ASKAYNAK MasterSTICK 505 User manual

Shielded Metal Arc
Welding Machine
3
Phase
2 years limited spare part waranty
(Clamps and cables excluded)
Welding Method and Specications
MMA Welding
Eczacıbaşı - Lincoln Electric, MasterStick 505’den yüksek performans elde
etmeniz için “ASKAYNAK” örtülü elektrod kaynak telini kullanmanızı tavsiye eder
USER MANUAL
380 V
USER
MANUAL

“AT” UYGUNLUK BEYANI
“EU” DECLARATION OF CONFORMITY
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
İmalatçı / Manufacturer
Teknik Hizmetler Müdürü - Technical Sevices Manager
Sertaç ÖZEN
Kocaeli, TURKEY
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41420 Çayırova, Kocaeli - TURKEY
CE sertifikası yılında eklenmiştir.
CE mark was first affixed in .
Ürün / Product
Marka - Model / Brand - Model
Yukarıda tanımlanan beyanın nesnesi, ilgili uyumlaştırılmış AB mevzuatı ile uyumludur.
The object of the declaration described above, is in conformity with the relevant union
harmonisation legislation.
Direktifler / Directives
Uyumlaştırılmış Standartlar / Harmonised Standards
Bu uygunluk beyanı yalnızca imalatçının sorumluluğu altında düzenlenir.
This declaration of conformity is issued under the sole responsability of the manufacturer.
03.10.2016
2015
2015
TS EN 60974-1:2013, TS EN 60974-10:2014
Örtülü Elektrod Kaynak Makinesi - MMA Welding Machine
®
Askaynak MasterSTICK 505
2014/35/EU, 2014/30/EU
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USER
MANUAL

37
Content
Life cycle specied by the Ministry of Industry and Trade is 10 years.
(The spare parts necessary for the product to function will be available for this period.)
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.
Safety in Welding ................................................................................. 38 - 45
Electromagnetic Compliance ............................................................... 46 - 47
General Characteristics ............................................................................... 48
Installation and Operator Instructions ........................................................ 49
Preparations for Work .......................................................................... 50 - 52
Maintenance and Troubleshooting ...................................................... 53 - 56
Environment Conditions .............................................................................. 56
Efcient Use in Terms of Energy Consumption .......................................... 57
Unpacking ................................................................................................... 57
Transportation and Storage Conditions ..................................................... 57
Decommissioning the Welding Machine .................................................... 57
Accessories Delivered With Machine ......................................................... 57
Spare Parts .......................................................................................... 58 - 59
Electrical Connection Diagram ............................................................ 60 - 61
Warning Label and Technical Specication Table ...................................... 62
USER
MANUAL

This machine is designed to perform arc welding with shielded electrodes.
It may not be used for any purpose other than that for which it is intended.
This machine shall be used by qualied personnel trained on welding. Ensure that all
connections, operations, maintenance and repair procedures are performed by authorized
persons. Read this operation manual before operating the machine. Failure to follow the
instructions given in the operation manual may lead to serious injuries, death or damage
to the machine. Please read the warnings against the symbols specied below. Kaynak
Tekniği Sanayi ve Ticaret A.Ş. cannot be held responsible for damages caused by improper
connections, storage conditions and usage.
WARNING: This symbols indicates that the instructions specied in the
operation manual shall always be followed to prevent possible serious
injuries, deaths and damages to the machine. Protect yourself and the
persons in the vicinity.
READ AND UNDERSTAND THE INSTRUCTIONS CAREFULLY : Read and
understand the operation manual before operating the machine. Failure to
follow the instructions specied in the operation manual may lead to serious
injuries, death or damage to the equipment.
Welding operation shall not be performed in a careless, preoccupied, tired
or sleepy mood.
Arc welding is a safe operation when measured required to protect the welder
from potential risks. If these measures are not noticed or neglected, serious
or even lethal risks such as electrocution, exposure to excessive smoke or
gases, arc radiation, re and explosion may occur.
Note: For detailed information on safety in welding read ANSI standard Z49.1.
Protective Equipment:
Welding operators shall wear clothes that protect them from burning risks.
Welding burns are frequent risks that are caused by splashing of welding
sparks on bare skin.
Clothes worn while welding may differ as per the welding method, but in
general the cloth shall provide ease of movement, and cover the welder’s
body so that it is protected against splashes, sparks and arc radiation.
Woollen clothes shall be preferred as they are resistant against re. Avoid
synthetic clothes as these will melt when they are exposed to heat.
Protective clothes shall be kept free of grease and oil. Such material may
catch re and burn in an uncontrolled manner in an environment of oxygen.
Do not fold your sleeves and trouser legs. Sparks and melted metal may
enter the folded parts. Keep trousers out of the work shoes, do not tuck them
inside the shoes. Otherwise, melted metal and sparks may enter the shoes.
Safety in Welding - 1
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Other protective clothes used in hazardous conditions are specied below:
• Flame resistant clothes,
• Leggings,
• Aprons,
• Leather armbands and cloaks,
• Hats worn under the welding mask.
Always wear gloves made of ame resistant material such as leather to protect
your hands from burns, cuts and scratches. In addition to that, ensure that
gloves made of ame resistant material such as leather are intact and dry to
provide some insulation against electrocution.
Noise:
Wear ear protectors to prevent hearing loss caused by the noise of arc
welding machine and to protect ear from sparks and melted metal. An
aural may be experienced when the noise in the working area reach a level
that disturbs the ears and that causes headache. Wear your ear protectors
immediately in such a case.
Hearing loss may not be detected until tested and after that, it may be too
late for treatment.
Neatness and Cleanliness of Working Environment:
Neatness and cleanliness of working environment is as important as the
maintenance of the welding machine. Moreover, the damage that may occur
is increased exponentially by the number of persons in the environment. Even
if you have read the warnings on the machine and have taken the required
precautions, someone tripping over a cable in the working environment may
cause risks of electrocution, contact with hot metal or falling for you or for
other persons around.
All equipment, cables, hoses and gas cylinders shall be kept away from
areas of movement such as doors, halls and stairway surroundings. Do your
best in keeping the environment clean and clean the working environment
when the welding operation is completed. This would improve operational
efciency besides the occupational safety. Also, other workers around the
welding area may inadvertently step inside the welding bath; therefore a
protective screen shall be installed around the area during welding.
GAS CYLINDER MAY EXPLODE: Only the gas cylinders specically
manufactured for welding purposes containing compressed gas should be
used. Make sure that correct regulators for the gas and cylinder pressure
used are installed properly. The cylinders must be kept in an upright position
and attached somewhere with the safety chain. Do not displace the cylinders
without installing the safety caps. Make sure that the electrodes, electrode
handles, work clamps and all types of parts carrying voltage do not come in
touch with the cylinders. Store the cylinders away from risky places, where
heat and sparks are generated.
Safety in Welding - 2
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WELDED MATERIAL MAY BURN: Intense heat may be released while
welding. Contact with the hot surfaces and materials may cause serious
burns. Gloves must be used without fail while touching or carrying such
materials.
ELECTRIC SHOCK CAN KILL: Electrical shock is the most serious risk that
the welding operator might face frequently. Contact with the live electrical
materials can lead to injuries, death, electrical shocks or sudden falls by
reex. Do not touch the electrode, grounding wire or work piece under
voltage attached to the machine. Insulate yourself against contact with the
electrode, grounding wire or work piece. Do not touch the plug’s metal pins
after disconnection from the power. It contains risk of electrical shock.
The electrical shock risk associated with the welding machine is divided in to two
categories:
• Primary voltage shock (e.g. 230 - 460 V)
• Secondary voltage shock (e.g. 20 - 100 V DC)
The primary electrical shock is much more dangerous, since the voltage is
higher than the welding voltage. Primary electrical shock may happened
by contact with a live part in the machine while the body is grounded when
there is power on the machine. Please do not forget that the ON/OFF switch
on the machine may not cut off the electricity connected to the machine
itself. In order to get a safe disconnection from mains supply; switch off the
fuse and disconnect the input cables from the connection terminals.
Never remove the side covers of the machine and in case of a failure, have
an authorized technician check and repair the machine.
Ground the machine and work piece without fail.
Do not use un-insulated cables and electrode holders, replace them with
new ones. Never immerse the electrodes in water for cooling.
Do not touch the electrode cables connected to two separate welding
machines; the voltage carried may be equal to the sum of the open circuit
voltage of both machines.
Please use a safety harness without fail while working on high places to
prevent falling because of an electrical shock.
FUMES AND GASES MAY BE DANGEROUS: The welding works may cause
the emission of smoke and gas hazardous for human health. In order to
protect the user against this hazard, the smoke or gases have to be removed
by providing adequate ventilation.
Generally short-term effects such as burns in the face and skin, dizziness,
nausea and fewer etc. may be experienced during the welding operations
depending on the exposure length to the smoke and amount of smoke
present. Longer exposure to smoke may lead to the accumulation of iron in
the lungs and may cause functional disorders. Bronchitis and lung brosis
are the most frequently seen effects.
Some electrodes may contain certain alloys that make special ventilation
Safety in Welding - 3
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compulsory. The labels on the products that require special ventilation
should not be ignored and the “Material Safety Data Sheet (MSDS)” must
be read carefully. Gas masks may have to be used while welding with such
materials.
Keeping the head out of the smoke cloud is one of the easiest ways of
protection against hazardous gases and smoke.
Do not breathe the smoke and gases and use mechanical air circulation
and ventilation apparatus; and if the ventilation is till insufcient, gas masks
should be used.
THE WELDING ARC MAY CAUSE BURNS: During the welding operations,
appropriate masks, lters and protective lenses should be used for protecting
the eyes against the light emitted by the welding arc and the ying particles.
The skin should be protected using re-resistant clothing. The people in
the vicinity should be protected by panels made of reproof materials, they
should not look at the welding arc directly and must be warned against
effects of the arc light.
Even short periods of exposure to the UV rays may cause eye burns called
“welding dazzle”. The person affected may not be aware of the “welding
dazzle” for hours after exposure, which can become extremely disturbing in
the end and even cause temporary loss of sight. Normally the eye dazzle is a
temporary condition, but long term exposure of the eyes to the UV rays may
result in permanent damages in the eyes. As protective measures besides
not looking at the welding arc, a protective welding mask with appropriate
ltering lens should be used.
The following table may be used for selecting the proper lter against arc
welding with shielded electrodes.
From ANSI Z49.1-2005
WELDING SPLASHES MAY CAUSE FIRE OR EXPLOSION: Keep the
ammable materials away from the welding areas and maintain a re
extinguisher at an easily accessible place. The splashes and hot materials
ejected by arc welding may y around easily even from the narrowest opening.
Do not perform any welding on any barrel, container or material until making
sure that the measures required for removing the ammable and noxious
Safety in Welding - 4
Welding
Method
Electrode
Diameter
(mm)
Current Range
(Amper)
Protective
Filter
(lower limit)
Protective
Filter
(recommended)
Covered
Electrode
Arc
welding
< 2.4
2.5 - 4.0
4.0 - 6.4
> 6.4
< 60
60 - 160
160 - 250
250 – 550
7
8
10
11
-
10
12
14
Protective Filter Selection Table
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gases from the environment are taken. Never operate the machine in places,
where ammable gases, vapors or uids may be present.
Keep the possibility of re risk in mind as arc welding may produce very high
temperatures.
The welding arc temperature may reach 5000°C, but heat alone is not a
reason for re generally. The re risk is created by the sparks and molten
metal particles splashing around. Such metal splashes may reach ten
meters of distance. Therefore, keep the easily ammable materials away
from the welding environment. Furthermore, make sure that your work piece
does not contact any material that might ame as it heats up. The materials
that might catch re when heated are divided in to three groups as uids
(gasoline, oil, paint, thinner, etc.), solids (wood, cardboard, paper etc.) and
gases (acetylene, hydrogen etc.)
Watch the welding environment. If there is any systems using gasoline
or hydraulic oil present and if the welding environment cannot be moved
elsewhere, place a re-resistant barrier in between. If you are welding at a
high place or on a ladder, make sure that no explosive or ammable materials
are stored below. Moreover do not forget the possibility of slag and sparks
falling on the people around.
Special measures have to be taken while welding in a dusty environment.
The dust particles may catch re and cause a sudden re or explosion. If you
have no idea about the ammability or volatility of the ambient dust, do not
start the welding or cutting works before obtaining the approval of an expert
or authorized person.
Before starting welding, check if the welding piece has a ammable coating
that could catch re when heated.
When you take a pause during the welding works, make sure that the
electrode handle does not touch the ground or work piece.
If you are carrying out welding works within ten meters from ammable
materials, keep an observer with you. The observer should watch where the
sparks and splashes are falling around and should have easy access to the
re extinguishers if necessary. Once the welding work is nished, check the
welding area for any trace of smoke for about half an hour with the observer.
The rst rule during a welding-related accident is not to panic just like any
other emergency situation. Depending on the magnitude of the re, activate
the re alarm, notify the re department, turn off the welding machine and
leave the area as fast as possible through the re exits.
ELECTRICAL EQUIPMENT: Before starting to work on the machine, cut
the power supply by means of the switch located in the fuse box. Make the
electrical connections in conformity with the rules currently in force.
GROUNDING: For your safety and trouble-free operation of the machine,
it should be connected to a power outlet with proper power supply and
grounding cables.
Safety in Welding - 5
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ELECTRICAL EQUIPMENT: Check the condition of the electrical cables such
as supply and welding cables regularly. In case of any irregular condition,
replace the defective parts immediately. In order to prevent any arc ashing
and re risks, do not leave the electrode clamp (handle) on the welding table
or any surface in contact with the grounding clamp.
ELECTRIC and MAGNETIC FIELDS MAY BE HAZARDOUS TO THE
HUMAN HEALTH: The current passing through the conductors creates
an electromagnetic eld. The electromagnetic eld thus formed may have
an effect on the pace-maker etc. equipment. The welders, who use pace-
makers, should consult with a physical therapist before working with the
machine. The electrical and magnetic elds could also cause other unknown
health—related problems.
MOVING PARTS MAY CRUSH YOUR HANDS: Do not place your hands on
or near the fan and the moving parts of the machine.
COMPLIANCE WITH CE NORMS: This machine has been manufactured in
compliance with the European Instructions.
SAFE OPERATION: This machine is suitable for carrying out welding works
in the places with high probability of electrical shock.
Not to be used in residential locations where the electrical power is provided
by the public low-voltage supply system.
Safety in Welding - 6
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EXTRA SAFETY MEASURES:
Applying the safety measures under certain circumstances may become difcult;
nonetheless, the rules set forth should be abided with. Keep your gloves dry and if that
becomes impossible, keep a spare pair with you.
Stand on a non-conducting material such as plywood, plastic mat etc. Insulate your body
from the welding piece.
If you have to carry out welding works with high possibility of electrical shock such as in
a moist environment, in wet clothing, grids or scaffolding on your knees or leaning out or,
where contact with the ground is prevented, prefer to use the machine types specied
below:
• Semi-automatic xed DC voltage machines,
• DC manual arc welding machines,
• Reduced voltage controlled AC welding machines.
The condition of the electrode handle and cables is very important. The plastic or ber
insulator on the handle prevents contact with live parts. Always check the condition of the
handle before operating the welding machine. Replace the old and worn out handles and
do not try to repair. Conduct the same checks on the cables as well and since replacing the
cable may be costly, repair them with a high-resistance heat shrink etc. Check the insulation
at all times before operating the machine.
If you feel an electrical shock, remember that this is a warning. In such a case, before
continuing with the work, check your working habits and work environment in terms of
electrical shock risks. In case of any abnormal situation, do not continue with welding
without taking the measures required. If you cannot identify the source of the problem, have
it checked by an authorized specialist.
PRECAUTIONS FOR THE OTHER PERSONS IN THE WORK AREA:
The cleanliness and order of the work area are very important for you and the other people
in the area both. Other welders or people walking around may step into your welding bath
accidentally or trip on the cables and fall inviting the risk of an electrical shock to you and
the other people around. Furthermore, the welding splashes may cause risk of burns to the
other people in the vicinity.
Segregating the welding site with a re-proof barrier could reduce the above risks.
Warn other people in the work area about using work safety equipment. In particular if
they have to work in a welding site, warn them about wearing re-resistant work outts,
work goggles, insulated shoes and gloves etc. remove the people, who do not heed your
warnings, from the work site.
If you are welding on a high place, use warning signs showing the risk of welding splashes
falling down on the people below.
Electromagnetic elds may be dangerous for the pace-makers.
Warn the people in the vicinity, regardless of welders or otherwise, regarding the above
and post warning signs. Tell such people that they should consult a doctor before entering
the welding area. The welding sites pose high risk of electrical shocks. Other people may
face the risk of an electrical shock by passing on a cable while working around. Do not use
un-insulated welding cables and pass the cables through insulated, plastic ducts where
possible.
Safety in Welding - 7
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INFORMATION ABOUT THE RESIDUAL RISKS :
ASKAYNAK MasterSTICK 505 welding machine has been designed and manufactured
in conformity with the safety rules setout by the TS EN 60974-1 standard. All the measures
required for eliminating the safety risks involved have been taken and the measures to be
taken by the users and the rules to be observed have been indicated in the user manual.
Eliminating the said risks is not possible if due care is not exercised and the safety measures
prescribed are not taken. Such risks may start from slight injuries, but the risk of explosion
may become fatal for multiple people as well. Ensuring the safety of the welding area is the
responsibility of the user and if the said measures are not taken properly, the work must be
stopped and the authorized persons must be notied
Safety in Welding - 8
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Electromagnetic Compliance - 1
Designed according to the TS EN 60974-1
The EMU class of the machine according to TS EN 55011 is Group 2, class A.
Pls. see TS EN 60974-10 for detailed information.
There is no idle state at this machine.
• Do not switch on-off machine during welding. This may cause uctuations in the
mains voltage and shorten the service life of the machine.
• Wait for approximately 5-10 seconds after turning on the power unit to stabilize the
machine, then start welding.
• 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;
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Electromagnetic Compliance - 2
•Product is subject to conditional connection. Maximum system impedance allowed
Zmax = 0.19 + j 0.12. (Ref : TS EN 61000-3-11)
•When the machine is used in environments with high electromagnetic elds, the change
in the set welding/cutting current may exceed ± 10%.
•This machine complies with the standard IEC/EN 61000-3-12.
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 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.
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ASKAYNAK MasterSTICK 505 welding machine is an arc welding machine that may be
used by a single person manually. Main components of this machine is the transformer,
rectier and inductance. This is a stepless current adjusted welding machine. It has the
properties of soft and stable arc, minimum splashes and good welding performance. This
machine may perform with rutile, basic and cellulosic electrodes. Provides good results in
welding metals such as soft steel, medium-carbon steel, soft-alloyed steel, stainless steel
and nickel alloy without iron content and copper alloy. It may be used in shipbuilding, boiler,
pressurized container, building, power machines and mining machines industries.
ASKAYNAK MasterSTICK 505 contributes to sustainable growth as it reduces the noise
on transfer and distribution lines as it generates a low amount of harmonic components.
Advantages of the ASKAYNAK MasterSTICK 505 welding machine:
1- High quality welding and stable arc with smooth DC current
2- Reduction of noise on transfer and distribution lines with its low harmonic current
drawing design
3- Easy control of melted welding bath
4- Easy ignition of electrode with its high open circuit voltage
5- Ease of handling, simple installation and operation
General Characteristics
Input
Input Voltage
380 - 400 V / 3 Phases
Height
750 mm
Height
475 mm
Length
950 mm Weight
190 kg
Cycle Rate
(10 minute period)
35%
60%
100%
Frequency
50/60 Hertz (Hz)
Output Voltage
(Volt)
38.0 V (DC)
33.0 V (DC)
30.0 V (DC)
Power Drawn from the Mains
39 kW (at 500 A maximum current)
Output Current
(Ampere)
450 A
325 A
250 A
Welding Current Interval
50 - 500 A
Maximum Open Circuit Voltage
80 V (DC)
Output Interval
Welding Current Output Ratios
Supply Cable : 4 x 6 mm2
Operating temperature from –10°C to +40°C
Physical Dimensions:
Insulation Class : F
Degree of Contamination : 3
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Installation and Operator Instructions
Position and Environment (Read this section carefully before installing or operating the
machine):
Taking some simple protective precautions specied below would be better to ensure that
this machine has a long service life and operates safely.
1- Do not place the machine on a surface with a slope of more than 10° and do not operate it
on such a surface.
2- Machine shall always be operated on an environment with clean air ow; no factors
preventing the ventilation or blocking the air ow shall be present where the machine is
located. Machine shall not be covered with paper, clothes or similar items while being
operated.
3- Dust and dirt may enter the machine. This shall be minimized as much as possible. Do not
operate the machine in dusty environments and environments containing water, paint and
oil particles and machining dust and abrasive gases in their atmosphere.
4- This machine has a protection class of IP21S. Keep the machine dry as much as possible,
do not place it on wet places or on puddles.
5- Welding machine shall be used in well-illuminated areas, it shall not be used in dark. It is
designed for indoor use, and it is not suitable for operation under sunlight, rain or snow.
Welding machine cannot be used for pipe melting operations.
6- Place the machine away from radio-controlled devices. Normal operation of the machine
may have an adverse effect on the operation of such devices and this may cause injuries
or equipment failure. Read the “Electromagnetic Compatibility” section in this operation
manual.
7- Do not operate this machine in environments where ambient temperature is lower than
–10° C or higher than +40° C and where humidity is higher than 70%. Heating tests are
performed at ambient temperature and duty cycle is determined at 40° C by simulation.
8- Opening of the machine cover and intervention on the machine by persons who are not
qualied on electrical equipment may cause lethal risks. Persons who act otherwise are
considered to accept the negative results that may occur in advance.
9- This is a dropping characteristic welding machine designed for welding with the
2.50 and 5.00 mm diameter welding electrodes with rutile, basic and cellulosic
coating electrodes.
Duty Cycle and Over Heating :
Operating efciency of the machine is the percentage of the period that the welder can
perform welding without excessive heating and without taking a break at the specied
welding current of the machine for 10 minutes.
Machine is protected against excessive heating thanks to its thermal protection. Warning
lamp on the front panel illuminates when this protection is activated. Lamb turns off when
the safe operation temperature is reached again, and it is possible to resume welding.
Idle Operation Mode :
As dened in standard EN 60974-10, this mode indicates the operation mode where the
machine is operated, but welding circuit is not energized. In this respect, this machine has
no idle operation mode.
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3
2
15
4
6
Preparation for Work - 1
FRONT PANEL
Input Cable Connection / Controls and Usage Features :
Check the input voltage, phases and frequency before operating the machine. Input voltage
values to be used are specied on the “Specications” section in the operation manual and
on the plate on the machine. Ensure that grounding of the cables connecting the machine
to the mains is proper and that current required for the normal operation of the machine
can be supplied. Welding machine can be connected to a network protected with a 30 A
delayed fuse only with the cable supplied on the machine.
1- This machine is designed to operate with a 3-phase supply voltage of 380 V (AC)
at 50 - 60 Hz. It shall only be used with 3-phase grounded systems.
2- There are no plugs supplied with the machine. Select a plug proper for the
connection point and install the yellow-green cable on the supply cable to the
grounding point of the plug to perform the power connection. Plug and outlet
ratings shall not be lower than the maximum current and voltage.
3- Never perform the mains connection and operate the machine without a protective
ground connection
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8
7
Preparation for Work - 2
Front and rear panel elements :
1- Current Indicator: Indicates the output current value of the machine.
2- Current Setting Lever: Sets the output current (welding amperage) of the machine.
3- Power Indicator Lamp: Indicates that the machine is on.
4- Temperature Warning Lamp: This lamp illuminates when the machine cannot provide
output current due to excessive heating. This happens when ambient temperature
exceeds 40° C and when duty cycle of the machine is exceeded. Keep the machine on
and wait until it is cooled down. Machine is ready for operation again when the lamp
turns off.
5- Machine On/Off Switch: Controls the input supply of the machine.
6- Welding Connectors: Welding cables are connected to these connectors as per the
proper pole.
7- Machine Power Input Cable: Supply cable that connects the machine to the mains.
8- Ventilation Grills: Cools the machine by allowing it to take air while it is being operated.
REAR PANEL
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Shielded Electrode Welding :
Perform the following before starting to weld:
1- Determine the proper pole for the electrode used rst. You may nd this information on
the data sheet of the electrode. Then, connect the welding cables to the outputs as per
the selected pole. For example, if you are using DC (+), connect the electrode cable
to the (+) output of the machine, and connect the grounding cable to the (–) output.
After inserting the connector so that the guide pin faces upwards, rotate it for 1/4 turns
clockwise. Make sure that the connector your sink is properly installed on its seat without
excessive tightening. Otherwise, loose connectors may burn due to excessive heating
on operations for long periods and when welding current is high. For the electrodes to
be used in DC (–), replace the cable connections so that electrode cable connects to (–)
output, and grounding clamp connects to (+) output. Selection of the wrong connection
causes generation of unstable arcs, excessive splashing and sticking of the electrode to
the work piece.
2- Connect the electrode to electrode clamp.
3- Install the grounding clamp to an unpainted, rust-free and clean surface of the work
piece so that its ends contact the surface fully.
4- Plug the mains connection cable (7) to the outlet with a proper plug.
5- Perform the following inspections before starting to weld:
a-Make sure that the welding machine is grounded safely
b-Ensure that all contact surfaces are connected well, especially the connection between
the clamp at the end of the ground cable and the work piece is performed well.
c- Check whether the welding cables are connected correctly.
d-Sparks and parts splashing during welding may cause re. Thus, ensure that
inammable materials are not kept in the welding environment.
6- Turn on the On/Off Switch (5) of the welding machine.
7- Set the proper welding current that you shall determine as per the diameter, type of the
electrode, welding position and electrode data sheet with the “Welding Current setting
lever (2)”. In general, welding current is between the values specied below. However, it
would be best practice to perform your settings according to the values specied in the
catalogue provided by the manufacturer of the shielded welding electrode you are using.
ASKAYNAK MasterSTICK 505 is a welding machine with decreasing characteristics
designed to burn bar welding electrodes with rutile, basic and cellulosic character
and a diameter of 2.50 and 5.05 mm.
Current Values For Rutile and Basic Electrodes:
ø 2.5 mm : 70 - 100 A
ø 3.2 mm : 100 - 140 A
ø 4.0 mm : 140 - 190 A
ø 5.0 mm : 180 - 240 A
8- Start welding following the welding rules.
Preparation for Work - 3
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Maintenance and Troubleshooting - 1
Periodical maintenance of the welding machine shall performed regularly to ensure it is
operated safely and with high efciency. User shall understand the maintenance methods,
know the welding machine well, perform simple inspections and safety operations by
himself, and care to extend machine’s service life by minimising error ratios. Detailed
information of periodical maintenance is given in the following table.
Warning: During maintenance, always disconnect the machine from the mains.
Maintenance operation shall be performed by authorized and qualied persons.
DAILY MAINTENANCE
Ensure that the welding current setting lever on the upper panel of the machine and
the on-off switch on the front panel of the machine are available and operational. If
the current setting lever is not installed correctly and if the on-off switch is removed
from its position or does not operate properly, contact the authorized service.
Check whether there is a juddering, whistling or a foul smell on the machine
after operating. In case of a problem, try to determine the cause of the problem;
eliminate the problem if it is caused by the environment; do not intervene if the
problem is cause by the machine and contact authorized service after cutting off
the mains connection.
Check whether the thermal protection of your machine operates. Inspection
procedure: Machine provides a current of 450 A at a duty cycle of 35%. If the
thermal protection blows after 4-5 minutes at this current, there is a problem on
the thermal protection. In this case, contact the authorized service. Because,
excessive heating may cause risk of re.
Make sure that the cooling fan is not damaged and rotates normally. Check whether
the propeller on the fan is blocked if the fan does not activate after the machine is
excessively heated. Contact the authorized dealership if the fan is damaged.
Check whether the weld connections are loose or excessively heated. Tighten the
connections or contact the authorized service if there is over heating or looseness.
Check if the current cable is damaged. If it is damaged, insulate by wrapping the
damaged part with a proper material or replace the cable with a new one.
MONTHLY MAINTENANCE
Clean the collected dust inside of the machine in the course of time using a dry air
compressor. Be careful about the pressure of the air used for cleaning to protect
smaller parts.
Check the screws on the machine, tighten them in case of looseness. Install new
screws if there are any missing screws. Replace the rusty screws with new ones.
ANNUAL MAINTENANCE
Contact the authorized service for annual maintenance. Continuity of the grounding
and insulation of the machine shall be inspected for annual maintenance. Ask for
these data in your annual maintenance report.
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Maintenance and Troubleshooting - 2
1- Welding machine is inspected for any fault before leaving the factory. Therefore, do not allow
unauthorized persons to tamper with the machine.
2- Repair operations shall only be performed by “Authorized Technical Services” authorized by
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
3- Be careful about the pressure of the air used for cleaning to protect smaller parts.
Do not apply water inside the welding machine for cleaning purposes.
4- Do not clean the welding machine with volatile and synthetic chemicals, a cloth moisturized
with soapy water shall be used for the cleaning of the external surface of the machine.
5- Maintenance operation shall be performed very carefully. Bending or incorrect connection of
any cable may be very dangerous for the user.
6- Prevent ingress of water and vapour inside the welding machine. If the machine is affected by
the humidity, its interior shall be dried and its insulation shall be inspected.
7- Welding machine shall not be thrown away randomly and shall be protected against impact
while it is being lifted or handled.
8- If the welding machine shall not be used for a long period of time, it shall be placed inside its
own packaging and stored in a dry place.
Secondary coil contacts
the casing.
PROBLEM POSSIBLE REASON SOLUTION
Electrical leakage in
the metal body.
A high noise is heard when
the machine is turned on.
Input fuse is blown.
Turn off the machine. Perform measurements.
Contact one milliohmmeter probe to the body
and the other one to the transformer coils.
If you read a low resistance value, there is a
leak from the coils to the body/core.
Call the authorized service.
Primary coil contacts the
casing.
Input cable contacts the
casing.
Input cable contacts the
casing.
Cable ends contact each
other.
Fuse is too small.
Rectier is faulty.
Correct the contacting cable or the welding
cable.
Check for short circuits and contact the
authorized service.
Find and separate the contacting ends.
Find and separate the contacting ends.
Call the authorized service.
Primary and secondary coil
contacts the ferrite core.
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