Expressweld MasterMIG - 350 - İngilizce Manual kontrol edilmiş

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www.askaynak.com.tr

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Eczacıbaşı - Lincoln Electric recommend to use “ASKAYNAK” gas metal arc welding wire for obtaining high performance from MasterMIG 350.

USER MANUAL

GMAW (MIG/MAG)Welding Method and Specifications

CO2 Phase

AT - UYGUNLUK BEYANIEU - DECLARATION of CONFORMITYEU - KONFORMITÄTSERKLÄRUNG

Déclaration de Conformité de l'EU

Pazarlama ve Lojistik Müdürü / Marketing and Logistics Manager / Directeur de Marché et Logistiques

Sertaç ÖZEN

18.06.2009Tarih / Date / Datum / Date :

KAYNAK TEKNİĞİ SANAYİ ve TİCARET A.Ş.

Şirket / Firm / Firma / Société

aşağıda modeli belirtilen kaynak makinesinindeclares that the welding machine

erklärt, daß die Bauart der Maschinedéclare que le poste de soudage

® ®EXPRESSWELD MasterMIG 350

aşağıda belirtilen yönergelere uygun olduğunuconforms to the following directives

den folgenden Bestimmungen entsprichtest conformé aux directives suivantes

2004/108/EC, 2006/95/EC

ve yine aşağıda belirtilen normlara uygun olarak tasarlandığını beyan eder.and has been designed in compliance with the following standards

und in Überienstimmung mit den nachstehenden normen hergestellt wurdeet qu'il a été conçu en conformité avec les normes

TS EN 60974-1:2007, TS EN 60974-10:2009

Kaynak Tekniği Sanayi ve Ticaret A.Ş.TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi

2. Cadde, No: 5, Şekerpınar 41480 Çayırova, Kocaeli - TURKEY

December 2014

Kaynak Tekniği Sanayi ve Ticaret A.Ş.

TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi

2. Cadde, No: 5, Şekerpınar 41480 Çayırova, KOCAELİ

Phone: (0262) 679 78 00 Fax: (0262) 679 77 00

www.askaynak.com.tr

MANUFACTURER

Manufactured in People's Republic of China by KAYNAK

TEKNİĞİ SANAYİ ve TİCARET A.Ş.

Physical life determined by Ministry of Industry and Trade is 10 years. (This is the period for providing spare parts required for the machine to operate.)

1. General Safety Rules

Electromagnetic Compatibility

2. General Information, Warnings and Operation Conditions

3. Specifications

4. Technical Data

5. Front Panel Controls

6. Back Panel Controls

7. Controls in Wire Feeder Unit

8. Connection Diagram

9. Installation and Operation of Machine

9.1. Mains Supply

9.2. Shielding Gas Connection

9.3. Welding Torch Connection

9.4. Connection Between Power Unit and Wire Feeder Unit

9.5. Installing Welding Wire

10. Functions of Wire Feeder Unit

11. Environment Conditions

12. GMAW (MIG/MAG) Method

13. Expirty of Machine's Physical Life

14. In Terms of Energy ConsumptionEfficient Use of Machine

15. Storage and Transportation

16. Maintenance and Repair

17. Unpacking

18. Troubleshooting Guide

19. Failures in Welding Seams

20. Spare Part List

21. Warning Label

22. Electrical Circuit Diagram

23. Wire Feeder and Power Unit Specifications

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Table of Contents

Expressweld MasterMIG 350


"Expressweld"is the registered trademark of Kaynak Tekniği

Sanayi ve Ticaret A.Ş.


"MasterMIG"is the registered trademark of Kaynak Tekniği

Sanayi ve Ticaret A.Ş.

Page 1


1 General Safety Rules

THIS MACHINE HAS BEEN DESIGNED FOR GMAW (MIG/

MAG). SHALL NOT BE USED FOR ANY OTHER PURPOSE.

READ AND UNDERSTAND THE INSTRUCTIONS CAREFULLY:

WARNING: This symbol indicates that the instructions within the user guide must be

followed to avoid potential serious personal injury, loss of life and damages on machine.

Protect yourself and other people.

Be sure that this machine should only operated by qualified personnel. Be sure that

all installation, operation, maintenance and repair procedures are performed only by

authorized personnel. Be sure to read user guide carefully before operating the

machine. Failure to follow the instructions included in the user guide may cause

serious injury, loss of life and damage on machine. Please read the warnings next to

the symbols stated below. "Kaynak Tekniği Sanayi ve Ticaret A.Ş." is not liable for any

damages due to improper connection, storage conditions and operation procedures.

Be sure to read and understand the user guide before operating the machine. Failure to follow the instructions stated in the user guide may cause serious injury, loss of life and damage on equipment.

Do not weld while you are unattentive, unattentive, tired and sleepless.

Arc welding is a safe application when necessary measures are taken to protect the

welder against potential dangers. If these measures missed or disregarded, there may

be dangers such as electric shock, exposing to high levels of fume and gas, arc

radiation, fire and explode which may cause serious injury or even death.

Note: For detailed information on safety in welding, please read ANSI Z49.1 standard.

Protective Equipments:

Welding operators should wear protective clothing to protect themselves against

burning risk. Welding burns is a frequent risk which may be caused due to splash of

welding sparks on bare skin.

Clothing used while welding may vary based on used welding method but generally it

should provide easy movements and should cover welder's body to protect against

splashes, sparks and arc radiation.

Page 2


Flame resistant clothing,

Gaiters,

Aprons,

Leather cuff gloves and capes,

Helmet used under the welding mask.

Noise:

Importance and Cleanliness of Working Environment:

Wool y clothing should be preferred due to its resistance against flame. Synthetic

clothing should not be worn since they will melt when exposed to heat.

Protective clothing should be protected from grease and oil. This kind of materials may

flare and burn uncontrolledly in an environment with oxygen.

Shirtsleeves and trouser hems should not be folded. Since sparks and melted metals

may enter into these folds. Trousers should be kept outside the work shoes and should

not be inserted into it. Otherwise melted metals and sparks may enter into shoe.

Other protective clothing used in dangerous situations are stated below:

To protect hands against burns, cuts and scratches, gloves made from flame resistant materials such as leather must be used. In addition, to provide some insulation against electric shock, care should be taken that the gloves made from flame resistant material are in good condition and dry.

To protect ears against sparks and melted metals and to prevent hearing impairment

due to noise of arc welder, ear protectors should be used. When the noise in working

environment is reached to a level that disturbing the ears and causing headache,

auditory problem may occur. In such a condition immediately use your ear protectors.

Hearing impairment may not be noticed until tested and then it may be too late for

treatment.

The tidiness and cleanliness of working environment is important as the maintenance of

welder. Even the level of potential damage rises up to number of people in the

environment. Although warnings related to machine are read and necessary measures

are taken, any of the personnel tripping over a cable may cause electric shock, contact to

hot metal or falling risk for himself, you and other people.

Page 3


Primary voltage shock (e.g. 230-460 V)

Secondary voltage shock (e.g. 20-100 V)

ELECTRIC SHOCK can kill.

All equipment, cables, hoses and gas cylinders should be kept away from busy places

such as doors, aisles and stairs. Care should be taken for the tidiness of the

environment and when welding is completed working environment should be cleaned.

By this way, both work safety and working efficiency will increase. Besides, other

workers near the welding area may step into weld pool by mistake, therefore safety

guards should be placed around the welding area during welding.

Electric shock danger is the most serious risk that operator may encounter frequently.

Contacting electrically hot parts may cause injuries, death or falling down due to electric

shock and sudden reflex. While machine is operating, do not touch to the electrode,

ground connection or live work piece connected to the machine. Insulate yourself

against electrode, grounding connection or work piece. Immediately after plugging out

the power cable, do not touch metal ends of power cable, there may be electric shock

danger.

Electric shock risk related to welding machine divides into two categories:

Primary electric shock is very dangerous since it is much higher than welding voltage.

When the power to the machine is open, you can encounter with primary electric shock

while your body is in contact with ground or touching a live point within the machine.

Please note that turning off the ON/OFF switch located on the machine do not cut off the

electric. To cut off the electric to the machine it is necessary to disconnect the supply

cable from connection point or to shut down the fuse of incoming electric.

Never remove side covers of the machine and in case of failure have an authorized

technician to inspect and repair it.

Be sure to ground the machine and work piece.

While installing the machine and making ground connection, follow general electric

rules, all local laws and regulations and instructions of the manufacturer company.

Do not use uninsulated cables and pliers, replace with the new ones. Never dip the

electrode in water for cooling.

Page 4


WELDING ARC and ARC RAYS can burn.

Never simultaneously touch electrically "hot" parts of electrode holders connected to

two separate welders, because voltage between the two can be the total of the open

circuit voltage of both welders.

When working above floor level, use a safety belt to protect yourself from a fall should

you get a shock.

In semi-automatic or automatic welding, welding wire, electrode reel, welding head,

nozzle or torch are also electrically “hot”.

Always be sure the work cable makes a good electrical connection with the metal being

welded. The connection should be as close as possible to the area being welded.

While the welder is electrically hot, do not insert your hand or any other object inside it.

Use a shield with proper filter and cover plates to protect your eyes from sparks and the

rays of the arc when welding or observing open arc welding. Skin should be protected by

clothing made from flame resistance material. Protect other nearby personnel with

suitable, non-flammable screening and/or warn them not to watch welding arc nor

expose themselves to the arc rays or to hot spatter or metal.

When eyes are exposed to UV rays even for a short time, also called as “Getting

Welder's Flash”, it may cause burns in your eyes. Getting Welder's Flash may not be

noticed after hours of exposing, but it is too irritating as well as may cause transient

blindness. Normally getting welder's flash is a temporary situation, but exposing eyes to

UV rays for a long time and frequently may cause permanent damage on eyes. As a

protection measure besides not to watch arc rays, also using welding goggles having

proper filter is necessary.

As a rule, welding should start with a dark colored protective filter then should continue

with a lighter colored filter sufficient to see the area being welded providing that not to fall

under the minimum level. Welding masks protect head, face, ears and neck against

electric shock risk, heat, sparks and fire.

Page 5


GASES and FUMES can be dangerous.

When welding with electrodes which require special ventilation such as stainless or hard

facing or on lead or cadmium plated steel and other metals or coatings which produce

highly toxic fumes, keep exposure as low as possible and keep the exposure level under

“Minimum Limit Values” using local exhaust or mechanical ventilation. In confined

spaces or in some circumstances, a respirator may be required even outdoors.

Additional precautions are also required when welding on galvanized steel.

Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,

cleaning or spraying operations. The heat and rays of the arc can react with solvent

vapors to form a highly toxic gas, and other irritating products.

Welding may cause fumes and gases that are injurious to health. Always enough

ventilation should be used or fumes and gases should be exhausted from breathing

place.

Generally in welding applications; temporary effects for short time can be seen such as

face and skin burning, dizziness, nausea and fever based on exposure period and

amount of fume. Long time fume exposure may cause iron loading and dysfunctions in

lungs. Bronchitis and pulmonary fibrosis are primary effects occurred.

Some electrodes may include alloys that entail special ventilation. Label of these

products that entails special ventilation should not be ignored and “Product Safety

Information Form” reports should be read carefully. When welding on this kind of

materials it may be necessary to use gas mask.

Keeping your head out of fume clouds is the easiest way for protection against toxic

fumes and gases.

Avoid breathing these fumes and gases, air circulation or mechanical ventilation

equipments should be used and if the ventilation is not enough gas mask should be

used.

Page 6

WELDING and CUTTING SPARKS can cause fire or explosion.


Where compressed gases are to be used at the job site, special precautions should be

used to prevent hazardous situations.

Do not heat, cut or weld tanks, drums or containers until the proper steps have been

taken to insure that such procedures will not cause flammable or toxic vapors from

substances inside. Tanks, drums or containers can cause an explosion even though

they have been cleaned. For information, read “Recommended Safe Practices for the

Preparation for Welding and Cutting of Containers and Piping That Have Held

Hazardous Substances”, AWS F4.1 from American Welding Society.

Connect work cable to the piece being welded as close as possible. Work cables

connected to the building framework or other locations away from the welding area

increase the possibility of the welding current passing through lifting chains, crane

cables or other alternate circuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

Keep away fire hazards from welding area and have a fire extinguisher readily available.

Remember that welding sparks and hot materials from welding operation can easily go

through small cracks and openings to adjacent areas. Until ensuring that precautions

are used to fully clean flammable and toxic gases, never weld any tanks, drums,

containers or material. Never operate welder in places that flammable gases, vapors or

liquid fuels exist.

Always keep in mind the fire risk due to high temperatures in arc welding. Welding arc

temperature may increase up to 5000 C°, but generally this temperature is not the only

fire reason. Fire risk may be occurred due to sparks or melted metals splashed around.

These metals may splash up to ten meters away. Therefore keep inflammable materials

away from welding area. Also make sure that your work piece do not contact with any

material that may flare when heated. Material, that may flare with contact are divided into

three categories as liquids (fuel, oil, paint, thinner etc.), solids (wood, cartoon, paper

etc.) and gases (acetylene, hydrogen etc.).

Inspect the welding area. If there are systems operating with fuel or hydraulic oil and if

you cannot move welding area or system, place fire-resistant protecting screen between

them. If you are welding above floor level or on stairway, make sure there is no

flammable or explosive material below. Also please remember that slag and sparks may

splash on people around.


Page 7

FIRE DANGER may cause accidents.

Special precautions should be used when welding in dusty environment. Dust particles

may burn and may cause sudden fire or explosion. If you don't have information about

the inflammableness and fugacity of the dust in the environment, do not start welding or

cutting until it is inspected and approved by expert and authorized person.

Before starting to the welding procedure, please check if there is any flammable or self-

ignition under heat coating on the surface of your work piece.

When you have a break in welding process, please make sure that the electrode holder

do not contact to the ground or work piece.

If you are welding within ten meters to the place where flammable materials located,

have a observor near you. This observer should watch where the sparks and splashes

go and should access easily to the fire extinguishers when necessary. After welding

process, please check if there is any fume around for half an hour with the observer.

As in other emergency situations, first rule is not to panic in situations where welding

accidents happen. According to the size of the fire, to warn the others activate the fire

alarm, inform fire station, shut down the plasma cutting machine and leave the building

from fire exits as soon as possible.

To prevent the risk for every kind of arc glare and fire, never leave the welding torch on

welding desk or any surface in contact with work clamp.

Never refuel near to the welding arc or if there is any engine operating in the surrounding

area. Stop the engine and allow it to cool before refueling to prevent spilled fuel from

vaporizing on contact with hot engine parts and igniting. While refilling the tank, do not

spill fuel around.


Page 8

Cylinders should be kept away from areas where they may be struck or

subjected to physical damage.

Cylinders should be located to a safe distance from arc welding or cutting

operations and any other source of heat, sparks or flame.

CYLINDER may explode if damaged.

MOVING PARTS may hurt your hands.

Use only compressed gas cylinders containing the correct shielding gas for the process

used and properly operating regulators designed for the gas and pressure used. All

hoses, fittings, etc. should be suitable for the welding application and maintained in good

condition with a proper installation.

Always keep cylinders in an upright position securely chained to an undercarriage or

fixed support.

Carefully choose the locations of the cylinders:

Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a

cylinder.

Keep your head and face away from the cylinder valve outlet when opening the cylinder

valve.

Valve protection caps should always be in place and hand tight except when the cylinder

is in use or connected for use (including the transportation of the cylinder).

Always keep all safety guards, coverings and equipments in place and maintain in good

condition. Always keep your hands, hair, clothing and tools away from V-belt, gears, fans

and all other moving parts when starting, operating or repairing the equipment.

In some cases, it may be necessary to remove safety guards to perform required

maintenance. Remove the guards only when necessary and replace them when the

maintenance requiring their removal is complete. Always use the greatest care when

working near moving parts.

Never put your hands near to the cooling fan while it is operating.

To prevent accidentally starting gasoline engines while turning the engine or welding

generator during maintenance work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

Page 9

For electrically powered equipment.

WELDED HOT material may cause burns.

ELECTRIC and MAGNETIC fields may be hazardous on human health.

Compliance with CE NORMS, SAFETY USAGE.


Turn off input power using the disconnect switch at the fuse box before working

on the equipment. Install equipment in accordance with local codes in force.

GROUNDING: Power cables should be connected to a well grounded plug for

your safety and proper operation of the equipment.

Periodically inspect the conditions of electrode cables, supply cables and cables

connected to the equipment. If you notice any improper situation, immediately

replace damaged parts with the new ones. To prevent the risk for every kind of

arc glare and fire, never leave the electrode holder on welding desk or any

surface in contact with work clamp.

High amounts of heat may be produced from welding process. Hot surfaces and material

may cause serious burns. While touching or moving this kind of material, always wear

gloves.

Electric current flowing through any conductor causes electromagnetic fields. This

electromagnetic field may interfere with devices such as pacemaker. Welders having a

pacemaker shall consult their physician before operating this equipment. Exposure to

electric and magnetic fields may have other health effects which are not known yet (For

detailed information, refer to Page 12).

This machine has been manufactured as per “European Instructions”.

This machine is suitable for welding in environments where there is high electric shock

risk.

Page 10

EXTRA SAFETY MEASURES:

Semi-automatic DC constant voltage welders,

DC manual arc welders,

AC welders with reduced voltage control.

PRECAUTIONS FOR OTHERS IN THE WORKING ENVIRONMENT:


In some situations applying safety measures may be difficult, but even so follow the

mentioned rules. Keep your gloves dry, if getting wet is unavoidable then have an extra

pair of gloves near you. Stand on a plywood, plastic mat or similar dry and insulating

material. Insulate your body from welding piece.

If welding must be performed under electrically hazardous conditions such as in damp

locations or while wearing wet clothing, on metal structures such as floors, gratings or

scaffolds, when in cramped positions such as sitting, kneeling or lying, if there is a high

risk of unavoidable or accidental contact with the workpiece or ground, prefer to use the

following equipment:

Conditions of electrode holder and cables are so important. Plastic or fiber insulating

material on holder prevents contact to electrically hot" places. Before starting the "

welder, always check the condition of the holder. Replace the old and worn ones, never

attempt to repair. Perform same checks for the cables, since the cost will be high to

replace cables, repair by using tubw with high insulation or similar. Always check the

insulations before every time you start the welder.

If you feel an electric shock, always remember that this is a warning. In such case

before continue to work, check your machine, working routines and working

environment against electric shock. If there is an abnormal situation, never continue

welding without using the necessary precaution. If you cannot determine the source of

problem, have an expert and authorized person to check it.

Cleanliness and tidiness of working environment is extremely important for your safety

as well as other people in the environment. While other welders working or people

walking around the welding area may step onto your weld puddle by mistake or may

cause you and others to fall down by tripping over cables and electric shock risk. Also

welding sparks may cause burn danger by splashing on other people around.

Surrounding welding area with fire resistant screens reduces potential risks.

Also warn other people in the working environment for the use of work safety

equipments. Especially when they have to be in welding area, warn them to use fire and

flame resistant work safety clothing, welding goggles, welding mask, insulated work

shoes and gloves. Keep away any people who do not follow the instructions.

Page 11

INFORMATION ON RESIDUAL RISKS:


When working above floor level, use related warning signs to prevent splashing of

melted metals and welding sparks on people under working area.

Electromagnetic fields may be hazardous for pacemakers.

Make the necessary warnings and use warning signs for other people working or

passing around who are not related to welding work. Inform them that they have to

contact with their doctors before working in a welding environment.

In welding environments there is high electric shock risk. Other people may encounter

electric shock risk by tripping over cables while working. Do not use uninsulated welding

cables, route cables through insulated, plastic channels if available.

Expressweld MasterMIG 350 welder has been designed and manufactured in

compliance with safety rules required by TS EN 60974-1 standard. To eliminate the

safety risks all necessary precautions have been taken, precautions that need to be

taken by operators and users and all rules to be followed have been stated in the user

manual. It is not possible to eliminate the risks in cases that necessary care is not taken

or safety measures are not used. These risks may cause slight injuries but at the same

time fire and explosion risks may be fatal for more than one people. It is the user's

responsibility to assure the safety of environment where the welding operation is

performed, in cases that precautions are not used or lacking, work must be stopped

immediately and authorized people should be informed.

Page 12

ELECTROMAGNETIC COMPATIBILITYELECTROMAGNETIC fields may be hazardous.


After turning on the power unit, you should wait approximately for 5-10 seconds for electrical stability of the machine and then

start to welding procedure.

Designed according to TS EN 60974-1.EMU Class of machine according to TS EN 55011 is Group 2 Class A.

For detailed information refer to TS EN 60974-10.

While welding do not turn on/off the power switch. This situation may cause voltage fluctuations in mains as well as shorten the

economic life of the machine.

Welding machine has been designed according to related norms and rules. In addition, it

may cause safety problem for the devices affected from electromagnetic waves since it

may produce interfering electromagnetic waves for telecommunication devices

(telephone, radio, television) and safety equipments. To prevent and eliminate the effect

of these electromagnetic waves (interferences) produced by the machine, please read

below explanations carefully.

Welding machine has been intended to use in industrial fields. In case of using in living

spaces, to eliminate potential effects of electromagnetic waves it is necessary to use

specific precautions. User should certainly install and operate the machine as per the

instructions included in the user guide. In case any electromagnetic interference is

detected, user should take necessary precautions for this. If necessary, Kaynak Tekniği

Sanayi ve Ticaret A.Ş. will help to the user in this matter. No modifications should be

made on the machine without the written consent of Kaynak Tekniği Sanayi ve Ticaret

A.Ş.

Before the installation of the welding machine, user should check if there is any device in

the working area that may be affected due to electromagnetic waves. Some of these

devices are stated below:

1 - Lead wires, control cables and phone cables near the working area and machine,

2 - Radio and/or television receivers and transmitters, telecommunication devices,

3 - Computers or computer controlled devices,

4 - Safety and control equipments for industrial processes,

5 - Personal medical devices such as pacemakers and hearing aids,

Electromagnetic fields may interfere with some pacemakers. Therefore welders having

pacemakers should contact with their physicians before welding process.

6 - Calibration and measuring devices.

Page 13


Electromagnetic resistance of the equipments located and working in working area

should be checked. User must be sure that other surrounding devices will operate in

harmony with the machine. To achieve this extra protection measures may be necessary.

To reduce the effect and exposure level of electromagnetic waves produced by the

machine, below warnings should certainly taken into account:

1 - Mains supply connection should be performed as explained in the user manual. If

electromagnetic interference occurs, it may be necessary to take some precautions

like filtering the electric main.

2 - Lead wires (electrode and work cables) should be as short as possible and should be

routed together. Never wrap these cables around your body and stand between the

cables and pay attention that the cables are not on the grounded surfaces.

3 - Work cable should be connected to the piece being welded as close as possible.

4 - While welding operation, keep the power unit in a place as far as possible.

5 - Insulation of cables within the working area may reduce the electromagnetic

interference. This situation may be necessary for some special applications.

6 - To reduce electromagnetic interference and increase work safety, ground the work

piece if possible. User should check if this grounding may cause problem for himself

and for the machine.

7 - Ideal measurements of the working area should be determined based on the

construction of this area and other factors included.

8 - To achieve respectively harmonic current emissions and voltage fluctuations and

flicker limits according to TS EN 61000-3-12 and TS EN 61000-3-11 standards,

recommended mains supply's minimum short circuit power should be 1.0 MVA and

maximum impedance should be 0.41 Ω.

Page 14


2 General Information, Warnings and Operation Conditions

Warning!

Read entire section before installing and starting the machine.

Do not install, operate or repair the welder without reading safety precautions included in

user manual. Keep this user manual and place to an easy accessible place.

After completing the work or if you will discontinue working for a long time, disconnect the

mains supply.

Do not insert any object into the welder. While the welder is operating, especially do not

touch to the moving parts with your fingers.

Do not perform any modification on the machine. This may affect the machine features

and cause change in technical values.

It is forbidden to perform any modifications and adaptations on the machine. Performing

any modifications and adaptations, not only cause losing guarantee rights but also may

endanger the usage safety of the machine and may cause electric shock for the users.

Always ground the welder before operating. Various welders or other electrical devices

should be connected in series if they are using the same grounding line, all machines or

devices should be connected in parallel to each other. Cross sectional area of the

grounding cable of the welder should not be less than the cross sectional area of the cable

in the mains input.

While welding, do not change the position of “Welding Voltage Selection Switch”.

Welder should be used in places with good environment lighting and should not be used

in dark places. Also the plasma cutting machine has been designed to be used indoors

and is not suitable for using under sunlight, rain and snow. Welder cannot be used for pipe

melting works.

Welder has been designed to be used indoors and is not suitable for using under sunlight,

rain and snow.

Misuse or welding machine damages due to user mistake voids the guarantee rights.

Do not step on torch cable and do not keep the folding angle of the cable too narrow.

Accepted ambient temperature while operating is between - 10°C and + 40°C.

Accepted ambient temperature while transporting and storing is between - 20 and +

55.

Allowable relative humidity rate is up to 90% at 20°C and up to 50% at 40°C.

Page 15


Heating tests have been performed in ambient temperature and operation cycle has been

determined with simulation at 40°C.

Operate the machine in a well ventilated environment and leave at least 50 cm free space

around it. Do not operate in places higher than 100 m.

To achieve a stabile arc when operating in a windy place, take precaution against wind.

Wind speed should be less than 1m/sec. If the wind speed is higher than this, use

protective screens.

Manufacturer company reserves its right to change specifications without notice.

For long economical life and safety operation, it is useful to take some simple precautions

stated below:

Do not place the machine on a surface with a slope over 15° and do not operate on such

surface.

Machine should always be operated in an environment having clean airflow and there

should be no obstacle that prevents ventilation or stops airflow. Do not cover the machine

while operating with paper, cloth or similar objects.

While welding, make sure that the cover of the wire drive unit is closed.

Dust and dirt may enter into machine. This should be reduced as much as possible. Do

not operate the machine in extremely dusty locations and environments having water,

paint and oil particles and also grinding dusts and abrasive gases in its atmosphere.

This machine has IP21S protection. Keep the machine dry as much as possible and do

not place it on wet ground or in puddles.

Place the machine far away from radio controlled devices. Normal operation of the

machine may interfere with this kind of devices nearby and in such case may cause injury

or failure of the equipment. Please read “Electromagnetic Compatibility” section included

in this manual.

If the frame cover is opened and interfered by people who are not qualified for electrical

equipments, life-threatening danger may occur. In case behaving on the contrary, be

regarded as accepting beforehand all potential negative consequences.

Page 16


3 Specifications

Electric Supply Requirement:

Physical life determined by Ministry of Industry and Trade is 10 years.

(This is the period for providing spare parts required for the machine to operate.)

Operation Cycle and Overheating:

MasterMIG 250CT is a compact type gas metal arc (MIG/MAG) welding machine with

combined wire feeder unit and power unit.

Especially suitable for spot welding and high quality welding of mild structural steels and

stainless steels with medium thickness used in metal manufacturing industry.

It enables welding without splashing problem with carbon dioxide (C02) gas.

It has 20 graded (2x10) welding voltage setting. By this way it is possible to precisely set

the welding parameters.

Wire feed speed can be set.

It has slow wire feed (soft start) feature that facilitates arc creating.

It has been equipped with thermal protection circuit against overheating load.

It is air-cooled.

It is safe and user friendly.

It protection class is IP21S.

It has been designed according to IEC 60974-1.

EMU Class of machine according to TS EN 55011 is Group 2 Class A.

Guarantee period is 2 (two) years (excluding torch and cables).Manufacturer company

reserves its right to change specifications without notice.

Operation efficiency is the percentage rate of welder's welding ability at given welding

current for 10 minutes without any brake and without overheating.

Machine is protected against overheating thanks to its thermal protection. Warning lamp

on the front panel lights on when this protection is activated. Lamp turns off when

returned to the safe operation temperature and welding operation can continue.

It has been designed for 380 V ± 10 , 50/60 Hz three-phase mains.%

Deviation ration between phases should not be higher than 5%.

Frequency yield deviation should not be higher than ±1%.

Power Unit Model

Nominal mains voltage

Maximum power consumption (60 )%

Current taken from mains (60 )%

(100 )%

Power factor (cos φ) (60 )%

Output

Welding current (60 )%

(100 )%

Idling voltage range

Welding current setting range

Welding voltage setting range

Welding voltage grade number

Protection class

Radio noise level

Insulation class

Supply cable

Fuse value and type

Ambient operating temperature

Weight (excl. cables)

Dimensions (Width x Height x Depth)

Wire Drive Unit Model

Wire drive speed (u ) rangen

Wire speed setting before welding (for arc start without splashing)

Wire diameters Steel wire (V type reels)

Flux cored wire (V type notched reels)

Aluminum wire (U type reels)

Supply voltage and power of wire drive unit

Maximum supply current

Protection class

Weight (excl. cables)

Dimensions (Width x Height x Depth)

MasterMIG 350

380 V ± 10%, 50/60 Hz, 3 Phases

15.1 kVA

23 A

17.8 A

0.95

75%

350 A, 31.5 V

270 A, 27.5 V

19 - 40 V

60 - 360 A

17 - 32 V

30 (3x10)

IP21S

W

F+H

4 x 4 mm²

3 x 25 A (delayed)

between and - 10°C + 40°C

140 kg

570 x 835 x 960 mm

MasterFeed MF-3

1 - 24 m/min

% 10 - % 100 (u )n

0.8 - 1.0 - 1.2 mm

1.2 mm

1.2 mm

42 V, 90 W

4 A

IP21

18 kg

290 x 440 x 675 mm

4 Technical Data

Page 17


5 Front Panel Controls

Page 18

Power indicator

On-Off switchDigital welding voltage indicator

Digital weldingcurrent indicator

Welding wire reel protection cabinet cover

Thermal protection

indicator

rear wheel

front wheel

Work cable connection socket

(high inductance)

Work cable connection socket (low inductance)

Welding voltage precise setting switch

Welding voltage coarse setting switch

Power unit transport lugwheels

torch connector (EURO)

Water inlet and outlet channels for connecting torch cooling water when required

Wire feed speed setting button

Wire feed control without welding button

2/4 trigger selection switch

Gas flow without welding control switch

Wire feeder unit handle


WARNING !While welding, changing welding voltage range may cause damage to the machine. Therefore stop welding to change the voltage range.

6 Back Panel Controls

Page 19

Wire feeder fuse (3A)

mains inlet energy cable

Hook for hanging cables

Shielding gas cylinder fixing slot

Wire feeder unit wheels

Power unit transport lug

metal plate for specifications

Welding wire reel protection cabinet

Rack for placing shielding gas cylinder

Shielding gas heater connection socket

rear wheel

Shielding gas (C02) heater fuse (8A)

Control cable connection socket

Wire feeder unit (+) power connection socket

Pin for placing wire feeder unit to

power unit

Wire feeder unit handle

Shielding gas inlet socket

Control cable connection socket

Wire feeder unit (+) power connection socket


Page 20

7 Controls in Wire Feeder Unit

Wire

fe

ed

sp

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d w

ith

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t w

eld

ing

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Co

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r p

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sy

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tern

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bu

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erio

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ett

ing

bu

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Wire

fe

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er

un

it

h

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Wire

fe

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er

ree

l p

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ed

se

ttin

g s

pin

dle

Wire

fe

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er

en

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Pin

slo

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wire

fe

ed

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un

it t

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po

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nit

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he

els

We

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g s

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re

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n

ca

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We

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ire

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pro

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n c

ab

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t

We

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g t

orc

h

co

nn

ectio

n s

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Wire

in

let

gu

ide

Wire

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tle

t g

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Wire

drive

re

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(4

un

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r co

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eq

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8 Connection Diagram

Page 21

Shie

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g

gas h

ose

main

s inle

t energ

y c

able

Control cable

Wire feeder unit power connection cable

WIR

E

F

EE

DE

R

U

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PO

WE

R

UN

IT

We

ldin

g t

orc

h

cable

Work

cable

Work

pie

ce

TO

RC

H

GA

S R

EG

ULA

TO

R


GAS TUBE PROTECTOR

CA

RB

ON

DIO

XID

E

GA

S H

EA

TE

R (

24

V-5

5W

)

Pla

ce a

nd s

ecure

the

shie

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the p

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Socket" (24 V)

Page 22

9.1 Mains Supply

9.2 Shielding Gas Connection

To connect shielding gas below operations should be done:

9.3 Welding Torch Connection

Connect the welding torch to “Welding Torch Connection Socket” (EURO Socket)

located in front of wire feeder unit.

9 Installation and Operation of Machine


Mains supply connection of the machine should be made as per rules and only by

qualified personnel trained with necessary information.

Welding machine has been designed for triphase mains supply, 380 V ± 10 , 50/60 Hz and %

should be protected by 25A delay action fuse. Supply cable should be at least 4 x 4 mm .

Mains supply connection should be grounded.

Before connecting the machine to mains, make sure that the machine is off.

Never perform a mains supply connection and start the machine until there is a

good protective ground connection approved by a qualified electrician. Electric

leakages constitute death risk for human health.

2

Secure the gas cylinder and protect against risks such as rollover.

Remove the safety valve cover of gas cylinder and leave open for a while to clean it from

foreign materials.

Install the gas regulator on gas cylinder.

Connect the gas hose to gas regulator.

Connect the other end of gas hose to “Shielding Gas Inlet Socket" located in the rear of

wire feeder unit.

If necessary, connect the plug of heater to “Shielding Gas Heater

located in the rear of power unit.

When it is not used, close the valve of gas cylinder.

Page 23

9.4 Connection Between Power Unit and Wire Feeder Unit


The connection between the power unit and wire feeder unit is performed with “Control

Cable” (combined cable), “Wire Feeder Unit Connection Cable” and “Coolant Hose

Kit”.

Transmission of voltage and control signals from power unit to wire feeder unit is

provided with the connection of “Control Cable Connection Sockets” located in the

rear of these two units, to each other via “Control Cable”.

Welding current circuit made by the connectio“nW oirfe Feeder Unit Power

Connection Sockets” located in the rear of power unit and wire feeder unit, to each

other via “Wire Feeder Unit Connection Cable”.

To provide shielding gas to wire feeder unit and welding torch, it is necessary to connect

“Shielding Gas Hose” to “Shielding Gas Inlet Socket” located in the rear of wire

feeder unit. At the end of gas hose, there is a pipe connection.

Page 24

9.5 Installing Welding Wire

Placing Welding Wire into Protective Cartridge

Installing Welding Wire to Wire Drive Unit


According to the procedure stated in “Wire Feeder Unit Functions” section on Page

26, select the welding torch mode by using “2/4 Trigger Selection Switch”.

Place the “Wire Feed Speed Setting Button” located in the front of wire feeder unit to

“O” position.

Make sure that the torch equipment (spiral and nozzle) is suitable for the welding wire

being used and connect the welding torch to “Torch Connection Socket" located in the

front panel of wire feeder unit.

After matching wire drive reels to each other which are suitable for the wire diameter and

wire type being used, connect the reels to wire feeder unit.

- Open the cover of “Welding Wire Reel Protection Cabinet” located in the rear of wire feeder

unit.

- Insert the welding wire reel to “Welding Wire Reel Connecting Rod” as the end of the wire

will be on the lower part of reel.

- If necessary, set the braking (tightening) torque of “Welding Wire Reel Connecting Rod”.

When the reel stops, it shouldn't freely turn around the connection axis.

- Cut the twisted end of the wire by taking out from open part of protector and file the sharp

corners.

- Open the side cover of wire feeder unit.

- Release the “Wire Feed Reel Press Forced Setting Spindle" by loosening.

- Run the welding wire through the “Wire Inlet Guide” of wire feeder unit.

- Install the welding wire to “Wire Outlet Guide” by running through wire drive reels.

- After setting the press force by fixing again the “Wire Feed Reel Press Forced

Setting Spindle”, start the machine with “On/Off Switch” located in the front panel of

power unit.

- Press the "Wire Feed Control Without Welding Button” located in the front panel of

wire feeder unit. During this action, always make sure that the contact nozzle of

welding torch is not in place. You can set the wire feed speed with “Wire Feed Speed

Without Welding Setting Button” located within the wire feeder unit.

- Release “Wire Feed Without Welding Control Button” after the welding wire is

seen and install the contact nozzle and gas nozzle to the welding torch and tighten

properly.

Page 25

Adjusting Press Force of Wire Drive Reel

-

Setting Braking Torque of Welding Wire Reel Connecting Shaft

Type and Selection of Wire Drive Reels

Changing Wire Drive Reels


Properly set the press force of reels. If the press force is too low, wire slips on reels; if the

press force is too high, reels crushes the wire or wire jams in. Press force increases

when driver reel press force setting turned clockwise, when turned counter clockwise

press force decreases.

- To prevent welding wire to discharge from the reel, fastener that holds the reel is

equipped with a braking system.

- Braking setting is performed with a spring located in the fastener.

- When springs tightened to the left, braking torque increases, when tightened to the

right, braking torque decreases.

- Wire drive unit is equipped with “V” channeled reels set for Ø 0.8, 1.0 and 1.2 mm

solid welding wire.

- Make sure that the diameter of installed reel is suitable for the diameter of welding

wire being used.

- There is a mark on the side surface of reels indicating the profile of wire drive groove

suitable for the wire diameter to be used. This mark is not seen after the installation.

- For steel and stainless steel welding wires “V” type reels should be used.

- For aluminum wires “U” type reels should be used.

- For flux cored “Notched-V” type reels should be used.

To change the reels:

- Release the press force setting of feeder reels.

- Remove the reel desired to be changed.

- Install the new reel making sure that it fits into its place.

- Fix pressure force setting again.

Page 26

10 Functions of Wire Feeder Unit

Wire drive unit has the following functions:

Welding Torch Operation Modes:

Wire Feeding Speed Setting:

- It is possible to set the wire feeder speed between 1-24m/min.

Test functions:

Soft Start

Approach Speed Setting of Welding Wire End to Workpiece Before Welding:

Burnback Control (0.02 - 0.25 sec):


- 2 Trigger Mode (manual): Welding procedure is started by pressing and

holding down the trigger on the welding torch. When trigger released welding

stops.

- 4 Trigger Mode (automatic operation): Welding procedure is started by

pressing once the trigger on the welding torch. When pressed second time,

welding stops.

- Wire Feed Without Welding: With this button, only wire feeder unit is started

without starting power unit and gas solenoid. This feature is used while driving

the welding wire to welding torch.

- Gas Flow Without Welding: With this button, only the gas solenoid may be

turned on and off without starting the power unit. This feature is used for

controlling the gas flow speed and gas connections.

- This feature is used for fixing the approach speed of welding wire to the

workpiece at the time of welding start. Also with this button wire feed speed

without welding can be set. Setting range is between 10% and 100% of wire

feed speed.

- This feature enables proper length for the welding wire exits from the contact

nozzle at the time of welding procedure ends and not sticking to contact nozzle

or workpiece after welding.

11 Environment Conditions

Before starting the machine following procedures should be performed:

Page 27


Provide the necessary environment conditions for the welding machine. For example

there shouldn't be any flammable gases and vapors, conducting dusts,

burner/flammable fumes and other factors that may be hazardous for insulation and

mechanical structure of the machine.

Welder has been designed to be used indoors and is not suitable for using under

sunlight, rain and snow.

Welding machine should be located to a place where can be seen at all times.

In case of overheating, fume or flame, smell of insulation burn, extreme shocks or

extreme noise, machine should be turned of, mains supply should be disconnected

and qualified electric technician or “Qualified Technical Service” should be

contacted immediately.

When current circuit is locked or electric voltage is determined on the body,

procedure indicated in the fourth article should be performed.

Also in case of mechanical damage such as machine falls down from a high place,

again procedure indicated in the fourth article.

Extremely damp environment may cause damage to the insulation of the machine

and electric shock danger.

While operating some internal parts of the machine may get heated and temperature

may increase up to 100°C. This is normal and machine is protected against

overheating with “Thermal Protection Circuit”.

Do not allow extremely high temperatures in cable connection points. If connections

overheated, this is the sign that they are not available to continue working. Parts

composing the connection should be checked and damaged ones should be replaced

immediately.

Page 28

12 GMAW (MIG/MAG) Method


13 Expirty of Machine's Physical Life

Make sure that the welding machine is installed according to the explanations included

on Page 22.

By considering the desired welding current values, install the work cable to the proper

“Work Cable Connection Socket” located in front of the power unit by using the fitting

screw at the end of work cable.

Note:

Inductance is a mechanism that stabilizes the welding current and used for minimizing

the splashings in the welding seam. It is recommended to use low value inductance

outlet (Ω) for welding current up to 250 amperes and to use high value inductance outlet

(ΩΩ ) for welding current higher than 250 amperes.

Connect the work cable holder to the clean surface of the workpiece to be worked on.

Make sure that the contact between them is as good as possible.

Start the machine by turning the “On/Off Switch” located in the front panel of the power

unit to "I” position. “Power Indicator” will light up.

Welding voltage value is approximately set with “Welding Voltage Coarse Setting

Switch” and precisely set with “Welding Voltage Precise Setting Switch” (Refer to the

table on Page 21). These switches are located in front of the power unit.

Warning!

While welding do not change the welding voltage! This may cause serious damage.

Value of welding current directly depends on the wire feeding speed value. Select the

proper wire feed speed with the "Wire Feed Speed Setting Button” located in front of

MasterFeed MF-3 wire drive unit. Wire drive speed can be set between 1-24 m/min.

You can start welding procedure by following related rules.

When the economical life of the machine expired and cannot operate should not be

disposed as domestic waste and not thrown into waste. Welding machine should be

disposed of as per local regulations.

15 Storage and Transportation

Page 29


14 In Terms of Energy ConsumptionEfficient Use of Machine

0.8 - 1.5

1.0 - 2.5

2.5 - 4.0

2 - 5

5 - 10

5 - 8

8 - 12

Part Thickness

(mm)

Welding Current

(A)

Welding Voltage

(V)

Wire Diamete

(mm)

Wire Guide Inner Diameter

(mm)

Gas Flow Speed

(lt/min.)

ø 0.8

ø 0.8

ø 0.8

ø 1.0

ø 1.0

ø 1.2

ø 1.2

ø 1.4

ø 1.4

ø 1.4

ø 1.6

ø 1.6

ø 1.6

ø 1.6

50 - 90

60 - 100

100 - 140

70 - 120

120 - 170

110 - 180

160 - 300

17 - 18

18 - 19

21 - 24

19 - 21

23 - 26

22 - 24

25 - 38

6

7

8

9

10

10

12

Marked ones are short circuit arc (short arc) transfer and others are drop arc (long arc) transfer.

Welding machine is designed and manufactured as to get low energy from mains while

in the On position.

While welding to prevent over energy consumption, current values that are suitable for

the used welding wire diameter should be used and current values higher than adequate

should be avoided.

Welding machine should be stored at confined rooms having temperature between -

20°C and + 55°C and at most 90% relative humidity rate at 20°C.

Room should be free from flammable, conductive dust or other similar items.

Preferably welding machine should be stored in its package.

Transportation inside the facility should be done by using its own frame or as an option a

crane or overhead travelling crane should be used.

In far distance transportations, welding machine should be packaged to be protected

against mechanical damages.

If the welding machine will be kept or not to be used for a long time before operating the

machine, it should be cleaned and placed into its box and should be stored in

environment without damp and dust.

16 Maintenance and Repair

DAILY MAINTENANCE


Page 30

Warning!

Proper usage and performing periodical maintenance fully will enable high

performance and are important for long economical life. Maintenance, repair and service

works should only performed by the qualified personnel who had the required

training!

Mains current of the welding machine should be disconnected and power cable

should be unplugged while performing maintenance and service.

- Follow general personal safety and fire safety rules related to the welding

procedures.

- Clean metal splashings from gas nozzle. These may cause weakness in shielding

gas flow that covers molten welding metal.

- Clean the gas nozzle at the end of welding torch against splashing with GMAW spray.

For this procedure you can use our "Focusweld" welding spray. Never attempt to

clean accumulated burrs by hitting the end of torch to a hard surface.

- If you notice any wear and crush on welding wire, check if the press force of wire

drive reels is suitable for the wire diameter and if you notice over pressure, decrease

the press force setting as appropriate.

- If wire drive reels are worn or damaged, you cannot achieve a smooth wire feed.

Frequently check the reels and if there is any wear replace with the new ones.

- Before installing a new welding wire reel, remove the gas nozzle and contact nozzle

and clean the spiral with compressed air. This procedure will prevent the sticking of

the wire.

- Check the welding torch and clean if necessary.

- Make sure that the welding current adjusting knob located in front panel and On/Off

switch located in rear panel are in place and properly operating. If current adjusting

knob is not installed properly and if On/Off switch is not exactly in place and is not

operating smoothly, contact with the service.

- Check if there is vibration, whistle or abnormal smell after starting the machine. If

there is any problem try to find the source of the problem, if there is a problem due to

environment eliminate this factor, if the problem source is the machine do not

interfere and contact with the service after disconnecting from the mains.

- Make sure that the welding current is compatible with set current value. If there is any

difference, perform the necessary adjustment since it will affect the welding

operation.

MONTHLY MAINTENANCE

YEARLY MAINTENANCE


17 Unpacking

Page 31

- Make sure that the cooling fan is not damaged and turns normally. If the fan doesn't

operate even after the overheating of the machine, check if the propeller of the fan is

blocked. If the fan is damaged, contact with authorized service.

- Check if the welding connections are loose or overheated. If there is overheating or

loosening, tighten the connections or contact with authorized service.

- Check if the current cable is damaged. If it is damaged, insulate the damaged part by

wrapping with a suitable material or change the cable with the new one.

- By using dry air compressor clean the internal part of the machine to remove

accumulated dusts. To protect small parts, be careful about the air pressure used in

cleaning.

- Check the screws on the machine and if they are loosen, tighten. If there is missing

screw, always install a new one. Replace rusted screws with the new ones.

- Check the conditions of all electric connections and tighten loosed connections when

necessary.

- Measure insulation impedance on main transformer, PCB and body. If the

measurement value is under 1MΩ, this means there is damage. In this case contact

authorized service.

- Check the continuity of the grounding. Do not perform this test on your own, contact

an authorized service.

EXPRESSWELD MasterMIG 350 Gas Metal Arc Welding Machine sold in its original

cartoon box and on a pallet. Do not purchase the machines without packaging. To

unpack the machine, cut the strap connected to the pallet and lift up the box.

Do not dispose of the box and keep it for future transporting and storing.

18 Troubleshooting Guide

There is problem in wire feeder unit, engine operates but wire does not advance properly.

Spiral is dirty. Clean the spiral.

Channels of the drive reels are not compatible with wire type or diameter being used. Grooves

Check the channels of reels and change with the reels suitable for the used wire. Clean the grooves.

Channels of drive reels are worn or grooves are crushed.

Replace worn reels with the new ones.

Welding wire jammed in contact nozzle.

Remove the welding wire from contact nozzle. Replace the contact nozzle if necessary.

Wire feed engine is faulty. Contact with technical service.

Control board (PC-board) is faulty. Contact with technical service.

Control cable (multiple cable) is faulty.

Change the control cable.

Trigger of welding torch is faulty. Replace the trigger of welding torch.

Makineye enerji gelmiyor. Check the power unit and mains supply connection. Turn on the machine if it is closed. If inlet fuse is blown, change the fuse.

REASON SOLUTIONPROBLEM

There is problem in wire feeder unit, engine doesn't operate. When pressed on torchtrigger, wire doesn't

Control board (PC-board) is faulty. Change the control cable.

Control cable (multiple cable) is faulty.

Change the potentiometer.There is open circuit voltage and gas flow, but wire feeding functions doesn't operate. Current setting potentiometer

is faulty.Contact with technical service.

There is no energy in AC contactor coil.

Contact with technical service.


There is wire feeding and gas flow, but there is no open circuit voltage.

Supply voltage value is too low (under 350 V).

Check the supply voltage as to be 380 ± % 10 V.

One of the phases is missing in supply voltage.

Check the mains phases.Open circuit voltage is low.

Diode group is faulty. Change the diode group.

There is disconnection in grounding cable.

Check the grounding cable connection.

There is too much oil, dirt and rust on workpiece. The contact between work clamp and workpiece is not good.

Provide good contact between the surfaces by performing necessary cleaning.

There is open circuit voltage and wire feeding function operates. But there is no arc.


Page 32

are dirty.

advance.

Arc is not stable and too much splashing occurs.

Contact nozzle and wire feed reels is not compatible with the used wire.

Check the contact nozzle and wire feed reels, change if necessary.

There is strain in any point of the torch.

Check wire guides and spiral. Clean or replace if necessary. Do not too much bend the torch cable.

One of the phases is missing in supply voltage.

Check the mains phases.

Diode group is faulty. Change the diode group.

There is incompatibility between wire feeding speed and voltage

Check the wire feeding speed and voltage value.

Welding current cannot be set correctly.

Current setting potentiometer is faulty.

Change the potentiometer.


There is no shielding gas flow.

Gas hose is not connected or there is disconnection in the hose.

Check the hose and gas connection system. Tighten the connections. Replace the hose if necessary.

Gas hose is crushed or blocked. Check the gas connection hose.

Gas solenoid is faulty. Clean the electronic valve or replace with the new one.

Wire is curled within torch, bended in feed reels or inlet guide.

End of the wire stucked to contact nozzle.

Change the contact nozzle and if necessary change the nozzle.

Inlet guide is too far away from the wire feed reels or guides are blocked.

Check the distance. Perform necessary adjustments. Clean the guides.

Inlet /outlet guides and wire feed reels are not on the same axis.

Perform the necessary changes to have them on the same axis.

Inner diameters of inlet/outlet guides are too wide or too narrow.

Change inlet/outlet guides.

Power indicator lamp doesn't light upon machine start.

Power indicator lamp lights but contactor doesn't operate.

Thermal protection is activated. Leave the machine to cool down.

There is no supply voltage. Check the mains voltage.

On/Off switch is faulty. Change On/Off switch.

Power indicator lamp is faulty. Change the power indicator lamp.


Page 33

REASON SOLUTIONPROBLEM

value.

Pore Creation

Possible Reasons:

Solutions:

Insufficient Fusion

Possible Reasons:

19 Failures in Welding Seams


Page 34

1. Insufficient gas shielding.

2. Used gas is dirty or gas flow speed is not suitable.

3. Surface of welding wire is dirty.

4. Work piece is dirty.

5. Voltage value is too high.

6. Distance between the nozzle and workpiece (free wire length) is too much.

1. To remove all air within the welding area, increase the gas flow rate. To prevent the

entry of turbulence and air into welding seam, do not set the flow rate to an

extremely high value. Clean splashed burr particles from nozzle. Prevent leakages

in the gas hose. Stop air flows that directly reach to arc (operating fans, open doors,

etc). When welding with C02 gas, to prevent clogging of the regulator due to

freezing use heater or connect several gas cylinders to each other. Decrease the

advancing speed. Decrease the distance between nozzle and workpiece. Until

molten metal become solid, keep the torch at the end of the welding seam.

2. Use a quality gas manufactured for welding. Adjust the gas flow rate.

3. Only use clean and dry welding wire.

4. Remove all oil, grease, rust, paint and dirt from workpiece surface. Use a welding

wire that contains more oxide solvent element.

5. Decrease the voltage value.

6. Shorten the length of free wire (at nozzle outlet).

1. There is coating or excessive oxide layer on the surface in welding area.

2. Heat input is insufficient.

3. Welding puddle is bigger than required.

4. Applied welding technique is wrong or movement given to the torch is not stabile.

5. Seam combination style is wrong.

6. Advancing speed is too high.

Solutions:

Insufficient Penetration

Possible Reasons:

1. Combination preparation is wrong.

2. Applied welding technique is wrong.

3. Heat input is insufficient.

Solutions:

Root Sagging

Possible Reasons:

1. Welding speed is too low.

2. Current is too high when compared to the voltage.


Page 35

1. Clean scale and oxide residues from all surfaces in the welding seam area.

2. Increase wire feed speed and arc voltage. Decrease free wire length.

3. To control welding puddle more easily do not perform over oscillatory welding.

Increase the advancing speed.

4. If you perform oscillatory welding, wait a moment at the edges of seam. Enhance

access to root of seam. Route the welding wire to the front of weld puddle. Adjust

torch angle at corner welding.

5. To enable access to seam soul, adjust combination angle properly. To fuse seam

corners, adjust free wire length or prepare (J) or (U) seam.

6. Decrease wire feed speed.

1. To access to the soul of seam, with the condition to provide correct free wire length

and arc characteristics, revise connection shape and connection preparation. Avoid

that the height in the root is extremely high. In butt joint welding, increase root

opening or deepen the groove opened reversely.

2. To achieve maximum penetration, hold the welding wire perpendicular to workpiece.

Route the arc to the front of weld puddle.

3. Current may be too low according to voltage. Increase the wire feeding speed, so the

current. Do not change the free wire length.

Solutions:

1. Increase the advancing speed. Adjust the torch angle.

2. Increase the arc voltage.

Splashing

Possible Reasons:

1. Welding wire short circuits by contacting to work piece.

2. CO is used as shielding gas.2

3. Welding process is performed with global conduction by using argon gas.

Solutions:

Edge Burn

Possible Reasons:

1. Advancing speed is too high.

2. Welding voltage is too high.

3. Welding current is too high.

4. Waiting time is insufficient.

5. Torch angle is wrong.

Solutions:

1. Decrease the advancing speed.

2. Decrease the voltage.

3. Decrease wire feed speed.

4. Wait more in the edges of molten weld puddle.

5. By adjusting the torch angle, enable arc to route the molten metal.


Page 36

1. Increase the arc voltage. If you are operating with short circuit conduction, limit the

current increase by increasing the inductance in welding machine.

2. Decrease the arc voltage or “immerse” the arc by increasing the wire feeding speed,

so limit the splashing.

3. By increasing the current, enter into spray conduction mode.

20 Spare Part List


Po

wer

Un

it

Page 37


Top panel

Control transformer

Contactor

Rear wheel

Gas cylinder support shaft (Left)

Fan

Rear panel

Heater fuse

Fuse holder

Heater socket (Female)

Heater plug (male)

Gas cylinder rest

Cable carriage hook

Welding cable connection socket (Female)

Gas cylinder platform

Cable holder

Control cable socket

Wire feed fuse

Insulator

External insulator

Gas cylinder fastening chain

Mains cable

Right upper side panel

Right lower side panel

Gas cylinder support shaft (Right)

Rear wheel shaft

Shaft connection element

Induction coil

Base metal sheet

Front swivel wheel

Precise voltage setting switch

Coarse voltage setting switch

Front panel

Part Name (Power Unit)

1

2

3

4

5

6

7

8

9

10

-

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

8212435201

8212435808

8220741022

8220507108

8212435403-5

8220789022

8212435804

8220752019

8220752028

8220757757

8220757756

8212435510

8212435420

8220757119

8212435211

8220430104

8220754122

8220752020

8212435218

8220501018

8220129006

8212435231

8212435219

8212435206

8212435403-6

8212435403-4

8212435403-3

8212435403-8

8212435403-1

8220507303

8220780566

8220780569

8212435803-1

Part Code ERP Code

1.24.354.09

1.24.354.10-2

2.07.41.004

2.05.07.108

1.24.354.03-5

2.07.89.022

1.24.354.02

2.07.52.019

2.07.52.028

2.07.57.757

2.07.57.756

1.24.355.10

1.24.354.20

2.07.57.119

1.24.354.11

2.04.30.104

2.07.54.122

2.07.52.020

1.24.352.18

2.05.01.018

2.01.29.006

1.24.352.31

1.24.354.07

1.24.354.04

1.24.354.03-6

1.24.354.03-4

1.24.354.03-3

1.24.354.03-8

1.24.354.03-1

2.05.07.303

2.07.80.566

2.07.80.569

1.24.354.01-1

Page 38


On/Off switch

Work cable

LED (Yellow)

LED (Green)

Current indicator

Pulling handle

Handle fitting (Left)

Handle fitting (Right)

Rectifier base

Rectifier bridge

Shunt

Main transformer

Electric terminal

Medium panel

Indicator board

Plastic card base

Filter capacitor board

Left upper side panel

Left lower side panel

Control cable - 1

Control cable - 2

Control cable - 3

Control cable - 4

Control cable - 5

Control cable - 6

Control cable - 7

Control cable socket (The power unit)

Part Name (Power Unit)

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

-

8220780213

8212435245

8220728211

8220728209

8220746553

8212435221

8220131061

8220131062

8212435214

8220737551

8220742009

8212435403-2

8220757059

8212435410-1

8212425005-3

8220791004

8212435810

8212435210

8212435205

8212435232

8212435233

8212435234

8212435235

8212435236

8212435237

8212435238

8220754120

Part Code ERP Code

2.07.80.213

1.24.352.45

2.07.28.211

2.07.28.209

2.07.46.553

1.24.352.21

2.01.31.061

2.01.31.062

1.24.352.14

2.07.37.551

2.07.42.009

1.24.354.03-2

2.07.57.059

1.24.354.10-1

1.24.250.05-3

2.07.91.004

1.24.358.10

1.24.354.08

1.24.354.05

1.24.352.32

1.24.352.33

1.24.352.34

1.24.352.35

1.24.352.36

1.24.352.37

1.24.352.38

2.07.54.120

Page 39


Wir

e F

eed

er

Un

it

Page 40

Plastic wire reel protector

Wire reel shaft

Inner medium panel

Rear panel

Handle

Gas solenoid

Gas connector

Control cable socket

Welding current cable connection socket (Female)

Induction coil

Water connection coupling

Current cable

Extension cord

Spiral

Socket gasket

Socket gasket

Right side panel

Rear fixed wheel

Hose

Support shaft housing

Support shaft

Swivel wheel

Base panel

Wire feed speed potentiometer

Wire feed potentiometer button

Front panel

Current connection cable

Switch

Insulating flange (Torch connector)

MIG Torch (MB 36)

Switch

Cable insulator

Wire drive control board

Part Name (MF-3 Wire Feeder Unit)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

8220505301

8220505101

8212406213-1

8212406212-1

8250202808

8220755006

8212406212-2

8220754104

8220757117

8212406212-3

8220757813

8212435801

8212435802

8220802200

8222012521

8220757819

8212406204

8220507313

8220802004

8212406210

8250202005

8220507314

8212406211

8220710043

8220711009

8212406209-1

8212406205

8220780634

8220505015

8222008061

8220780371

8220431108

8212406201

Part Code ERP Code

2.05.05.301

2.05.05.101

1.24.062.13-1

1.24.062.12-1

5.02.02.808

2.07.55.006

1.24.062.12-2

2.07.54.104

2.07.57.117

1.24.062.12-3

2.07.57.813

1.24.358.01

1.24.358.02

2.08.02.200

2.20.12.521

2.07.57.819

1.24.062.04

2.05.07.313

2.08.02.004

1.24.062.10

5.02.02.005

2.05.07.314

1.24.062.11

2.07.10.043

2.07.11.009

1.24.062.09-1

1.24.062.05

2.07.80.634

2.05.05.015-1

2.20.08.061

2.07.80.371

2.04.31.108

1.24.062.01


Page 41

Magnet

Wire drive engine

Insulating gasket

Insulating sheet

Torch connection

Wire reel section cover

Potentiometer button

Wire drive reel 0.8 - 1.0 mm (Solid wire)

Wire drive reel 1.0-1.2 mm (Solid wire)

Wire drive reel 1.2-1.6 mm (Solid wire)

Wire drive reel 1.2 mm (Flux cored)

Wire drive reel 1.2 mm (Aluminum wire)

Control cable socket (Power unit)

Kontrol kablosu soketi (Tel sürme ünitesi)

Part Name (MF-3 Wire Feeder Unit)

34

35

36

37

38

39

40

-

-

-

8220751703

8220740312

8220506012

8220506011

8212405006

8212406208

8220711006

8220740314

8220740315

8220740316

8220740317

8220740318

8220754120

8220754130

Part Code ERP Code

2.07.51.703

2.07.40.312

2.05.06.012

2.05.06.011

2.07.57.140

1.24.062.08

2.07.11.006

2.07.40.314

2.07.40.315

2.07.40.316

2.20.09.609

2.20.09.605

2.07.54.120

2.07.54.130


21 Warning Label

Page 42

BEFORE STARTING and OPERATING THIS EQUIPMENT READ OPERATION

INSTRUCTIONS. TO INSTALL THE MACHINE IN COMPLY WITH SPECIFICATIONS

DETERMINED IN THE “ELECTROMAGNETIC COMPATIBILITY REGULATION” and FOR

DETAILED INFORMATION ON USAGE LIMITS, ALWAYS REFER TO USER MANUAL.

ELECTRIC SHOCK CAN KILL. THIS EQUIPMENT MUST BE OPENED ONLY BY QUALIFIED

PERSONNEL.

Pa

ko

Şa

lte

rY

ön

Rig

ht

Sid

e

Le

ftS

ide

Rig

ht

Sid

e

Le

ftS

ide

Up

Do

wn

Up

Do

wn

Up

Do

wn

Up

Do

wn

Lo

ca

tio

ns

tn

drd

thth

th1

Layer

2 L

ayer

3 L

ayer

4 L

ayer

5 L

ayer

6 L

ayer

Ma

in E

lec

tric

al

Cir

cu

it C

on

ne

cti

on

Dia

gra

m

V

Ala

rm

A

Ma

ch

ine

Co

ntr

ol

Cir

cu

it C

on

ne

cti

on

Dia

gra

m

Hea

ter

Ele

ctr

on

ic P

ow

er

Ind

ica

tor

Wir

e F

ee

d S

oc

ke

t

Wir

e F

ee

de

r U

nit

Cir

cu

it C

on

ne

cti

on

Dia

gra

m

So

len

oid

To

rch

Sw

itc

hG

as

Co

ntr

ol

Sw

itc

h

K4

K6

Cu

rre

nt

Co

ntr

ol

Sw

itc

h

K5

K2

K3

W1

W2

W3

Slo

w W

ire

Fe

ed

Wir

e F

eed

Sp

eed

w/o

wel

din

g

Bu

rnb

ac

kT

ime EX

PR

ES

SW

EL

DM

aste

rMIG

350

Pacco

Sw

itch

Dir

ecti

on

22 Electrical Circuit Diagram


Page 43

Page 44


23 Wire Feeder and Power Unit Specifications

Wire Feeder Unit

Power Unit

Made in China

MF-3Model :

TS EN 60974-5, TS EN 60974-10

Serial No. :

X

I2

60 % 100 %

500 A 350 A

IP21

U1 = 42 V I max1 = 4 A

DC 42 V - 90 W

Wire Size

Wire Feed Speed

: 0.8 - 1.6 mm

: 1 - 24 m/dak

1 ~

50 Hz

Kaynak Tekniği Sanayi ve Ticaret A.Ş.TOSB Taysad Org. San. Bölgesi, 2. Cadde, No: 5, 41480 Çayırova, Kocaeli - TURKEY

" EXPRESSWELD "

Made in China

MasterMIG 350Model : Serial Number :

60 A / 17 V ~ 360 A / 32 V

60 % 100 %

350 A 270 A

31.5 V 27.5 VU0 = 19 - 40 V

IP21S cos = 0.95 (350 A) P max1 = 14.4 kW

U1 = 380 V I max1 = 23 A I eff max1 = 17.8 A

Designed and Powered by ASKAYNAK

3 ~

50 Hz

S

3 ~

Kaynak Tekniği Sanayi ve Ticaret A.Ş.TOSB Taysad Organize San. Bölgesi, 2. Cadde, No: 5, Şekerpınar 41480 Çayırova, Kocaeli - TURKEY

" EXPRESSWELD "

TS EN 60974-1, TS EN 60974-10

X

I2

U2

www.askaynak.com.tr

Kaynak Teknigi Sanayi ve Ticaret A.S.TOSB - Taysad Organize Sanayi Bolgesi, 2. Cadde, No: 5, Çayırova

41435 Kocaeli - TURKEYPhone: +(90.262) 679 78 00 Fax: +(90.262) 679 78 26

Manufacturer

December 2011 - CanO

Documents

Expressweld MasterMIG - 350 - İngilizce Manual kontrol edilmiş