Kemppi Minarc 220 User Manual

Minarc

220

Operating manual • English

Käyttöohje • Suomi

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Bruksanvisning • Norsk

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Gebruiksaanwijzing • Nederlands

Manuel d’utilisation • Français

Manual de instrucciones • Español

Instrukcja obsługi • Polski

Инструкции по эксплуатации • По-русски

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OPERATING MANUAL

English

Minarc 220 / © Kemppi Oy / 1117

EN

CONTENTS

Minarc 220 / © Kemppi Oy / 1117

EN

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

1.1 General ..........................................................................................................................3

1.2 Machine properties ................................................................................................3

1.3 About welding ..........................................................................................................3

2. MACHINE USE ..................................................................................................4

2.1 Before commissioning the machine ............................................................4

2.2 General view of the machine ...........................................................................5

2.3 Distribution network ............................................................................................. 5

2.4 Cable connections ..................................................................................................6

2.5 Welding power selection and electrodes ..................................................6

2.6 Function controls and indicator lights ........................................................8

2.6.1 Welding current regulation and remote control ................................ 9

2.6.2 MMA welding settings .................................................................................9

2.6.3 TIG welding function .................................................................................... 9

2.6.4 The VRD feature .............................................................................................. 9

3. MAINTENANCE ............................................................................................10

3.1 Daily maintenance...............................................................................................10

3.2 Disposal .....................................................................................................................10

4. ORDERING NUMBERS ......................................................................... 11

5. TROUBLESHOOTING ............................................................................12

6. TECHNICAL DATA ..................................................................................... 12

2

1. PREFACE

1.1 GENERAL

Congratulations on choosing the Minarc 220 equipment. Used correctly,
Kemppi products can signicantly 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 specications
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.

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 specications 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.

1.2 MACHINE PROPERTIES

The Minarc 220 is intended for use in a three-phase electric network. It is
designed to be a compact and ecient direct current MMA/TIG machine.
Extremely light in weight for its high 220 A output power, the machine is easy
to carry to the work place with either the inbuilt moulded carry handle or the
shoulder strap provided.

Minarc 220 / © Kemppi Oy / 1117

EN

1.3 ABOUT WELDING

Minarc 220 provides high quality welding results time after time provided
the correct operational procedures are followed. Welding quality is not only
inuenced by the machine itself. Personal expertise, ancilliary equipment and
consumables also play an essential role, as does the correct, fused supply power.

Welding is carried out when an electric arc is established between the
welding electrode and work piece. Welding is not possible unless the
equipment is correctly set-up, including the earthing cable attached to the
work piece. This cable creates the welding circuit that allows the welding
current to ow. Please check the earthing clamp is on the work piece to be
welded, and that the area of the clamps contact is clean and free from paint.

3

MMA Welding

The MMA is a simple welding process. A coated MMA electrode is short
circuited to the work piece and the resulting electric arc creates a molten
pool into which the electrode wire melts. The coating around the electrode
burns to create a protective gaseous atmosphere and slag, which directly
protects the molten weld pool from atmospheric contamination. The slag
oats on the molten weld pool and solidies on the surface of the resulting
weld bead, protecting the cooling weld.

The electrode is moved slowly along the weld seam. The travel speed
is directly proportional to the size of the electrode and welding current
selected. The slag is nally removed with a chipping hammer to reveal the
weld (always use eye protection).

Minarc 220 / © Kemppi Oy / 1117

EN

TIG Welding

In TIG welding, the welding arc is formed between a non-consumable
tungsten electrode and the work piece. The resulting high temperature arc
melts the work piece to form a molten pool, into which ller wire of a similar
alloy composition is slowly melted. The molten weld pool and ller wire are
protected from the harmful eects of atmospheric contamination by an inert
shielding gas that ows out from the TIG welding torch’s ceramic nozzle at a
rate of approximately 8–15 litres per minute. (Gas regulator, ow meter and
pure argon shielding gas are not provided in this package.)

2. MACHINE USE

2.1 BEFORE COMMISSIONING THE MACHINE

Minarc 220 is packed in sturdy, custom-made packaging. However, always
ensure that the equipment has not been damaged in transportation. Even so,
make sure that all in-transport damage is reported to the machine supplier.
Do not unpack the machine under these circumstances. In addition, before
commissioning, check that you have received all of the items you ordered
along with their operating instructions.

Transportation

The machine should be transported in an upright position.

Environment

The machine is suitable for both indoor and outdoor use. In outdoor use,
protect it from heavy rain and sunshine. Store the machine in a dry and clean

4

environment and protect it from sand and dust during use and storage.
The recommended operating temperature range is -20 to +40 degrees
centigrade. Site the machine so that it does not come into contact with hot
surfaces, sparks and welding spatter. Make sure the airow to and from the
machine is unrestricted.

2.2 GENERAL VIEW OF THE MACHINE

1.2.

1. MMA welding cable

2. Earthing cable and earthing clamp

3. Main switch

4. Mains cable

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.

3.

4.

Minarc 220 / © Kemppi Oy / 1117

EN

5

Minarc 220:

This equipment complies with IEC 61000-3-12 provided that the short-circuit
power Ssc is greater than or equal to 1.6 MVA at the interface point between
the user's supply and the public supply network. It is the responsibility of
the installer or user of the equipment to ensure, by consultation with the
distribution network operator if necessary, that the equipment is connected
only to a supply with a short-circuit power Ssc greater than or equal to

1.6 MVA.

2.4 CABLE CONNECTIONS

Connection to mains

Minarc 220 / © Kemppi Oy / 1117

EN

Minarc 220 is delivered with a ve-metre mains cable that does not have a plug.

NOTE! Check the fuse size in Technical specications. The plug may be installed

only by electrical contractors and installers authorised to perform such
operations.

If you use an extension power supply cord, its cross sectional area should
be at least as large as the supply voltage cable tted to the machine. The
maximum length for the extension cable is 50 m.

Restrictions on generator type and power may apply in generator use. Fault­free operation of the machine requires a suciently high-power generator.
The power recommendation is more than 15 kVA.

Earthing cable

Connect the earthing cable to the negative pole in MMA welding, and to the
positive pole in TIG welding.

Before you start welding, clean the work piece surface and x the earth
return clamp to the work piece in order to create a closed and interference
free welding circuit.

Shielding gas

In TIG welding, shielding gas is used to prevent atmospheric contamination of
the molten weld pool and cooling weld. Normally, the shielding gas is argon
(Ar). Normally the gas ow rate is approximately 8–15 litres per minute, but this
can vary according to the welding current used and the size of gas nozzle.

2.5 WELDING POWER SELECTION AND ELECTRODES

MMA welding electrodes

In MMA welding, the welding electrodes must be connected to the correct
pole. Normally, the electrode holder is connected to the positive and the

6

earthing cable to the negative connector.
It is also important to properly adjust the welding current so that the ller

material and coating will melt properly and the welding is ecient. The table
below presents the electrode sizes available with the Minarc 220 welding
machine and the corresponding welding current values.

MMA Electrodes and corresponding current settings range

Electrode
diameter

Fe-Rutile
Fe-Basic

1.6 mm 2.0 mm 2.5 mm 3.25 mm 4.0 mm 5.0 mm

30-60 A 40-80 A 50-110 A 80-150 A 120-210 A 170-220 A

30-55 A 50-80 A 80-110 A 110-150 A 140-200 A 200-220 A

TIG welding electrodes and gas nozzles

In DC TIG welding we recommend the use of the WC20 (grey) type electrode,
however other types are available.

The welding electrode size (diameter) is selected depending on the welding
current/power to be used. An electrode with an insucient diameter
compared to the welding current will melt, while excessive electrode size will
make it more dicult to ignite the arc.

Generally speaking, a 1.6 mm tungsten electrode will cover currents up to
150 A, and 2.4 mm tungsten electrode up to 250 A DC current.

Before use, grind the tungsten electrode to a sharp point at approximately

1.5 times the diameter of the electrode.

Minarc 220 / © Kemppi Oy / 1117

EN

7

2.6 FUNCTION CONTROLS AND INDICATOR LIGHTS

1. 2.

Minarc 220 / © Kemppi Oy / 1117

6.

EN

3. 4. 5.

1. Standby indicator. In the VRD version, a VRD safe indicator
(see The VRD feature)

2. Overheating indicator.

3. Welding process selection button (MMA or TIG).

4. Current adjustment selector: panel adjustment or hand-held remote
control.

5. Welding current control knob.

6. Welding value table

Switching the machine on

When you power on the machine, the green standby indicator and the main
switch are lit.

If the machine overheats or the supply voltage is too high or too low, the
welding operation automatically switches o, and the yellow overheating
indicator is illuminated. The light switches o again, when the machine
is ready for operation. Make sure that there is enough space around the
machine to allow the air to freely circulate and ow into and out o the
machine.

8

2.6.1 Welding current regulation and remote control

The welding current can be adjusted steplessly with the control knob, if panel
adjustment (PANEL) is selected.

If you want to adjust the welding current with the remote control, connect
the remote control to the machine and then select remote control with the
current adjustment selector (4). Supported remote control units are the R10
or the RTC10 of the TTV 220 GV TIG torch.

2.6.2 MMA welding settings

MMA welding is selected when the indicator next to either of the electrode
symbols is lit. The options are RUTILE or BASIC. If needed, press the process
selection button to select the MMA process (3). The machine automatically
sets suitable values to the ignition time, ignition pulse and arc dynamics
based on the rutile/basic selection.

2.6.3 TIG welding function

Select the TIG welding process by pressing the process selection button (3).

Ignition with switch control
(TTC 220 GV torch)

When using the TTC 220 GV torch, the TIG arc can be ignited with switch
control. Gently touch the work piece with the electrode, then press the torch
switch while quickly lifting the electrode o the work piece. This will ignite
the arc quickly and eciently. To stop welding, release the switch, which will
stop the current and turn o the torch voltage.

Minarc 220 / © Kemppi Oy / 1117

EN

Ignition by scratch-start
(other than TTC 220 GV torch)

You can also ignite a TIG arc with the scratch-start method. Gently touch the
work piece with the electrode and quickly lift the electrode from the work
piece to a suitable welding distance to ignite the arc. To stop welding, quickly
pull the electrode away from the work piece.

NOTE! The torch voltage will remain on.

2.6.4 The VRD feature

The VRD model of the Minarc 220 contains a voltage reduction device, which
reduces the open-circuit voltage below 35 V. This reduces the risk of electric
shock in particularly dangerous environments, such as closed or damp
spaces.

9

3. MAINTENANCE

All electromechanical devices require routine service maintenance
depending on usage. This type of routine maintenance will prevent hazards
and malfunctions.

We recommend that you schedule a service inspection of your welding
machine every six months. An authorised Kemppi service agent will inspect
and clean your machine, ensuring that all power connections are tight and
secure. Power connections can become loose and oxidised with frequent and
high changes in temperature.

NOTE! Disconnect the machine from the mains power supply before handling

electric cables.

Minarc 220 / © Kemppi Oy / 1117

3.1 DAILY MAINTENANCE

• Check the welding torch electrode. Sharpen the electrode or replace a
damaged one.

EN

3.2 DISPOSAL

• Check the tightness of the earthing cable connections.

• Check the condition of mains and welding cables and replace damaged

cables.

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.

10

4. ORDERING NUMBERS

Product Part number

Minarc 220 6102220

Minarc 220 VRD Reduced open-circuit voltage 30 V 6102220VRD

Cables

Welding cable 16 mm² 5 m 6184103

Welding cable 25 mm² 5 m 6184201

Welding cable 25 mm² 10 m 6184202

Earthing cable 16 mm² 5 m 6184113

Earthing cable 25 mm² 5 m 6184211

Earthing cable 25 mm² 10 m 6184212

TIG torches

TTC 220GV Switch control and RTC10 remote 627022304

TTM 15 BC Scratch-start 627143201

Remote control units

R 10 5 m 6185409

R 10 10 m 618540901

RTC10 6185477

Other accessories

Gas ow gauge AR/clock 6265136

Carrying straps 9592162

Supply voltage cable W002982

Minarc 220 / © Kemppi Oy / 1117

EN

11

5. TROUBLESHOOTING

Problem Cause
The main switch indicator will not

light up

Poor welding result

Minarc 220 / © Kemppi Oy / 1117

Overheating indicator lit

No electricity connected to the machine

• Check the mains supply fuses.

• Check the mains cable and plug.

Several factors aect the welding quality.

• Check that the earthing clamp is rmly attached, the point of

attachment is clean and that the cable and its connectors are

intact.

• Check that the shielding gas ows out of the torch tip.

• Check that the electric voltage is not irregular or too low/high.

The device has overheated.

• Ensure that cooling air has unrestricted ow.

• If the machine’s duty cycle has been exceeded, wait for indicator
to turn o.

• Too low or high supply voltage.

EN

If the machine’s malfunction is not eliminated with these measures, contact
KEMPPI service.

6. TECHNICAL DATA

Minarc 220
Connection voltage
Rated power at max. current

Supply current, I

Supply current, I

Connection cable
Fuse (delayed)

Load capacity 40 °C

1max

1eff

3 ~, 50/60 Hz 400 V –20 %... +15 %

MMA 8.2 kVA (220 A/28.8 V)

TIG 7.2 kVA (220 A/18,8 V)

MMA 12 A (220 A/28.8 V)

TIG 8 A (220 A/18.8 V)

MMA 8 A (150 A/26.0 V)

TIG 6 A (160 A/16.4 V)

H07RN-F 4G1.5 (5 m)

10 A

MMA 35 % ED 220 A/28.8 V

100 % ED 150 A/26.0 V

12

Welding range

TIG 35 % ED 220 A/18.8 V

100 % ED 160 A/16.4 V

MMA 10 A/20.4 V – 220 A/28.8 V

TIG 10 A/10.4 V – 220 A/18.8 V

Open circuit voltage

Idle power
Power factor at 100% ED

Efficiency at 100% ED

Stick electrodes
External dimensions (L × W × H)
Weight
Temperature class
Degree of protection
EMC class
Minimun short circuit power Ssc of

supply network*
Operating temperature range
Storage temperature range
Recommended generator

* See paragraph 2.3.

MMA 85 V (30 V in the VRD version)

TIG 60 V (30 V in the VRD version)

MMA 40 W

TIG 0.92

MMA 0.91

TIG 0.80

MMA 0.86

MMA ø 1.5–5.0 mm

400 × 180 × 340

9.2 kg (10.2 kg with connector cable)

H (B)

IP23S

A

1.6 MVA

-20 °C ... +40 °C

-40 °C ... +60 °C

> 15 kVA

Minarc 220 / © Kemppi Oy / 1117

EN

13

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