ExpressWeld MasterMIG 500W User Manual
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ExpressWeld MasterMIG 500W User Manual

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USER GUIDE
Welding Method
CO
2
GMAW (MIG/MAG)
Eczacıbaşı - Lincoln Electric recommend to use ASKAYNAK gas metal arc welding
wire for obtaining high performance from MasterMIG 500W.
www.
Guarantee Period and Features
2 Years Guarantee (excl. torch and cables)
"
askaynak
.com.tr
"

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Summary of Contents for ExpressWeld MasterMIG 500W

  • Page 1 Welding Method Guarantee Period and Features GMAW (MIG/MAG) 2 Years Guarantee (excl. torch and cables) Eczacıbaşı - Lincoln Electric recommend to use ASKAYNAK gas metal arc welding “ ” wire for obtaining high performance from MasterMIG 500W. askaynak www. .com.tr...
  • Page 2 Bauart der Maschine déclare que le poste de soudage ® ® EXPRESSWELD MasterMIG 500W a a da belirtilen yönergelere uygun oldu unu ş ğı ğ conforms to the following directives den folgenden Bestimmungen entspricht est conformé...
  • Page 3 Expressweld MasterMIG 500W Dear Customer, ® ® Thank you for having choosen the Expressweld MasterMIG 500W metal arc welding machine. All connections, operations and maintenance-repair work of your product should be performed by authorized personnel. To get optimized efficiency from your welder, before starting your machine please carefully read and understand the user guide and keep it as a supplementary resource for future reference.
  • Page 4 Expressweld MasterMIG 500W "Expressweld" "Expressweld" is the registered trademark of Kaynak Tekniği Sanayi ve Ticaret A.Ş..
  • Page 5 Expressweld MasterMIG 500W "MasterMIG" is the registered trademark of Kaynak Tekniği Sanayi ve Ticaret A.Ş..

  • Page 6: Table Of Contents

    Expressweld MasterMIG 500W Table of Contents 1. General Safety Rules Electromagnetic Compatibility 2. General Information, Warnings and Operation Conditions 3. Specifications 4. Technical Data 5. Front Panel Controls 6. Back Panel Controls 7. Controls in Wire Feeder Unit 8. Connection Diagram 9.

  • Page 7: General Safety Rules

    Expressweld MasterMIG 500W 1 General Safety Rules THIS MACHINE HAS BEEN DESIGNED FOR GMAW (MIG/MAG). SHALL NOT BE USED FOR ANY OTHER PURPOSE. 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.
  • Page 8 Expressweld MasterMIG 500W Wool y clothing should be preferred due to its resistance against flame. 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 flare and burn uncontrolledly in an environment with oxygen.
  • Page 9 Expressweld MasterMIG 500W 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.
  • Page 10 Expressweld MasterMIG 500W 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 floor level, use a safety belt to protect yourself from a fall should you get a shock.
  • Page 11 Expressweld MasterMIG 500W GASES and FUMES can be dangerous. When welding with electrodes 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 “...
  • Page 12 Expressweld MasterMIG 500W 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 flammable or toxic vapors from substances inside.
  • Page 13 Expressweld MasterMIG 500W If you are working above floor level or on stairway, make sure there is no flammable 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 fire or explosion.
  • Page 14 Expressweld MasterMIG 500W 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, fittings, etc. should be suitable for the welding application and maintained in good condition with a proper installation.
  • Page 15 Expressweld MasterMIG 500W 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.
  • Page 16 Expressweld MasterMIG 500W EXTRA SAFETY PRECAUTIONS: In some situations, it may be difficult to use safety precautions, but even so follow stated instructions. Keep your gloves dry, if getting wet is unavoidable, have a spare gloves. Stand on a dry and insulating material such as plywood, plastic mat etc.
  • Page 17 INFORMATION ON RESIDUAL RISKS: Expressweld MasterMIG 500W 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 operator and users and all rules to be followed have been stated in the user manual.

  • Page 18: Electromagnetic Compatibility

    Expressweld MasterMIG 500W ELECTROMAGNETIC COMPATIBILITY ELECTROMAGNETIC fields may be hazardous. Designed according to TS EN 60974-1:2007. EMU Class of machine according to TS EN 55011:2007 is Group 2 Class A. For detailed information refer to TS EN 60974-10:2009. While welding do not turn on/off the power switch. This situation may cause voltage fluctuations in mains as well as shorten the economic life of the machine.
  • Page 19 Expressweld MasterMIG 500W Electromagnetic resistance of the equipments located and working in working area should be checked. User must be sure that other surrounding devices will operate in harmony with the machine. To achieve this extra protection measures may be necessary.

  • Page 20: General Information, Warnings And Operation Conditions

    Expressweld MasterMIG 500W 2 General Information, Warnings and Operation Conditions 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.
  • Page 21 Expressweld MasterMIG 500W 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.

  • Page 22: Specifications

    Expressweld MasterMIG 500W 3 Specifications MasterMIG 500W is a water cooled and semi-automatic gas metal arc (MIG/MAG) welding machine with a wire drive unit that can be detachable from the power unit. Only removing the wire feeder unit is enough to increase the working flexibility and to be able to perform welding in areas that are more distant from power unit.

  • Page 23: Technical Data

    Expressweld MasterMIG 500W 4 Technical Data Power Unit MasterMIG 500W Nominal mains voltage 380 V ± 10, 50/60 % Hz, 3 Phase Maximum power consumption (60%) 28.3 kVA Current taken from mains (% 60) 38 A (% 100) 28 A 0.94...

  • Page 24: Front Panel Controls

    Expressweld MasterMIG 500W 5 Front Panel Controls Wire feeder unit handle Welding wire reel protection cabinet cover 2/4 trigger selection switch Gas flow control button Wire feed speed without welding setting button Torch connection socket (EURO) Wire feed speed setting button...

  • Page 25: Back Panel Controls

    Expressweld MasterMIG 500W 6 Back Panel Controls Welding wire reel Wire feeder unit handle protection cabinet Shielding gas inlet socket Pin for placing wire feeder unit to power unit Control cable connection socket Coolant inlet and outlet sockets Wire feeder unit (+) power...

  • Page 26: Controls In Wire Feeder Unit

    Expressweld MasterMIG 500W 7 Controls in Wire Feeder Unit Page 20...

  • Page 27: Connection Diagram

    Expressweld MasterMIG 500W 8 Connection Diagram Page 21...

  • Page 28: Installation And Operation Of Machine

    Expressweld MasterMIG 500W 9 Installation and Operation of Machine 9.1 Mains Supply Mains supply connection of the machine should be made as per rules and only by qualified personnel trained with necessary information. Welding machine has been designed for triphase mains supply, 380 V 10, 50/60% ±...

  • Page 29: Connection Between Power Unit And Wire Feeder Unit

    Expressweld MasterMIG 500W Check the water level with Coolant Level Indicator located in the rear panel of power “ ” unit. Connect BLUE colored hose union located on the welding torch to Torch Coolant “ ” “ Inlet Socket located in the front panel of wire feeder unit and connect "RED" colored ”...

  • Page 30: Installing Welding Wire

    Expressweld MasterMIG 500W 9.5 Installing Welding Wire According to the procedure stated in “ Wire Feeder Unit Functions ” section on Page 26, select the welding torch mode by using “ 2/4 Trigger Selection Switch ” Place the “ Wire Feed Speed Setting Button ”...
  • Page 31 Expressweld MasterMIG 500W Adjusting Press Force of Wire Drive Reel Properly set the press force of reels. If the press force is too low, wire slips on reels if the press force is too high, reels crushes the wire or wire jams in. Press force increases when driver reel press force setting turned clockwise, when turned counter clockwise press force decreases.

  • Page 32: Functions Of Wire Feeder Unit

    Expressweld MasterMIG 500W 10 Functions of Wire Feeder Unit Wire drive unit has the following functions: Welding Torch Operation Modes: 2 Trigger Mode (manual): Welding procedure is started by pressing and holding down the trigger on the welding torch. When trigger released welding stops.

  • Page 33: Environment Conditions

    Expressweld MasterMIG 500W 11 Environment Conditions Before starting the machine following procedures should be performed: Provide the necessary environment conditions for the welding machine. For example there shouldn t be any flammable gases and vapors, conducting dusts, burner/flammable fumes and other factors that may be hazardous for insulation and mechanical structure of the machine.

  • Page 34: Gmaw (Mig/Mag) Method

    Expressweld MasterMIG 500W 13 GMAW (MIG/MAG) Method Make sure that the welding machine is installed according to the explanations included on Page 22. By considering the desired welding current values, install the work cable to the proper “Work Cable Connection Socket”...

  • Page 35: Productive Usage In Terms Of Energy Consumption

    Expressweld MasterMIG 500W 14 Productive Usage In Terms of Energy Consumption Part Wire Wire Guide Welding Welding Thickness Voltage Flow Speed Diameter Inner Diameter Current (mm) (mm) (mm) (lt/ min. 0.8 - 1.5 ø 0.8 ø 1.4 50 - 90 17 - 18 1.0 - 2.5...

  • Page 36: Maintenance And Repair

    Expressweld MasterMIG 500W 16 Maintenance and Repair Warning ! Proper usage and performing periodical maintenance fully will enable high performance and important for long economical life. Maintenance, repair and service works should only performed by the qualified personnel who had the required...

  • Page 37: Unpacking

    17 Unpacking EXPRESSWELD MasterMIG 500W Gas Metal Arc Welding Machine sold in its original cartoon box and on a pallet. Do not purchase the machines without packaging. To unpack the machine, cut the strap connected to the pallet and lift up the box.

  • Page 38: Troubleshooting Guide

    Expressweld MasterMIG 500W 18 Troubleshooting Guide PROBLEM REASON SOLUTION Spiral is dirty. Clean the spiral. Channels of the drive reels are Check the channels of reels and not compatible with wire type or change with the reels suitable for diameter being used.
  • Page 39 Expressweld MasterMIG 500W PROBLEM REASON SOLUTION Contact nozzle and wire feed Check the contact nozzle and wire reels is not compatible with the feed reels, change if necessary. used wire. There is strain in any point of Check wire guides and spiral. Clean the torch.

  • Page 40: Failures In Welding Seams

    Expressweld MasterMIG 500W 19 Failures in Welding Seams Pore Creation Possible Reasons: 1.Insufficient gas shielding. 2.Used gas is dirty or gas flow speed is not suitable. 3.Surface of the welding wire is dirty. 4.Workpiece is dirty. 5.Voltage value is too high.
  • Page 41 Expressweld MasterMIG 500W Solutions: 1. Clean scale and oxide residues from all surfaces in welding seam area. 2. Increase wire feeding speed and arc voltage. Decrease free wire length. 3. To control the weld puddle easier, do not weld with extreme oscillating. Increase the advancing speed.
  • Page 42 Expressweld MasterMIG 500W Solutions: : 1. Increase the advancing speed. Adjust the torch angle. 2. Increase arc voltage. Splashing Possible Reasons: 1. Welding wire creates short-circuit by contacting to the workpiece. 2. C02 is used as shielding gas. 3. Welding process is performed with global conduction by using argon gas.

  • Page 43: Spare Part List

    Expressweld MasterMIG 500W 20 Spare Part List Page 37...
  • Page 44 Expressweld MasterMIG 500W Part Name (Power Unit) Part Code ERP Code Wire feeder fuse (3A) 8220752020 2.07.52.020 Wire feeding fuse slot 8220752028 2.07.52.028 Mains cable 8211150008 1.11.500.08 Cable holder 8220430104 2.04.30.104 Control cable socket 8220754122 2.07.54.122 Water hose connection socket 8220757822 2.07.57.822...
  • Page 45 Expressweld MasterMIG 500W Part Name (Power Unit) Part Code ERP Code Shunt 8220742006 2.07.42.006 Front panel 8212450926-1 1.24.509.26-1 On/Off switch 8220780213 2.07.80.213 LED (Green) 8220728209 2.07.28.209 LED (Yellow) 8220728211 2.07.28.211 Coolant pump switch 8220780211 2.07.80.211 Digital current and voltage indicators 8220746553 2.07.46.553...
  • Page 46 Expressweld MasterMIG 500W Page 40...
  • Page 47 Expressweld MasterMIG 500W Part Name (MF-3 Wire Feeder Unit) Part Code ERP Code Plastic wire reel protector 8220505301 2.05.05.301 Wire reel shaft 8220505101 2.05.05.101 Inner medium panel 8212406213-1 1.24.062.13-1 Rear panel 8212406212-1 1.24.062.12-1 Handle 8250202808 5.02.02.808 Gas solenoid 8220755006 2.07.55.006...

  • Page 48: Warning Label

    Expressweld MasterMIG 500W Part Name (MF-3 Wire Feeder Unit) Part Code ERP Code Magnet 8220751703 2.07.51.703 Wire drive engine 8220740312 2.07.40.312 Insulating gasket 8220506012 2.05.06.012 Insulating sheath 8220506011 2.05.06.011 Torch connection socket (inner) 8212405006 1.24.050.06 Wire reel section cover 8212406208 1.24.062.08...

  • Page 49: Electrical Circuit Diagram

    Expressweld MasterMIG 500W 22 Electrical Circuit Diagram Page 43...

  • Page 50: Wire Feeder And Power Unit Specifications

    Made in China IP21S Designed and Powered by ASKAYNAK Wire Feeder Unit Kaynak Tekniği Sanayi ve Ticaret A.Ş " EXPRESSWELD " TOSB Taysad Org. San. Bölgesi, 2. Cadde, No: 5, 41480 Çayırova, Kocaeli - TURKEY MF-3 Model : Serial No. :...
  • Page 51 Our Technical Services ADANA : ERZURUM : KAYSER : İ SAMSUN : Kalyon Elektrik Elektronik Garanti Bobinaj Elektroland Elektrik Elektronik Tele Radyo TV Enerji ve Güç Sistemleri ş ğı Mumcu Caddesi, 2. Korukçu Sokak Makina ve Metal Sanayi Ticaret Ltd. ti. Ş...
  • Page 52 IMPORTER COMPANY FACTORY/HEADQUARTER Kaynak Tekni i Sanayi ve Ticaret A. . ğ Ş TOSB Taysad Organize Sanayi Bölgesi, 2. Cadde, No: 5, ekerp nar 41480 Çay rova - Kocaeli Ş ı ı / Turkey Phone: (0262) 679 78 00 Fa : (0262) 679 77 00 ISTANBUL Regional Sales Office Rauf Orbay Caddesi, Evliya Çelebi Mahallesi, No: 3/C, çmeler, 34944 Tuzla - stanbul İ...

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