Kemppi Minarc 150AU User Manual

Operation instructions • english

MINARC 150 AU

1910150AU

CONTENTS

1. PREFACE ..............................................................................................................3

1.1. Introduction ...................................................................................................3

1.2. Product introduction......................................................................................3

1.3. Operation safety............................................................................................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..........................................................................................4

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

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

3. USE ......................................................................................................................5

3.1. Welding processes........................................................................................5

3.1.1. Manual Metal Arc welding (MMA)............................................................5

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. DC TIG welding .......................................................................................7

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

3.4.1. Earthing ...................................................................................................7

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

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

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

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

4.2. Troubleshooting ............................................................................................8

5. ORDERING NUMBERS.........................................................................................8

6. TECHNICAL DATA................................................................................................9

2 – Minarc 150AU / 0411

© COPYRIGHT KEMPPI OY

1. PREFACE

1.1. INTRODUCTION

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 as well as its technical data.
Read the instructions before taking the machine into use or servicing it for the fi rst time.
Additional information on Kemppi products and their use can be obtained from Kemppi
or a Kemppi dealer.
The specifi cations and designs presented in this manual are subject to change without prior
notice.
In this document, for 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 INTRODUCTION

Kemppi Minarc 150AU is a Manual Metal Arc welding machine, small in size, suitable
for industry, site and repair welding. The unit uses one phase connection voltage.
Minarc 150AU is equipped with so called Voltage Reduction Device (VRD) function to
avoid danger of electric shock. VRD maintains open circuit voltage under 35 V.
Minarc tolerates a great fl 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 electrode holder, earth clamps and connections for the unit.
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 under 5. Ordering
numbers.

1.3. OPERATION SAFETY

Read the warning texts carefully and follow the instructions.

Arc and welding spatter

Arc and the refl ected 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 fi re and explosion

Observe the fi re safety instructions. Remove fl ammable material around the place where
you will weld. Have necessary fi re extinguishing equipment at hand when you weld. Note
dangers caused by special jobs, such as risk of fi re and explosion when welding tanks.
Note! Sparks may ignite fi re even hours later!
Welding is working with fi re, note special instructions for such work.

© COPYRIGHT KEMPPI OY

Minarc 150AU / 0411 – 3

Mains voltage

Never take welding machine inside the work piece (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 fi re. 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 protective
clothing. Never work on a wet surface. Never use damaged welding cables. Never set
neither 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 containing
lead, cadmium, zinc, mercury or beryllium.

2. BEFORE YOU START USING THE UNIT

2.1. UNPACKING

The unit is packed in durable packages, designed specially for it. Nevertheless, always
before using the unit, 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.

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.

4 – Minarc 150AU / 0411

© COPYRIGHT KEMPPI OY

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 VRD safe ON
F Signal light for overheating
G Electrode holder and welding cable
H Earth cable and clamp

B

C

D

E

F

A

G

+

H

-

2.5. CONNECTING TO POWER SUPPLY MAINS

The unit has a mains cable and a wall plug. You can fi nd fuse and cable sizes in the end
of these instructions in Technical data.

2.6. 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 table on unit’s front panel as well as
in the end of these instructions in Technical data.

1. Use welding specifi 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 fi rmly in holder.

3. USE

It is forbidden to weld in places where there is a danger of fi re or explosion!

3.1. WELDING PROCESSES

3.1.1. Manual Metal Arc welding (MMA)

In manual metal arc (MMA) the welding fi ller material is melted from the electrode to the
weld pool. Filler and rate of welding current is selected on the basis of electrode size used
and welding position. Arc is formed between electrode tip and work piece. The melting
electrode coating forms gas and slag, which protects the weld pool. Slag solidifi ed over
the weld is removed after welding e.g. with a chipping hammer.

© COPYRIGHT KEMPPI OY

Minarc 150AU / 0411 – 5

3.1.2. TIG welding

In DC TIG welding, the arc between a non-melting tungsten electrode and the work piece
melts the work piece, thus forming a weld pool. Arc and electrode are shielded by an inert
shielding gas (Argon). If necessary, fi ller can be used. Filler wire is fed into the weld pool
from the outside of the arc. Filler and rate of welding current are selected on the basis of
diameter of tungsten electrode and welding position.

3.2. OPERATING FUNCTIONS

See also 2.4. Main components and 3.4. Welding selections.
A Signal light VRD safe ON

B Welding process selecting switch
C Welding current regulator

D Signal light for overheating
E Table of suitable electrodes

Main switch and signal light

A

D

B

C

E

When you switch the main switch at the back of machine to position I, signal light on main
switch 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 (A)

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.

Welding process selector, MMA

Switch is used for selecting either MMA or TIG welding, depending on welding target.
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 the welding current (C)

Welding current rate is regulated steplessly with an adjusting potentiometer.

Signal light for overheating (D)

A yellow signal light for 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.

/ TIG (B)

3.3. WELDING SELECTIONS

3.3.1. Manual Metal Arc welding (MMA)

Select welding parameters according to fi ller manufacturer’s recommendations.

1. Select polarity (+ or -) of welding current cable and return current cable according
to fi ller.

2. Select MMA welding with the switch

3. Select suitable welding current by adjusting the potentiometer according to table of
suitable electrodes (E).

6 – Minarc 150AU / 0411

.

© COPYRIGHT KEMPPI OY

3.3.2. DC TIG welding

Select welding parameters according to fi ller manufacturer’s recommendations.

1. Connect TIG torch to - pole and earth cable to + pole

2. Select TIG welding with switch

3. Select suitable welding current by adjusting the potentiometer.

.

3.4. WELDING

Welding fumes may be dangerous for 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 fi x earth cable clamp directly on the work 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 3.3. Welding selections. Note! It is recommended
that you try welding and rate of welding current fi 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. Arc length is regulated by holding electrode tip at a
suitable distance from work 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 the current value.
Shielding gas is used in DC TIG welding. Your dealer will give you advice on choosing the
gas and equipment. Open the gas valve on the TTM 15V TIG torch. When gas starts to fl ow,
arc is lit by lightly scratching the 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 the current rate. Stop welding
by lifting the torch off the work piece and by closing the gas valve on the torch.
Note! Always fi 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
fi 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.

4. MAINTENANCE

Be careful when handling electric cables!

In maintenance of 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.

© COPYRIGHT KEMPPI OY

Minarc 150AU / 0411 – 7

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 cable 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

Main switch signal light is not lit.

Unit does not get electricity.

 Check mains fuses and replace if 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 fi xed and that contact surface is clean and

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

Signal light for overheating 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

ventilation.

 Check welding settings. See 3.3. Welding selections.

If problems in use are not solved with above mentioned measures, please contact a
Kemppi service workshop.

5. ORDERING NUMBERS

Item Ordering number

Minarc 150AU welding machine 6102150AU
(includes earth- and welding cables)
Earth cable and clamp 6184015
Welding cable and electrode holder 6184005
Carrying strap 9592162
Optional:
TIG torch TTM15V, 4 m 6271432

8 – Minarc 150AU / 0411

© COPYRIGHT KEMPPI OY

6. TECHNICAL INFORMATION

Minarc 150AU

Connection voltage,
1 ~ phase 50/60Hz 240 V +10%...-20%
Connection capacity
35 % ED MMA 140 A/7,5 kVA
35 % ED TIG 150 A/5,0 kVA
100 % ED MMA 100 A/5,1 kVA
100 % ED TIG 110 A/3,3 kVA
Mains cable/fuse, delayed 2,5 mm² S - 3,3 m / 15 A
Welding current range,
TIG 5 A/10 V... 150 A/16 V
Metal arc welding (MMA) 10 A/20,5 V...140 A/25,6 V
Electrodes, diameter Ø1,5...3,25 mm
Welding current control stepless
Open circuit voltage (VRD) 30 V
Open circuit power <10 W
Effi ciency 80%
Power factor 0,60 (140A/25,5 V))

Degree of protection IP 23C
Temperature class B (130°C)/H (180°C)
Range of working temperature -20...+40°C
Range of storage temperature -40...+60°C

External dimensions:
length 320 mm
width 123 mm
height 265 mm
Weight 4,0 kg without connection cable

4,6 kg with connection cable

Norms AS 1674.2
AS/NZS 3652
WTIA Tech note 22

IEC 60974-1
IEC 60974-10
EN 50199

The products meet conformity requirements for CE marking.

© COPYRIGHT KEMPPI OY

Minarc 150AU / 0411 – 9

KEMPPI OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
www.kemppi.com

KEMPPIKONEET OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
e-mail: myynti.@kemppi.com

KEMPPI SVERIGE AB
Box 717
S – 194 27 UPPLANDS VÄSBY
SVERIGE
Tel [phone]
Telefax (08) 59 082 394
e-mail: [e-mail]

KEMPPI NORGE A/S
Postboks 2151, Postterminalen
N – 3103 TØNSBERG
NORGE
Tel [phone]
Telefax 33 34 60 10
e-mail: [e-mail]

KEMPPI DANMARK A/S
Literbuen 11
DK – 2740 SKOVLUNDE
DANMARK
Tel [phone]
Telefax 44 941 536
e-mail:[e-mail]

KEMPPI BENELUX B.V.
Postbus 5603
NL – 4801 EA BREDA
NEDERLAND
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI (UK) Ltd
Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK443WH
ENGLAND
Tel [phone]
Fax [phone]
e-mail: [e-mail]

KEMPPI FRANCE S.A.
S.A. au capital de 5 000 000 F.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
Telefax (01) 30 90 04 45
e-mail: [e-mail]

KEMPPI GmbH
Otto – Hahn – Straße 14
D – 35510 BUTZBACH
DEUTSCHLAND
Tel [phone]
Telefax (06033) 72 528
e-mail:[e-mail]

KEMPPI SP. z o.o.
Ul. Piłsudskiego 2
05-091 ZA¸BKI
Poland
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI SWITZERLAND AG
Chemin de la Colice 4
CH-1023 Crissier/ Lausanne
SUISSE
Tel. [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI WELDING
MACHINES AUSTRALIA PTY LTD
P.O. Box 404 (2/58 Lancaster Street)
Ingleburn NSW 2565, Australia
Tel. [phone]
Telefax [phone]
e-mail: [e-mail]

Ver. 7

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