Kemppi HiArc S 140 User manual

Operating manual
Manual de instrucciones
Manuel d’utilisation
Manual de utilização
Инструкции по эксплуатации
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HiArc
S 140

© Kemppi Oy / 1418
OPERATING MANUAL
English

4Hiarc S 140
EN
4
CONTENTS
1. Preface .................................................................................... 5
1.1 General...................................................................................... 5
1.2 Product introduction................................................................ 5
2. Before starting..................................................................... 6
2.1 Main components .................................................................... 6
2.2 Distribution network................................................................ 7
2.3 Cable connections.................................................................... 7
2.4 Filler materials and equipment ............................................... 8
3. Use............................................................................................ 9
3.1 Welding processes.................................................................... 9
3.1.1 Manual Metal Arc welding (MMA).............................. 9
3.1.2 TIG welding .................................................................. 9
3.2 Operating functions...............................................................10
3.3 Welding selections .................................................................11
3.3.1 Manual Metal Arc welding (MMA)............................11
3.3.2 DC TIG welding ..........................................................11
3.4 Earthing and welding.............................................................11
3.4.1 Earthing......................................................................11
3.4.2 Welding ......................................................................11
3.5 Storing.....................................................................................12
4. Maintenance.......................................................................12
4.1 Daily maintenance .................................................................12
4.2 Troubleshooting.....................................................................13
4.3 Disposal...................................................................................13
5. Ordering numbers ...........................................................14
6. Technical data....................................................................14

5© Kemppi Oy / 1418
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1. PREFACE
1.1 General
Congratulations on choosing the HiArc 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 included with the package.
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 Product introduction
HiArc S 140 is a manual metal arc welding machine, small in size, suitable
for industry, site and repair welding. The unit uses one phase connection
voltage (230 V).
HiArc tolerates a great uctuation of input voltage and is thus suitable
for work on sites using generator as well as to be used with long power
cables. Inverter technology has been used when designing the unit. Power
regulation in power source is done with IGBT transistors. Welding and earth
return cables are supplied with the unit. They are equipped with suitable
connections for the unit electrode holder, earth clamps and connections.
HiArc can also be used for TIG welding. TIG arc is started by scratching.
Ordering numbers of additional equipment for TIG welding can be found in
chapter 5. Ordering numbers.

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2. BEFORE STARTING
The equipment is packed in durable packages, designed specially for them.
Nevertheless, always before using the equipment, make sure it was not damaged
during transportation. Also check that you have received what you ordered and
that there are instructions for it. NOTE! The packaging material of the products is
suitable for recycling.
Place the unit on horizontal, solid and clean surface. Shield it from heavy rain and
scorching sun. Make sure that cooling air circulates freely.
Serial number
Serial number of the unit is marked on the rating plate of the unit. The serial
number makes it possible to trace product manufacturing series. You might
need the serial number when placing spare parts orders or when planning
maintenance.
2.1 Main components
Connect welding cable and earth return cable to their connections on the power
source. Mains cable and wall plug are already installed.
Parts of the unit
1. Body of machine
2. Main power switch
3. Selector switch for welding process
4. Welding current regulator
5. Signal light, machine 'ON'
6. Signal light for overheating
7. Electrode holder and welding cable
8. Earth return cable and clamp
1
2 3
4
5
678

7© Kemppi Oy / 1418
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2.2 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.
HiArc S 140
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.
2.3 Cable connections
Connection to mains
The unit has a mains cable and a wall plug. You can nd fuse and cable sizes
in the end of these instructions in Technical data.
NOTE! Check the fuse size in Technical specications. The plug may
be installed only by electrical contractors and installers specialised in
performing 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.
The minimum power of a single-phase machine generator must be 3.5 kVA.
The recommended power is 7.0 kVA for using the machine at maximum
power.
Restrictions on generator type and power may apply in generator use. Fault-
free operation of a three-phase machine also requires a suciently high-
power generator. The power recommendation is more than 15 kVA.
Earth return cable
Connect the earth return 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.
Welding torch (TIG)
The welding torch is used to supply shielding gas and electrical arc energy
to the work piece. Connect the TIG torch to the negative pole. Open the gas
valve of the TTM 15V TIG torch. The arc is ignited by touching the work piece
lightly with the TIG electrode (scratch ignition).

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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.
Connect the TTM 15V TIG torch gas hose to the outlet of the regulator.
NOTE! Under no circumstances should you connect the hose directly to
the cylinder valve. Always use a regulator and ow meter for safe and
accurate operation.
1. Connect the hose to the reduced pressure side of the cylinder
regulator, or ow meter and tighten the connector.
2. Adjust the shielding gas ow rate with the ow regulation adjustment
screw. A suitable gas ow rate is 8–15 l/min
3. Close the cylinder valve after use.
2.4 Filler materials and equipment
See also 2.1 Main components. You can use all electrodes intended for
welding with DC. Suitable electrode sizes for the unit are listed in the end of
these instructions in Technical data.
1. Use welding specications given on electrode package.
2. Check that you have selected the correct welding process before
starting to weld.
3. Check that welding cable and earth return cable connections are tight.
If a connection is slack, it will result in voltage drop that will cause the
connection to heat.
4. Mount the electrode rmly in holder.

9© Kemppi Oy / 1418
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3. USE
NOTE! It is forbidden to weld in places where there is a danger of re or
explosion!
3.1 Welding processes
3.1.1 Manual Metal Arc welding (MMA)
In manual metal arc welding (MMA) the welding ller material is melted
from the electrode to the weld pool. The rate of the welding current is
selected based on the electrode size used and the welding position. Arc
forms between electrode tip and welding piece. The melting electrode
coating forms gas and slag, which protects the weld pool. Slag solidied
over the weld is removed after welding e.g. with a chipping hammer (use of
eye protection is strongly advised).
3.1.2 TIG welding
In DC TIG welding, the arc between the tungsten electrode and the welding
piece melts the welding piece, thus forming a weld pool. Arc and electrode
are shielded by an inert shielding gas (argon). If necessary, ller is used. Filler
wire is fed into the weld pool from the outside of the arc. The ller wire and
the welding current level are decided according to the base material type
and thickness, joint form and welding position.

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3.2 Operating functions
See also 2.1. Main components and 3.3. Welding selections.
1. Signal light, machine 'ON'
2. Welding process selecting switch
3. Welding current adjuster
4. Signal light for overheating
5. Suitable electrodes; reference values for welding current
1
3
2
4
5
Main switch and signal light
When you turn the main switch to position I, signal light is lit and the unit is
ready for welding. Signal light is always on, when the unit is connected to
the mains and the main switch is in position I.
NOTE! Always start and stop the machine from the main switch, never
use the plug as a switch!
Welding process selector, MMA / TIG
Switch is used for selecting either MMA or TIG welding, depending on
welding target.
Regulating welding current
Welding current rate is regulated steplessly by adjusting control knob.
Signal light for overheating
A yellow signal light of overheating is lit, when thermostat has tripped due
to the unit’s overheating. Fan will cool the unit and after the signal light goes
o, the unit is again ready for welding.

11© Kemppi Oy / 1418
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3.3 Welding selections
3.3.1 Manual Metal Arc welding (MMA)
Select welding parameters according to ller manufacturer’s
recommendations.
1. Select polarity (+ or -) of welding current cable and return current
cable according to ller.
2. Select MMA welding with the switch .
3. Select suitable welding current by adjusting control knob.
3.3.2 DC TIG welding
Select welding parameters according to ller manufacturer’s
recommendations.
1. Connect TIG torch to - pole and earth return cable to + pole
2. Select TIG welding with the switch .
3. Select suitable welding current by adjusting control knob.
3.4 Earthing and welding
NOTE! Welding fumes may be dangerous to your health, see that there
is ample ventilation during welding! Never look at the arc without face
shield made for arc welding! Protect yourself and your surroundings
from the arc and hot spatter!
3.4.1 Earthing
If possible, always x earth return cable clamp directly on the welding piece.
1. Clean connection surface of earth clamp from paint and rust.
2. Connect the clamp carefully so that contact surface is as large as
possible.
3. Finally check that the clamp sits tight.
3.4.2 Welding
See also 3.1. Welding processes and 3.3. Welding selections.
NOTE! It is recommended that you try welding and rate of welding
current rst on something else than the actual work piece.
You can start welding after having made the necessary selections. Arc is lit
by scratching the welding piece with electrode. Length of arc is regulated by
holding electrode tip at a suitable distance from welding piece. Suitable arc
length is usually about half the diameter of the electrode core wire. When
arc is lit move the electrode slowly forwards tilting it to appr. 10-15° pulling
angle. If necessary, adjust current value.

12 Hiarc S 140
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Shielding gas is used in DC TIG welding. Your dealer will give you advice on
choosing gas and equipment. Open the gas valve on the TTM 15V TIG torch.
When gas starts to ow, arc is lit by lightly scratching work piece with the tip
of the tungsten electrode. When arc is lit, its length is regulated by holding
the tip of the tungsten electrode at a suitable distance from the work piece.
Move the torch forwards from the starting point, usually in appr. 10-15°
pushing angle forwards. If necessary, regulate current rate. Stop welding by
lifting the torch o the welding piece and by closing the gas valve on the
torch.
NOTE! Always x the gas cylinder so that it stays steadily in upright
position either in specially made wall rack or cylinder trolley. Always
close the cylinder valve after having nished welding.
3.5 Storing
Store the unit in a clean and dry place. Shield it from rain, and in
temperatures exceeding +25° C from direct exposure to sun.
4. MAINTENANCE
NOTE! Be careful when handling electrical cables!
In maintaining the unit, take into consideration the rate of use and the
environment it is used in. When the unit is used properly and serviced
regularly, you will avoid unnecessary disturbances in use and production.
4.1 Daily maintenance
Perform the following maintenance daily:
• Clean electrode holder and TIG torch’s gas nozzle. Replace damaged or
worn parts.
• Check TIG torch’s electrode. Replace or sharpen, if necessary.
• Check tightness of welding and earth return cable connections.
• Check condition of mains and welding cables and replace damaged
cables.
• See that there is enough space in front of and back of the unit for
ventilation.

13© Kemppi Oy / 1418
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4.2 Troubleshooting
Problem Cause
The main switch indicator will
not light up
No electricity connected to the machine
• Checkthemainssupplyfuses.
• Checkthemainscableandplug.
Poor welding result Severalfactorsaecttheweldingquality.
• Checkthattheearthingclampisrmlyattached,thepoint
ofattachmentiscleanandthatthecableanditsconnectors
areintact.
• Checkthattheshieldinggasowsoutofthetorchtip.
• Checkthattheelectricvoltageisnotirregularortoolow/
high.
Overheating indicator lit Thedevicehasoverheated.
• Ensurethatcoolingairhasunrestrictedow.
• Ifthemachine’sdutycyclehasbeenexceeded,waitfor
indicatortoturno.
• Tooloworhighsupplyvoltage.
If the machine’s malfunction is not eliminated with these measures, contact
KEMPPI service.
4.3 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.

14 Hiarc S 140
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5. ORDERING NUMBERS
Item Ordering number
HiArc S 140 6302140
Earthreturncableandclamp 6184015
Weldingcableandelectrodeholder 6184005
Carryingstrap 9592162
Optional:TIGtorchTTM15V,4m 6271432

15© Kemppi Oy / 1418
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6. TECHNICAL DATA
HiArc S 140
Connection voltage 1~,50/60Hz 230V±15%
Rated power at max. current 35%EDMMA 140A/7.5kVA
100%EDMMA 100A/5.1kVA
35%EDTIG 150A/5.0kVA
100%EDTIG 110A/3.3kVA
Supply current 35%EDI1max 27 A
100%EDI1e 16 A
Connection cable H07RN-F 3G2.5(2.5mm,3m)
Fuse (delayed) 16 A
Welding range MMA 10A/20.5V–140A/25.6V
TIG 5A/10V–150A/16V
Welding current control stepless
Open circuit voltage 85V
Idle power < 10W
Power factor at 100% ED 0,60
Efficiency at 100% ED 80%
Stick electrodes ø1.5–3.25mm
External dimensions LxWxH 320x123x265mm
Weight without connection
cable
4.0kg
Weight with connection cable 4.6kg
Temperature class B(130°C)
Operating temperature range -20...+40°C
Storage temperature range -40...+60°C
Degree of protection IP23S
EMC class A
Standards IEC60974-1
IEC60974-10

1921810
1418
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