Kemppi Minarc 120 AU User manual

Minarc 150, 151
150 VRD
120 AU, 150 AU
Operating manual • English
Käyttöohje • Suomi
Bruksanvisning • Svenska
Bruksanvisning • Norsk
Brugsanvisning • Dansk
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Manuel d’utilisation • Français
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OPERATING MANUAL
English
Minarc 150, 151 / © Kemppi Oy / 1117

EN
CONTENTS
1. PREFACE.................................................................................................................3
1.1 General..........................................................................................................................3
1.2 Product introduction ............................................................................................4
2. BEFORE YOU START USING THE UNIT ...............................4
2.1 Unpacking...................................................................................................................4
2.2 Placing the unit........................................................................................................4
2.3 Serial number............................................................................................................5
2.4 Main components...................................................................................................5
2.5 Distribution network.............................................................................................6
2.6 Connecting to power supply mains .............................................................6
2.7 Filler materials and equipment.......................................................................6
3. USE................................................................................................................................7
3.1 Welding processes..................................................................................................7
3.1.1 Manual Metal Arc welding (MMA) ...........................................................7
3.1.2 TIG welding......................................................................................................7
3.2 Operating functions ..............................................................................................8
3.3 Welding selections .................................................................................................9
3.3.1 Manual Metal Arc welding (MMA) ...........................................................9
3.3.2 DC TIG welding ...............................................................................................9
3.4 Welding selections ..............................................................................................10
3.4.1 Earthing..........................................................................................................10
3.4.2 Welding ..........................................................................................................10
3.5 Storing........................................................................................................................10
4. MAINTENANCE............................................................................................11
4.1 Daily maintenance...............................................................................................11
4.2 Troubleshooting...................................................................................................11
4.3 Disposal .....................................................................................................................12
5. ORDERING NUMBERS.........................................................................12
6. TECHNICAL DATA.....................................................................................13
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1. PREFACE
1.1 GENERAL
Congratulations on choosing the Minarc 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.
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1.2 PRODUCT INTRODUCTION
Kemppi Minarc is a manual metal arc welding machine, small in size, suitable
for industry, site and repair welding. The unit uses one phase connection
voltage and it is manufactured for two dierent mains voltages: 230 V (Minarc
150) and 110 V (Minarc 151).
Minarc 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 cables are supplied with the unit. They are equipped with suitable
connections for the unit electrode holder, earth clamps and connections.
Minarc 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.
MInarc 150VRD is equipped with so called Voltage Reduction Device (VRD)
function. VRD maintains open circuit voltage under 35 V.
Minarc 150AU and 120AU for mains voltages 240 V and with VRD function are
on market only for Australia and New Sealand.
2. BEFORE YOU START USING THE UNIT
2.1 UNPACKING
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.
2.2 PLACING THE UNIT
Place the unit on horizontal, solid and clean surface. Shield it from heavy rain and
scorching sun. Make sure that cooling air circulates freely.
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2.3 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.
2.4 MAIN COMPONENTS
Connect welding cable and earth cable to their connections on the power source.
Mains cable and wall plug are already installed. (Note! Minarc 151 (110 V) is
delivered without a plug).
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', (VRD: 'VRD safe ON').
6. Signal light for overheating
7. Electrode holder and welding cable
8. Earth cable and clamp
1
2 3
4
5
678
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2.5 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.
Minarc 150, 150 VDR, 120 AU, 150 AU
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.
Does not apply to model Minarc 151.
2.6 CONNECTING TO POWER SUPPLY MAINS
The unit has a mains cable and a wall plug (Note! Minarc 151 (110 V) is
delivered without a plug). You can nd fuse and cable sizes in the end of
these instructions in Technical data.
2.7 FILLER MATERIALS AND EQUIPMENT
See also 2.4 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 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.
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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 (MMA) the welding ller material is melted from the
electrode to the weld pool. Rate of welding current is selected on the basis of
electrode size used and 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.
3.1.2 TIG welding
In DC TIG welding, the arc between 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 2.4. Main components and 3.4. Welding selections.
1. Signal light, machine 'ON', (VRD: 'VRD safe 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!
Signal light VRD safe ON (1)
The machine is equipped with an OCV reduction circuit. The signal light is lit
when the circuit is activated and the unit is in working order.
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Welding process selector, MMA / TIG
Switch is used for selecting either MMA or TIG welding, depending on
welding target.
VRD: When you have switched the unit to TIG welding, VRD is constantly
active, thus reducing terminal voltage to 30 V. This facilitates arc cut-o when
you stop welding.
Regulating welding current
Welding current rate is regulated steplessly with an adjusting potentiometer.
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.
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 potentiometer.
3.3.2 DC TIG welding
Select welding parameters according to ller manufacturer’s
recommendations.
1. Connect TIG torch to - pole and earth cable to + pole
2. Select TIG welding with the switch .
3. Select suitable welding current by adjusting potentiometer.
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3.4 WELDING SELECTIONS
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 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 3.4. 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.
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.
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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 cables 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.
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.
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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.
5. ORDERING NUMBERS
Item Ordering number
Minarc150weldingmachine
(includesearth-andweldingcables) 6102150
Minarc150weldingmachine(Denmark)
(includesearth-andweldingcables) 6102150DK
Minarc151weldingmachine
(includesearth-andweldingcables) 6101151
Minarc120AUweldingmachine
(includesearth-andweldingcables) 6102120AU
Minarc150AUweldingmachine
(includesearth-andweldingcables) 6102150AU
Minarc150VRDweldingmachine
(includesearth-andweldingcables) 6102150VRD
Earthcableandclamp 6184015
Weldingcableandelectrodeholder 6184005
Carryingstrap 9592162
Optional:TIGtorchTTM15V,4m 6271432
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6. TECHNICAL DATA
Minarc 150, 150 VRD Minarc 151
Connection voltage 1 ~ phase 50/60 Hz 230 V ± 15 % 110 V ± 15 %
Rated power at max. current
35 % ED MMA 140A/7.5kVA 140A/7.5kVA
100 % ED MMA 100A/5.1kVA 100A/5.1kVA
35 % ED TIG 150A/5.0kVA 150A/5.0kVA
100 % ED TIG 110A/3.3kVA 110A/3.3kVA
Supply current
35 % ED I1max 27 A 59 A
100 % ED I1eff 16 A 39 A
Connection cable H07RN-F,3G2.5(2.5mm,3m) H07RN-F,3G6(6mm,2 m
Fuse (delayed) 16 A 32 A
Welding range
MMA 10A/20.5V–140A/25.6V 10A/20.5V–140A/25.6V
TIG 5A/10V–150A/16V 5A/10V–150A/16V
Welding current control stepless stepless
Open circuit voltage 85V,(VRD30V) 85 V
Idle power <10 W <10 W
Power factor at 100% ED 0,60 0,60
Efficiency at 100% ED 80 % 80 %
Stick electrodes ø1.5–3.25mm ø1.5–3.25mm
External dimensions LxWxH 320x123x265mm 320x123x265mm
Weight without connection cable 4.0kg 4.4kg
Weight with connection cable 4.6kg 5.2kg
Temperature class B(130°C) B(130°C)
Operating temperature range -20...+40°C -20...+40°C
Storage temperature range -40...+60°C -40...+60°C
Degree of protection IP23S IP23S
EMC class A A
Norms EN/IEC60974-1 EN/IEC60974-1
EN/IEC60974-10 EN/IEC60974-10
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Minarc 120AU Minarc 150AU
Connection voltage 1 ~ phase 50/60 Hz 240V+10%...-20% 240V+10%...-20%
Rated power at max. current
ED MMA 50%,110A/5.5kVA 35%,140A/7.5kVA
ED MMA 100%,80A/3.9kVA 100%,100A/5.1kVA
ED TIG 50%,120A/3.5kVA 35%,150A/5.0kVA
ED TIG 100%,80A/2.2kVA 100%,110A/3.3kVA
Supply current
35 % ED I1max 20 A 26 A
100 % ED I1eff 12 A 15 A
Connection cable H07RN-F,3G1.5(1.5mm,3m) H07RN-F,3G6(2.5mm,2 m
Fuse (delayed) 10 A 15 A
Welding range
MMA 10A/20.5V–110A/24.4V 10A/20.5V–140A/25.6V
TIG 5A/10V–120A/15V 5A/10V–150A/16V
Welding current control stepless stepless
Open circuit voltage 30V 30V
Idle power <30W <30W
Power factor 100% ED 0.60 0,60
Efficiency 100% ED 80 % 80 %
Stick electrodes Ø1.5–2.5mm Ø1.5–3.25mm
External dimensions LxWxH 320x123x265mm 320x123x265mm
Weight without connection cable 4.0kg 4.0kg
Weight with connection cable 4.6kg 4.6kg
Temperature class B(130°C) B(130°C)
Operating temperature range -20...+40°C -20...+40°C
Storage temperature range -40...+60°C -40...+60°C
Degree of protection IP23S IP23S
EMC class A A
Norms AS1674.2 AS1674.2
AS/NZS3652 AS/NZS3652
WTIATechnote22 WTIATechnote22
EN/IEC60974-1 EN/IEC60974-1
EN/IEC60974-10 EN/IEC60974-10
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KEMPPI OY
Hennalankatu39
PL13
FIN-15801LAHTI
FINLAND
Tel+358389911
Telefax+3583899428
[email protected]
www.kemppi.com
Kotimaan myynti:
Tel+358389911
Telefax+35837348398
myynti.@kemppi.com
KEMPPI SVERIGE AB
Box717
S-19427UPPLANDSVÄSBY
SVERIGE
Tel+46859078300
Telefax+46859082394
[e-mail]
KEMPPI NORGE A/S
Postboks2151,Postterminalen
N-3103TØNSBERG
NORGE
Tel+4733346000
Telefax+4733346010
[e-mail]
KEMPPI DANMARK A/S
Literbuen11
DK-2740SKOVLUNDE
DANMARK
Tel+4544941677
Telefax+4544941536
[e-mail]
KEMPPI BENELUX B.V.
Postbus5603
NL-4801EABREDA
NEDERLAND
Tel+31765717750
Telefax+31765716345
[e-mail]
KEMPPI (UK) Ltd
MarttiKemppiBuilding
FraserRoad
PrioryBusinessPark
BEDFORD,MK443WH
UNITEDKINGDOM
Tel+44(0)8456444201
Telefax+44(0)8456444202
[e-mail]
KEMPPI FRANCE S.A.S.
65AvenuedelaCouronnedesPrés
78681EPONECEDEX
FRANCE
Tel+33130900440
Telefax+33130900445
[e-mail]
KEMPPI GmbH
Otto-Hahn-Straße14
D-35510BUTZBACH
DEUTSCHLAND
Tel+49603388020
Telefax+49603372528
[e-mail]
KEMPPI SPÓŁKA Z O.O.
Ul.Borzymowska32
03-565WARSZAWA
POLAND
Tel+48227816162
Telefax+48227816505
info[email protected]
KEMPPI AUSTRALIA PTY LTD.
13CullenPlace
P.O.Box5256,GreystanesNSW2145
SMITHFIELDNSW2164
AUSTRALIA
Tel.+61296059500
Telefax+61296055999
info[email protected]
OOO KEMPPI
Polkovayastr.1,Building6
127018MOSCOW
RUSSIA
Tel+74957394304
Telefax+74957394305
info[email protected]
ООО КЕМППИ
ул.Полковая1,строение6
127018Москва
Tel+74957394304
Telefax+74957394305
info[email protected]
KEMPPI, TRADING (BEIJING) COMPANY,
LIMITED
Room420,3Zone,BuildingB,
No.12HongdaNorthStreet,
BeijingEconomicDevelopmentZone,
100176Beijing
CHINA
Tel[phone]6064
[phone]1282
Telefax[phone]5259
[e-mail]
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中国北京经济技术开发区宏达
北路12号
创新大厦B座三区420室
(100176)
电话：[phone]6064
[phone]1282
传真：[phone]5259
[e-mail]
KEMPPI INDIA PVT LTD
LAKSHMITOWERS
NewNo.2/770,
FirstMainRoad,
KAZURAGardens,
Neelangarai,
CHENNAI-600041
TAMILNADU
Tel[phone]1200
Telefax[phone]1234
[e-mail]
www.kemppi.com
1910150
1117