Kemppi Minarc 110 User manual

Operation instructions  english

Gebrauchsanweisung  deutsch

Gebruiksaanwijzing  nederlands

Manuel dutilisation  français

1910010E

0244

©COPYRIGHT KEMPPI OY

2 – Minarc/0244

CONTENTS

1. INTRODUCTION .............................................................................3

1.1. For the reader ...........................................................................3

1.2. Product presentation ................................................................3

1.3. Safety precautions ...................................................................3

2. BEFORE YOU START USING THE UNIT ....................................... 4

2.1. Unpacking ................................................................................ 4

2.2. Placing the unit ......................................................................... 4

2.3. Serial number ...........................................................................4

2.4. Main components of the unit ..................................................... 5

2.5. Connecting to power supply mains .......................................... 5

2.6. Filler materials and equipment ................................................ 5

3. USE .................................................................................................. 6

3.1. Welding processes ...................................................................6

3.1.1. Manual Metal arc welding ..................................................... 6

3.1.2. TIG welding ........................................................................... 6

3.2. Operating functions .................................................................. 6

3.3. Welding selections .................................................................... 6

3.3.1. Manual Metal arc welding (MMA) .......................................... 6

3.3.2. TIG welding ........................................................................... 7

3.4. Welding selections .................................................................. 7

3.4.1. Earth ...................................................................................... 7

3.4.2. Welding ................................................................................. 7

3.5. Storing ..................................................................................... 7

4. MAINTENANCE ............................................................................... 7

4.1. Daily maintenance .................................................................... 8

4.2. Ordering numbers ................................................................... 8

4.3. Troubleshooting ....................................................................... 8

5. TECHNICAL INFORMATION / GUARANTEE CLAUSES ................ 9

5.1. Technical information ............................................................... 9

5.2. Guarantee clauses .................................................................. 10

©COPYRIGHT KEMPPI OY

Minarc/0244 – 3

1. INTRODUCTION

1.1. FOR THE READER

Congratulations on having purchased a KEMPPI product. Properly installed and used

KEMPPI products should prove to be productive machines requiring only a small

amount of regular maintenance.

This manual is arranged to give you a good understanding of the equipment and its safe

use. There is also information on both servicing the unit and its technical information

in the end of the booklet. Read the instructions before taking the machine into use or

servicing it for the ﬁrst time. Additional information on Kemppi products and their use

can be obtained from Kemppi or a Kemppi dealer.

Kemppi reserves the right to make changes in technical data, printed on these instruc-

tions.

In this document, where ever there exists a danger to life or injury the following symbol

is used:

Read the warnings carefully and follow the instructions. Please also study the operation

safety instructions and respect them when installing, operating and servicing the

machine.

1.2. PRODUCT PRESENTATION

Kemppi Minarc is a manual metal arc welding machine, small in size, suitable for

industry, site and repair welding. The unit uses a one phase connection voltage and it is

manufactured in two different welding power sizes 110 A and 140 A.

Minarc tolerates a great ﬂuctuation of input voltage and there-fore 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 4.2. Ordering

numbers.

1.3. SAFETY PRECAUTIONS

Read the warning texts carefully and follow the instructions.

Arc and welding spatter

Arc and the reﬂected radiation from it can damage unprotected eyes. Shield your eyes

and protect your surroundings appropriately, before you start welding. Arc and welding

spatter will burn unprotected skin. When welding – use protective gloves and clothing.

Danger of ﬁre and explosion

Observe the ﬁre safety instructions. Remove ﬂammable material near the place where

you will weld. Have necessary ﬁre extinguishing equipment at hand when you weld.

Note dangers caused by special jobs, such as risk of ﬁre and explosion when welding

tanks. Note! Sparks may ignite ﬁre even hours later!

Welding is working with ﬁre, note special instructions for such work.

©COPYRIGHT KEMPPI OY

4 – Minarc/0244

Mains voltage

Never take welding machine inside the piece you are working on (e.g. container or car).

Never set the welding machine on wet surface. Replace faulty cables immediately, they

create a danger to life and can cause a ﬁre. See that the connecting cable does not stick

nor touch sharp edges or a hot welding piece.

Welding current circuit

Isolate yourself from the welding current circuit by wearing dry and undamaged protec-

tive clothing. Never work on a wet surface. Never use damaged welding cables. Never

set electrode holder, earth clamp nor the welding cables on top of the power source or

other electric equipment.

Welding fumes

Ensure adequate ventilation. Always take special measures when welding metals con-

taining lead, cadmium, zinc, mercury or beryllium.

2. BEFORE YOU START USING THE UNIT

2.1. UNPACKING

The equipment is packed in durable, specially for them designed packages. Neverthe-

less, always before using the equipment to use, make certain 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 level, solid and clean surface. Shield it from heavy rain and scorching

sun. Make certain cooling air circulates freely.

2.3. SERIAL NUMBER

Serial number of the unit is marked on the name plate on the unit. The serial number

makes it possible to trace product manufacturing series. You might need the serial

number placing spare parts orders or when planning maintenance .

©COPYRIGHT KEMPPI OY

Minarc/0244 – 5

2.4. MAIN COMPONENTS OF THE UNIT

Connect welding cable and earth cable to their connections on the power source. Mains

cable and wall plug are already installed.

Parts of the unit

A Body of machine

B Main power switch and signal light

C Selector switch for welding

process

D Welding current regulator

E Signal light for overheating

F Electrode holder and welding

cable

G Earth cable and clamp

H Mains cable

2.5. CONNECTING TO POWER SUPPLY MAINS

The unit has a mains cable and a wall plug. You can ﬁnd fuse and cable sizes in the end

of these instructions on Technical information table.

2.6. FILLER MATERIALS AND EQUIPMENT

See also 2.4. Main components of the unit. 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 chapter Technical information.

1. Use welding speciﬁcations 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 connec-

tion is slack, it will result in voltage drop, that will cause the connection

to heat.

4. Mount the electrode ﬁrmly in holder.

©COPYRIGHT KEMPPI OY

6 – Minarc/0244

3. USE

It is forbidden to weld in places where is a danger of ﬁre or explosion!

3.1. WELDING PROCESSES

3.1.1. Manual Metal arc welding (MMA)

In manual metal arc (MMA) the welding ﬁller material is melted from the electrode to

the weld pool. Filler and rate of welding current is selected on basis of used electrode

size and welding position. Arc forms between electrode end and welding piece. The

melting electrode coating forms gas and slag, that protects the weld pool. Slag solidiﬁed

over the weld is removed after welding with e.g. a chipping hammer.

3.1.2. TIG welding

In DC TIG welding the arc between a non-melting tungsten electrode and the welding

piece melts the welding piece, where weld pool forms. Arc and electrode are shielded by

an inert shielding gas (Argon). If necessary, ﬁller is used. Filler wire is fed into the weld

pool from the outside of the arc. Filler and rate of welding current is selected on the

basis of diameter of tungsten electrode and welding position in use.

3.2. OPERATING FUNCTIONS

See also 2.4. Main components and 3.4. Welding selections.

A Main switch and signal light

B Welding process selecting switch

C Welding current adjuster

D Signal light on overheating

Main switch and signal light

When you put the main switch in 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 steplessly regulated with an adjusting potentiometer.

Signal light for overheating

A yellow signal light of overheating is lit, when thermostat has tripped because of the

unit’s overheating. Fan will cool the unit and after the signal light goes off, the unit is

again ready for welding.

3.3. WELDING SELECTIONS

3.3.1. Manual Metal arc welding (MMA)

Select welding parameters based on ﬁller manufacturer’s recommendations.

1. Select polarity (+ or -) of welding current cable and return current cable in

accordance with ﬁller.

2. Select MMA welding with the switch .

3. Select suitable welding current on adjusting potentiometer scales.

©COPYRIGHT KEMPPI OY

Minarc/0244 – 7

3.3.2. DC TIG welding

Select welding parameters based on ﬁller 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 on adjusting potentiometer scales.

3.4. WELDING SELECTIONS

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. Earth

If possible, always ﬁx 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 advisable to

test welding and rate of welding current ﬁrst on something else than the actual welding

piece.

You can start welding after having made necessary selections. Arc is lit by scratching

the welding piece with electrode. Length of arc is regulated by holding electrode tip

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

ﬂow, arc is lit by lightly scratching welding 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 welding 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 off the welding piece and by closing the gas

valve on the torch.

Note! Always ﬁx 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

ﬁnishing welding.

3.5. STORING

Store the unit in a clean and dry place. Shield it from rain, and in temperatures

exceeding 25 °C shield it from direct exposure to sun.

4. MAINTENANCE

Be careful when handling electrical cables!

In maintaining the unit take into consideration rate of use and the environment it is used

in. When the unit is used properly and regularly serviced, you will avoid unnecessary

disturbances in use and production.

©COPYRIGHT KEMPPI OY

8 – Minarc/0244

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 and back of the unit for ventilation.

4.2. ORDERING NUMBERS

Item Ordering number

Minarc 140 welding machine 6102140

(includes earth- and welding cables)

Minarc 110 welding machine 6102110

(includes earth- and welding cables)

Earth cable and clamp 6184005

Welding cable and electrode holder 6184015

Optional:

TIG torch TTM15V and welding cable 6271432

4.3. TROUBLESHOOTING

Main switch signal light is not lit.

Unit does not get electricity.

Check mains fuses and replace when necessary.

Check mains cable and plug, replace damaged parts.

Unit does not weld well.

Arc is uneven and goes off. Electrode gets stuck in weld pool.

Check welding settings and adjust when necessary. See 3. Use.

Check that earth clamp is properly ﬁxed and that contact surface is clean and

the cable is undamaged. See 3.4. Welding and 4.1. Daily maintenance.

Overheat signal light is lit.

The unit has overheated. See 3.2. Operating functions.

Check that there is ample space in front of and back of the unit for ventilati-

on.

Check welding settings. See 3.3. Welding selections.

If problems in use are not solved with above mentioned measures, contact Kemppi serv-

ice.

©COPYRIGHT KEMPPI OY

Minarc/0244 – 9

5. TECHNICAL INFORMATION AND GUARANTEE

CLAUSES

5.1. TECHNICAL INFORMATION

Minarc 140 Minarc 110

Connection voltage,

1 ~ phase 50/60Hz 220V-10%...240V + 6% 220V-10%...240V + 6%

Connection capacity

35 % ED 140 A

50 % ED 110 A

100 % ED 100 A 80 A

Mains cable/fuse, delayed 2,5 mm2S /3,3 m 16 A 1,5 mm2S /2,0 m 13 A

Welding current range,

Metal arc welding (MMA) 10 A/20,5 V...140 A/25,6 V 10 A/20,5 V...110 A/24,4 V

Electrodes, diameter Ø1,5...3,25 mm Ø1,5...2,5 mm

Welding current control range stepless stepless

Open-circuit voltage 85V 85V

Open-circuit power <10 W <10W

Efﬁciency 80% 80%

Power factor 0,60 (140A/25,5 V) 0,60 (110A/24,4 V)

Degree of protection IP 23C IP 23C

Temperature class B (130°C)/H (180°C) B (130°C)/H (180°C)

Range of working temperature -20...+40°C -20...+ 40°C

Range of storage temperature -40...+60°C -40...+60°C

Degree of protection IP23C IP23C

Norms IEC 974-1 IEC 974-1

EN 50199 EN 50199

External dimensions:

length 305 mm 123 mm

height 250 mm (207 mm) 250 mm (207 mm)

Weight 4,2 kg (4,8 kg) 4,2 kg (4,6 kg)

The unit fulﬁls CE marking demands.

©COPYRIGHT KEMPPI OY

10 – Minarc/0244

5.2. GUARANTEE CLAUSES

KEMPPI OY gives the machines and equipment it manufactures and sells a guaran-

tee concerning defects in manufacturing or raw materials. Guarantee repairs can only

be made by approved KEMPPI repair shop. Buyer will pay for packaging, freight and

insurance. Guarantee is valid from the day of purchase. Orally given promises, not

included in guarantee clauses do not bind the guarantor.

Restrictions in guarantee

Guarantee does not cover damage caused by natural wear, use not in accordance with

the instructions, overload, carelessness, neglect of following maintenance instructions,

wrong mains voltage or gas pressure, disturbances or problems in mains network, dam-

ages during transportation or storing, or caused by ﬁre or natural fenomena. Guarantee

does also not cover direct nor indirect travel expenses (day allowances, accommodation,

freight etc. ).

Guarantee does also not cover welding torches and their consumables, nor feed rolls and

wire conduits in wire conduit units. Guarantee does not cover direct or indirect damages

caused by faulty product.

Guarantee expires if there are any changes made into the unit, that are not approved

by the manufacturer, or if other than original spare parts are used in repair works.

Guarantee expires, if repair works are performed by other than KEMPPI or authorised

by KEMPPI service workshop.

Guarantee period

Guarantee period is 1 (one) year, the unit is used in one shift daily. If it is used in

two shifts daily, guarantee period is 6 (six) months and in three daily shifts guarantee

period is 4 (four) months .

Making guarantee repairs

Faults that need guarantee repairs must be immediately, within guarantee period,

reported to KEMPPI or authorised by KEMPPI service workshop. Before starting

guarantee repair, the customer must present a guarantee document ﬁlled by the seller

or otherwise proof in writing, with a purchasing receipt, bill or delivery documents,

that the guarantee period has not expired. The document must contain date of purchase

and manufacturing number of the unit to be repaired. Parts changed in guarantee repair

remain KEMPPI property. Guarantee of repaired or exchanged machine or equipment

continues until the end of original guarantee period.

This manual suits for next models

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