USER MANUAL - Magmaweld Welding and Cutting
Contents
1. RA 300 E RA 400 E RA 650 E Hot Start P3 APPENDIX 4 ELECTRICAL DIAGRAM FOR RA 650 E o o L 2 o 9 0001 T v RU yms x 5 d E Lb l o 6 juaun z 6 4 3 ZHL IHL o s 9 el r 718 01817 9 9 711021618 z D g O iam Sc M l Vc e zo 24 LO D o kEi sz x seg N ld Zd a OVASL z modu s 2 c E LL 5 m ey bu E OVASL HA IL LL 5 zl 4 o 063 ed i s m 5 E VM w LA m ug n v c z A 5 DE N O II VL OVAGL 4001 bd e eo m pamen x VE OVASLXE ZML 1 1 s MEN s N kaa LHL 900 Joys IA e M 109 2198 EN ug 16 FACTORY e Organize Sanayi B lgesi 5 Kisim 5503 Sokak No 1 MANISA 90 236 226 27 00 90 236 226 27 28 OWM 06 07 2011 Made in TURKIYE MAGMA MEKATRON K MAK NE SANAY VE T CARET A www magmaweld com2. A OFF For Rutile and Basic On For Cellulosic Electrode B OFF For Carbon Electrode P1 Current Regulator P2 Arc Force P3 Hot Start L1 120 13 RA 300 7 RA 400 E RA 650 E 15 Hot Start P3 APPENDIX 3 ELECTRICAL DIAGRAM FOR RA 400 E o o L 2 o 9 0001 T v RU yms x 5 d E Lb l o 6 juaun z 6 4 3 ZHL IHL o s 9 el r 718 01817 9 9 711021618 z D g O iam Sc M l Vc e zo 24 LO D o kEi sz x seg N ld Zd a OVASL z modu s 2 c E LL 5 m ey bu E OVASL HA IL LL 5 zl 4 o 063 ed i s m 5 E VM w LA m ug n v c z A 5 DE N O II VL OVAGL 4001 bd e eo m pamen x VE OVASLXE ZML 1 1 s MEN gt 901 N kaa LHL 900 Joys IA e M 109 2198 EN ug RA 300 E RA 400 E RA 650 E
3. If the adjustment is not correct arc can burn through the workpiece ARC FORCE is useful for electrodes which have tendency to stick into the weld pool during welding Turning the knob 3 clock wise will decrease the tendency to stick Start welding and observe welding current A and voltage V by V Ameters 5 3 2 2 Remote Control Optional t is possible to connect a remote control box via long control cable as long as it is necessary In this case appropriate control socket must be installed onto the front panel by a certified Magma Service When the remote control connector is connected to the machine ampere adjustment knob on the machine is disabled automatically and current adjustment is made by the remote control MAINTENANCE AND TROUBLESHOOTING 4 MAINTENANCE AND TROUBLESHOOTING Before removing any screw on the machine for maintenance power v l supply must be disconnected from the electric lines and 10 seconds Y should be allowed for capacitor discharging x rs 4 1 MAINTENANCE ONCE IN EVERY 3 MONTHS Clean the labels on the w machine replace the worn out labels Repair or replace the worn out welding cables x Z terminals electrode holder earth Clean and tighten weld the lt Check the isolation of the FS 67 clamp and their cables Ze ONCE IN EVERY 6 MONTHS Open the covers of the machine and clean with dry air NOTE The above recommended maintenance period
4. welding behavior is excellent and if a proper TIG starting unit is connected they can perform as a DC TIG welder as well These units can be grouped as 4 6 8 or 9 machines in a rack for large construction sites like shipbuilding etc Due to thyristor SCR and electronic close loop control technology current is adjusted precisely by a potentiometer initial striking ability of the electrodes can be improved via Hot Start potentiometer and certain electrodes like basic electrodes which have tendency to short circuit and stick to the weld pool could be avoided by adjusting the Arc Force potentiometer Also due to this technology pre adjusted current stays stable even during mains fluctuations or if additional welding cables are used Electrical efficiency of these machines are 70 Even though there is a certain level of electronics is involved in this machine the PCB is protected in a separate cabinet inside of the machine against dust and corrosion With its telescopic arms and big wheels it can be pulled easily across the working area especially at outdoor welding sites Also stepless remote current controlling is possible as an option These machines are fan cooled and thermally protected against overheating and phase failures 1 2 COMPONENTS OF RA 300 E RA 400 RA 650 E 11 7 6 8 9 5 1 4 2 3 Figure 1 Components of the Machine 1 Power Switch Changeover Switch 7 Weldi
5. 68 p pu E Duty Cycle Temperature C 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 RA 300 E RA400 E RA 650 E 7 TECHNICAL INFORMATION 1 4 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS UNIT RA 300 E RA 400 E RA 650 E Line Voltage 3 Phases 50 Hz 380V Input Power 35 kVA 20 25 45 Input Current 35 A 30 38 68 Recommended Line Fuses A 3x32 3x40 3x80 Open Circuit Voltage Vpc 66 58 68 Welding Current Range Apc 10 300 20 400 20 650 Rated Welding Current 3596 Apc 300 400 650 Carbon Gouging mm 6 9 Dimensions LxWxH mm 950x660x640 950x660x640 950x660x640 Weight kg 155 173 5 208 Protection Class IP22 IP22 IP22 Electrode Diameter mm 2 4 2 5 2 6 1 5 ACCESSORIES RA 300 E RA 400 E RA 650 E Electrode Holder and Cable 35mm 5m K301000405 K301000405 5 Electrode Holder and Cable 70mm 5m 2 2 K301000605 Earth Clamp and Cable 35mm 5m K301100403 K301100403 Earth Clamp and Cable 70mm 5m K301100603 Remote Control Box With 10m Cable K301400210 K301400210 K301400310 Remote Control Box With 20m Cable K301400220 K301400220 K301400320 Remote Control Box With 50m Cable K301400250 K301400250 K301400350 RA 300 E RA400 E RA650 E INSTALLATION 2 INSTA
6. 9500001 Knob Small A229500002 A229500002 A229500002 Knob Big A410801004 A410801004 A410801004 Potentiometer 10K A310310002 A310310002 A310310002 Mains LED N733 220VAC A310310004 A310310004 A310310004 Thermal Protection LED N733 24VAC A310100006 A310100006 A310100006 Switch 2 Position 1 Pole A490400001 A490400001 A490400001 EMC Filter A300190001 A300190001 A300190001 Glass Fuse Socket 20x5mm A300102005 A300102005 A300102005 Glass Fuse Delayed 1A A420000003 A420000003 A420000003 Capacitor 100 NF 250V A314800102 A314800102 A314800102 Temperature Limiting Switch 125 Degrees A830900004 A830900008 A830900016 Hall Effect Sensor Plastic Wheel 300x50x20 Main Transformer RA 300 E RA400 E RA650 E 13 APPENDIX 2 ELECTRICAL DIAGRAM FOR RA 300 E K4 K 1121314 E901A C1 100n C 100n N a g 15VAC 9 2 o Ww N t lz il EX B Hd ll 6 100n 100n t H amp m 5 32 AM LE I XS 4 d i kara 4 i ACA j I H M ic ir im H T2 18 19 120117 16 fas 14 H3112 B 15VAC 1A 8 i z een i
7. LLATION 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 pallet contains o Power Source Electrode Holder Cable n 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 40 C 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 RA 300 E RA 400 E RA 650 E e e 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
8. S za 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 avoiding 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 Be sure all equipment
9. USER MANUAL magmaweld RA 300 E RA 400 E RA 650 E WELDING RECTIFIER MAGMA MEKATRONIK MAKINE SANAYI VE TICARET A S eld com CONTENTS SAFETY 2 T TECHNICAE INFORMATION 3 2 teet Mba Bela E DR E D tea ded aaa ra atu panes 6 1 4 GENERAE EXPLANATIONS a tite t trot tute ae e i to tet s tatnen 6 1 2 COMPONENTS OF RA 300 E RA 400 E RA 650 E nennen 6 TIS DATA PLAT E iiiter eee ue e ceo pv anl cs Gna ned ee aya ala an SAYIDA ea 7 14 TECHNIGAL SPEGCIFICATIONS sase tere R em et eee amu tee ote tectis 8 1 5 AGCESORR ES uin REOR kl eoi tin 8 2 INSTAEEATION icto e e rper deena alee tga Rea eae 9 24 UPON RECEIPT AND CLAIMS t ee e E b eee a lella ani 9 2 2 WORKING GONDUITIONG BL p DR du Dod ha ilede lar ss 9 2 3 ELECTRIC PEUG GCONNECGCTION 2 raro hare et e Er Lebe e ade 10 2 4 CONNECTIONS FOR MMA WELDING nnn enne enhn nennen ener enne 10 2 5 1 6 52 22 nnne enhn entes nennen nennen trennen renis 10 3 OPERATION pe PUE 11 3 1 CONNECTING TO THE MAINS zu au nun a Re RM Tr RD RR OR AR EYE 11 3 2 WELDING ADJUSTMENT O iiie etie RE ua d tes E ee cix tap eres api Wend 11 3 2 1 Welding AdjUSIMONtS rim ebd Abd adi anaya sana eed ER IRR DR ed RS 11 3 2 2 Remote Control
10. 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 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 Topreventinjuries 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 RA 300 E RA400 E RA650 E 3 SAFETY RULES NOISE CAN DAMAGE HEARING Noise from certain industrial processes or equipments can damage hearing Wear approved ear protection if noise level is high WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS Ta 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 Donot point the torch toward any part of a human body other persons or any type of metal when
11. e 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 ELECTRICAL SHOCK CAN BE FATAL h 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 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 zf e Do nottouch hot parts Allow cooling time bef
12. etse diede erae e ue A a 11 4 MAINTENANCE AND 12 44 MAINTENANGE Ee Mat m Z a s n 12 4 2 TROUBEESHOOTING e itr rere ire er depen A AR SAA si A z 12 APPENDIX 1 SPARE PARTS LIST FOR 3 13 APPENDIX 2 ELECTRICAL DIAGRAM FOR RA 300 E eene enne 14 APPENDIX 3 ELECTRICAL DIAGRAM FOR RA 400 E m 15 APPENDIX 4 ELECTRICALDIAGRAMFORRA650E nnns 16 RA 300 E RA400 E RA650 E 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 machin
13. in the welding area is electromagnetically compatible 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 RD Donotexpose the welding machine to rain protect from water drops and vapour ENERGY EFFICIENCY Choose appropriate welding 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 RA 300 E RA400 E RA650 E 5 TECHNICAL INFORMATION 1 TECHNICAL INFORMATION 1 1 GENERAL EXPLANATIONS RA300E RA400E and RA650E are thyristor SCR controlled welding machines designed to weld all type of coated electrodes from 2mm 300 model up to 5 mm 400 amp 650 models up to 6mm while 400 model can carbon gauge up to 6mm 650 model can carbon gauge up to 10mm For RA650E cellulosic welding at low currents is not recommended Since 300 amp 400 models can go as low as 20 Amps their cellulosic
14. 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 INSTALLATION 2 3 ELECTRIC PLUG CONNECTION 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 labeled as QD After installing the electric plug DO NOT INSERT IT INTO THE SOCKETAT THIS STAGE Figure 2 Electric Plug Connection 2 4 MMA WELDING CONNECTIONS According to the polarity of the electrode to be used insert welding cables into the appropriate outlet 10 and tighten them by turning clock wise Connect the earth clamp tightly to the workpiece as close as possible to the welding area Figure 3 MMA Welding Connections 2 5 TIG WELDING CONNECTIONS TIG torch with a valve should be used Connect the TIG torch power cable to the negative outlet and the earth cable to the positive outlet 10 ofthe machine Install the Argon gas regu
15. lator onto the Argon gas cylinder Connect the gas hose of the torch to the gas regulator Figure 4 TIG Welding Connections 10 RA 300 E RA400 E RA650 E OPERATION 3 OPERATION 3 1 CONNECTING TO THE MAINS 9 Figure 6 Mains Connection 3 2 WELDING ADJUSTMENTS 3 2 1 Welding Adjustments Figure 7 Control Panel Select via the selection switch 6 the type of the electrode rutile basic cellulosic to be used Forcarbon gauging toggle the selection switch 7 downwards Welding current is adjusted via current adjustment knob 4 and the adjusted current value can be observed from the ammeter 5 Below table can be used as a rough reference for mild steel electrodes For exact parameters please refer to the electrode manufacturer s recommendations 2 0 40 60 2 9 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 180A 120 170A 5 0 200 240 A 200 250 A 160 200 A 6 0 260 320 A RA 300 E RA400 E RA650 E While inserting the plug into the 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 insert the plug into the socket SWITCH ON the machine via power switch 1 Observe the fan noise and illumination of the mains LED 8 and V Adigital meters 5 For better ignition turn the HOT START knob 2 clock wise
16. ng Carbon Gouging Selection Switch 2 HOT START Current Knob 8 Mains LED 3 ARC FORCE Adjustment Knob 9 Thermal Protection LED 4 Current Adjustment Knob 10 Welding And Earth Cable Outlets 5 WA Digital Meter 11 Handles 6 Rutile Basic Cellulosic Selection Switch 12 Lifting Eyes 6 RA 300 E RA400 E RA650 E TECHNICAL INFORMATION 1 3 DATA PLATE MAGMA MEKATRON K MAK NE SAN VE T C A s ifi Organize Sanayi B lgesi 5 Kisim T 0 E id 3 Phase Transformer Rectifier RA 300E DEP D z 300 A 32 V Saa 4 Stick Electrode Welding 300A 190A 150A 32V 28V 22V Do U1 V 39 Descending Characteristics Line Input 3 Phase Alternative Current E Direct Current 380 T32A 5 Tm os MAGMA MEKATRONIK MAKINE SAN VE TIC A S EN 60974 1 YACMA MEKATRONK MAKE SAN VE AR EN eA X Duty Cycle RA 400E Uo Open Circuit Voltage 3c 22 NE U1 Line Voltage and Frequency gl Uz Rated Welding Voltage Appropriate For Dangerous Work Area LS 400 A 36 V H Input Current 12 Rated Welding Current l2 400A 305A 235A S Input Power CL I insulation Class D Ut 39 v 380 T40A 38 four Os asa toma 348 F MAGMA MEKATRON K MAK NE SAN VE T C A EN 60974 1 Organize Sanayi B lgesi 5 K s m Manisa T RK YE EN 60974 10 KDP 20A 21V 650A 46 V AE l2 650A 500A 385A 46V 40V 35V D 2 v En 380 T80A
17. ore servicing Ifneeded to hold hot parts use appropriate tool insulating gloves and fireproof clothes 2 RA 300 E RA400 E RA650 E 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 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 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 Do not perform welding operations near chlorinated hydrocarbon vapors produced by degreasing or painting 7 m Shielding gasses such as
18. s are indicative these may vary according to the work shop conditions DO NOT PLUG THE MAINS ELECTRIC CABLE BEFORE CLOSING ALL THE CABINET PANELS 4 2 TROUBLESHOOTING TROUBLE REASON Phase failure Machine does not work Noneutral line Fuse blown out Phase failure Welding current is low Diode breakdown Aprimary or secondary coil burn down Fansupply voltage phase failure Fan is out of order Fan motor break down 12 RA 300 E RA 400 RA 650 E APPENDIX 1 SPARE PARTS LIST FOR RA 300 E RA 400 E RA 650 E 000000000 nn 5 D MATERIAL CODE N RA 300E RA400E RAG650E DESIGNATION 1 A410500002 A410500002 A410500002 Rheostat 250W 2 A410801003 A410801003 A410801001 Carbon Potentiometer 3 A377900106 A377900106 A377900106 Welding Socket T 35 70 4 K405000068 K405000068 K405000068 Electronic Board E101A 5 K405000016 K405000016 K405000016 Ammeter Voltmeter Board E901A 6 A430902001 A430902002 A430902003 Rectifier 7 A250200002 A250200002 A250200002 Cooling Fan SF 350 8 A308033102 A308033102 A308034102 Changeover Switch 9 K100200003 K100200003 K100200003 Body 10 K304500012 K304500016 K304500024 Impedance Coil A225222012 A225222012 A225222012 K304000024 K304000016 K304000032 K302200004 K302200016 K302200024 Primary Secondary Spool A229500001 A229500001 A22
19. 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 AR 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 position 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 1 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 RA 300 E RA400 E RA650 E SAFETY RULE
Download Pdf Manuals
Related Search