Monostick 200i User Manual.cdr - Magmaweld Welding and Cutting
Contents
1. 12 MONOSTICK 200i PFC 1 SAFETY RULES OBEY ALL THE SAFETY RULES STATED IN THE MANUALI 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 VVARNINGS 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 Learn to operate the machine and how make the controls properly Operate your machine in convenient work areas Improper modifications affect the safety of your machine negatively and shorten its lifetime ELECTRICAL SHOCK CAN BE FATAL 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 ground or another electrode which is connected to a different machin2. VE T CARET A www magmaweld com
3. welding helmet MOVING PARTS CAN CAUSE INJURY Keep away from moving parts e Keep all doors panels and guards closed and secured e Wear shoes with metal protection over the fingers MONOSTICK 200i PFC SAFETY RULES NOISE CAN DAMAGE HEARING 88 e Noise from certain industrial processes or equipments can damage hearing e Wear approved ear protection if noise level is high WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS amp e While welding and cutting in small confined places always have a trained watchperson nearby e Avoid working in such confined places WELDING WIRE MAY CAUSE INJURY e Do not point the torch toward any part of a human body other persons or any type of metal when unwinding welding wire e 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 NA 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 explosions Welding equipments warms up so never posit
4. N60974 1 EN60974 10 1 5 ACCESORRIES STANDARD ACCESORRIES PIECE H010 Electrode Holder and Cable 16mm 3m 1 K301000203 Earth Clamp and Cable 16mm 3m 1 K301100203 MONOSTICK 200i PFC 7 INSTALLATION AND OPERATION 2 INSTALLATION 2 1 UPON RECEIPT 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 box contains o Power Source Electrode Holder Cable n Earth Clamp Cable User Manual 2 2 INSTALLATION AND WORKING RECOMMENDATIONS e DO NOT USE THE MACHINE WITH LONG ELECTRIC CABLES AT CONSTRUCTION SITES Do not forget that electric cable carries 220V 50 Hz and these cables are not suitable to work in harsh environments they can easily wear and tear which may lead to electric leakage to the metals where welders may be working on ELECTRIK SHOCK CAN KILL or cause people to FALL DOWN from dangerously high places like scaffolding iskele Instead ALWAYS use long WELDING CABLES for safety reasons For a better performance keep the machine at least 20 cm away from the surrounding objects Beware of excessive heat dust and humidity around the machine Try n
5. USER MANUAL magmaweld MONOSTICK 2001 PFC DC INVERTER ARC WELDING MACHINE MAGMA MEKATRONIK MAKINE SANAY VE T CARET A NDEK LER Xalu nd 8 2 1 E F N CAL INFORMATION i 6 1 1 GENERAL EXPLANATIONS ba E d nde laa l edad 6 1 2 COMPONENTS OF THE MACHINE susana dd 6 1 3 DATA 530 500 7 1 4 TECHNICAL SPEC F CAT ONS aaa alin ne a e aa ne lane Bea edie 7 KIACCESSORRIES emare ayr alama 7 0 7 2 INSTALLATION AND OPERATION sarri cus si aze ira bra a Ra gana kn R apa a as 8 2 1 UPON RECE PT AND GLAM Sasa al m iya ia aaa cans Ba AER E S AAA EA aaa 8 2 2 2 1 8 2 3 CONNECTIONS FOR MMA aii 8 2 4 CONNECTIONS FOR TIG WELDING 9 3 5 222 10 3 1 PERIODIC MAINTENANCE 10 3 2 NONPERIODIC 22 10 mina Bs elek man silen alla 10 APPENDIX APPENDIX 1 5BARE PART 11 APPENDIX 2 ELECTRICAL DIAGRAM
6. ables and hoses For gas cylinders not to fall over attach it to the mobile machine or to the wall with a chain Ensure that operators easily reach the controls and connections on the machine m OVERUSE CAN CAUSE OVERHEATING b e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again Donotblock airflow through the unit e Donotfilter airflow to unit without the approval of manufacturer ez ARC VVELDING CAN CAUSE INTERFERENCE 121 e 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 e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the 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 e e Donotexpose the welding machine to rain protect from water drops and vapour ENERGY EFFICIENCY e Choose appropriate welding method and wel
7. current and the machine is ready to weld Below table is given as a reference for current adjustment of mild steel electrodes please refer to the electrode manufacturer s recommendations 2 0 40 60 A 2 5 60 90 A 60 90 A 60 100 A 3 25 100 140 A 100 130 A 70 130 A 4 0 140 180 A 140 180 A 120 170 A MONOSTICK 200i PFC INSTALLATION AND OPERATION 2 4 CONNECTIONS FOR TIG WELDING Before plugging your machine to the electrical line check if the correct voltage exists While inserting the plug into the socket pay attention that main switch is positioned to OFF 0 SWITCH ON the machine via power switch 1 and check if power LED 2 lights up and cooler fan works TIG torch with a valve should be used e Connect the TIG torch power cable to the negative welding socket 5 and the earth cable to the positive welding socket 6 of the machine Figure 2 TIG Welding Connections MONOSTICK 200i PFC Install the Argon gas regulator onto the Argon gas cylinder e Connect the gas hose of the torch to the gas regulator Adjust the desired current and the machine is ready to weld Figure 3 Connecting Gas Cylinder Diameter of Diameter of Welding Electrode Nozzle Current mm mm Abc 15 70 30 150 6 8 Gas Debit 6 8 1 6 9 5 MAINTENANCE AND TROUBLESHOOTING 3 MAINTENANCE AND TROUBLESHOOTING Strictly follow the instructions contained in safety rule
8. ding machine for your work e Choose appropriate welding current and welding voltage for the material and its thickness e If you will have a long break after welding turn off the machine after cooler fan cooled the machine MONOSTICK 200i PFC 5 TECHNICAL INFORMATION 1 TECHNICAL INFORMATION 1 1 GENERAL EXPLANATIONS Monostick 200i PFC is an inverter type portable mono phase DC MMA vvelding machine designed to vveld stick electrodes up to 4 mm Even though the machine is mono phase due to the inverter technology it provides stable arc and good re striking performance Thanks to its PFC technology the electric consumption is approximately 40 less than the inverters without PFC and the magnetically controlled equipments It does the same work with less energy therefore you bring down the energy costs and you help protecting the environment Another advantage of PFC technology is to provide working without efficiency loss when you work with long cables This unit can also be used as a DC TIG power source for touch start applications Monostick 200i PFC proved well that it can work between 160 to 240 V 50 60 Hz line voltages Therefore this machine is quite immune to mains voltage fluctuations and perfectly welds with generator sets Monostick 200i PFC can also be used with long welding cables up to 25 mt The machine is fan cooled and thermally protected against over heating Whatis PFC Technology PFC is the technology which is used f
9. e 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 zf e Do nottouch hot parts e Allow cooling time before servicing e Ifneeded to hold hot parts use appropriate tool insulating gloves and fireproof clothes 2 MONOSTICK 200i PFC SAFETY RULES BREATHING VVELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH Inhaling fumes and gases over a long period of time generated during welding is dangerous and forbidden 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 Install a natural or forced air ventilation system in the work area Install an adequate ventilation system in the welding and cutting area if needed install a system that can remove the fume and vapor accumulated in the entire wo
10. er Rectifier Organize Sanayi B lgesi 5 K s m Manisa T RK YE WONOSTICK 200i PFC seme SSAC l m EN 60974 1 EN 60974 101 777 Direct Current 30A 21 2V 200A 28V PS Descending Characteristics Ie Line Input 1 Phase Alternating Current Uz 28V 24 6v 23 6v sl Appropriate To Operate In Dangerous Work Area 85 h 29A 145A 106A 1 x Duty Cycle S 6 6kVA 3 2 4kVA U Open Circuit Voltage U U DEDA U 230V i Line Voltage and Frequency 1 50 60Hz Manual Metal Arc VVelding Bi 2 Rated Welding Voltage 1 Input Current 5 ss CE Rated Welding Current IP23S Protection Class S Input Power 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 Single Phase V 230 Input Power 20 KVA 6 6 Rated Input Current 9620 A 29 Power Factor 0 99 Open Circuit Voltage 85 Welding Current Range Apc 30 200 Rated Welding Current 20 Apc 200 Fuse A 32 Delayed Protection Class IP23S Cooling Method Air Dimensions LxWxH mm 450x160x312 Weight kg 9 1 Standards and Approvals CE E
11. ion them on flammable surfaces Welding sparks can cause fire For that 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 x e Electrical devices should not be repaired by unqualified persons Improper repairs can cause serious injuries or even death during applications e 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 MONOSTICK 200i PFC SAFETY RULES Ea FALLING UNIT CAN CAUSE INJURY A Wrong positioned power source or other equipment may cause serious injury to persons or damage to objects e While repositioning the power source always carry by using the lifting eye Never pull cable hose or torch Always carry the gas cylinders separately e 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 avoiding the risk of falling caused by c
12. is working but the machine does not weld turn off the machine for 1 minute then turn it on again and try to weld If it still doesn t weld contact to your authorized technical service 10 MONOSTICK 200i PFC NO DESIGNATION APPENDIX 1 SPARE PARTS LIST IN ELECTRICAL DIAGRAM MATERIAL CODE 1 Electronic Card Control Monostick 200i PFC CNT K405000146 2 Electronic Card Filter E203A FLT K405000142 3 Electronic Card PFC E203A PFC K405000143 4 Electronic Card Power Monostick 200i PFC PWR K405000147 b Knob A229500001 Current Adjustment Potentiometer Pot A410801001 6 Thermic Error LED Red Thermic A430800001 7 Povver LED Green Povver A430800002 8 Power Switch A310100008 9 Fan Fan A250200017 MONOSTICK 200i PFC 11 APPENDIX 2 ELECTRICAL DIAGRAM E203A CNT V32 PFC_Out 1 E203A CNT V32 PFC_Out 2 E203A PFC BOARD Fo l N Eartho E203A PVVR V34 Earth E203A PFC Board P1 1 E203A PFC Board P1 2 urent Thermic E203A CNT V32 AZ 1 ZN M1 2 Fan Front Panel 5mm Green 5mm Red Power Thermic MONOSTICK 200i PFC 12 FACTORY Organize Sanayi B lgesi 5 K s m Yal n zaras Caddesi No 1 45030 MAN SA 90 236 226 27 00 90 236 226 27 28 OWM 06 24 2013 Made in TURKIYE MAGMA MEKATRON K MAK NE SANAY
13. or filtering harmonic currents of welding inverters Thanks to PFC input power decreases and that directly effects the electric bill and provides environment protection with energy efficiency No performance loss occurs due to voltage fluctations No performance loss occurs while operating with long power cables For more information about TIG welding check page 9 1 2 COMPONENTS OF THE MACHINE 7 O mu Ti Figure 1 Components of Monostick 200i PFC 1 Povver Svvitch 6 Earth Cable and Welding Cable Socket 2 Power LED 7 Line Cable Inlet 3 Thermic Error LED 8 Handle 4 Current Adjustment Knob 9 Fan 5 Earth Cable and Welding Cable Socket 6 MONOSTICK 200i PFC TECHNICAL INFORMATION 1 3 DATA PLATE SHANE Single Phase Static Frequency Converter MAGMA MEKATRON K MAK NE SAN VE T C A Transform
14. ot to operate the machine under direct sunlight Machines should be operated on lower capacities when ambient air temperature exceeds 40 C 2 3 CONNECTIONS FOR MMA WELDING Before plugging your machine to the electrical line check if the correct voltage exists While inserting the plug into the socket pay attention that main switch is positioned to OFF 0 SWITCH ON the machine via power switch 1 and check if power LED 2 lights up and cooler fan works 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 Use suitable welding fume extraction systems Use breathing apparatus if there is a risk of inhaling in confined places Respect the duty 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 According to the polarity of the electrode to be used insert welding cables into the appropriate socket 5 6 and tighten them by turning clock wise Connect the earth clamp tightly to the workpiece as close as possible to the welding area Adjust the desired
15. rk 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 Do not perform welding operations near chlorinated hydrocarbon vapors produced by degreasing or painting 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 ARC RAYS CAN BURN EYES AND SKIN e Use adequate welding helmet with correct shade of filter 4 or 13 considering EN 379 to protect your eyes and face e Protect open parts of your body arms neck and ears from arc rays by adequate protective clothing e 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 e Welding wire brushing and grinding cause sparks and flying metal e Topreventinjuries wear appropriate safety glasses with side shields even under your
16. s while servicing the machine Before removing any screw on the machine for maintenance power supply must be disconnected from the electric lines and enough time should be allowed for capacitor discharging 3 1 PERIODIC MAINTENANCE ONCE IN EVERY 3 MONTHS Clean the labels on the machine replace the worn out labels Repair or replace the worn out welding cables EV terminals electrode holder earth Clean and tighten the weld A Check isolation of the Ca clamp and their cables Zi 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 according to the work shop conditions 3 2 NONPERIODIC MAINTENANCE generally give better results Contact tip and nozzle on the torch have to be cleaned regularly and changed if required Contact tips must be in good condition longer tips 3 3 TROUBLESHOOTING Ifthe Thermal Protection LED 3 lights up while cooling fan is working and the machine doesn t weld machine maybe overheated and stopped for auto protection due to overheat Hot weather or working in high current values for long time may cause this Let the machine on for a while in order to cool down itself with the cooling fan After it cools enough Thermal Protection LED 3 fades away and the machine can weld When the Power LED 2 is lighting cooling fan
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