Kemppi MinarcMig 180 User manual

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MinarcMig™ 180
191017210
0640

MinarcMig™ Adaptive 180
© Kemppi Oy 0640 1
OPERATION INSTRUCTIONS
ENGLISH
EN

MinarcMig™ Adaptive 180
2 © Kemppi Oy 0640
CONTENTS
1. INTRODUCTION ..................................................................3
1.1. PROPERTIES .............................................................................3
1.2. ABOUT WELDING ......................................................................3
2. SAFETY INSTRUCTIONS ...................................................4
2.1. USE OF PROTECTIVE ACCESSORIES .................................... 4
2.2. SAFE USE OF THE WELDING GUN ..........................................4
2.3. FIRE SAFETY .............................................................................4
2.4. SUPPLY VOLTAGE ..................................................................... 5
2.5. WELDING CIRCUIT ....................................................................5
2.6. WELDING FUMES ......................................................................5
3. MACHINE USE ....................................................................6
3.1. BEFORE IMPLEMENTATION .....................................................6
3.2. GENERAL VIEW OF THE MACHINE ..........................................7
3.3. CABLE CONNECTIONS .............................................................7
3.4. FILLER WIRE ............................................................................10
3.4.1. Changing the feed roll groove ................................................10
3.4.2. Threading the ller wire .......................................................... 11
3.4.3. Reversing polarity ..................................................................12
3.5. CONTROLS AND INDICATOR LIGHTS ....................................13
3.5.1. Display in automatic mode .....................................................14
3.5.2. Welding power adjustment in automatic mode ....................... 15
3.5.3. Arc length trimmer in automatic mode ....................................15
3.5.4. Display in manual mode .........................................................16
3.5.5. Adjustments in manual mode .................................................17
3.6. THREADING THE SHOULDER STRAP .................................... 17
4. SERVICE ............................................................................18
4.1. DAILY MAINTENANCE ............................................................. 18
4.2. MAINTENANCE OF THE WIRE FEED MECHANISM ..............18
4.3. MACHINE DISPOSAL ...............................................................20
4.4. ORDERING NUMBERS.............................................................21
5. TROUBLESHOOTING........................................................22
6. TECHNICAL DATA .............................................................23
7. TERMS OF GUARANTEE .................................................24
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1. INTRODUCTION
MinarcMig™Adaptive 180 is an easy-to-use MIG welding machine suitable for
both hobby and professional use. Before using or doing any maintenance work
on the machine, read the operating manual and keep it for further reference.
1.1. PROPERTIES
The welding machine is small, efcient and extremely light. It is easy to carry
with the help of a shoulder strap. The machine is suitable for a range of different
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.
The machine has both an automatic and manul mode. In the automatic mode,
you must rst select the ller wire material after which the welding voltage and
wire feed speed can be adjusted with one control according to the thickness
of the welded sheet. Thus, selecting the right parameters is easy. In automatic
mode, the length of the arc, or welding heat, is trimmed with another control. In
manual mode, the welding voltage and wire feed speed are adjusted separately
with their own controls. The use of the machine is aided with a display which
also displays the welding current, welding voltage and wire feed speed.
You can also use steel wire (solid or cored wire), stainless steel wire or
aluminium wire as ller wire in the machine. The steel wire can be 0.6 mm,
0.8 mm or 1.0 mm thick, but the machine’s welding properties are optimum
with a steel wire of 0.8 mm diameter. The stainless steel wire can be 0.8 mm,
0.9 mm or 1.0 mm in diameter and the aluminium wire 1.0 mm.
1.2. ABOUT WELDING
In addition to the welding machine, welding outcome is inuenced by the piece
being welded and the welding environment. Therefore, recommendations in
this manual must be followed.
During welding electric current is led with the welding gun’s current nozzle
to the ller wire and via that to the welded piece. Earthing cable attached to
the workpiece guides the current back to the machine, forming the needed
closed circuit. Unrestricted current ow is possible when the earthing clamp
is properly attached to the workpiece and the xing point of the clamp on the
workpiece is clean, paintless and rustfree.
Shielding gas must be used during welding in order to prevent air from mixing
with the weld pool. Pure carbon dioxide or a mixture of argon and carbon
dioxide is suitable for steel wire shielding gas. Argon + 2 % CO² mixture is
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suitable for stainless steel wires. Argon is suitable for welding aluminium
wires. Some ller wires form a shielding gas from the wire’s lling as it melts
thus eliminating the need for a separate shielding gas.
2. SAFETY INSTRUCTIONS
The machine is safe to use due to its plastic cover, which does not conduct
electricity. The welding gun has an overheating protector which prevents
operation when the machine is overheated. The machine is also protected from
too low or too high supply voltage.
However, there are some risk factors connected to welding. You should
therefore read and follow the following safety instructions carefully.
2.1. USE OF PROTECTIVE ACCESSORIES
The arc and its reecting radiation damage unprotected eyes. Always protect
your eyes and face with an appropriate welding mask. The arc and welding
spatters burn unprotected skin. When welding, always use protective gloves
and clothing.
2.2. SAFE USE OF THE WELDING GUN
Parts of the machine, such as the end of the ller wire and welding gun, become
burning hot during use. The wire is also sharp and moves quickly, so be careful
when threading it to place.
Never carry the machine on your shoulder during welding, but place it on an
even surface. Also, do not store the machine by hanging it from the shoulder
strap. The shoulder strap is for carrying only.
Do not keep the machine near or on hot objects, as the plastic cover may
melt.
Do not move the shielding gas bottle when the control valve is in place. Fix the
gas bottle securely in an upright position to a separate wall rack or bottle cart.
Always close the gas bottle after use.
2.3. FIRE SAFETY
Welding is always classied as hot work, so pay attention to re safety
regulations. Protect the environment from welding spatters. Remove
inammable material, such as burning uids, from the vicinity of the welding
site and supply the site with adequate re-ghting equipment.
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Take into account dangers caused by special workplaces, such as re risk and
danger of explosion, when welding container-like pieces.
NOTE! Fire caused by sparks may brake out even after several hours!
CAUTION! Welding in inammable and explosive sites is strictly
forbidden!
2.4. SUPPLY VOLTAGE
• Do not take the welding machine inside a workpiece, for example in to a
container or a car.
• Do not place the welding machine on a wet surface.
• Change faulty cables immediately for they are life-threatening and may
cause a re.
• Ensure that cables are not squeezed or in contact with sharp edges or a hot
workpiece.
2.5. WELDING CIRCUIT
• Insulate yourself from the welding circuit by using dry and undamaged
protective clothing.
• Do not work on a wet surface.
• Do not use damaged welding cables.
• Do not place the welding gun or earthing clamp on the welding machine or
other electrical device.
2.6. WELDING FUMES
Make sure ventilation is sufcient. Take special precautions when welding
metals containing lead, cadmium, zinc, mercury or beryllium.
Supply of sufcient clean air can also be ensured with the use of a fresh air
mask.
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3. MACHINE USE
The machine is delivered ready for operation without adjustments with 0.8 mm
diameter ller wire.
If you use different thickness 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. If you mainly use aluminium or stainless steel wire, we recommend
you change the wire guide to a plastic one which is better suited for the wire
type.
3.1. 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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3.2. GENERAL VIEW OF THE MACHINE
Figure 3.1. General view
1. Welding gun
2. Earthing cable
3. Main switch
4. Supply voltage cable
5. Shielding gas hose connector
3.3. 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.
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.
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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 factory-installed wire guide in the welding gun is best suited for steel
wire welding. However, it can temporarily be used for stainless steel wire
and aluminium wire welding. Then, however, friction is greater and thus the
wire feed may tangle. If you mainly use stainless steel or aluminium wire, we
recommend you change the wire guide to a plastic wire guide.
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. Shielding gas for
stainless steel wires is a mixture of argon and carbon dioxide (2%) and argon
for aluminium wires. 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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Figure 3.2. Connecting the gas hose to a typical control valve
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.
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3.4. FILLER WIRE
The machine is delivered with the welding gun connected to +pole making it
suitable for steel solid wire, stainless steel wire and aluminium wire welding
without adjustments.
3.4.1. 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.
Figure 3.3. Changing the feed roll groove
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 off 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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3.4.2. Threading the ller wire
Figure 3.4. 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.
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9. Press the welding gun trigger and wait for the wire to come out.
10.Close the reel housing cover.
CAUTION! 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.
3.4.3. 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.
Figure 3.4. Reversing polarity
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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3.5. CONTROLS AND INDICATOR LIGHTS
Figure 3.6. Machine's front panel in automatic mode
1. Welding power control (automatic mode) OR Wire feed speed control
(manual mode)
2. Arc length trimmer (automatic mode) OR Welding voltage control
(manual mode)
3. Standby indicator light
4. Overheating indicator light
5. Mode selection button
6. Material selection button (automatic mode)
7. Display
In automatic mode, the welding power is adjusted according to the thickness of
the welded sheet. The machine also has a trimmer for arc length in automatic
mode . There are three material options for ller wires and you can browse
through them with the material selection button.
In manual mode, the wire feed speed and welding voltage are adjusted
separately. Modes can be changed with the mode selection button. Note that
material or sheet thickness selections made in the automatic mode are not valid
in manual mode or manual mode’s selections in automatic mode.
Indicator lights display the machine’s standby mode and inform of a possible
overheating.
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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 off and the yellow overheating indicator light switches
on. The light switches off 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.
3.5.1. Display in automatic mode
Figure 3.7. Machine display in automatic mode
1. Sheet thickness
2. Chart for sheet thickness and arc length trimmer
3. Operating mode
4. Material
5. Shielding gas and wire diameter recommendation
6. Wire feed speed chart
7. Welding values: wire feed speed, welding voltage and welding current
Sheet thickness displays the selected welding power setting which is based on
the llet weld’s sheet thickness in millimetres. When you adjust the welding
power according to sheet thickness, the sheet thickness in the chart changes
thinner or thicker correspondingly.
The selected operating mode and material are shown on the display. The display
also shows a recommendation as to what shielding gas and wire diameter
should be used with the material in question.
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During welding, the wire feed speed chart displays the wire’s speed.
Of all the welding parameters, only ller wire feed speed is visible on the
display all the time. Welding voltage and welding current are visible on the
display during welding. The last used values remain on the display until
welding is restarted or settings are changed.
When adjusting the arc length, the voltage display shows a comparative scale
(-9…0…9) which will disappear from the display after some time once the
adjustment is made.
3.5.2. Welding power adjustment in automatic mode
Adjusting the welding power according to sheet thickness affects simultaneously
both wire feed speed and amount of current lead to the wire. This is a good
starting point for welding in different 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 different
thickness, use their average as a default parameter.
Sheet thickness display has been given in millimetres and it is based on , with
steel and stainless steel wires, 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. With aluminium
wires, the welding power adjustment is based on 1.0 mm wire diameter.
NOTE! When welding for the rst time, we recommend that you set the arc
length trimmer to 0.
3.5.3. Arc length trimmer in automatic mode
The arc length trimmer adjusts the length of the arc shorter or longer and affects
the welding temperature. A shorter arc is colder and a longer one hotter. The
arc length trimmer also affects the arc’s welding properties and spatters with
different combinations of ller wire diameters and shielding gases. The trimmer
range is -9...0...9: negative values shorten and positive values lenghten the arc.
The trimmer is preset at 0 which is, in most cases, a suitable basic setting.
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.
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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.
When adjusting the arc length, the weld on the arc trimmer chart on the display
correspondingly changes more concave or convex.
Once the arc has been trimmed, it usually does not need to be changed when
the welded sheet thickness changes.
3.5.4. Display in manual mode
Figure 3.8. Machine display in manual mode
1. Operating mode
2. Wire feed speed chart
3. Welding values: wire feed speed, welding voltage and welding current
The selected operating mode is visible on the display. During welding, the wire
feed speed chart displays the wire’s speed.
Wire feed speed is the only welding parameter always visible on the display.
When adjusting welding voltage, the display shows the set value for the
voltage, and only during welding does the display show the actual value.
Welding current is visible on the display only during welding.
Values for actual welding voltage and welding current remain on the display
after welding until welding is restarted or settings are changed.
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3.5.5. Adjustments in manual mode
In manual mode, the wire feed speed and welding voltage are both adjusted
separately. Welding current and power are dened according to wire feed
speed. The desired arc and welding properties can be reached by adjusting the
voltage.
3.6. THREADING THE SHOULDER STRAP
Figure 3.9. Threading the shoulder strap in place
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.
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4. 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.
CAUTION! Disconnect the machine from the mains before handling the
electrical cables.
4.1. 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.
4.2. MAINTENANCE OF THE WIRE FEED MECHANISM
Figure 4.1. Parts of the welding gun and wire guide
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.
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