
connected to a public low voltage system, 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 may be
connected.
2.4 CABLE CONNECTIONS
Connection to the mains
The machine is equipped with a 3.3 m long supply voltage cable and plug.
Connect the supply voltage cable to the mains.
NOTE! The fuse size needed is 16 A delayed.
If you use an extension cord, its cross-sectional area should be at least as
large as the supply voltage cable’s (3 x 2.5 mm²). The maximum length for the
extension cord is 50 m.
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The machine can also be used with a generator. The minimum power for the
generator is 4.2 kVA, and the recommended power 8.0 kVA in order for the
machine to be used at maximum capacity.
Earthing
The earthing cable is already connected to the machine. Clean the workpiece
surface and x the earthing cable clamp to the piece in order to create a
closed and interference-free circuit needed for welding.
Welding gun
The welding gun is already connected to the machine. The welding gun
leads the ller wire, shielding gas and electric current to the weld. When you
press the welding gun trigger, shielding gas ow and wire feed begin. The arc
ignites, when the ller wire touches the welded piece.
The gun neck can be rotated 360°. When turning the neck, always make
sure that the neck is twisted almost all the way to the bottom. This prevents
damaging and overheating the neck.
NOTE! If you use other than 0.8 mm diameter ller wire, change the welding gun
contact tip to match the wire thickness.
Shielding gas
The shielding gas used for steel wires is carbon dioxide or a mixture of argon
and carbon dioxide which replaces air in the arc’s area. Thickness of the
welded sheet and welding power dene the ow rate of the shielding gas.
The machine is delivered with a 4.5 m long shielding gas hose. Connect the
bayonet socket of the shielding gas hose to the machine’s hose connector
and the hose connector end to the gas bottle’s control valve.
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1. Connect the hose to the gas bottle’s control valve and tighten the
connector.
2. Adjust the ow rate with the control valve screw. A suitable shielding gas
ow rate is 8 – 15 l/min.
3. Close the bottle’s valve after use.
NOTE! Use a shielding gas suitable for the material’s welding. Fix the gas bottle
securely in an upright position before installing the control valve.
2.5 FILLER WIRE
The machine is delivered with the welding gun connected to +pole making it
suitable for steel solid wire welding without adjustments.
2.5.1 Changing the feed roll groove
The feed roll groove is factory set for welding ller wires of 0.8 – 1.0 mm
diameter. The feed roll groove must be changed if you use 0.6 mm thick ller
wire.
1. Open the feed roll from the pressure control lever.
2. Switch the machine on from the main switch.
3. Press the welding gun trigger and drive the feed roll in such a position
that its locking screw is up and can be opened.
4. Switch the power o from the main switch.
5. Open the feed roll locking screw with a 2.0 mm Allen wrench
approximately half a turn.
6. Pull the feed roll from its shaft.
7. Turn the feed roll and reinstall it to its shaft all the way to the bottom
making sure that the screw is on the shaft’s level.
8. Tighten the feed roll locking screw.
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2.5.2 Threading the ller wire
1. Open the reel housing by pressing on the opening button and install
the wire reel in such a way that it rotates counter clockwise. You can
use either a 5 kg (diameter 200 mm) or 1 kg (100 mm) wire reel in the
machine.
2. Attach the reel with a reel lock.
3. Unfasten the wire end from the reel, but hold on to it all the time.
4. Straighten the wire end for approximately 20 cm and cut the wire in the
straightened location.
5. Open the pressure control lever which then opens the feed gear.
6. Thread the wire through the wire’s rear guide to the gun’s wire guide.
7. Close the feed gear and fasten it with the pressure control lever. Make
sure that the wire runs in the feed roll groove.
8. Adjust the compression pressure with the pressure control lever no
higher than to the middle of the scale. If the pressure is too high, it
removes metal fragments from the wire surface and may damage the
wire. On the other hand, if the pressure is too low, the feed gear slips and
the wire does not run smoothly.
9. Press the welding gun trigger and wait for the wire to come out.
10. Close the reel housing cover.
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NOTE! When driving the wire in to the gun, do not point the gun at yourself or
others or put, for example, your hand in front of the tip, because the cut wire end
is extremely sharp. Also, do not put your ngers near the feed rolls, because they
might get squeezed between the rolls.
2.5.3 Reversing polarity
Some ller wires are recommended to be welded with the gun in the –pole,
so the polarity should be reversed. Check the recommended polarity from
the ller wire package.
1. Disconnect the machine from the mains.
2. Bend the rubber cover of the earthing cable’s pole in such way that the
cable can be disconnected.
3. Remove poles’tightening nuts and washers. Note the correct order of
the washers!
4. Interchange the cables.
5. Install the washers in place and close the tightening nuts to spanner
tightness.
6. Put the rubber cover of the earthing cable’s pole rmly in place. The
rubber cover must always protect the earthing cable’s pole.
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2.6 CONTROLS AND INDICATOR LIGHTS
2
3
4
1
1. Welding power control
2. Arc length trimmer
3. Standby indicator light
4. Overheating indicator light
The welding power is adjusted according to the thickness of the welded
sheet. The machine also has a trimmer for arc length.
Indicator lights display the machine’s standby mode and inform of a possible
overheating.
When you switch the machine on, a green standby light switches on.
Simultaneously, the main switch indicator light switches on. If the machine
overheats or the supply voltage is too low or too high, the welding operation
automatically switches o and the yellow overheating indicator light
switches on. The light switches o when the machine is ready for operation
again. Make sure that there is enough space around the machine allowing air
to freely ow and cool the machine.
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2.6.1 Welding power adjustment
Adjusting the welding power according to sheet thickness aects
simultaneously both wire feed speed and amount of current lead to the wire.
This is a good starting point for welding in dierent operating situations.
However, connection type and root opening may inuence the amount of
welding power needed.
Select the correct parameter with the welding power control according
to the welded llet weld’s sheet thickness. If the llet weld’s sheets are of
dierent thickness, use their average as a default parameter.
Sheet thickness scale has been given in millimetres and it is based on 0.8 mm
wire diameter. When using a 0.6 mm wire, set the welding power control
slightly higher than the used sheet thickness and correspondingly slightly
lower with 0.9 – 1.0 mm wires.
NOTE! When welding for the rst time, we recommend that you set the arc length
trimmer to the middle position.
2.6.2 Arc length trimmer
The arc length trimmer adjusts the length of the arc shorter or longer and
aects the welding temperature. A shorter arc is colder and a longer one
hotter. The arc length trimmer also aects the arc’s welding properties and
spatters with dierent combinations of ller wire diameters and shielding
gases.
If the weld is too convex, the arc is too short or cold. Then adjust the arc
longer or hotter by turning the control clockwise.
If, on the other hand, you want to weld with a colder arc to prevent for
example the parent material from burning through, adjust the arc shorter by
turning the control counter clockwise. You can also adjust the welding power,
if need be.
Once the arc has been trimmed, it usually does not need to be changed
when the welded sheet thickness changes.
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2.7 THREADING THE SHOULDER STRAP
The machine is delivered with a shoulder strap which helps carrying the
machine. Thread the shoulder strap in place according to the picture.
NOTE! The machine should not be hung up from the shoulder strap.
3. SERVICE
When servicing the machine, its utilization degree and environmental
circumstances should be taken into account. If you use the machine
appropriately and service it regularly, you will spare yourself from
unnecessary malfunctions.
NOTE! Disconnect the machine from the mains before handling the electrical
cables.
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3.1 DAILY MAINTENANCE
• Remove welding spatters from the welding gun’s tip and check the
condition of the parts. Change damaged parts to new ones immediately.
Only use original Kemppi spare parts.
• Check that the insulating tips of the welding gun’s neck are undamaged
and in place. Change damaged insulation parts to new ones
immediately.
• Check the tightness of the welding gun’s and earthing cable’s
connections.
• Check the condition of the supply voltage and welding cable and
replace faulty cables.
3.2 MAINTENANCE OF THE WIRE FEED MECHANISM
Service the wire feed mechanism at least every time the reel is changed.
• Check the wear of the feed roll groove and change the feed roll when
necessary.
• Clean the welding gun wire guide with compressed air.
Parts of the welding gun and wire guide
Cleaning the wire guide
Pressure of the feed rolls remove metal dust from the ller wire’s surface
which then nds its way to the wire guide. If the wire guide is not cleaned, it
gradually clogs up and causes wire feed malfunctions. Clean the wire guide
in the following manner:
1. Remove the welding gun’s gas nozzle, contact tip and contact tip’s
adapter.
2. With a pneumatic pistol, blow compressed air through the wire guide.
3. Blow the wire feed mechanism and reel housing clean with compressed
air.
4. Reattach the welding gun’s parts. Tighten the contact tip and contact
tip’s adapter to spanner tightness.
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Changing the wire guide
If the wire guide is too worn or totally clogged, change it to a new one
according to the following instructions:
1. Disconnect the welding gun from the machine.
a. Disconnect the cable clamp of the gun’s power cable by opening the
screws.
b. Disconnect the gun’s power cable from the machine’s pole.
c. Disconnect the connector of the trigger conductors from the machine.
d. Open the gun’s mounting nut.
e. Extract the gun gently from the machine whereupon all parts come
through the front part’s cable hole.
2. Open the mounting nut of the wire guide which exposes the end of the
wire guide.
3. Straighten the welding gun’s cable and withdraw the wire guide from
the gun.
4. Push a new wire guide in to the gun. Make sure that the wire guide
enters all the way into the contact tip’s adapter and that there is an
o-ring at the machine-end of the guide.
5. Tighten the wire guide in place with the mounting nut.
6. Cut the wire guide 2 mm from the mounting nut and le the sharp
edges of the cut round.
7. Reattach the gun in place and tighten the parts to spanner tightness.
4. DISPOSAL
Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical
and electronic equipment, and its implementation in accordance with
national law, electrical equipment that has reached the end of its life must
be collected separately and taken to an appropriate environmentally
responsible recycling facility.
The owner of the equipment is obliged to deliver a decommissioned unit
to a regional collection centre, per the instructions of local authorities
or a Kemppi representative. By applying this European Directive you will
improve the environment and human health.
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5. TROUBLESHOOTING
Problem Cause
The wire does not move
or wire feed entangles
Feed rolls, wire conduit or contact tips are defective
• Check that feed rolls are not too tight or too loose
• Check that the feed roll groove is not too worn
• Check that the wire conduit is not blocked
• Check that there are no spatters on the conduit tip and that the hole is not
cramped or worn loose
Main switch indicator
light does not switch on
The machine has no supply voltage
• Check supply voltage fuses
• Check supply voltage cable and plug
Machine welds badly Welding outcome is inuenced by several factors
• Check wire feed is stable
• Check the trimming settings of welding power control and arc length
• Check that the earthing clamp is xed properly, xing point is clean, and
both cable and its connections are undamaged
• Check the ow of shielding gas from the tip of the welding gun
• Supply voltage is uneven, too low or too high
Over-heating indicator light
switches on
The machine has over-heated
• Check that cooling air can ow without obstructions
• Machine’s volume-capacity ratio has been exceeded; wait for the indicator
light to switch o
• The supply voltage is too low or too high
If the machine’s malfunction can not be corrected with these measures,
contact the Kemppi maintenance service.
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6. ORDERING NUMBERS
Product Ordering number
MinarcMig™ Adaptive 170
(including gun, cables, gas hose and shoulder strap)
6108170
Welding gun MMG20 (3 m) 6250200
Earthing cable and clamp (3 m) 6184003
Shielding gas hose (4.5 m) W001077
Shoulder strap 9592162
Consumables for wire feed mechanism
Feed roll 0.6 – 1.0 mm W000749
Feed roll 0.8 – 1.0 mm, knurled W001692
Pressure roll 9510112
Wire rear guide W000651
Parts for wire reel hub
Reel flange W000728
Spring W000980
Wire reel lock W000727
Consumables for MMG20 gun
Gas nozzle 9580101
Gas nozzle insulating bush 9591010
Contact tip M6 ø 0.6 mm 9876634
Contact tip M6 ø 0.8 mm 9876635
Contact tip M6 ø 0.9 mm 9876633
Contact tip M6 ø 1.0 mm 9876636
Contact tip adapter 9580173
Neck insulating ring 9591079
Wire guide 0.6–1.0 mm 4307650
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7. TECHNICAL DATA
MinarcMig™ Adaptive 170
Connection voltage 50/60 Hz 1 ~ 230V ±15%
Rated power 25% ED 8.0 kVA 170 A
60% ED 5.3 kVA 120 A
100% ED 4.2 kVA 100 A
Supply current, I1max 30 A
Supply current, I1eff 16 A
Connection cable HO7RN-F 3G2.5(3 m)
Fuse (delayed) 16 A
Load capacity 40 °C 25% ED 170 A/22.5V
60% ED 120 A/20.0V
100% ED 100 A/19.0V
Adjustment range 20 – 170 A/15 – 22.5V
Wire feed adjustment range 1 – 12 m/min
Open circuit voltage 22 – 33V
Power factor 100% ED 0.6 (170A/22.5V)
Efficiency 100% ED 80 % (150A/21.5V)
Filler wires Fe solid wire ø 0.6 – 1.0 mm
Fe cored wire ø 0.8 – 1.0 mm
Shielding gases CO₂, Ar+CO₂ -mixed gases
Wire spool (max. ø) 200 mm
Temperature class H (180 °C)/F (155 °C)
External dimensions LxWxH 400 x 180 x 340 mm
Weight
(incl. gun and cables 3,0 kg)
9.8 kg
Operating temperature range -20 °C...+40 °C
Storage temperature range -40 °C...+60 °C
EMC class A
Degree of protection IP23S
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KEMPPI OY
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KEMPPI (UK) Ltd
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UNITED KINGDOM
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KEMPPI GmbH
Otto-Hahn-Straße 14
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KEMPPI SPÓŁKA Z O.O.
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POLAND
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KEMPPI AUSTRALIA PTY LTD.
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P.O. Box 5256, Greystanes NSW 2145
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RUSSIA
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ООО КЕМППИ
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KEMPPI, TRADING (BEIJING) COMPANY,
LIMITED
Room 420, 3 Zone, Building B,
No.12 Hongda North Street,
Beijing Economic Development Zone,
100176 Beijing
CHINA
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肯倍贸易（北京）有限公司
中国北京经济技术开发区宏达
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(100176)
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KEMPPI INDIA PVT LTD
LAKSHMITOWERS
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