ASKAYNAK MASTERMIG 420W User manual

3
Phase
Welding Method and Specications
GMAW (MIG/MAG)
Eczacıbaşı - Lincoln Electric recommend to use “ASKAYNAK” gas metal arc
welding wire for obtaining high performance from MasterMIG 420W.
Gas Metal Arc
Welding Machine
USER MANUAL
USER
MANUAL
2 years limited spare part warranty
(Clamps and cables excluded)
Welding Machine
USER MANUAL

AT - UYGUNLUK BEYANI
EU - DECLARATION of CONFORMITY
DECLARATION de CONFORMITE de l'EU
СЕРТИФИКАТ СООТВЕТСТВИЯ АТ
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41420 Çayırova, Kocaeli - TURKEY
KAYNAK TEKNİĞİ SANAYİ ve TİCARET A.Ş.
Şirket / Firm / Société
выдан Компании
aşağıda modeli belirtilen kaynak makinesinin
declares that the welding machine
déclare que le poste de soudage
нижеуказанная модель сварочного аппарата
® ®
ASKAYNAK MasterMIG 420W
aşağıda belirtilen yönergelere uygun olduğunu
conforms to the following directives
est conformé aux directives suivantes
соответствует нижеуказанным положениям и
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.
et qu'il a été conçu en conformité avec les normes.
разработан в соответствии с нижеуказанными нормами.
TS EN 60974-1:2013, TS EN 60974-10:2009
Teknik Hizmetler Müdürü / Technical Sevices Manager
Directeur des Services Techniques / Менеджер по техническому обслуживанию
Sertaç ÖZEN
05.07.2015Tarih / Date / Date / Дата :
и свидетельствует о том, что
CE sertifikası 2009 yılında eklenmiştir.
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Safety in Welding ................................................................................. 50 - 57
Electromagnetic Compliance ............................................................... 58 - 59
General Information ............................................................................. 60 - 61
Specications ....................................................................................... 62 - 63
Preparations for Work .......................................................................... 64 - 67
Installation and Operation .................................................................... 68 - 70
Functions of Wire Feeder System................................................................. 71
Environment Conditions .............................................................................. 72
Storage and Transportation ........................................................................ 72
GMAW (MIG/MAG) Method ......................................................................... 73
Efcient Use of Machine In Terms of Energy Consumption ............................ 74
Unpacking .................................................................................................... 74
De-commissioning the Welding Machine .................................................... 74
Maintenance and Troubleshooting ...................................................... 75 - 78
Failures in Welding Seams ................................................................... 79 - 80
Electrical Circuit Diagram ............................................................................ 81
Spare Parts .......................................................................................... 82 - 85
Warnings Label ........................................................................................... 85
Wire Feeder and Power Unit Specications ............................................... 86
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Contents
October 2015
MANUFACTURER
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41420 Çayırova, KOCAELİ - TURKEY
Tel: [phone] Fax: [phone]
www.askaynak.com.tr
Manufactured in People’s Republic of China by
KAYNAK TEKNİĞİ SANAYİ ve TİCARET A.Ş.

This Machines has been designed for GMAW (MIG/MAG). Shall not be used for any
other purpose.
Be sure that this machine should only operated by qualied 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.
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.
READ AND UNDERSTAND THE INSTRUCTIONS CAREFULLY: 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, re 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.
Wooly clothing should be preferred due to its resistance against ame.
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 are 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.
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Other protective clothing used in dangerous situations are stated below:
• Flame resistant clothing,
• Gaiters,
• Aprons,
• Leather cuff gloves and capes,
• Helmet used under the welding mask.
To protect hands against burns, cuts and scratches, gloves made from ame
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 ame resistant material are in good condition and dry.
Noise:
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.
Importance and Cleanliness of Working Environment:
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.
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
efciency 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 CAN KILL: 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
reex. 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 voltage shock (e.g. 230-460 V)
• Secondary voltage shock (e.g. 20-100 V)
Safety in Welding - 2
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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.
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 oor 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.
WELDING ARC and ARC RAYS CAN BURN: Use a shield with proper lter
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 ame resistance material. Protect other nearby personnel with
suitable, non-ammable 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 ash 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
lter is necessary.
As a rule, welding should start with a dark colored protective lter then should
continue with a lighter colored lter sufcient 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 re.
Safety in Welding - 3
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GASESandFUMESCANBEDANGEREOUS:Whenweldingwithelectrodes
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 conned 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 brosis
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.
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 ammable 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 re
hazards or overheat lifting chains or cables until they fail.
Keep away re hazards from welding area and have a re extinguisher readily
available. Remember that welding sparks and hot materials from welding
Safety in Welding - 4
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operation can easily go through small cracks and openings to adjacent
areas. Until ensuring that precautions are used to fully clean ammable and
toxic gases, never weld any tanks, drums, containers or material. Never
operate welder in places that ammable gases, vapors or liquid fuels exist.
Always keep in mind the re 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 re 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 inammable materials away from welding
area. Also make sure that your work piece do not contact with any material
that may are when heated. Material, that may are 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 working above oor level or on
stairway, make sure there is no ammable or explosive material below. Also
please remember that slag and sparks may splash on people around.
Special precautions should be used when welding in dusty environment.
Dust particles may burn and may cause sudden re or explosion. If you
don’t have information about the inammableness 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
ammable 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 ammable materials
located, have a observor near you. This observer should watch where the
sparks and splashes go and should access easily to the re 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 re, to warn
the others activate the re alarm, inform re station, shut down the plasma
cutting machine and leave the building from re exits as soon as possible.
FIRE DANGER MAY CAUSE ACCIDENTS : To prevent the risk for every
kind of arc glare and re, 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 relling the tank, do not spill fuel around.
Safety in Welding - 5
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CYLINDER MAY EXPLODE IF DAMAGED : 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, ttings, 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 xed support.
Carefully choose the locations of the cylinders:
• Cylinders should be kept away from areas where they may be struck or
subjectedto physical damage.
•Cylinders should be located to a safe distance from arc welding or cutting
operations and any other source of heat, sparks or ame.
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).
MOVING PARTS MAY HURT YOUR HANDS : 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.
FOR ELECTRICALLY POWERED EQUIPMENT : 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 re, never leave the electrode holder on
welding desk or any surface in contact with work clamp.
Safety in Welding - 6
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WELDED HOT MATERIAL MAY CAUSE BURNS : 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 and MAGNETIC FIELDS MAY BE HAZARDOUS ON
HUMAN HEALTH : Electric current owing 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 elds may have other health effects which are not known yet (For
detailed information, refer to Page 58-59).
COMPLIANCE WITH CE NORMS: This machine has been manufactured in
compliance with the European Instructions.
SAFE OPERATION : This machine is suitable for welding in environments
where there is high electric shock risk.
Not to be used in residential locations where the electrical power is provided
by the public low-voltage supply system.
EXTRA SAFETY MEASURES:
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 oors, 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 :
• Semi-automatic DC constant voltage welders,
• DC manual arc welders,
• AC welders with reduced voltage control.
Conditions of electrode holder and cables are too important. Plastic or ber 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.
Safety in Welding - 7
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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.
PRECAUTIONS FOR OTHERS IN THE WORKING ENVIRONMENT:
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 re 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 re and ame resistant
work safety clothing, welding goggles, welding mask, insulated work shoes and gloves.
Keep away any people who do not follow the instructions.
When working above oor level, use related warning signs to prevent splashing of melted
metals and welding sparks on people under working area.
Electromagnetic elds 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.
INFORMATION ON RESIDUAL RISKS:
Askaynak MasterMIG 420W 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 re 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.
Safety in Welding - 8
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Electromagnetic Compliance - 1
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
uctuations in mains as well as shorten the economic life of the machine.
• 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.
• This Class A equipment is not intended for use in residential locations where the
electrical power is provided by the public low-voltage supply system. There can be
potential difculties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radiated radio-frequency disturbances.
The welding machine is designed according to the relevant norms and rules. However, it may
still cause problems for the telecommunication equipment (telephone, radio, television etc.)
and safety devices susceptible to the electromagnetic elds as it generates electromagnetic
waves. In order to reduce the effects of the electromagnetic waves (interference) generated
by the machine, please read the following carefully.
The Welding machine is designed for operating in industrial areas. If it is used in residential
areas, certain measures have to be taken in order to eliminate the possible effects of the
electromagnetic waves.
Installation and use
General : The user is responsible for installing and using the arc welding equipment
according to the manufacturer’s instructions. If electromagnetic disturbances are detected,
then it shall be the responsibility of the user of the arc welding equipment to resolve the
situation with the technical assistance of the manufacturer. In some cases this remedial
action may be as simple as earthing the welding circuit (see note). In other cases, it could
involve constructing an electromagnetic screen enclosing the welding power source and
the work complete with associated input lters. In all cases electromagnetic disturbances
shall be reduced to the point where they are no longer troublesome.
NOTE : The practice for earthing the welding circuit is dependent on local safety regulations.
Changing the earthing arrangements to improve EMC can affect the risk of injury or
equipment damage. Further guidance is given in IEC 60974-9.
Assessment of area : Before installing arc welding equipment the user shall make an
assessment of potential electromagnetic problems in the surrounding area. The following
shall be taken into account:
a) other supply cables, control cables, signalling and telephone cables, above, below and
adjacent to the arc welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, for example guarding of industrial equipment;
e) the health of the people around, for example the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ensure that other
equipment being used in the environment is compatible. This may require additional
protection measures;
h) the time of day that welding or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the
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Electromagnetic Compliance - 2
building and other activities that are taking place. The surrounding area may extend beyond
the boundaries of the premises.
Assessment of welding installation
In addition to the assessment of the area, the assessment of arc welding installations may be
used to evaluate and resolve cases of interference. An emission assessment should includ
in situ measurements as specied in Clause 10 of CISPR 11:2009. In situ measurements
may also be used to conrm the efciency of mitigation measures.
Mitigation measures
Public supply system : Arc welding equipment should be connected to the public supply
system according to the manufacturer’s recommendations. If interference occurs, it may
be necessary to take additional precautions such as ltering of the public supply system.
Consideration should be given to shielding the supply cable of permanently installed arc
welding equipment, in metallic conduit or equivalent. Shielding should be electrically
continuous throughout its length. The shielding should be connected to the welding power
source so that good electrical contact is maintained between the conduit and the welding
power source enclosure.
Maintenance of the arc welding equipment : The arc welding equipment should be
routinely maintained according to the manufacturer’s recommendations. All access and
service doors and covers should be closed and properly fastened when the arc welding
equipment is in operation. The arc welding equipment should not be modied in any way,
except for those changes and adjustments covered in the manufacturer’s instructions. In
particular, the spark gaps of arc striking and stabilising devices should be adjusted and
maintained according to the manufacturer’s recommendations.
Welding cables : The welding cables should be kept as short as possible and should be
positioned close together, running at or close to the oor level.
Equipotential bonding : Bonding of all metallic objects in the surrounding area should be
considered. However, metallic objects bonded to the work piece will increase the risk that
the operator could receive an electric shock by touching these metallic objects and the
electrode at the same time. The operator should be insulated from all such bonded metallic
objects.
Earthing of the workpiece : Where the workpiece is not bonded to earth for electrical safety,
nor connected to earth because of its size and position, for example, ship’s hull or building
steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but
not all instances. Care should be taken to prevent the earthing of the workpiece increasing
the risk of injury to users or damage to other electrical equipment. Where necessary,
the connection of the workpiece to earth should be made by a direct connection to the
workpiece, but in some countries where direct connection is not permitted, the bonding
should be achieved by suitable capacitance, selected according to national regulations.
Screening and shielding : Selective screening and shielding of other cables and equipment
in the surrounding area may alleviate problems of interference. Screening of the entire
welding area may be considered for special applications.
To achieve respectively harmonic current emissions and voltage uctuations and icker
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 3.2 MVA and maximum impedance
should be 0.14 Ω.
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General Information - 1
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 ngers.
• Do not perform any modication on the machine. This may affect the machine features
and cause change in technical values.
• It is forbidden to perform any modications and adaptations on the machine. Performing
any modications 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°C and
+55°C.
• Allowable relative humidity rate is up to 90% at 20°C and up to 50% at 40°C.
• 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 specications without notice.
• For long economical life and safety operation, it is useful to take some simple precautions
stated below:
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MANUAL
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General Information - 2
• 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 airow and there
should be no obstacle that prevents ventilation or stops airow. 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 qualied for electrical
equipments, life-threatening danger may occur. In case behaving on the contrary, be
regarded as accepting beforehand all potential negative consequences.
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Specications - 1
• MasterMIG 420W, 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 (CO2) gas.
• It has 30 steps (3x10) 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 water-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 specications without notice.
Operation Cycle and Overheating :
• Operation efciency 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.
Electric Supply Requirement :
• It has been designed for 380 V ± 10, 50/60 % three-phase mains.
• Deviation ration between phases should not be higher than 5%.
• Frequency yield deviation should not be higher than ±1%.
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.)
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Pollution degree : 3
Specications - 2
Wire drive speed (un) range
1- 24 m/dak
Wire speed setting before welding
(for arc start without splashing)
10 % - 100 % (un)
Height
440 mm
Width
290 mm
Depth
675 mm Weight (excl. cables)
19 kg
Steel wire (V type reels)
0.8 - 1.0 - 1.2 mm
Flux cored wire (V type notched reels)
1.2 - 1.6 mm
Aluminum wire (U type reels)
1.2 - 1.6 mm
Wire Drive Unit Model : MasterFeed MF-4
Wire Diameters
Maximum supply current : 4 A
Protection Class : IP21S
Supply voltage and power of wire drive unit : 42 V, 90 W
Physical Dimensions
Input
Power Factor (Cos j) (min.)
0.94
Input Voltage
380 V ± 10 / 3 Phase
Duty Cycle
(10 minutes period)
25 %
60 %
100 %
Power Consumption
21 kVA (25% operation cycle)
Output Current
(Amper)
420 A
325 A
255 A
Welding current setting range
60 - 420 A
Open circuit voltage range
18.1 - 46 V
Height
810 mm
Width
600 mm
Depth
1030 mm
Weight (excl. cables)
(without coolant)
154 kg
Frequency
50/60 Hertz (Hz)
Current Taken
From Mains
32.0 A (25 %)
Output (min.)
73 %
Output Voltage
(Volt)
35.0 V (DC)
30.3 V (DC)
26.8 V (DC)
Welding voltage range
17 - 35 V
Welding voltage steps
30 (3x10)
Output Range
Welding Current Output Rates
Fuse value and type : 3 x 40 A (delayed)
Radio noise level : W
Supply Cable : 4 x 4 mm2
Ambient Operating Temperature : Between –10°C and +40°C
Physical Dimensions
Insulation Class : F + H Protection Class : IP21S
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FRONT PANEL CONTROLS
Preparation for Work - 1
Torch connector (EURO)
Rear wheel
Front wheel
WARNING !
While welding,
changing welding
voltage range may
cause damage to the
machine. Therefore
stop welding to
change the voltage
range.
Welding wire reel protection
cabinet cover
Gas ow without welding
control switch
Water pump switch
Digital welding
voltage indicator
Digital welding
current indicator
Wire feeder unit handle
Wire feed speed setting button
Wheels
Power indicator
On-Off switch
2/4 trigger selection switch
Wire feed control without
welding button
termal koruma göstergesi
welding voltage
precise setting switch
welding voltage
coarse setting switch
Work cable
connection socket
(high inductance)
Work cable connection
socket (low inductance)
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MANUAL
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BACK PANEL CONTROLS
Preparation for Work - 2
Wire feeder unit (+)
power connection socket
Shielding gas
cylinder xing slot
Shielding gas (CO2)
heater fuse (8A)
Rear wheel
Wire feeder unit handle
Shielding gas inlet socket
Control cable connection socket
Specication plate
Rack for placing shielding
gas cylinder
Welding wire reel
protection cabinet
Coolant inlet and
outlet sockets
Wire feeder unit
rear wheels
Mains inlet
energy cable
Control cable
connection socket
Cooling water
level indicator
Cooling water
connection fuse (3A)
Wire feeder unit
fuse (5A)
Control unit
fuse (4A) Wire feeder unit (+)
power connection socket
Pin for placing wire
feeder unit to power unit
Front wheel
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MANUAL
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Preparation for Work - 3
CONTROLS IN WIRE FEEDER UNIT
Wire feeder reel press forced setting spindle
Welding wire reel protection cabinet cover Welding wire reel protection cabinet rear wheels Welding wire reel connecting shaft and braking torque setting
Wire outlet guide
Wire drive reels (4 unit)
Wire feeder
engine
Wire inlet
guide
Pin slot for placing
wire feeder unit to
power unit
Wire feeder unit
handle
Cover providing easy
access to internal panel
burnback period setting
button
Wire feed speed without
welding setting button
Welding torch
connection socket
Water inlet and outlet
channels for connecting
torch cooling water when
required
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MANUAL
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