Master 450 - Welding machine GYS - Free user manual and instructions

USER MANUAL Master 450 GYS

Notice originaleWARNING - SAFETY RULES GENERAL INSTRUCTIONS Read and understand the following safety recommendations before using or servicing the unit.Any change or servicing that is not specied in the instruction manual must not be undertaken. The manufacturer is not liable for any injury or damage caused due to non-compliance with the instructions featured in this manual . In the event of problems or uncertainties, please consult a qualied person to handle the installation properly. ENVIRONMENT This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in the user manual. The operator must respect the safety precautions that apply to this type of welding. In case of inedaquate or unsafe use, the manufacturer cannot be held liable for damage or injury. This equipment must be used and stored in a place protected from dust, acid or any other corrosive agent. Operate the machine in an open, or well-ventilated area.Operating temperature:Use between -10 and +40°C (+14 and +104°F).Store between -20 and +55°C (-4 and 131°F).Air humidity:Lower or equal to 50% at 40°C (104°F).Lower or equal to 90% at 20°C (68°F).Altitude:Up to 1000 meters above sea level (3280 feet).

INDIVIDUAL PROTECTIONS AND OTHERS

Arc welding can be dangerous and can cause serious and even fatal injuries. Welding exposes the user to dangerous heat, arc rays, electromagnetic elds, noise, gas fumes, and electrical shocks. People wearing pacemakers are advised to consult with their doctor before using this device.To protect oneself as well as the other, ensure the following safety precautions are taken: In order to protect you from burns and radiations, wear clothing without cus. These clothes must be insulated, dry, reproof and in good condition, and cover the whole body.Wear protective gloves which guarantee electrical and thermal insulation. Use sucient welding protective gear for the whole body: hood, gloves, jacket, trousers... (varies depending on the application/ operation). Protect the eyes during cleaning operations. Do not operate whilst wearing contact lenses.It may be necessary to install reproof welding curtains to protect the area against arc rays, weld spatters and sparks.Inform the people around the working area to never look at the arc nor the molten metal, and to wear protective clothes. Ensure ear protection is worn by the operator if the work exceeds the authorised noise limit (the same applies to any person in the welding area).Stay away from moving parts (e.g. engine, fan...) with hands, hair, clothes etc... Never remove the safety covers from the cooling unit when the machine is plugged in - The manufacturer is not responsible for any accident or injury that happens as a result of not following these safety precautions. The pieces that have just been welded are hot and may cause burns when manipulated. During maintenance work on the torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. The cooling unit must be on when using a water cooled torch in order to ensure that the liquid does not cause any burns.ALWAYS ensure the working area is left as safe and secure as possible to prevent damage or accidents.

WELDING FUMES AND GAS

The fumes, gases and dust produced during welding are hazardous. It is mandatory to ensure adequate ventilation and/or ex- traction to keep fumes and gases away from the work area. An air fed helmet is recommended in cases of insucient air supply in the workplace.Check that the air intake is in compliance with safety standards. Care mu be taken when welding in small areas, and the operator will need supervision from a safe diance. Welding certain pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic. The user will also need to degrease the workpiece before welding. Gas cylinders mu be ored in an open or ventilated area. The cylinders mu be in a vertical position secured to a support or trolley. Do not weld in areas where grease or paint are ored.

MASTER 250 / 350 / 450

Translation of the original instructionsFIRE AND EXPLOSIONS RISKS Protect the entire welding area. Compressed gas containers and other inammable material must be moved to a minimum safe distance of 11 meters. A re extinguisher must be readily available. Be careful of spatter and sparks, even through cracks. It can be the source of a re or an explosion. Keep people, ammable objects and containers under pressure at a safe diance. Welding of sealed containers or closed pipes should not be undertaken, and if opened, the operator mu remove any inammable or explosive materials (oil, petrol, gas...). Grinding operations should not be directed towards the device itself, the power supply or any ammable materials. ELECTRIC SAFETY The machine must be connected to an earthed electrical supply. Use the recommended fuse size. An electrical discharge can directly or indirectly cause serious or deadly accidents . Do not touch any live part of the machine (inside or outside) when it is plugged in (Torches, earth cable, cables, electrodes) because they are connected to the welding circuit. Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged. Do not touch the torch or electrode holder and earth clamp at the same time. Damaged cables and torches mu be changed by a qualied and skilled professional. Make sure that the cable cross section is adequate with the usage (extensions and welding cables). Always wear dry clothes in good condition, in order to be insulated from the electrical circuit. Wear insulating shoes, regardless of the environment in which you work in. EMC CLASSIFICATION These Class A devices are not intended to be used on a residential site where the electric current is supplied by the public network, with a low voltage power supply. There may be potential diculties in ensuring electromagnetic compatibility on these sites, because of the interferences, as well as radio frequencies. ELECTROMAGNETIC INTERFERENCES The electric currents owing through a conductor cause electrical and magnetic elds (EMF). The welding current generates an EMF eld around the welding circuit and the welding equipment. The EMF elds may disrupt some medical implants, such as pacemakers. Protection measures should be taken for people wearing medical implants. For example, access rerictions for passers-by or an individual risk evaluation for the welders. All welders should take the following precautions in order to minimise exposure to the electromagnetic elds (EMF) generated by the welding circuit::

• position the welding cables together – if possible, attach them;

• keep your head and torso as far as possible from the welding circuit;

• never enroll the cables around your body;

• never position your body between the welding cables. Hold both welding cables on the same side of your body;

• connect the earth clamp as close as possible to the area being welded;

• do not work too close to, do not lean and do not sit on the welding machine

• do not weld when you’re carrying the welding machine or its wire feeder. People wearing pacemakers are advised to consult their doctor before using this device. Exposure to electromagnetic elds while welding may have other health eects which are not yet known. RECOMMENDATIONS TO ASSESS THE WELDING AREA AND WELDING INSTALLATION Overview The user is responsible for inalling and using the arc welding equipment in accordance with the manufacturer’s inructions. If electromagnetic diurbances are detected, it is the responsibility of the user of the arc welding equipment to resolve the situation with the manufacturer’s technical assiance. In some cases, this remedial action may be as simple as earthing the welding circuit. In other cases, it may be necessary to conruct an electromagnetic shield around the welding power source and around the entire piece by tting input lters. In all cases, electromagnetic interferences mu be reduced until they are no longer bothersome. Welding area assessment Before inalling the machine, the user mu evaluate the possible electromagnetic problems that may arise in the area where the inallation is planned. . In particular, it should consider the following:

Translation of the original instructionsa) the presence of other power cables (power supply cables, telephone cables, command cable, etc...)above, below and on the sides of the arc welding machine. b) television transmitters and receivers ; c) computers and other hardware; d) critical safety equipment such as indurial machine protections; e) the health and safety of the people in the area such as people with pacemakers or hearing aids; f) calibration and measuring equipment g)The isolation of the equipment from other machinery. The user will have to make sure that the devices and equipments that are in the same room are compatible with each other. This may require extra precautions; h) make sure of the exact hour when the welding and/or other operations will take place. The surface of the area to be considered around the device depends on the the building’s ructure and other activities that take place there. The area taken in consideration can be larger than the limits determined by the companies. Welding area assessment Besides the welding area, the assessment of the arc welding syems intallation itself can be used to identify and resolve cases of diurbances. The assessment of emissions mu include in situ measurements as specied in Article 10 of CISPR 11. In situ measurements can also be used to conrm the eectiveness of mitigation measures. RECOMMENDATION ON METHODS OF ELECTROMAGNETIC EMISSIONS REDUCTION a. National power grid: The arc welding machine mu be connected to the national power grid in accordance with the manufacturer’s recommendation. If interferences occur, it may be necessary to take additional preventive measures such as the ltering of the power suplly network. Consideration should be given to shielding the power supply cable in a metal conduit. It is necessary to ensure the shielding’s electrical continuity along the cable’s entire length. The shielding should be connected to the welding current’s source to ensure good electrical contact between the conduct and the casing of the welding current source. b. Maintenance of the arc welding equipment: The arc welding machine should be be submitted to a routine maintenance check according to the manufacturer’s recommendations. All accesses, service doors and covers should be closed and properly locked when the arc welding equipment is on.. The arc welding equipment mu not be modied in any way, except for the changes and settings outlined in the manufacturer’s inructions. The spark gap of the arc art and arc abilization devices mu be adjued and maintained according to the manufacturer’s recommendations. c. Welding cables: Cables mu be as short as possible, close to each other and close to the ground, if not on the ground. d. Electrical bonding : consideration shoud be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the riskof electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects. e. Earthing of the welded part : When the part is not earthed - due to electrical safety reasons or because of its size and its location (which is the case with ship hulls or metallic building ructures), the earthing of the part can, in some cases but not syematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries that do not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national regulations. f. Protection and plating : The selective protection and plating of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specic situations. TRANSPORT AND TRANSIT OF THE WELDING MACHINE Do not use the cables or torch to move the machine. The welding equipment mu be moved in an upright position. Do not place/carry the unit over people or objects. EQUIPMENT INSTALLATION

• Put the machine on the oor (maximum incline of 10°.)

• Ensure the work area has sucient ventillation for welding, and that there is easy access to the control panel.

• The machine mu not be used in an area with conductive metal dus.

• The machine mu be placed in a sheltered area away from rain or direct sunlight.

• The machine protection level is IP21S, which means : - Protection again acess to dangerous parts from solid bodies of a ≥12.5mm diameter and, - A protection again vertical rainfall when its moving parts (fan) are not in motion.. The manufacturer does not incur any responsability regarding damages to both objects and persons that result from an incorrect and/or dangerous use of the machine. MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualied person. Annual maintenance is recommended.

• Ensure the machine is unplugged from the mains, and wait for two minutes before carrying out maintenance work. DANGER High Voltage and Currents inside the machine.

• Remove the casing 2 or 3 times a year to remove any excess dust. Take this opportunity to have the electrical connections checked by a qualied person, with an insulated tool.

• Regularly check the condition of the power supply cable. If the power cable is damaged, it must be replaced by the manufac- turer, its after sales service or an equally qualied person.

• Ensure the ventilation holes of the device are not blocked to allow adequate air circulation.

• Do not use this equipment to thaw pipes, to charge batteries, or to start any engine.

Translation of the original instructionsINSTALLATION – PRODUCT OPERATION DESCRIPTION MASTER welders are traditional stick welders for welding in direct current (DC). They can weld rutile, cast-iron, basic and stainless steel electrodes. They work on a 380 V tri-phase power supply.It is recommended to use the welding cables supplied with the unit in order to obtain the optimum product settings.

POWER SUPPLY – STARTING UP

• The welders must be connected to a three-phase 400V (50 - 60 Hz) power supply tted with four wires and one earthed neutral.

• The absorbed eective current (I1e) is displayed on the machine, for optimal use. Check that the power supply and its protec- tion (fuse and/or circuit breaker) are compatible with the current needed by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings.• The machine has a specication with a “dropping current output”• Power Cord Selection Guide :Power cable section H07 RNF from 2 to 10 m over 10 mMASTER 250 4 X 4 mm² 4 X 6 mm²MASTER 350 4 X 4 mm² 4 X 6 mm²MASTER 450 4 X 6 mm² 4 X 10 mm² USE 1. Ensure the earth clamp is connected to the work piece (as close as possible to the welding area) 2. Select the welding current by adjusting the knob according to the diameter of the electrode to weld. • Adjust the welding current by turning the knob form 1 to 7. 3. Thermal protection : After a long period of welding or intensive use, it is neFssary to wait until the machine cools down. These machines are protected by a thermostat which will automatically cut out the power to the unit to prevent damage during an overload.

4. After using the welding unit, turn o the unit switch and unplug the machine.

Never switch the button during welding! ADVICE

• Respect welding polarities and currents indicated on the electrode packaging• Remove the electrode from the electrode holder when you do not use it.• Keep the ventilated parts of the machine clean to allow in/out air circulation. TROUBLESHOOTING Anomalies Causes RemediesOnly the green indicator is on but you cannot weld.Connection failure of the earth clamp or electrode holder.Check the connections.If, when the unit is on and you put your hand on the welding unit’s body, you feel tingling connec-tion.The welding unit is not correctly connected to the earth.Check the plug and the earth of your electrical network.Your unit does not weld correctly. Polarity error (+/-).Check the polarity advised on the electrode packaging. WARRANTY The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).The warranty does not cover:• Transit damage.• Normal wear of parts (eg. : cables, clamps, etc..).• Damages due to misuse (power supply error, dropping of equipment, disassembling).• Environment related failures (pollution, rust, dust).In case of failure, return the unit to your distributor together with:- The proof of purchase (receipt etc ...)- A description of the fault reported

WAARSCHUWING - VEILIGHEIDSINSTRUCTIES

• While under intensive use (> to duty cycle) the thermal protection can turn on, in that case, the arc swictes o and the indicator switches on.