Minarc 150, 151 150 VRD 120 AU, 150 AU
Contents
1. KEMPPI The Joy of Welding 150 151 Minarc 150 VRD 120 AU 150 AU Operating manual English Kaytt ohje Suomi Bruksanvisning Svenska Bruksanvisning Norsk Brugsanvisning Dansk Gebrauchsanweisung Deutsch Gebruiksaanwijzing Nederlands Manuel d utilisation Fran ais Manual de instrucciones Espa ol Instrukcja obstugi Polski VHcTpyklinn no 3k cnnyarauw lt lo pycckn EN FI SV NO DA DE NL FR ES PL RU OPERATING MANUAL English Minarc 150 151 Kemppi Oy 1117 rm Minarc 150 151 Kemppi Oy 1117 rm CONTENTS 1 1 1 1 2 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 3 3 1 3 2 3 3 3 4 3 5 4 1 4 2 4 3 KREE Eet 3 ICI anpati kote opi 3 Product introduction sn 4 BEFORE YOU START USING THE UNIT 4 Unpacking eT Placing the unit ins Serial number Main components Distribution network Connecting to power supply Mains 6 Filler materials and equipment 6 USE 7 Welding processes nn 7 3 1 1 Manual Metal Arc welding MMA 400000e 0000 eaaa eea eea ea nean enan aane 7 3 1 2 TIG welding e Operating functions Welding selections ss 3 3 1 Manual Metal Arc welding MMA 000000 a eea eea ttttnnnnnnnnnn 9 3 3 2 DC TIGwelding EEN 9 Welding selecto Sannia 10 341 Earthing t 102. SEW ennemies 10 SION ee EAE PERE item Gda 10 MAINTENANCE 11 Daily maintenance Troubleshooting DS OO SA k kte ay dat at o ets ORDERING NUMBERS 12 TECHNICAL DATA ttes 13 1 1 PREFACE GENERAL Congratulations on choosing the Minarc equipment Used correctly Kemppi products can significantly 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 specifications of the equipment can be found at the end of the manual Please read the manual carefully before using the equipment for the first 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 specifications 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 Minarc 150 151 Kemppi Oy 1117 rm Minarc 150 151 Kemppi Oy 1117 rm 1 2 2 1 2 2 PRODUCT INTRODUCTION
3. when the circuit is activated and the unit is in working order 3 3 3 3 1 3 3 2 Welding process selector MMA 77 TIG fm 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 off 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 off the unit is again ready for welding WELDING SELECTIONS Manual Metal Arc welding MMA Select welding parameters according to filler manufacturer s recommendations 1 Select polarity or of welding current cable and return current cable according to filler 2 Select MMA welding with the switch FE 3 Select suitable welding current by adjusting potentiometer DCTIG welding Select welding parameters according to filler manufacturer s recommendations 1 Connect TIG torch to pole and earth cable to pole 2 Select TIG welding with the switch fm 3 Select suitable welding current by adjusting potentiometer Minarc 150 151 Kemppi Oy 1117 rm Minarc 150 151 Kemppi Oy 1117 m 3 4 3 4 1 3 4 2 3 5
4. A 20 5 V 140 A 25 6V 5 A 10V 150 A 16V stepless 85V VRD 30 V lt 10W 0 60 80 9 1 5 3 25 mm 320x123x265 mm 4 0 kg 4 6 kg B 130 C 20 40 C 40 60 C IP235 A EN IEC 60974 1 EN IEC 60974 10 Minarc 151 110V 15 140 A 7 5 kVA 100 A 5 1 kVA 150 A 5 0 kVA 110 A 3 3 kVA 59A 39A HO7RN F 3G6 6 mm2 2 m 32A 10 A 20 5 V 140 A 25 6V 5 A 10V 150 A 16 V stepless 85V lt 10W 0 60 80 9 1 5 3 25 mm 320x123x265 mm 44kg 5 2kg B 13070 20 40 C 40 60 C IP235 A EN IEC 60974 1 EN IEC 60974 10 13 Minarc 150 151 Kemppi Oy 1117 rm Minarc 150 151 Kemppi Oy 1117 m z 14 Connection voltage 1 phase 50 60 Hz Rated power at max current ED MMA ED MMA ED TIG ED TIG Supply current 35 EDI 100 ED I y Connection cable Fuse delayed Welding range MMA TIG Welding current control Open circuit voltage Idle power Power factor 100 ED Efficiency 100 ED Stick electrodes External dimensions LxWxH Weight without connection cable Weight with connection cable Temperature class Operating temperature range Storage temperature range Degree of protection EMC class Norms Minarc 120AU 240V 10 2096 50 110 A 5 5 kVA 100 80 A 3 9 kVA 50 120 A 3 5 kVA 100 80 A 2 2 kVA 20A 12A HOZRN F 3G1 5 1 5 mm 3 m 10A 10 A 20 5 V 110 A 24 4V 5 A 10V 120 A 15V stepless 30V lt 30W
5. INDIA PVT LTD LAKSHMI TOWERS New No 2 770 First Main Road KAZURA Gardens Neelangarai CHENNAI 600 041 TAMIL NADU Tel 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com 0510161 ZILI
6. Kemppi Minarc isa manual metal arc welding machine small in size suitable for industry site and repair welding The unit uses one phase connection voltage and itis manufactured for two different mains voltages 230V Minarc 150 and 110 V Minarc 151 Minarc tolerates a great fluctuation 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 Mlnarc 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 BEFORE YOU START USING THE UNIT 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 pro
7. slag which protects the weld pool Slag solidified over the weld is removed after welding e g with a chipping hammer TIG welding In DCTIG 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 filler is used Filler wire is fed into the weld pool from the outside of the arc The filler wire and the welding current level are decided according to the base material type and thickness joint form and welding position Minarc 150 151 Kemppi Oy 1117 rm Minarc 150 151 Kemppi Oy 1117 rm 3 2 OPERATING FUNCTIONS See also 2 4 Main components and 3 4 Welding selections 1 Signal light machine ON VRD VRD safe ONT Welding process selecting switch Welding current adjuster Signal light for overheating Suitable electrodes reference values for welding current oP wu 150 A M KEMPPI Minarc 03 25 80 140 110 14 Main switch and signal light When you turn the main switch to position 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 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
8. 0 60 80 1 5 2 5 mm 320x123x265 mm 4 0kg 4 6 kg B 130 C 20 40 C 40 60 C IP235 A AS 1674 2 AS NZS 3652 WTIA Tech note 22 EN IEC 60974 1 EN IEC 60974 10 Minarc 150AU 240V 1006 20 35 96 140 A 7 5 KVA 100 100 A 5 1 kVA 35 96 150 A 5 0 kVA 100 90 110 A 3 3 kVA 26A 15A HO7RN F 3G6 2 5 mm 2 m 15A 10 A 20 5 V 140 A 25 6V 5A 10V 150 A 16V stepless 30V 30W 0 60 80 1 5 3 25 mm 320x123x265 mm 4 0 kg 4 6 kg B 130 C 20 40 C 40 60 C IP235 A AS 1674 2 AS NZS 3652 WTIA Tech note 22 EN IEC 60974 1 EN IEC 60974 10 ZILI AQ 1dduusy 6 Let OSL 2IEUIIN 15 KEMPPI OY Hennalankatu 39 PL13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 export kemppi com www kemppi com Kotimaan myynti Tel 358 3 899 11 Telefax 358 3 734 8398 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 S 194 27 UPPLANDS V SBY SVERIGE Tel 46 8 590 783 00 Telefax 46 8 590 823 94 sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 sales no kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345 sales nl kemppi com www kemppi com KEMPPI U
9. 10 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 Earthing 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 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 first 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 flow arc is lit by lightly scratching work piece with the tip of the tungsten electrode When arc is lit its length is regulated b
10. K Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM Tel 44 0 845 6444201 Telefax 44 0 845 6444202 sales uk kemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 33 1 30 90 04 40 Telefax 33 1 30 90 0445 sales fr kemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SP KA Z 0 0 UI Borzymowska 32 03 565 WARSZAWA POLAND Tel 48 22 7816162 Telefax 48 22 7816505 info pl kemppi com 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 au kemppi com 000 KEMPPI Polkovaya str 1 Building 6 127018 MOSCOW RUSSIA Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com 000 KEMIIN yn lonkoBaa 1 crpoeHne 6 127018 MockBa Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com KEMPPI TRADING BEIJING COMPANY LIMITED Room 420 3 Zone Building B No 12 Hongda North Street Beijing Economic Development Zone 100176 Beijing CHINA Tel 86 10 6787 6064 86 10 6787 1282 Telefax 86 10 6787 5259 sales cn kemppi com THERE AR SIR A PE ILRARRRA RK BIA de125 GIM A IS BS X420 100176 if 86 10 6787 6064 86 10 6787 1282 J amp Ei 86 10 6787 5259 sales cn kemppi com KEMPPI
11. ducts is suitable for recycling 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 2 3 2 4 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 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 Body of machine Main power switch Selector switch for welding process Welding current regulator Signal light machine ON VRD VRD safe ON Signal light for overheating Electrode holder and welding cable Earth cable and clamp go NU PWN gt Minarc 150 151 Kemppi Oy 1117 rm Minarc 150 151 Kemppi Oy 1117 rm 2 5 2 6 2 7 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
12. ill not light up Poor welding result Overheating indicator lit Cause No electricity connected to the machine lt Check the mains supply fuses lt Check the mains cable and plug Several factors affect the welding quality lt Check that the earthing clamp is firmly attached the point of attachment is clean and that the cable and its connectors are intact lt Check that the shielding gas flows out of the torch tip lt Check that the electric voltage is not irregular or too low high The device has overheated Ensure that cooling air has unrestricted flow Ifthe machines duty cycle has been exceeded wait for indicator to turn off lt Too low or high supply voltage If the machine s malfunction is not eliminated with these measures contact KEMPPI service 11 Minarc 150 151 Kemppi Oy 1117 rm Minarc 150 151 Kemppi Oy 1117 m z 4 3 12 DISPOSAL Do not dispose of electrical eguipment with normal waste In observance of European Directive 2002 96 EC on waste electrical and electronic eguipment and its implementation in accordance with national law electrical eguipment 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 Kemp
13. pi representative By applying this European Directive you will improve the environment and human health 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 4m 6271432 6 TECHNICAL DATA Connection voltage 1 phase 50 60 Hz Rated power at max current 35 ED MMA 100 ED MMA 35 ED TIG 100 ED TIG Supply current 35 ED lqmax 100 96 ED heff Connection cable Fuse delayed Welding range MMA TIG Welding current control Open circuit voltage Idle power Power factor at 100 ED Efficiency at 100 ED Stick electrodes External dimensions LxWxH Weight without connection cable Weight with connection cable Temperature class Operating temperature range Storage temperature range Degree of protection EMC class Norms Minarc 150 150 VRD 230V 15 140 A 7 5 kVA 100 A 5 1 kVA 150 A 5 0 kVA 110 A 3 3 kVA 27A 16A HOZRN F 362 5 2 5 mm 3 m 16A 10
14. 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 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 find fuse and cable sizes in the end of these instructions in Technical data 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 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 connection is slack it will result in voltage drop that will cause the connection to heat 4 Mount the electrode firmly in holder 3 1 3 1 1 3 1 2 USE NOTE It is forbidden to weld in places where there is a danger of fire or explosion WELDING PROCESSES Manual Metal Arc welding MMA In manual metal arc MMA the welding filler 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
15. y 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 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 having finished welding 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 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 lt Clean electrode holder and TIG torch s gas nozzle Replace damaged or worn parts lt Check TIG torch s electrode Replace or sharpen if necessary lt Check tightness of welding and earth cables connections lt Check condition of mains and welding cables and replace damaged cables lt See that there is enough space in front of and back of the unit for ventilation 4 2 TROUBLESHOOTING Problem The main switch indicator w
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