Assembly (Fig. D) - Telwin MasterMIG 405i Bedienungsanleitung

8- Numerical display A:
- measured current display in welding in MIG MAG 2T (or 4T) mode;
- set current display in MMA or TIG mode.
9- m/min numerical display:
- set wire feeding speed display in MIG MAG 2T (or 4T) mode.
5. INSTALLATION
ATTENTION! THE WELDING MACHINE MUST BE TURNED OFF AND
DISCONNECTED FROM THE MAINS BEFORE COMMENCING ANY INSTALLATION
AND POWER CONNECTION OPERATIONS.
THE ELECTRICAL CONNECTIONS MUST ONLY BE CARRIED OUT BY EXPERT OR QUALIFIED
TECHNICIANS.

ASSEMBLY (Fig. D)

Unpack the welding machine and assemble the separate parts included in the package.
Assembling the clamp-return cable Fig. E
Assembling the welding cable electrode-holder clamp FIG. F
5.1 POSITIONING THE WELDING MACHINE
Choose the place where the welding machine is to be installed so that there are no obstructions
to the cooling air inlets and outlets; at the same time make sure that conductive dust, corrosive
vapours, humidity etc. cannot be drawn into the machine.
Leave at least 250 mm of free space all around the welding machine.
WARNING! Position the welding machine on a level surface with sufficient
load-bearing capacity, so that it cannot be tipped over or shift dangerously.
5.2 CONNECTION TO THE MAIN POWER SUPPLY
- Before making any electrical connection, check the rating plate data on the welding machine
to make sure they correspond to the voltage and frequency of the available power supply
where the machine is to be installed.
- The welding machine must be connected only and exclusively to a power supply with the
neutral conductor connected to earth.
- To guarantee protection against indirect contact use the following types of residual current
devices:
- Type A ( ) for single-phase machines.
- Type B ( ) for 3-phase machines.
- In order to satisfy the requirements of the EN 61000-3-11 (Flicker) standard we recommend
connecting the welding machine to the interface points of the main power supply that have
an impedance of less than Zmax = 0.12 ohm.
- The IEC/EN 61000-3-12 Standard does not apply to the welding machine.
If the welding machine is connected to an electrical grid, the installer or user must make sure
that the machine can indeed be connected (if necessary, consult the company that manages
the electrical grid).
5.2.1 Plug and outlet
Connect a normalised plug (3P + P.E) - 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 (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.
WARNING! Non-compliance with the above regulations renders the
manufacturer's safety system (class I) inefficient, with resulting serious risks
to people (e.g. electric shock) and things (e.g. fire).
5.3 WELDING CIRCUIT CONNECTION
5.3.1 Recommendations
ATTENTION! BEFORE CARRYING OUT THE FOLLOWING CONNECTIONS, MAKE
SURE THE WELDING MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.
Table 1 (TAB. 1) gives the recommended values for welding cables (in mm
maximum energy supplied by the welding machine.
In addition:
- Fully rotate the welding cable connectors in the quick couplings (if present), to guarantee
perfect electric contact; if this is not the case the connectors will overheat with consequent
fast deterioration and loss of efficiency.
- Use the shortest welding cables possible.
- Do not use metal structures that are not part of the workpiece to replace the welding current
return cable; this can endanger safety and give unsatisfactory welding results.
5.3.2 WELDING CIRCUIT CONNECTION IN MIG-MAG MODE
5.3.2.1 Connecting the gas bottle (if used)
- Gas bottle that can be loaded onto the supporting surface of the trolley: max. 60 kg.
- When using Argon gas or an Argon/CO
bottle valve, placing the relative pressure reducing valve supplied as an accessory.
- Connect the gas input hose to the pressure reducing valve and tighten the strip.
- Loosen the adjustment ring nut of the pressure reducing valve before opening the gas bottle
valve.
(*) Accessory to be purchased separately if not supplied with the product.
5.3.2.2 Connecting the welding current return cable
Connect the cable to the piece to be welded or the metal bench on which the workpiece is
placed, as close as possible to the joint being worked.
5.3.2.3 Torch (Fig. B)
Insert the torch (B-5) into the dedicated connector (B-6), fully tightening the locking ring nut
manually. Prepare the torch to receive the wire for the first time, removing the nozzle and the
contact pipe, to make exiting easier.
5.3.3 WELDING CIRCUIT CONNECTIONS IN TIG MODE
5.3.3.1 Gas cylinder connection
- Screw the pressure reducer onto the cylinder gas valve, if necessary, inserting the specific
reduction supplied as an accessory.
- Connect the input hose of the gas reducer and tighten with the supplied strip.
- Loosen the setting ring nut of the pressure reducer before opening the cylinder valve.
- Open the cylinder and adjust the quantity of gas (l/min) according to the illustrative use data,
) according to the
2
mixture, screw the pressure reducer(*) onto the gas
2
see table (TAB. 6); any adjustments in gas flow can be carried out during welding always
using the pressure reducer ring nut. Check the tubing and fittings.
ATTENTION! Always close the gas cylinder valve at the end of work.
5.3.3.2 Connecting the welding current return cable
- Connect the cable to the piece to be welded or the metal bench on which the workpiece is
placed, as close as possible to the joint being worked. Connect this cable to the clamp with
the symbol (+) (Fig B-2).
5.3.3.3 Torch
- Insert the current cable in the specific fast clamp (-) (Fig. B-3). Connect the gas hose of the
torch to the cylinder.
5.3.4 WELDING CIRCUIT CONNECTIONS IN MMA MODE
Almost all the coated electrodes should be connected to the positive pole (+) of the generator;
an exception is the negative pole (-) for electrodes with acid coating.
5.3.4.1 Connection of the electrode-holder clamp welding cable
Bring a special clamp on the clamp used to tighten the exposed part of the electrode. Connect
this cable to the clamp with the symbol (+) (Fig B-2).
5.3.4.2 Connecting the welding current return cable
- Connect the cable to the piece to be welded or the metal bench on which the workpiece is
placed, as close as possible to the joint being worked. Connect this cable to the clamp with
the symbol (-) (Fig B-3).
5.4 LOADING THE WIRE SPOOL (Fig. G-G1)
ATTENTION! BEFORE LOADING THE WIRE, MAKE SURE THE WELDING MACHINE
IS OFF AND DISCONNECTED FROM THE MAINS.
MAKE SURE THE WIRE FEEDERS, THE WIRE GUIDE HOSE AND THE TORCH CONTACT PIPE
CORRESPOND WITH THE DIAMETER AND NATURE OF THE WIRE TO BE USED AND THAT THEY
ARE CORRECTLY MOUNTED. DO NOT WEAR PROTECTIVE GLOVES WHEN THREADING THE WIRE.
- Open the reel area door.
- Unscrew the spool lock nut.
- Position the wire spool on the reel; make sure the reel pulling pin is correctly housed in its
hole (1a).
- Tighten the spool lock nut, using spacers as and where necessary (1a).
- Free the pressure counter-roller/s and distance it/them from the lower roller/s (2a);
- Make sure the pulling feeder/s is/are suitable for the wire being used (2b).
- Free the wire end, cut off the misshaped end by cutting it cleanly and without leaving a
burr; rotate the spool counter-clockwise and position the wire end into the wire feed input,
pushing it by 50-100 mm into the torch connecting wire feed (2c).
- Reposition the counter-roller/s, adjusting the pressure at an intermediate value, make sure
the wire is positioned correctly in the hollow of the lower feeder/s (3).
- Remove the nozzle and contact tube (4a).
- Insert the welding machine plug into the mains socket, switch on the welding machine,
press the torch push-button and wait for the end of the wire which is running along the
whole wire feed casing, to exit by 10-15 cm from the front of the torch, then release the push-
button.
ATTENTION! During these operations the wire is being powered and is subject
to mechanical force; if suitable precautions are not taken there is a danger of
electric shock and wounds, and electric arcs striking:
- Do not direct the torch mouth against parts of the body.
- Do not approach the torch gas cylinder.
- Remount the contact tube and the nozzle onto the torch (4b).
- Make sure the wire exits regularly; set the roller pressure and reel braking (1b) to the lowest
values possible, making sure the wire does not slide in the hollow and that when the drive
stops the wire turns do not become loose because of too much spool inertia.
- Cut the end of the wire that exits from the nozzle by 10-15 mm.
- Close the reel area door.
5.5 REPLACING THE TORCH WIRE GUIDE SHEATH (FIG. H)
Before replacing the sheath, straighten out the torch cable to make sure there are no loops.
5.5.1 Spiral sheath for steel wire
1- Remove the nozzle and contact tube from the torch head.
2- Unscrew the sheath lock nut on the central connector and slide out the existing sheath.
3- Slide the new sheath into the torch cable and gently push it until it comes out of the torch
head.
4- Hand tighten the sheath lock nut back in place.
5- Cut the wire flush with the sheath and gently squeeze them together; remove it from the
torch cable.
6- Bevel the sheath cutting zone and reposition it in the torch-cable duct.
7- Use a key to tighten the lock nut back in place.
8- Remount the contact tube and the nozzle.
5.5.2 Synthetic sheath for aluminium wire
Perform operations 1, 2 and 3 foreseen for steel sheaths (do not consider operations 4, 5, 6, 7
and 8).
9- Screw the aluminium contact tube back in place checking that it comes into contact with the
sheath.
10- Insert the brass nipple, the OR ring onto the opposite end of the sheath (torch coupling
side), maintain a light pressure on the sheath and tighten the sheath lock nut. The excess
section of the sheath shall be removed later on (see (13)). Slide out the capillary tube for
steel sheaths from the wire feeder torch coupling.
11- NO CAPILLARY TUBE IS FORESEEN for aluminium sheaths with diameters of 1.6-2.4 mm
(yellow colour); the sheath will be inserted in the torch coupling without it.
Cut the capillary tube for aluminium sheaths measuring 1-1.2 mm (red colour) to a length
of 2 mm less than the one used for the steel tube and insert it on the free end of the sheath.
12- Insert and block the torch in the wire feeder coupling, mark the sheath at 1-2 mm from the
rollers, now extract the torch again.
13- Cut the sheath to the foreseen measurement without deforming the inlet hole.
Remount the torch in the wire feeder coupling and mount the gas nozzle.
6. MIG-MAG WELDING: PROCESS DESCRIPTION
6.1 SHORT ARC
Wire welding and detachment of the drop takes place via subsequent short-circuits of the wire
tip and weld pool (up to 200 times per second). The stick-out length of the wire is normally
between 5 and 12mm.
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