Kemppi HiArc T 180 User manual

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

© Kemppi Oy / 1410
OPERATING MANUAL
English

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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.)