Yeni TD 355 User Manual.cdr
Contents
1. Organize Sanayi B lgesi 5 K s m Manisa T RK YE EN 60974 10 U0 Open Circuit Voltage U1 Line Voltage and Frequency U2 Rated Welding Voltage 11 Input Current 12 Rated Welding Current IP 22 Protection Class S1 Input Power 14 Insulation Class Descending Characteristics ez ie 3 Phase Transformer Rectifier Stick Electrode VVelding Er Fuse D i m Line Input Phase Alternative Current 3 s Appropriate To Operate In Dangerous Work Area Direct Current Duty Cycle Temperature C 6 min 4 min 6 min 4 min 6 min 4 min Time min Duty cycle defines the percentage of welding time out of a period of 10 minutes at a given current and ambient temperature standard is 40 C For example a welder with 60 duty cycle must be rested 2 for 4 minutes after 6 minutes of continuous welding 1 1 4 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS UNIT VALUE Line Voltage 3 Phases V 380V 50 Hz Input Power 9635 kVA 20 Input Current 7635 A 31 Recommended Line Fuses A 3x32 Open Circuit Voltage Vpc 54 64 Welding Current Range Apc 60 350 Rated Welding Current 9635 Apc 320 Dimensions LxVVxH mm 950x660x650 Weight kg 125 Protection Class IP22 1 5 ACCESORRIES STANDARD ACCESORRIES QUANTITY PRODUCT CODE Electrode Holder and Cable 35 mm 5 m 1 K301000405 Earth Clamp and Cable 35 mm 3 m 1 K301100403 TD 355 7 INSTALLATION amp OPERATION 2 INSTALLATION 2 1 UPON R2. cycles given at the data plate Exceeding the duty cycles frequently can damage the machine and this would void the warranty Do not use stronger fuses than those stated on the data plate Ensure that the earth clamp is tightly connected as close as possible to the welding location Do not let welding current flow through any media other than welding cables e g over the machine itself gas tubes chains ball bearings etc TD 355 INSTALLATION amp OPERATION 2 3 ELECTRIC PLUG INSTALLATION AND CONNECTION TO THE MAINS Since mains connection sockets may vary from factory to factory an appropriate plug must be installed to the built in mains cable of the machine by qualified electricians Please observe that the earth cable is in yellow green colour and labelled as While inserting the plug into the mains socket pay attention that main switch is positioned to OFF 0 Before plugging your machine to the electrical line check carefully the 3 phase with a voltmeter and then insertthe plug into the mains socket SWITCH ON the machine via power switch 1 and observe the fan noise and illumination of the power lamp 2 4 WELDING CONNECTIONS 3 Figure 4 Welding Cable Sockets 2 5 WELDING ADJUSTMENTS K 7 Figure 5 Current Adjustment Lever By turning the current adjustment lever 2 clockwise current is increased Figure 5 Approximate value of the adjusted current can be read on the current adjustm
3. 503 Sokak No 1 MAN SA 90 236 226 27 00 90 236 226 27 28 OWM 02 02 2011 Made in T RK YE MAGMA MEKATRON K MAK NE SANAY VE T CARET A www magmaweld com
4. ECEIPT AND CLAIMS Be sure that you have received all the items that you have ordered In case of any item is missing or damaged contact your supplier immediately In the event of damaged or missing delivery draw up a record take a photo of the damage and report it to the shipping agency and MAGMA MEKATRONIK with the photocopy of shipping bill E mail servis magma com tr Fax 90 236 226 27 28 Standard pallet contains o Power Source Electrode Holder Cable Earth Clamp Cable User Manual 2 2 INSTALLATION AND WORKING RECOMMENDATIONS Use lifting eyes or fork lift to carry the machine Transport and place the device on a firm and level ground so that it may not fall over The maximum permissible angle of inclination for transport and assembly is 10 For a better performance keep the machine at least 30 cm away from the surrounding objects Beware of excessive heat dust and humidity around the machine Try not to operate the machine under direct sunlight Machines should be operated on lower capacities when ambient air temperature exceeds 409C Avoid welding at outdoors where it is windy and rainy if this is a must protect the welding area with curtains mobile screens or tents Ensure that operators can easily reach the machine controls and connections Use suitable welding fume extraction systems Use breathing apparatus if there is a risk of inhaling in confined places Respect the duty
5. TS LIST FOR TD 955 aaa a aaa T asa 11 APPENDIX 2 ELECTRICAL DIAGRAM FOR TD 355 12 TD 355 1 SAFETY RULES OBEY ALL THE SAFETY RULES STATED IN THE MANUAL IDENTIFYING SAFETY INFORMATION These symbols are being used to identify potential risks When seen a safety symbol in the manual it must be understood that there is an injury risk and following instructions must be read carefully to avoid potential risks While welding keep the third persons and especially the children away from the work area UNDERSTANDING THE SAFETY WARNINGS Read carefully the manual and the labels and the safety warnings on the machine Make sure that the warning labels positioned on your machine are in good order Renew the damaged and the missing labels Learntooperate the machine and how to make the controls properly Operate your machine in convenient work areas Improper modifications affect the safety of your machine negatively and shorten its lifetime EN ELECTRICAL SHOCK CAN BE FATAL h gt Installation procedure must comply with national electricity standards and other relevant regulations and ensure that installation is performed by qualified persons Wear dry insulating gloves free of damage and body protection Do not touch electrode with bare hand Do not wear wet or damaged gloves and body protection Do not touch live electrical parts Never touch electrode while in contact with working surface g
6. USER MANUAL magmaweld 1000 WELDING RECTIFIER MAGMA MEKATRON K MAK NE SANAY VE T CARET A CONTENTS SAFETY RULES si eas irte etae eh tee id ANAR ala d s rut ase de b te epa qaa Bu broth ia 2 12 TECRINIGAL INFORMATION z decur Ba ir c eee Ee gua al a alm Ba gla Sadin edes 6 1 4 GENERAL EXPLANATIONS ai te amaa ee aH Dette ATADA Dn a nee nOD ede L qhasa adds 6 T2 COMPONENTS OF TD 355 Say ce dalan ay er Ay AA tie ie 6 143 DATA PLATE saa 7 1 4 TECFINICAE SPEGIFIGATIONGS tne te ettet tee E tite Dan D abled hits Den an ied ln 7 1 5 AGGESORRIES needed nid ite itte epa ama kaale pad 7 2 INSTALLATION p 8 21 UPON REGEIBTAAND GLAIMS tee tee tee beta ph sh DAD 8 2 2 WORKING CONDITIONS aaa th code ga ede la Ma eins ch area era ke ng a ai 8 2 3 ELECTRIC PEUG CONNECTION u nte to trt ette re mere te Pr dE RR azla lke 9 2 4 WELDING CONNECTIONS eios rette tenes li alla dae te be niae an te a i 9 2 5 CONNECTING TO THE MAING thc ei da dente a a saya lama alla olma ana 9 2 6 WELDING ADJUSTMENTOS dtt oai d cett de nec etim ze yatal m Fuld o asi 9 3 MANTENANCEANDTROUBLESHOOTING 11 111 10 3 1 MAINTENANCE 5 ee t u Ane 10 3 2 TROUBLESHOOTING tik DE 10 APPENDIX 1 SPARE PAR
7. ccording to the work shop conditions DO NOT PLUG THE MAINS ELECTRIC CABLE BEFORE CLOSING ALL THE CABINET PANELS 3 2 TROUBLESHOOTING TROUBLE REASON Phasefailure Machine does not work Noneutralline Fuse blown out Phasefailure Welding current is low Diodeunitbreakdown Primary or secondary coil burn down Fansupply voltage phase failure Fan is out of order Fan motor break down 10 TD 355 APPENDIX 1 SPARE PARTS LIST FOR TD 355 2 NO MATERIAL CODE DESIGNATION 1 A310100008 Changeover Switch 16A 220V 2 K000000306 Current Adjustment Lever 3 A377900106 VVelding Socket 4 K090300004 Current Scale 5 A430901008 Diode Group 6 K000000110 Current Adjustment Shaft 7 K302000004 Primary Coil 8 K302100004 Secondary Coil 9 K304000004 Main Transformer 10 A300190001 Glass Fuse Socket 11 A311200032 Contactor 12 A250200002 Cooling Ventilator 13 A225222012 VVheel A490400001 EMC Filter TD 355 11 12 APPENDIX 2 ELECTRICAL DIAGRAM FOR TD 355 Br1 EMI Filter Earth R o To No S1 F1 Mf Th1 Th2 Br1 Tr1 C1 Changeover Switch Glass Fuse Ventilator Motor 220 VAC 0 18 kW 1450 rpm Thermic Diode Bridge Thermic Transformer Diode Bridge Main Transformer Contactor TD 355 FACTORY e Organize Sanayi B lgesi 5 Kisim 5
8. elding method and welding machine for your work Choose appropriate welding current and welding voltage for the material and its thickness If you will have along break after welding turn off the machine after cooler fan cooled the machine TD 355 5 TECHNICAL INFORMATION 1 TECHNICAL INFORMATION TD 355 is a moving coil welding machine designed to weld all type of coated electrodes from 2 0 to 5 0 mm Excellent welding performance with cellulosic electrodes The equipment is very easy to use current adjustment is made by just turning the lever in front of the machine clockwise or counter clockwise and adjusted value of the current is observed by the scale on the machine Although it is not an electrically efficient machine due to its very simple concept it is down time and operation costs are very low Since there is no electronics involved the machine can perform great at dusty humid corrosive very hot and very cold environments With its telescopic arms and big wheels it can be pulled easily across the working area especially at outdoor welding sites The machine is fan cooled and thermally protected against overheating and phase failures Figure 1 Components of TD 355 1 Power Switch 5 Lifting Eye 2 Current Adjustment Lever 6 Handle 3 Welding Cable Sockets and 7 Wheel 4 Current Adjustment Indicator 6 TD 355 TECHNICAL INFORMATION 1 3 DATA PLATE ASMA MEKATRON MAR NE SAN YET AS mm X Duty Cycle
9. ent indicator 4 above the machine The machine is ready to weld TD 355 Figure 2 Electric Plug Connection Figure 3 Mains Connection According to the electrode to be used insert the welding cables with correct polarity into the welding and earth cable sockets 3 and tighten them by turning clock wise Connect the earth clamp tightly to the workpiece as close as possible to the welding area Below table is given as a reference for current adjustment of mild steel electrodes please refer to the electrode manufacturer s recommendations 2 0 5 40 60A e 2 5 60 90 A 60 90 A 60 100 A 3 25 100 140A 100 130 A 70 130 A 4 0 140 180 A 140 180 A 120 170 A 5 0 200 240 A 200 250 A 160 200 A MAINTENANCE AND TROUBLESHOOTING 3 MAINTENANCE AND TROUBLESHOOTING Obey all the safety rules during maintenance and troubleshooting Before removing any screw on the machine for maintenance power supply must be disconnected from the electric lines 3 1 MAINTENANCE ONCE IN EVERY 3 MONTHS Clean the labels on the z machine replace the labels that worn out Repair or replace the worn out welding cables EILA terminals electrode holder earth Clean and tighten the weld lt Check the isolation of the FS 67 clamp and their cables e ONCE IN EVERY 6 MONTHS Open the covers of the machine and clean with dry air NOTE The above recommended maintenence periods are indicative these may vary a
10. ies wear appropriate safety glasses with side shields even under your welding helmet MOVING PARTS CAN CAUSE INJURY Keepaway from moving parts Keepall doors panels and guards closed and secured Wear shoes with metal protection over the fingers TD 355 SAFETY RULES NOISE CAN DAMAGE HEARING 0 Noise from certain industrial processes or equipments damage hearing Wearapproved ear protection if noise level is high WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS While welding and cutting in small confined places always have a trained watchperson nearby Avoid working in such confined places WELDING WIRE MAY CAUSE INJURY Do not point the torch toward any part of a human body other persons or any type of metal when unwinding welding wire While extracting the wire from the spool by hand it may spring suddenly and injure you or a nearby person protect especially your eyes and face a WELDING CAN CAUSE FIRE OR EXPLOSION Wy Never weld near flammable material It may cause fire or explosions Before starting to weld move flammables away or protect them with flame proof covers Do not weld on and cut closed tubes or pipes Before welding on closed containers open and clear them entirely Welding operations on these parts must be performed with the utmost caution Never weld containers or pipes containing or which have contained substances that could give rise to explosi
11. l a system that can remove the fume and vapor accumulated in the entire work area to prevent pollution use adequate filtration in discharge In the event of welding in small confined places or welding lead beryllium cadmium zinc zinc coated or painted materials also wear a fresh air supplied respirator in addition to the above mentioned rules Always have a trained watchperson nearby while working in small confined places Avoid working in such confined places if possible If gas cylinders are grouped in a different area make sure that it is a well ventilated area When not being used turn off the main cylinder valve and watch out for gas leakage Shielding gasses such as argon is denser than air and when being used in confined places it can be inhaled which is dangerous for health Do not perform welding operations near chlorinated hydrocarbon vapors produced by degreasing or painting ARC RAYS CAN BURN EYES AND SKIN Use adequate welding helmet with correct shade of filter 4 or 13 considering EN 379 to protect your eyes and face Protect open parts of your body arms neck and ears from arc rays by adequate protective clothing To protect others by arc rays and hot metals surround the working area with flame proof curtains which are higher than eye level and put up warning boards SPARKS amp FLYING METALS CAN INJURE EYES Welding wire brushing and grinding cause sparks and flying metal Topreventinjur
12. ng the risk of falling caused by cables and hoses For gas cylinders notto fall over attach itto the mobile machine orto the wall with a chain Ensurethatoperators easily reach the controls and connections on the machine inu OVERUSE CAN CAUSE OVERHEATING E Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block airflow through the unit Donotfilter airflow to unit without the approval of manufacturer ARC WELDING CAN CAUSE INTERFERENCE 11 Electromagnetic energy arising during welding and cutting operations can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots Besureall equipmentin the welding area is electromagnetically compatible Toreduce possible interference keep weld cables as short as possible close together and down low such asonthe floor To avoid possible EMC damages locate welding operation as far as possible 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area PROTECTION RD e Donotexpose the welding machine to rain protect from water drops and vapour ENERGY EFFICIENCY Choose appropriate w
13. ons Welding equipments warms up so never position them on flammable surfaces Welding sparks can cause fire Forthat reason keep extinguishing means such as fire extinguishers water and sand which are easy to reach Keep security valves regulators and other valves used on flammable explosive and compressed gas circuits in good condition MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES 4 Electrical devices should not be repaired by unqualified persons Improper repairs can cause serious injuries or even death during applications The components of the gas circuit works under pressure The service given by unqualified persons may cause explosions and operators can be injured seriously 4 TD 355 SAFETY RULES FALLING UNIT CAN CAUSE INJURY A Wrong positioned power source or other equipment may cause serious injury to persons or damage to objects While repositioning the power source always carry by using the lifting eye Never pull cable hose or torch Always carry the gas cylinders separately Before carrying the welding and cutting equipment disassemble all the connections between and separately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriate vehicles like forklifts Install your machine on flat platforms having maximum 10 slope that it does not fall over Install it on well ventilated non confined places away from the dust also avoidi
14. round or another electrode which is connected to a different machine Protect yourself from electric shock by insulating yourself from work and ground Use non flammable dry insulating material if possible or use dry rubber mats dry wood or plywood or other dry insulating material big enough to cover your full area of contact with the work or ground and watch for fire Never connect more than one electrode to the electrode holder Turn off the machine when not in use Disconnect input plug or swtich off the power before working on the machine Frequently inspect input power cord for damage or bare wiring repair or replace cord immediately if damaged Be sure that the machine is properly grounded HOT PARTS CAN CAUSE SEVERE BURNS 2 Donottouch hot parts Allow cooling time before servicing Ifneeded to hold hot parts use appropriate tool insulating gloves and fireproof clothes 2 TD 355 SAFETY RULES BREATHING WELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH Inhaling fumes and gases over a long period of time generated during welding is dangerous and forbidden e Irritation of the eyes nose and throat are symptoms of inadequate ventilation Take immediate steps to improve ventilation Do not continue welding if symptoms persist Installa naturalorforced air ventilation system in the work area Install an adequate ventilation system in the welding and cutting area if needed instal
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