Technical Specifications; Introduction And General Description - Telwin MasterMIG 405i Bedienungsanleitung

- RISK OF BURNS
Some parts of the welding machine (torch, electrode-holder clamp) and the adjacent
areas can reach temperatures over 65°C: adequate protective clothing must be worn.
Allow the just welded piece to cool before touching it!
- IMPROPER USE: the use the welding machine by more than one operator at the same
time may be dangerous.
- MOVING THE WELDING MACHINE: Always secure the gas bottle, taking suitable
precautions so that it cannot fall accidentally (if used).
- Do not use the handle to hang the welding machine.
The safety guards and moving parts of the covering of the welding machine and of the
wire feeder should be in their proper positions before connecting the welding machine
to the power supply.
WARNING! Any manual operation carried out on the moving parts of the wire feeder, for
example:
- Replacing rollers and/or the wire guide;
- Inserting wire in the rollers;
- Loading the wire reel;
- Cleaning the rollers, the gears and the area underneath them;
- Lubricating the gears.
SHOULD BE CARRIED OUT WITH THE WELDING MACHINE SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
ENVIRONMENTAL CONDITIONS (EN 60974-1)
- Use the welding machine with the following environmental conditions only:
• ambient temperature between -10°C and 40°C;
• relative humidity of the air not exceeding 50% at 40°C;
• relative humidity of the air not exceeding 90% at 20°C;
• The surrounding air must be free of dust, acid, gas or corrosive substances, etc.
STORAGE
- Position the machine and its accessories (with or without packaging) in closed
premises.
- The ambient temperature must be between -20°C and 55°C.
If the machine is planned with liquid cooling and an ambient temperature under 0°C: use
the anti-freeze liquid suggested by the manufacturer or completely empty the hydraulic
circuit and the tank of liquid.
Always use adequate measures to protect the machine from humidity, dirt and corrosion.
DISPOSAL
Do not dispose of this welding machine as normal household waste at the end of its life
cycle.
The user is responsible for disposing of this electrical equipment in collection points
designated for disposal and recycling of electrical equipment or contact the shop where
you purchased the product. This provision only refers to disposal of the equipment
within the European Union (WEEE).

2. INTRODUCTION AND GENERAL DESCRIPTION

This welding machine is a source of current for arc welding, made specifically for MAG welding
carbon steel or weak alloys with CO
2
electrode wires (tubular).
It is also ideal for MIG welding stainless steel with Argon gas containing + 1-2% oxygen and
aluminium and CuSi3, CuAl8 (brazing) with Argon gas, using electrode wires that are suitable
for the workpiece to be welded.
The welding machine can be used for TIG welding in direct current (DC), with arc striking upon
contact (LIFT ARC mode). It welds all types of steel (carbon, low- and high-alloy) and heavy
metals (copper, nickel, titanium and their alloys) with a gas shield of pure (99.9%) Ar or, for
special uses, with an Argon/Helium mix. It can also be used for MMA electrode welding in
direct current (DC) using coated electrodes (rutile, acid, basic).
2.1 MAIN CHARACTERISTICS
MIG-MAG
- Operating modes:
- 2T manual;
- 4T manual;
- Electronic reactance (INDUCTANCE), welding voltage and wire feeding speed adjustment.
- Set welding voltage shown on display.
- Set wire feeding speed shown on display.
- Welding current shown on display.
MMA
- Arc force (DYNAMIC ARC) and welding current adjustment.
- Set welding current shown on display.
- Welding voltage shown on display.
- Anti-stick protection.
TIG
- Welding current adjustment.
- Set welding current shown on display.
- Welding voltage shown on display.
- Start LIFT.
PROTECTION
- Thermostatic protection.
- Protection against accidental short-circuits caused by contact between torch and earth.
- Protection against irregular voltage (power supply voltage too high or too low).
2.2 STANDARD ACCESSORIES
- MIG torch
- Return cable complete with earth clamp.
- Torch holder stand.
protective gas or Argon/CO mixes, using full or core
2
2.3 OPTIONAL ACCESSORIES
- Argon bottle adapter.
- Self darkening mask.
- MIG/MAG welding kit.
- MMA welding kit.
- TIG welding kit.

3. TECHNICAL SPECIFICATIONS

3.1 DATA PLATE
WELDING MACHINE
The main data on use and performance of the welding machine are summarised on the rating
plate with the following meaning:
1- EUROPEAN reference standard for safety and construction of arc welding machines.
2- Manufacturer's name and address.
3- Name of model.
4- Symbol of welding machine internal structure.
5- Symbol of planned welding procedure.
6- Symbol S : indicates cleaning operations can be carried out in an environment with
increased risk of electric shock (e.g. in close proximity of large metal masses).
7- Symbol of the power supply:
1~: single-phase alternating voltage;
3~: three-phase alternating voltage.
8- Protection rating of the casing.
9- Characteristic data of the power supply:
- U : Alternating voltage and power supply frequency to the welding machine (allowed
1
limits ±10%).
- I
: Absorbed maximum current from line.
1 max
- I : Effective power supply current.
1 eff
10- Welding circuit performance:
- U : maximum no load voltage (welding circuit open).
0
- I /U
: Normalized corresponding current and voltage which can occur supplied by the
2 2
welding machine during welding.
- X : Duty cycle ratio: indicates the time during which the welding machine can supply the
corresponding current (same column). It is expressed as a %, based on a 10min cycle (e.g.
60% = 6 working minutes, 4 rest minutes; and so on).
If the use factors (of plate, referring to 40°C ambient temperature) are surpassed, the
thermal switch activates (the welding machine stays in stand-by until its temperature
goes back within the permitted limits).
- A/V-A/V : It indicates the settings range of the welding current (minimum- maximum) at
the corresponding arc voltage.
11- Serial number to identify the welding machine (essential for technical assistance, spare
part requests, tracing of product origin).
12- : Value of delayed activation fuses to implement for line protection.
13- Symbols referring to safety standards whose meaning is outlined in chapter 1 "General
safety for arc welding".
NB: The rating plate shown is an example to explain the meanings of the symbols and figures;
the exact technical specifications for the welding machine should be taken directly from the
rating plate on the welding machine.
3.2 OTHER TECHNICAL DATA
- WELDING MACHINE: see table 1 (TAB. 1)
- AVERAGE CONSUMPTION OF WIRE AND WELDING GAS: see table 2 (TAB. 2)
- MIG TORCH: see table 3 (TAB. 3)
- TIG TORCH: see table 4 (TAB. 4)
- ELECTRODE-HOLDER CLAMP: see table 5 (TAB. 5)
The weight of the welding machine and wire feeder unit is outlined on table 1 (TAB. 1).
4. DESCRIPTION OF THE WELDING MACHINE (FIG. B)
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES
At the front:
1- Control panel (see description);
2- Positive (+) quick coupling for connecting the welding cable;
3- Negative (-) quick coupling for connecting the welding cable;
4- Earth return cable and clamp;
5- Welding cable and torch;
6- Torch coupling;
At the back:
7- Main ON/OFF switch;
8- Power cable;
9- Hose connector for torch protective gas;
4.2 WELDING MACHINE CONTROL PANEL (Fig. C)
1- Green indicator led:
a) fixed: mains voltage present.
b) flashing: stand-by mode (operating status at low energy consumption where the
machine is powered but the welding circuit and/or fans were disabled). Reactivation is
automatic as soon as the welding process starts.
2- Yellow indicator led:
a) fixed: activation of safety thermostat, over/undervoltage (ATTENTION: exceeding the
upper voltage limit can seriously damage the device).
b) flashing: anti-stick intervention in MMA mode.
c) fixed with intermittent m/min display: one of the machine fuses shuts-off.
3- Machine setting selector:
- : MIG MAG 2T mode.
- : MIG MAG 4T mode.
- : MMA mode.
- : TIG mode.
4- Knob, whose rotation allows:
- electronic reactance adjustment in MIG MAG 2T (or 4T) mode;
- "DYNAMIC ARC" dynamic overcurrent in MMA mode.
5- Knob, whose rotation allows:
- welding voltage adjustment in MIG MAG 2T (or 4T) mode;
- welding current adjustment in MMA or TIG mode.
6- Knob, whose rotation allows:
- wire feeding speed adjustment in MIG MAG 2T (or 4T) mode.
7- Numerical display V:
- set voltage display in MIG MAG 2T (or 4T) mode;
- measured voltage display in welding in MMA or TIG mode.
- 6 -
Fig. A