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Minarc
Evo 150
OPERATING MANUAL
English
Minarc Evo 150 / © Kemppi Oy / 1110
EN
CONTENTS
1. PREFACE ......................................................................................3
1.1 General ....................................................................................................................................... 3
1.2 Product introduction ............................................................................................................ 3
2. BEFORE YOU START USING THE UNIT ......................................4
2.1 Unpacking ................................................................................................................................. 4
2.2 Positioning and location of the machine ...................................................................... 4
2.3 Distribution network ............................................................................................................. 4
2.4 Serial number ........................................................................................................................... 4
2.5 General view of the machine ............................................................................................. 5
2.6 Cable connections ................................................................................................................. 5
2.7 Operating functions .............................................................................................................. 6
3. USE ...............................................................................................7
3.1 Prepare to weld ....................................................................................................................... 7
3.2 MMA welding ........................................................................................................................... 8
3.2.1 Filler materials and equipment ....................................................................................... 8
3.2.2 Earth return cable and clamp ......................................................................................... 8
3.2.3 Manual metal arc welding (MMA) .................................................................................. 8
3.3 TIG welding ............................................................................................................................... 9
3.3.1 DC TIG welding ..............................................................................................................10
3.3.2 Earth return cable and clamp .......................................................................................10
3.3.3 Tungsten inert gas welding (TIG) .................................................................................10
3.4 Using the shoulder strap ...................................................................................................11
4. MAINTENANCE ......................................................................... 12
4.1 Daily maintenance ...............................................................................................................12
4.2 Troubleshooting ...................................................................................................................12
4.3 Storage .....................................................................................................................................12
4.4 Disposal of the machine ....................................................................................................13
5. ORDERING CODES ....................................................................13
6. TECHNICAL DATA .....................................................................14
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Minarc Evo 150 / © Kemppi Oy / 1110
EN
1. PREFACE
1.1 GENERAL
Congratulations on choosing Minarc Evo welding equipment. Used correctly, Kemppi
products can signicantly 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 specications 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.
Read also the separate Kemppi Safety Instructions booklet delivered in the product package.
Pay particular attention to the risks associated with re and explosion.
For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi
dealer, or visit the Kemppi web site at www.kemppi.com.
For Kemppi’s standard safety instructions and warranty terms and conditions, please visit our
web site at www.kemppi.com.
The specications presented in this manual are subject to change without prior notice.
NOTE! Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with this symbol. Read these sections carefully and follow their
instructions.
Disclaimer
While every eort 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 specication 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 PRODUCT INTRODUCTION
Minarc Evo 150 is an easy-to-use welding machine for MMA (stick welding). It is suitable
for professional use in metal industry, work sites and repair welding. Before use or doing
any maintenance work on the machine, read the operating manual and keep it for further
reference.
A model equipped with a voltage reduction device (Minarc Evo 150VRD) is available for
maintaining the open-circuit voltage below 30 volts. There are also special models equipped
with mains plug types suitable for Australia, New Zealand and Denmark. If you need another
type of plug, please see the section 2.6 "Connecting cable connections" later in this manual.
Minarc Evo 150 tolerates uctuations in input voltage, and it is suitable for on-site work using
power generators and long power cables. The power source utilises PFC technology to ensure
optimum usage on a single phase power supplies. IGBT inverter design delivers reliable arc
ignition and welding performance with all electrode types.
Welding and earth return cables are supplied in the delivery package, including electrode
holder, earth clamps and connections.
Minarc Evo can also be used for basic TIG welding, where the TIG arc is started by the lift arc
ignition technique. Order numbers for the additional equipment required for TIG welding and
for the remote current control devices can be found in section 5 "Ordering numbers".
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Minarc Evo 150 / © Kemppi Oy / 1110
EN
2. BEFORE YOU START USING THE UNIT
NOTE! Please read the separate safety instruction booklet provided before you commence welding.
Pay particular attention to the risks associated with re and explosion.
2.1 UNPACKING
Always before using the equipment, make sure it was not damaged during transportation.
Also check that you have received what you ordered and that instructions are included.
The packaging material of the products is suitable for recycling.
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 cable or other cables.
Environment
The machine is suitable for both indoor and outdoor use, but it should be protected from 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…+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.
2.2 POSITIONING AND LOCATION OF THE MACHINE
Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other
impurities to enter the machines cooling air ow. Preferably site the machine above oor level.
Notes for positioning the machine
• The surface inclination should not exceed 15 degrees.
• Ensure the free circulation of the cooling air. There must be at least 20 cm of free space
around the machine for cooling air to circulate.
• Protect the machine against heavy rain and direct sunshine.
NOTE! Do not operate the machine in rain. The protection class of the machine is IP23S, which
allows for outside preserving and storage only.
NOTE! Never use a wet welding machine.
NOTE! Never aim metallic grinding spray or sparks towards the equipment.
2.3 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 Evo 150 complies with IEC 61000-3-12.
2.4 SERIAL NUMBER
The serial number of the unit is marked on the rating plate. 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.
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Minarc Evo 150 / © Kemppi Oy / 1110
EN
2.5 GENERAL VIEW OF THE MACHINE
1.
2.
3.
4.
5.
6.
7.
1. Machine case
2. ON/OFF power switch
3. Welding current display
4. Positive and negative welding circuit connection sockets
5. Electrode holder and welding cable
6. Earth return cable and clamp
7. Connection socket for remote control of welding current
2.6 CABLE CONNECTIONS
Connection to the mains
The machine is equipped with a 3 m long supply voltage cable and plug. Connect the supply
voltage cable to the mains. The mains supply cable and electrical plug are already installed to
the machine. Should you need to t an alternative plug type, ensure installation is completed
by an authorised electrician.
If you use an extension cable, its cross-sectional area should be at least as large as the
machines supply cable (3 x 1.5 mm²). It is recommended to use 3 x 2.5 mm² extension cable.
The maximum length for the extension cable is 100 meters.
The machine can also be used with a generator. The minimum power for the generator is
4.5 kVA, and the recommended power 7.0 kVA in order for the machine to be used at
maximum capacity.
Electrode holder
Connect the welding cable to the power source. Normally, the welding cable with electrode
holder is connected to the positive terminal (electrode +).
Earth return
Connect the earth return cable to the power source. Normally, the earth return cable and
clamp is connected to the negative terminal ( – ). Clean the workpiece surface and x the
earth return cable clamp to the work piece in order to create a welding circuit.
5
Minarc Evo 150 / © Kemppi Oy / 1110
EN
2.7 OPERATING FUNCTIONS
1. Welding current adjustment knob
2. Welding process selection button
3. Welding current meter display
4. Indicator lights, machine 'ON', (VRD: 'VRD safe ON')
5. Overheating indicator
6. Remote control ON/OFF button
1.
3.
5.
2.
6.
4.
Main switch and 'ON' indicator
When you turn the main switch to position I, the indicator light is illuminated and the unit is
ready for welding. The indicator 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!
Indicator 'VRD safe ON'
VRD active units reduce the open circuit voltage to a lower level. The indicator is illuminated
when the circuit is activated and the unit is in working order.
Welding process selector, MMA/TIG
This switch is used for selecting either MMA or TIG welding mode, depending on the welding
process chosen.
Regulating welding current
The welding current level is regulated via a stepless adjustment knob. Set the welding current
level according to the target weld piece, position and electrode type and size.
Overheating indicator
The thermostatic temperature switch may become active during heavy welding or high
ambient temperatures. This is indicated by a yellow indicator light. The power source fan will
cool the unit and after the indicator goes o, the unit is again ready for welding.
Local and remote control
The welding machine can be controlled with a remote control device. Select remote control
by pressing the Remote control ON/OFF button.
Details of available remote current control devices can be found in the Ordering codes section
later in this manual.
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Minarc Evo 150 / © Kemppi Oy / 1110
EN
3. USE
NOTE! Welding fumes may be dangerous to your health. Ensure that there is ample ventilation
during welding! Never look at the arc without a face shield specically designed for arc welding!
Protect yourself and your surrounding area from the arc and hot welding spatter!
3.1 PREPARE TO WELD
NOTE! Always wear protective clothing, gloves, face and eye shields suitable for welding. It is
recommended that you make practice welds before you commence welding your main work
piece. If when igniting the arc or during welding, the electrode sticks or freezes to the work piece,
note that it will quickly heat up, and may start to glow red hot. To release the electrode, twist the
electrode holder away from the work piece and start again. If this fails, switch of the machine at the
main switch and then release the electrode after it has cooled down. Note: the electrode and work
piece will be very hot.
You can start welding after you have made the necessary preparation described throughout
these instructions.
In addition to the welding machine, welding outcome is inuenced by the work piece type,
welding position and the welding environment. Therefore, recommendations in this manual
must be followed.
During welding, an electric current is owing through the cable, clamp and electrode to the
workpiece.
The earth return cable attached to the workpiece guides the current back to the machine,
forming the closed welding circuit. Unrestricted current ow is only possible when the earth
return clamp is properly attached to the workpiece and the xing point of the clamp is clean,
free from paint and rust free.
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Minarc Evo 150 / © Kemppi Oy / 1110
EN
3.2 MMA WELDING
In manual metal arc (MMA) welding, the ller material is melted from the electrode to the
weld pool. The rate of welding current is selected on the basis of the electrode size and
welding position. The arc forms between the electrode tip and work piece. The melting
electrode coating forms a gas and slag shield, which protects the molten metal in transfer
to the weld pool and during solidication. As the slag solidies over the hot weld metal, it
prevents weld metal oxidation. This slag coating is removed after welding e.g. with a chipping
hammer. When removing the slag coating, ensure you protect your eyes and face with suitable
equipment.
For more info, visit www.kemppi.com > Welding ABC.
3.2.1 Filler materials and equipment
Minarc Evo can be used with all electrode types suitable for DC welding. Electrode sizes for the
unit are listed in Technical data section later in this manual.
1. Follow the welding specications given on the electrode package.
2. Before you start welding, check that you have selected the correct welding process.
3. Check that the welding cable and earth cable connections are hand tight. If a cable
connection is loose, it will result in a decrease of welding performance, overheating of
the connection, and it may aect your product warranty cover.
4. Select and mount the correct electrode type rmly in holder.
3.2.2 Earth return cable and clamp
If possible, always x the earth return cable and clamp directly to the welding work piece.
1. Clean the connection surface of earth clamp from paint, dirt and rust.
2. Connect the clamp carefully so that contact surface is as large as possible.
3. Finally check that the clamp remains fastened.
3.2.3 Manual metal arc welding (MMA)
Select your required welding parameters according to the manufacturer’s ller material
recommendations and the joint to be welded.
1. Select the required polarity (+ or –) of welding current cable (normally + ) and
return current cable (normally –) according to the ller material manufacturers
recommendations.
2. Select MMA welding mode by pressing the process selection button on the control
panel.
3. Select a suitable welding current by adjusting the current adjustment knob.
4. Make a small test weld to check the selections made.
8
Minarc Evo 150 / © Kemppi Oy / 1110
EN
Site your equipment in a suitable location, ensuring there is adequate cable length to
complete the weld pass. Before you start welding, ensure you are comfortably positioned in
front of the work piece, and that you are well balanced with your weight equally distributed.
Ensure that the power source current setting is correct for the electrode size selected. Draw
the welding face shield over your eyes. (Electronic welding face shields like Kemppi BETA
90X, allow you to see the welding start point more accurately and better concentrate on the
welding process. This reduces the possibility of arc ash). Ensure others in the welding area are
aware that you're going to weld. To establish the arc, scratch the electrode on the surface of
the work piece.
As the arc starts to burn you will see a bright molten material form, this is molten slag,
formed from the electrode coating and the darker coloured material is the molten weld metal
itself, formed from the melting core wire. Hold the electrode at an angle of approximately
75–85 degrees from the horizontal, leaning away from the weld itself. Hold this position,
maintaining a 3 mm distance from electrode tip to work surface. As the electrode burns, this
arc length distance needs constant maintenance throughout the welding cycle. Slowly travel
the electrode away from the deposited weld pool material, maintaining a constant travel
speed. Your completed weld bead should be straight and of even width and bead height,
consistent in its appearance. Travel too slowly and the weld pool will get too big and may
burn through the weld piece, too fast and the resulting weld will be too small and may have
slag entrapments and/or poor strength. After welding, the solidied slag on the weld surface
should easily remove with a chipping hammer. Ensure you wear eye and face protection when
removing the slag from the weld surface.
3.3 TIG WELDING
Minarc Evo 150 can also be used for basic TIG welding and remote current control. The TIG
arc is started by the touch and lift ignition technique. Order numbers for the additional
equipment required for TIG welding and/or remote current control devices can be found in
Ordering codes section later in this manual. Ensure you select TIG process on the Minarc Evo
control panel before you commence welding.
The TIG process forms an arc between the tungsten electrode and the work piece. The arc
melts the work piece forming a molten weld pool. The arc and tungsten electrode mounted
in the TIG torch are shielded by an inert shielding gas that is connected to, and ows through,
the nozzle of the TIG torch. The gas required is argon and the ow rate is approximately 8 to 10
litres per minute. If necessary, suitable ller material is added to the weld pool to complete the
9
Minarc Evo 150 / © Kemppi Oy / 1110
EN
weld joint. Filler wire is fed into the weld pool from the outside of the arc and gas shield. The
ller wire and the welding current level are decided according to the base material type and
thickness, joint form and welding position.
0.5 s
NOTE! Ensure you protect your eyes and face with suitable equipment.
NOTE! The tungsten electrode tip should be sharpened as described.
D
2xD
3.3.1 DC TIG welding
Select your required welding parameters according to the joint to be welded.
1. Connect TIG torch to the negative (–) pole of the power source, and earth cable to
positive (+) pole.
2. Select TIG welding mode by pressing the process selection button on the control panel.
3. Select a suitable welding current by adjusting the current adjustment knob.
4. Ensure your argon shielding gas supply is switched on and the ow rate is approximately
8 to 10 litres per minute.
5. Make a small test weld to check the selections made.
3.3.2 Earth return cable and clamp
If possible, always x the earth return cable and clamp directly to the work piece.
1. Clean the connection surface of earth clamp from paint, dirt and rust.
2. Connect the clamp carefully so that contact surface is as large as possible.
3. Finally check that the clamp remains fastened.
3.3.3 Tungsten inert gas welding (TIG)
Argon shielding gas is used in DC TIG welding. Your dealer will give you advice on choosing
the correct gas, supplier, and supporting equipment. Open the gas valve on the Kemppi
TTM 15V TIG torch. When the gas starts to ow, ignite the arc. The arc is activated by lightly
touching the work piece with the tungsten electrode and lifting away. A reliable technique to
practice is, lightly and briey touch the tungsten electrode to the work piece surface and then
rock backwards onto the ceramic nozzle of the TIG welding torch, so the tungsten is no longer
in contact with the work piece surface. This action makes and breaks a momentary contact of
the tungsten electrode in a controlled manner, rst making the electrical circuit and secondly
establishing the TIG welding arc the moment the tungsten leaves contact to the work piece
surface.
10
Minarc Evo 150 / © Kemppi Oy / 1110
EN
The length of arc is regulated by holding the tungsten electrode tip at a suitable distance
from work piece. A suitable arc length is usually about the diameter of the tungsten electrode.
When the arc is burning, move the electrode slowly forwards to the start of the weld, tilting
the torch to approximately 10-15° pulling angle. If necessary, adjust power source current
value so that a constant weld pool size is maintained for the forward travel speed. If necessary
to complete the weld, add compatible ller wire to the weld pool.
Stop welding by lifting the torch away from the work piece and by closing the gas valve on
the torch.
NOTE! Always secure the gas cylinder in an upright position with either a specially made wall rack
or cylinder trolley. Always close the cylinder valve after welding.
3.4 USING THE SHOULDER STRAP
1.
3.
2.
4.
Using and xing the shoulder strap
The machine is delivered with a fabric shoulder strap and metal clip set. The shoulder strap
can be used as a convenient and comfortable way to transport both the machine and cables
set. There are two identical metal clips. Fix one clip to each of the metal lifting eyes, located at
the top of the machine. Adjust the shoulder strap to a comfortable length. The machine can
now be carried.
Should you also wish to transport and secure the cables set, place the cable bundle over the
strap as shown, bring the strap and remaining free clip over the top of the cable bundle and
secure to the already fastened rear clip. As you take the weight of the machine with the strap,
the cable set is clamped securely into position ready for transport.
NOTE! The machine should not be used when hanging from the shoulder strap.
11
Minarc Evo 150 / © Kemppi Oy / 1110
EN
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 the electrode holder and TIG torch’s gas nozzle. Replace damaged or worn parts.
• Check TIG torch’s electrode. Replace or sharpen, if necessary.
• Check the tightness of welding cable and earth return cable connections.
• Check the condition of mains lead and welding cables, and replace damaged cables.
• See that there is enough space around 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 results. Several factors aect the welding quality.
• Ensure that the welding current selected is adequate for the selected electrode type
and size.
• Ensure the cable connections are correct and secure.
• Ensure the process selection is correct.
• Check that the earth return clamp connection area is clean and that the cable and
clamp are not damaged.
• For TIG welding, check that the shielding gas ow is switched on and set correctly.
Poor ignition and arc quality in TIG welding may be a result of a poorly prepared
tungsten electrode. Always maintain and grind a point on the TIG torch electrode tip
before welding.
Overheating indicator is illuminated. Normally, this indicates that the device has reached its maximum designed operating
temperature. The thermostat has become active, switching the welding power o.
Allow the unit to cool and the machine will soon automatically reset and allow
welding to restart.
• Ensure that cooling air has unrestricted ow.
• If the machine’s duty cycle has been exceeded, wait for indicator to turn o.
In certain circumstances, this light may also indicate irregularity in the supply voltage.
Too low or high supply voltage.
If the machine’s malfunction is not eliminated with the above measures, contact Kemppi
service.
4.3 STORAGE
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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Minarc Evo 150 / © Kemppi Oy / 1110
EN
4.4 DISPOSAL OF THE MACHINE
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 CODES
Minarc Evo 150 welding machine
(includes earth return and welding cables) 61002150
Minarc Evo 150 welding machine (Denmark)
(includes earth return and welding cables) 61002150DK
Minarc Evo 150VRD welding machine
(includes earth return and welding cables) 61002150VRD
Earth return cable and clamp
6184015
Welding cable and electrode holder
6184005
Carrying strap
9592163
Optional: TIG torch TTM15V
4 m 6271432
BETA 90X electronic welding helmet
9873047
R10 hand held remote control
5 m 6185409
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Minarc Evo 150 / © Kemppi Oy / 1110
EN
6. TECHNICAL DATA
Minarc Evo 150
Connection voltage
1 ~ 50/60 Hz 230 V ± 15 %
Rated power at max. current
35 % ED MMA 140 A/4.5 kVA
35 % ED TIG 150 A/3.2 kVA
Supply current
35 % ED I
1max
19.7 A
100 % ED I
1e
12.9 A
Connection cable
H07RN-F 3G1.5 (1.5 mm, 3 m)
Fuse
type C 16A: 140A ED 35%
10A: 140A ED 28%
Output 40 °C
35 % ED MMA 140 A/25.6 V
100 % ED MMA 100 A/24.0 V
35 % ED TIG 150 A/16.0 V
100 % ED TIG 110 A/14.4 V
Welding range
MMA 10 A/15 V – 140 A/37 V
TIG 10 A/1 V – 150 A/36 V
No-load voltage; peak
90 V (VRD 30 V)
Idle power
17 W
Voltage steps
stepless
Power factor at 100 % ED
0.99
Efficiency at 100 % ED
MMA 82 %
Stick electrodes
ø 1.5 – 3.25 mm, and some 4 mm
External dimensions LxWxH
height with handle 361x139x267 mm
Weight
without connection cable 5.4 kg
with connection cable 5.85 kg
Temperature class
B (130 °C)
EMC class
A
Degree of protection
IP23S
Operating temperature range
-20...+40 °C
Storage temperature range
-40...+60 °C
Standards
IEC 60974-1
IEC 60974-10
IEC 61000-3-12
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Minarc Evo 150 / © Kemppi Oy / 1110
www.kemppi.com
1910010
1110
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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
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