Telwin MASTERMIG 500 R.A. [5/80] Technical data
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Telwin MASTERMIG 500 R.A. [5/80] Technical data

Telwin MASTERMIG 500 R.A. [5/80] Technical data
2.2 WELDING MACHINE WITH REMOVABLE WIRE FEEDER (FIG.A2)
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.
generator - wire feeder connecting cables assembly (only for welding machine with
removable wire feeder);
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.
5.2.2 PLUG AND OUTLET: connect a normalised plug (3P + T for 3ph) 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
2.3 STANDARD ACCESSORIES:
supply.
- torch (water-cooled in the R.A. version);
- To carry out voltage change operations, take off the panel to gain access to the inside
- return cable complete with earth clamp;
of the machine, and prepare the voltage change terminal board so that the
- wheels kit;
connection indicated on the special indicator plate corresponds to the available
- ARGON bottle adapter;
power supply voltage.
- pressure reducing valve;
FIG. E
- wire feeder;
Reassemble the panel carefully using the appropriate screws.
- R.A. water cooling unit (only for the R.A. version);
Warning!
In the factory the machine is set at the highest voltage of the available range,
2.4 OPTIONAL ACCESSORIES
e.g.
- electronics board with dual timer;
U 400V Ü Voltage setting at the factory.
1
-
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- R.A. water cooling unit (where present);
(standard accessory on R.A. version);
WARNING!
- Reel cover kit (where present);
Failure to observe the above rules will make the (Class 1) safety system installed
- Aluminium welding kit;
by the manufacturer ineffective with consequent serious risks to persons (e.g.
- Flux-core wire welding kit;
electric shock) and objects (e.g. fire).
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3. TECHNICAL DATA
3.1 DATA PLATE
5.3 CONNECTION OF THE WELDING CABLES
The most important data regarding use and performance of the welding machine are
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summarised on the rating plate and have the following meaning:
FIG. B
WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
1- EUROPEAN standard of reference, for safety and construction of arc welding
SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
machines.
THE POWER SUPPLY OUTLET.
2- Symbol for internal structure of the welding machine.
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3- Symbol for welding procedure provided.
4- Symbol S: indicates that welding operations may be carried out in environments with
2
Table 1 (TAB. 1) gives the recommended values for the welding cables (in mm )
heightened risk of electric shock (e.g. very close to large metallic volumes).
depending on the maximum current supplied by the welding machine.
5- Symbol for power supply line:
1~: single phase alternating voltage;
5.3.1 Connection to the gas bottle
3~: 3-phase alternating voltage.
- Gas bottle can be loaded on welding machine bottle support platform: max 20 kg.
6- Protection rating of the covering.
- Screw the pressure reducing valve onto the gas bottle valve, inserting the
7- Technical specifications for power supply line:
appropriate adapter supplied as an accessory, for when the gas used is Argon or
- U : Alternating voltage and power supply frequency of welding machine (allowed
1
an Argon /CO mixture.
2
limit ±10%).
- Connect the gas inlet pipe to the pressure-reducing valve and tighten the band
- I : Maximum current absorbed by the line.
1 max
supplied.
- I : : effective current supplied.
- Loosen the adjustment ring nut on the pressure-reducing valve before opening the
1eff
8- Performance of the welding circuit:
bottle valve.
- U : maximum no-load voltage (open welding circuit).
0
5.3.2 Connecting the welding current return cable
- I /U : current and corresponding normalised voltage that the welding machine can
2 2
This is connected to the piece being welded or to the metal bench supporting it, as close
supply during welding.
as possible to the join being made.
- X : Duty cycle: indicates the time for which the welding machine can supply the
This cable is connected to the terminal with the symbol (-).
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).
5.3.3 Connecting the torch
If the usage factors (on the plate, referring to a 40°C environment) are exceeded,
Engage the torch with its dedicated connector by tightening the locking ring manually as
the thermal safeguard will trigger (the welding machine will remain in standby until
far down as it will go. Prepare the wire for loading the first time by dismantling the nozzle
its temperature returns within the allowed limits).
and the contact tube to ease its exit.
- A/V-A/V: shows the range of adjustment for the welding current (minimum
maximum) at the corresponding arc voltage.
5.3.4 Connection to the wire feeder (for model with external wire feeder)
9- Manufacturer's serial number for welding machine identification (indispensable for
- Make the connections with the electrical generator (rear panel):
technical assistance, requesting spare parts, discovering product origin).
- welding current cable to quick connection (+);
10- : Size of delayed action fuses to be used to protect the power line.
- control cable to appropriate connector.
11- Symbols referring to safety regulations, whose meaning is given in chapter 1
- Make sure the connectors are firmly tightened in order to prevent overheating and
“General safety considerations for arc welding”.
loss of efficiency.
Note: The data plate shown above is an example to give the meaning of the symbols and
- Connect the gas pipe from the pressure-reducing valve on the bottle and lock it with
numbers; the exact values of technical data for the welding machine in your possession
the clip supplied.
must be checked directly on the data plate of the welding machine itself.
5.3.5 Warnings
3.2 OTHER TECHNICAL DATA
- Turn the welding cable connectors right down into the quick connections (if present),
- WELDING MACHINE: see table 1 (TAB.1)
to ensure a perfect electrical contact; otherwise the connectors themselves will
- TORCH: see table 2 (TAB.2)
overheat, resulting in their rapid deterioration and loss of efficiency.
The welding machine weight is shown in table 1 (TAB. 1).
- The welding cables should be as short as possible.
- Do not use metal structures which are not part of the workpiece to substitute the
4.DESCRIPTION OF THE WELDING MACHINE
return cable of the welding current: this could jeopardise safety and result in poor
welding.
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.
5.4 LOADING THE WIRE REEL (FIG. F-F1)
THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
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AUTHORISED OR QUALIFIED PERSONNEL.
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WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
5.1 PREPARATION (FIG. C)
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
Unpack the welding machine, assemble the separate parts contained in the package.
FROM THE MAIN POWER SUPPLY OUTLET.
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5.1.1 Assembling the return cable-clamp (FIG. D)
MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND
THE CONTACT TIP OF THE TORCH MATCH THE DIAMETER AND TYPE OF WIRE
5.2 HOW TO LIFT THE WELDING MACHINE
TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN
None of the welding machines described in this manual is equipped with a lifting device.
INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES.
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- Open the reel compartment door.
- Position the wire reel on the spindle, holding the end of the wire upwards; make sure
WARNING! Position the welding machine on a flat surface with sufficient
the tab for pulling the spindle is correctly seated in its hole (1a).
carrying capacity for its weight, to prevent it from tipping or moving hazardously.
- Release the pressure counter-roller/s and move it/them away from the lower roller/s
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(2a).
- Make sure the puller roller is suitable for the wire being used (2b).
5.2.1 CONNECTION TO THE MAIN POWER SUPPLY
- Free the end of the wire and remove the distorted end with a clean cut and no burr;
- Before making any electrical connection, make sure the rating data of the welding
turn the reel anti-clockwise and thread the end of the wire into the wire-guide infeed,
machine correspond to the mains voltage and frequency available at the place of
pushing it 50-100mm into the wire guide of the torch fitting (2c).
installation.
- Re-position the counter-roller/s, adjusting the pressure to an intermediate value, and
- The welding machine should only be connected to a power supply system with the
make sure that the wire is correctly positioned in the groove of the lower roller (3).
neutral conductor connected to earth.
- Use the adjustment screw located at the centre of the spindle to apply a slight braking
- To comply with the requirements of the EN 61000-3-11 (Flicker) standard we
pressure on the spindle itself (1b).
recommend connecting the welding machine to interface points of the power supply
- Remove the nozzle and contact tip (4a).
that have an impedance of less than Zmax = 0.04 ohm.
- 5 -

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