Kemppi HiArc T 180 User manual

Operating manual
Manual de instrucciones
Manuel d’utilisation
Manual de utilização
Инструкции по эксплуатации
EN
ES
FR
PT
HiArc
T 180
RU

© Kemppi Oy / 1410
OPERATING MANUAL
English

4Hiarc T 180
EN
4
CONTENTS
1. Introduction ......................................................................... 5
1.1 General...................................................................................... 5
1.2 About the product ................................................................... 5
2. Before starting..................................................................... 6
2.1 Main components .................................................................... 6
2.2 Distribution network................................................................ 7
2.3 Cable connections.................................................................... 7
2.4 Welding power selection and electrodes ............................... 9
3. Use..........................................................................................10
3.1 Welding processes..................................................................10
3.1.1 Manual Metal Arc welding (MMA) ............................10
3.1.2 TIG welding ................................................................10
3.2 Operating functions...............................................................11
3.3 Welding selections .................................................................12
3.3.1 Welding current regulation and remote control .....12
3.3.2 MMA welding settings ..............................................12
3.3.3 TIG welding function.................................................12
3.4 Setup features.........................................................................13
4. Error codes ..........................................................................14
5. Troubleshooting ...............................................................15
6. Maintenance.......................................................................16
6.1 Daily maintenance .................................................................16
6.2 Disposal...................................................................................16
7. Ordering numbers ...........................................................17
8. Technical data ...................................................................18

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1. INTRODUCTION
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.
Disclaimer
While every eort 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. Kemppi reserves 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
from Kemppi.
1.2 About the product
HiArc T 180 is a compact and robust direct current welding machine suitable
for MMA and TIG welding. Extremely light in weight for its output power, the
machine is easy to carry to the work place with either the inbuilt moulded
carry handle or the shoulder strap provided.
The T 180 model can be used in regular lighting circuits, i.e., in single-phase
electric networks.

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2. BEFORE STARTING
HiArch is packed in purpose made, recyclable 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 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.
2.1 Main components
1.2.
3.
5.
4.
1. Welding torch
2. Earth return cable and clamp
3. Main switch
4. Mains cable
5. Shielding gas hose connector

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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 T 180
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 machine is equipped with a 3.3 m supply voltage cable and plug. Plug
the mains cable to a single-phase electric network.
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 weld piece. When you press the welding torch switch, the shielding
gas begins to ow and the arc is established. The TIG torch is connected to
the negative pole.

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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.
The machine is delivered with a 4.5 m shielding gas hose. Connect the gas
hose snap connector to the male connector on the machine. The other end
of the gas supply hose should be connected 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.

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2.4 Welding power selection and electrodes
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.
In general, a 1.6 mm tungsten electrode will cover currents up to 150 A.
Before use, grind the tungsten electrode to a sharp point at approximately
1.5 times the diameter of the electrode. If the electrode touches the work
piece during welding, re-sharpen the electrode.
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
earth return 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 HiArc T 180 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
Fe-Rutile 30-60 A 40-80 A 50-110 A 80-140 A
Fe-Basic 30-55 A 50-80 A 80-110 A 110-140 A

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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
HiArc T 180 is a precise welding tool and will provide high quality results
time after time provided the correct operational procedures are followed.
Welding quality is not only inuenced by the machine itself. Personal
expertise, ancillary 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 earth return cable attached to
the work piece. This cable creates the welding circuit that allows the welding
current to ow. Please check that the earthing clamp is on the work piece
and that the contact area of the clamp is clean and free from paint and rust.
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.
(Gas regulator, ow meter and pure argon shielding gas are not provided in
this package.)

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3.2 Operating functions
HF
TIG
MMA
1.
2.
3.
4.
5. 6. 7.
8.
9.
10.
1. Standby indicator.
2. Pre/Post gas, upslope/downslope and main current parameter
indicator.
3. Welding parameter selector arrow keys.
4. Welding process selection button (MMA or TIG).
5. 2T or 4T TIG torch switch selection button. Select 2T for short welds or
4T for long welds.
6. Ignition method selection button.
7. Current adjustment selector: panel control, TIG Torch remote or foot
pedal remote.
8. Welding current and parameter value control knob.
9. Welding current and parameter value display: time and amperes.
10. Overheating indicator.
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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3.3 Welding selections
3.3.1 Welding current regulation and remote control
The welding current can be adjusted steplessly with the control knob, if
panel adjustment (PANEL) is selected.
If you want to adjust the welding current with the remote control, connect
the remote control to the machine and then select remote control with the
current adjustment selector (7). The following remote control options are
available: RTC10, RTC20, R10 and R11F. The remote foot pedal R11F can only
be used with TIG welding in 2T operation mode.
3.3.2 MMA welding settings
MMA welding is selected when the indicator next to the MMA symbol is lit.
If needed, press the process selection button to select the MMA process (4).
The machine automatically sets suitable values to the ignition time, ignition
pulse and arc dynamics.
3.3.3 TIG welding function
Select the TIG welding process by pressing the MMA/TIG button.
Torch switch control in 2T mode and HF arc ignition
The shielding gas starts to ow when the torch switch is pressed and the
welding arc is established automatically via HF ignition. The current starts to
rise (if an upslope time is established) to the set welding current level. When
you release the switch, the current starts to decrease. After the specied
downslope time, the arc is disconnected and the set post-gas time begins.
Torch switch control in 4T mode and HF arc ignition
The shielding gas starts to ow when the torch switch is pressed. When the
switch is released, the arc is automatically established via HF ignition. The
current starts to rise (if an upslope time is established) to the set welding
current level. When ready to end the welding cycle, press and release the
torch switch again. The welding current starts to drop (if a downslope time is
established) until the arc is extinguished and the set post-gas time begins.
HF or Contact ignition
The TIG arc can be established with or without an HF pulse.
If the HF indicator is not lit, the arc can be established by lightly contacting
the tungsten electrode to the work piece. Press the torch trigger and then
quickly lift the contact of the tungsten electrode from the work piece (2T
function); the arc is established simultaneously and eectively.
For HF ignition, press the HF button so that the indicator is on (item 6). Press
the TIG torch trigger and hold or release, depending on whether 2T or 4T is

13© Kemppi Oy / 1410
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selected. The shielding gas ows and the HF (High Frequency arc) ignites the
welding arc.
Setting parameters
Select the welding parameters with the arrow keys (3) and adjust the
parameter values with the control knob (8). When setting the parameters,
the indicators (2) will show the parameter being adjusted and the display (9)
will show the numeric value that will be set. After three seconds, the display
returns to normal state and shows the welding current value.
3.4 Setup features
Conguring additional features
The machine has additional features that can be selected and adjusted with
the SETUP feature. To activate and deactivate it, press both arrow buttons (3)
simultaneously for at least 5 seconds.
In the SETUP mode, the display will show the name of the parameter to be
adjusted and its numerical value. Select the parameter to be adjusted with
the arrow buttons and change the parameter value with the control knob.
The following parameters and values are available:
Name
displayed
Parameter
values
Factory
setting
Description
A 1/0 0 End current level selection, 1=I min / 0 =15%
b 1/0 1 Open-circuit voltage selection,
1 = 30V (VRD) / 0 = 95V
C 1/0 0 Forced stop during downslope
with a brief pressing of the switch,
1 = On / 0 = O
d 1/0 1 Alternative switch logic of the MLP panel,
1 = Minilog / 0 = 4T-LOG
E 5% … 40% 20% Start current level selection
(% of the welding current)
F 1/0 0 Restore factory settings *),
1 = Restore / 0 = No restore
h 0.0…2.0 s 0 Minimum setting for pre-gas time
J 0,0…10,0 s 1.0 s Minimum setting for post-gas time
L 5.0…20.0 s 10.0 s Maximum setting for pre-gas time
o 15…99 s 30 s Maximum setting for post-gas time
S -3…5 0 Arc dynamics (Arc Force)

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t -9…0 0 Electrode ignition pulse
(-9 = No pulse / 0 = Max pulse)
U 1/0 0 Disable automatic remote control recognition.
0 = Enable automatic recognition, 1 = Disable
automatic recognition.
*) Happens when exiting SETUP mode and value is 1.
Voltage reduction device (VRD)
HiArc T 180 contains a voltage reduction device (VRD), which reduces the
open-circuit voltage below 35 V. This reduces the risk of electric shock in
particularly dangerous environments, such as closed or damp spaces. VRD is
activated through the setup menu.
4. ERROR CODES
The machine always checks its operation automatically during start-up and
reports any failures detected. If failures are detected during start-up, they
are shown as error codes on the control panel display.
E 2: Power source undervoltage
The device has stopped because it has detected a mains undervoltage that
disturbs welding. Check the quality of the supply network.
E 3: Power source overvoltage
The machine has stopped the welding because it has detected momentary
voltage spikes or continuous overvoltage dangerous to the machine in the
electric network. Check the quality of the supply network.
E 4: Power source overheating
The power source has overheated. The cause may be one of the following:
• The power source has been used for a long time at maximum power.
• The circulation of cooling air to the power source is blocked.
• The cooling system has experienced a failure.
Remove any obstacle to air circulation, and wait until the power source fan
has cooled down the machine.
Other error codes:
The machine can show codes not listed here. In the event of an unlisted
code appearing, contact an authorised Kemppi service agent and report the
error code shown.

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5. 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 properly 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.
• The electric network voltage is irregular, too low or too
high.
Overheating indicator lit The device has overheated.
• Ensure that cooling air has unrestricted ow.
• 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.

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6. MAINTENANCE
All electromechanical devices require routine service maintenance
depending on usage. This type of routine maintenance will prevent hazards
and malfunctions.
We recommend that you schedule a service inspection of your welding
machine every six months. An authorised Kemppi service agent will inspect
and clean your machine, ensuring that all power connections are tight and
secure. Power connections can become loose and oxidised with frequent
and high changes in temperature.
NOTE! Disconnect the machine from the mains power supply before
handling electric cables.
6.1 Daily maintenance
• Check the welding torch electrode. Sharpen the electrode or replace a
damaged one.
• Check the tightness of the earth return cable connections.
• Check the condition of mains and welding cables and replace
damaged cables.
6.2 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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7. ORDERING NUMBERS
Product Part number
Power Sources
HiArcT 180, TTC 160 4 m P350
HiArcT 180, TTC 160 8 m P351
Cables
Welding cable, 16 mm² 5 m 6184103
Welding cable, 25 mm² 5 m 6184201
Welding cable, 25 mm² 10 m 6184202
Earth return cable, 16 mm² 5 m 6184113
Earth return cable, 25 mm² 5 m 6184211
Earth return cable, 25 mm² 10 m 6184212
Torches
TTC 160, 4 m 627016004
TTC 160, 8 m 627016008
TTC 220, 4 m 627022004
TTC 220, 8 m 627022008
Ancillary devices
TIG welding torch controls
RTC 10 6185477
RTC 20 6185478
Gas ow gauge AR/clock 6265136
Shielding gas hose (4.5 m) W001077
Carrying straps 9592162
Remote control units
R10 6185409
R11F 6185407

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8. TECHNICAL DATA
HiArc T 180
Connection voltage 1 ~, 50/60 Hz 230V ±15 %
Rated power at max. current TIG 6.7 kVA (180 A/17.2 V)
MMA 7.0 kVA (140 A/25.6V)
Supply current, I1max TIG 29 A (180 A/17.2V)
MMA 31 A (140 A/25.6 V)
Supply current, I1eff TIG 18 A (120 A/14.8V)
MMA 22 A (100 A/24.0 V)
Connection cable H07RN-F 3G2.5(3x2.5 mm²) - 3 m Euro
Schuko
Fuse (delayed) 16 A
Duty cycle 40 °C TIG 35 % ED 180 A/17.2V
100 % ED 120 A/14.8V
MMA 35 % ED 140 A/25.6 V
100 % ED 100 A/24V
Welding range TIG 5 A/10.2V–180 A/17.2V
MMA 10 A/20.4 V-140 A/25.6V
Open circuit voltage 95V (VRD 30V)
Idle power TIG –
MMA 25 W
Power factor at max. current TIG 0.62
MMA 0.63
Efficiency at max. current TIG 0.75
MMA 0.81
Striking voltage 10 kV
Stick electrodes MMA Ø 1.5-3.25 mm
External dimensions (L × W × H) 400 × 180 × 340
Weight 7.8 kg (8.4 kg with connection
cable)
Temperature class H (B)
Degree of protection IP23S

19© Kemppi Oy / 1410
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EMC class A
Operating temperature range -20 °C...+40 °C
Storage temperature range -40 °C...+60 °C
Recommended generator > 7 kVA
Standards IEC 60974-1
IEC 60974-3
IEC 60974-10

1921820
1410
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