Introduction And General Description; Technical Data; Description Of The Welding Machine - Telwin MASTERMIG 300 Manuel D'instructions

- Lubricating the gears.
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
- Never lift the welding machine .

2. INTRODUCTION AND GENERAL DESCRIPTION

2.1 COMPACT WELDING MACHINE (FIG. A1, A2)
This welding machine is a power source used for arc welding and has been designed
specifically for MAG welding of carbon steel and low-alloy steel with either CO or
Argon/CO mixture shielding gas using solid or cored (tubular) electrode wires.
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They are also suitable for MIG welding of stainless steel using Argon gas + 1-2% oxygen
and of aluminium with Argon gas using electrode wires with a composition suited to the
piece to be welded.
A typical example of MIG brazing would be on galvanised sheet with copper alloy wire
(e.g. copper-silicon or copper-aluminium) with pure Argon (99.9%) protective gas.
2.2 WELDING MACHINE WITH REMOVABLE WIRE FEEDER (FIG.A3)
Continuous wire, three-phase, fan-cooled welding machine on wheels, for MIG-
MAG/FLUX welding and brazing, with 4-ROLLER, removable wire feeder. Flexibility of
use with different types of materials such as steel, stainless steel and aluminium. Large
number of arc voltage adjustment steps.
2.3 STANDARD ACCESSORIES:
- torch (water-cooled in the R.A. version);
- return cable complete with earth clamp;
- wheels kit;
- ARGON bottle adapter;
- pressure reducing valve;
- wire feeder;
- R.A. water cooling unit (only for the R.A. version);
2.4 OPTIONAL ACCESSORIES
- electronics board with dual timer;
- generator - wire feeder connecting cables assembly (only for welding machine with
removable wire feeder);
- R.A. water cooling unit (where present);
(standard accessory on R.A. version);
- Reel cover kit (where present);
- Aluminium welding kit;
- Flux-core wire welding kit;

3. TECHNICAL DATA

3.1 DATA PLATE
The most important data regarding use and performance of the welding machine are
summarised on the rating plate and have the following meaning:
1- EUROPEAN standard of reference, for safety and construction of arc welding
machines.
2- Symbol for internal structure of the welding machine.
3- Symbol for welding procedure provided.
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- Symbol for power supply line:
1~: single phase alternating voltage;
3~: 3-phase alternating voltage.
6- Protection rating of the covering.
7- Technical specifications for power supply line:
- U : Alternating voltage and power supply frequency of welding machine (allowed
1
limit ±10%).
- I : Maximum current absorbed by the line.
1 max
- I : effective current supplied.
1eff
8- Performance of the welding circuit:
- U : maximum no-load voltage (open welding circuit).
0
- I /U : current and corresponding normalised voltage that the welding machine can
2 2
supply during welding.
- X : Duty cycle: indicates the time for which the welding machine can supply the
corresponding current (same column). It is expressed as %, based on a 10 min.
cycle (e.g. 60% = 6 minutes working, 4 minutes pause, and so on).
If the usage factors (on the plate, referring to a 40°C environment) are exceeded,
the thermal safeguard will trigger (the welding machine will remain in standby until
its temperature returns within the allowed limits).
- A/V-A/V: shows the range of adjustment for the welding current (minimum
maximum) at the corresponding arc voltage.
9- Manufacturer's serial number for welding machine identification (indispensable for
technical assistance, requesting spare parts, discovering product origin).
10- : Size of delayed action fuses to be used to protect the power line.
11- Symbols referring to safety regulations, whose meaning is given in chapter 1
"General safety considerations for arc welding".
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
must be checked directly on the data plate of the welding machine itself.
3.2 OTHER TECHNICAL DATA
- WELDING MACHINE: see table 1 (TAB.1)
- TORCH: see table 2 (TAB.2)
The welding machine weight is shown in table 1 (TAB. 1).

4.DESCRIPTION OF THE WELDING MACHINE

4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES (FIG. A)
5. INSTALLATION
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WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
ELECTRICAL CONNECTIONS WITH THE WELDING MACHINE COMPLETELY
SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET.
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
AUTHORISED OR QUALIFIED PERSONNEL.
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5.1 PREPARATION (FIG. C)
Unpack the welding machine, assemble the separate parts contained in the package.
5.1.1 Assembling the return cable-clamp (FIG. D)
5.2 HOW TO LIFT THE WELDING MACHINE
None of the welding machines described in this manual is equipped with a lifting device.
FIG. B
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WARNING! Position the welding machine on a flat surface with sufficient
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
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5.2.1 CONNECTION TO THE MAIN POWER SUPPLY
- Before making any electrical connection, make sure the rating data of the welding
machine correspond to the mains voltage and frequency available at the place of
installation.
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- The welding machine should only be connected to a power supply system with the
neutral conductor connected to earth.
- To comply with the requirements of the EN 61000-3-11 (Flicker) standard we
recommend connecting the welding machine to interface points of the power supply
that have an impedance of less than Zmax = 0.04 ohm.
- The welding machine falls within the requisites of IEC/EN 61000-3-12 standard.
5.2.2 PLUG AND OUTLET: connect a normalised plug (3P + T) having sufficient
capacity- to the power cable and prepare a mains outlet fitted with fuses or an automatic
circuit-breaker; the special earth terminal should be connected to the earth conductor
(yellow-green) of the power supply line. Table 1 (TAB.1) shows the recommended
delayed fuse sizes in amps, chosen according to the max. nominal current supplied by
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
of the machine, and prepare the voltage change terminal board so that the
connection indicated on the special indicator plate corresponds to the available
power supply voltage.
Reassemble the panel carefully using the appropriate screws.
Warning!
In the factory the machine is set at the highest voltage of the available range,
e.g.
U 400V Ü Voltage setting at the factory.
1
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WARNING!
Failure to observe the above rules will make the (Class 1) safety system installed
by the manufacturer ineffective with consequent serious risks to persons (e.g.
electric shock) and objects (e.g. fire).
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5.3 CONNECTION OF THE WELDING CABLES
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WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
THE POWER SUPPLY OUTLET.
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Table 1 (TAB. 1) gives the recommended values for the welding cables (in mm )
depending on the maximum current supplied by the welding machine.
5.3.1 Connection to the gas bottle
- Gas bottle can be loaded on welding machine bottle support platform: max 20 kg.
- Screw the pressure reducing valve onto the gas bottle valve, inserting the
appropriate adapter supplied as an accessory, for when the gas used is Argon or
an Argon /CO mixture.
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- Connect the gas inlet pipe to the pressure-reducing valve and tighten the band
supplied.
- Loosen the adjustment ring nut on the pressure-reducing valve before opening the
bottle valve.
5.3.2 Connecting the welding current return cable
This is connected to the piece being welded or to the metal bench supporting it, as close
as possible to the join being made.
This cable is connected to the terminal with the symbol (-).
5.3.3 Connecting the torch
Engage the torch with its dedicated connector by tightening the locking ring manually as
far down as it will go. Prepare the wire for loading the first time by dismantling the nozzle
and the contact tube to ease its exit.
5.3.4 Connection to the wire feeder (for model with external wire feeder)
- Make the connections with the electrical generator (rear panel):
- welding current cable to quick connection (+);
- control cable to appropriate connector.
- Make sure the connectors are firmly tightened in order to prevent overheating and
loss of efficiency.
- Connect the gas pipe from the pressure-reducing valve on the bottle and lock it with
the clip supplied.
5.3.5 Warnings
- Turn the welding cable connectors right down into the quick connections (if present),
to ensure a perfect electrical contact; otherwise the connectors themselves will
overheat, resulting in their rapid deterioration and loss of efficiency.
- The welding cables should be as short as possible.
- Do not use metal structures which are not part of the workpiece to substitute the
return cable of the welding current: this could jeopardise safety and result in poor
welding.
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.
- Switch ON the G.R.A. following the procedure described in the manual supplied with
the cooling unit.
5.4 LOADING THE WIRE REEL (FIG. F-F1-F2)
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WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OUTLET.
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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
TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN
INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES.
- Open the reel compartment door.
- Position the wire reel on the spindle, holding the end of the wire upwards; make sure
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FIG. E
2