- 6 -
- Loading the wire reel;
5.2 HOW TO LIFT THE WELDING MACHINE
- Cleaning the rollers, the gears and the area underneath them;
None of the welding machines described in this manual is equipped with a lifting device.
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- Lubricating the gears.
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND
WARNING! Position the welding machine on a flat surface with sufficient
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
- Never lift the welding machine .
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5.2.1 CONNECTION TO THE MAIN POWER SUPPLY
2. INTRODUCTION AND GENERAL DESCRIPTION
- Before making any electrical connection, make sure the rating data of the welding
2.1 COMPACT WELDING MACHINE (FIG. A1, A2)
machine correspond to the mains voltage and frequency available at the place of
This welding machine is a power source used for arc welding and has been designed
installation.
specifically for MAG welding of carbon steel and low-alloy steel with either CO or
2
- The welding machine should only be connected to a power supply system with the
Argon/CO mixture shielding gas using solid or cored (tubular) electrode wires.
2
neutral conductor connected to earth.
They are also suitable for MIG welding of stainless steel using Argon gas + 1-2% oxygen
- To comply with the requirements of the EN 61000-3-11 (Flicker) standard we
and of aluminium with Argon gas using electrode wires with a composition suited to the
recommend connecting the welding machine to interface points of the power supply
piece to be welded.
that have an impedance of less than Zmax = 0.04 ohm.
A typical example of MIG brazing would be on galvanised sheet with copper alloy wire
-
The welding machine falls within the requisites of IEC/EN 61000-3-12 standard.
(e.g. copper-silicon or copper-aluminium) with pure Argon (99.9%) protective gas.
5.2.2 PLUG AND OUTLET:
connect a normalised plug
(3P + T)
having sufficient
2.2 WELDING MACHINE WITH REMOVABLE WIRE FEEDER (FIG.A3)
capacity- to the power cable and prepare a mains outlet fitted with fuses or an automatic
Continuous wire, three-phase, fan-cooled welding machine on wheels, for MIG-
circuit-breaker; the special earth terminal should be connected to the earth conductor
MAG/FLUX welding and brazing, with 4-ROLLER, removable wire feeder. Flexibility of
(yellow-green) of the power supply line. Table 1
(TAB.1)
shows the recommended
use with different types of materials such as steel, stainless steel and aluminium. Large
delayed fuse sizes in amps, chosen according to the max. nominal current supplied by
number of arc voltage adjustment steps.
the welding machine, and the nominal voltage of the main power supply.
- To carry out voltage change operations, take off the panel to gain access to the inside
2.3 STANDARD ACCESSORIES:
of the machine, and prepare the voltage change terminal board so that the
- torch (water-cooled in the R.A. version);
connection indicated on the special indicator plate corresponds to the available
- return cable complete with earth clamp;
power supply voltage.
- wheels kit;
FIG. E
- ARGON bottle adapter;
Reassemble the panel carefully using the appropriate screws.
- pressure reducing valve;
Warning!
- wire feeder;
In the factory the machine is set at the highest voltage of the available range,
- R.A. water cooling unit (only for the R.A. version);
e.g.
U 400V
Ü
Voltage setting at the factory.
1
2.4 OPTIONAL ACCESSORIES
- electronics board with dual timer;
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- generator - wire feeder connecting cables assembly (only for welding machine with
removable wire feeder);
WARNING!
- R.A. water cooling unit (where present);
(standard accessory on R.A. version);
Failure to observe the above rules will make the (Class 1) safety system installed
- Reel cover kit (where present);
by the manufacturer ineffective with consequent serious risks to persons (e.g.
- Aluminium welding kit;
electric shock) and objects (e.g. fire).
- Flux-core wire welding kit;
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5.3 CONNECTION OF THE WELDING CABLES
3. TECHNICAL DATA
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3.1 DATA PLATE
The most important data regarding use and performance of the welding machine are
WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
summarised on the rating plate and have the following meaning:
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
FIG. B
THE POWER SUPPLY OUTLET.
1-
EUROPEAN standard of reference, for safety and construction of arc welding
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machines.
2-
Symbol for internal structure of the welding machine.
2
Table 1
(TAB. 1)
gives the recommended values for the welding cables (in mm )
3-
Symbol for welding procedure provided.
depending on the maximum current supplied by the welding machine.
4-
Symbol
S
: indicates that welding operations may be carried out in environments with
heightened risk of electric shock (e.g. very close to large metallic volumes).
5.3.1 Connection to the gas bottle
5-
Symbol for power supply line:
- Gas bottle can be loaded on welding machine bottle support platform: max 20 kg.
1~: single phase alternating voltage;
- Screw the pressure reducing valve onto the gas bottle valve, inserting the
3~: 3-phase alternating voltage.
appropriate adapter supplied as an accessory, for when the gas used is Argon or
6-
Protection rating of the covering.
an Argon /CO mixture.
7-
Technical specifications for power supply line:
2
- Connect the gas inlet pipe to the pressure-reducing valve and tighten the band
- U :
Alternating voltage and power supply frequency of welding machine (allowed
1
supplied.
limit ±10%).
- Loosen the adjustment ring nut on the pressure-reducing valve before opening the
- I
:
Maximum current absorbed by the line.
1 max
bottle valve.
- I
:
effective current supplied.
1eff
8-
Performance of the welding circuit:
5.3.2 Connecting the welding current return cable
- U :
maximum no-load voltage (open welding circuit).
This is connected to the piece being welded or to the metal bench supporting it, as close
0
as possible to the join being made.
- I /U :
current and corresponding normalised voltage that the welding machine can
2
2
This cable is connected to the terminal with the symbol (-).
supply during welding.
- X :
Duty cycle: indicates the time for which the welding machine can supply the
5.3.3 Connecting the torch
corresponding current (same column). It is expressed as %, based on a 10 min.
Engage the torch with its dedicated connector by tightening the locking ring manually as
cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on)
.
far down as it will go. Prepare the wire for loading the first time by dismantling the nozzle
If the usage factors (on the plate, referring to a 40°C environment) are exceeded,
and the contact tube to ease its exit.
the thermal safeguard will trigger (the welding machine will remain in standby until
its temperature returns within the allowed limits).
5.3.4 Connection to the wire feeder (for model with external wire feeder)
- A/V-A/V:
shows the range of adjustment for the welding current (minimum
- Make the connections with the electrical generator (rear panel):
maximum) at the corresponding arc voltage.
- welding current cable to quick connection (+);
9-
Manufacturer's serial number for welding machine identification (indispensable for
- control cable to appropriate connector.
technical assistance, requesting spare parts, discovering product origin).
- Make sure the connectors are firmly tightened in order to prevent overheating and
10-
:
Size of delayed action fuses to be used to protect the power line.
loss of efficiency.
11-
Symbols referring to safety regulations, whose meaning is given in chapter 1
- Connect the gas pipe from the pressure-reducing valve on the bottle and lock it with
“General safety considerations for arc welding”.
the clip supplied.
Note: The data plate shown above is an example to give the meaning of the symbols and
numbers; the exact values of technical data for the welding machine in your possession
5.3.5 Warnings
must be checked directly on the data plate of the welding machine itself.
- Turn the welding cable connectors right down into the quick connections (if present),
to ensure a perfect electrical contact; otherwise the connectors themselves will
3.2 OTHER TECHNICAL DATA
overheat, resulting in their rapid deterioration and loss of efficiency.
- WELDING MACHINE: see table 1 (TAB.1)
- The welding cables should be as short as possible.
- TORCH:
see table 2 (TAB.2)
- Do not use metal structures which are not part of the workpiece to substitute the
The welding machine weight is shown in table 1 (TAB. 1).
return cable of the welding current: this could jeopardise safety and result in poor
welding.
4.DESCRIPTION OF THE WELDING MACHINE
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES (FIG. A)
5.3.6 Connection of G.R.A. -water-cooling unit -(only for R.A. version)
- Secure the G.R.A. to the machine by means of the bracket supplied.
- Connect the water piping to the quick-couplers.
5. INSTALLATION
- Switch ON the G.R.A. following the procedure described in the manual supplied with
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the cooling unit.
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
5.4 LOADING THE WIRE REEL (FIG. F-F1-F2)
ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY
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SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
AUTHORISED OR QUALIFIED PERSONNEL.
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
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FROM THE MAIN POWER SUPPLY OUTLET.
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5.1 PREPARATION (FIG. C)
Unpack the welding machine, assemble the separate parts contained in the package.
MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND
THE CONTACT TIP OF THE TORCH MATCH THE DIAMETER AND TYPE OF WIRE
5.1.1 Assembling the return cable-clamp (FIG. D)
TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN
INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES.
Summary of Contents for MASTERMIG 220/2
Page 83: ...83 FIG D FIG E 230V 220V 240V 400V 380V 415V...
Page 84: ...84 0 8 0 8 0 8 0 6 0 6 4 3 a b 2 1 a b a b c 200mm kg5 300mm kg15 FIG F...
Page 85: ...85 FIG F1 200mm 300mm 1 a a b b 4 2 a b c 3 0 8 0 8 0 6 0 6...
Page 86: ...86 FIG F2 200mm 300mm 1 a a b b 4 2 a b c 3 0 8 0 8 0 6 0 6 MAX 5kg MAX 15kg...
