Magmaweld 521M0200m0 megaMIG Welding Machine User Manual

: October 30, 2023
: magmaweld

Table of Contents

Magmaweld 521M0200m0 megaMIG Welding Machine
Product Information
Product Usage Instructions
SAFETY PRECAUTIONS
Technical Information
INSTALLATION
Operation
Unit Error
References
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Download This Manual (PDF format)

Magmaweld 521M0200m0 megaMIG Welding Machine

Magmaweld-521M0200m0-megaMIG-Welding-Machine

Product Information

The megaMIG is a MIG/MAG welding machine manufactured by Magma Mekatronik Makine Sanayi ve Ticaret A. The machine is designed to provide high-quality welding results with a range of materials. The product comes with various components and accessories, including a grounding clamp, gas connections, and torch consumables. The machine has a user-friendly interface, allowing for easy operation and control. The product also includes safety features to prevent electric shocks and other hazards.

Product Usage Instructions

Safety Precautions

Before using the megaMIG welding machine, it is essential to follow all safety precautions outlined in the user manual. The machine comes with safety symbols that indicate potential hazards and how to operate the machine safely. It is crucial to ensure that the installation procedures comply with national electrical standards and relevant regulations and that the machine is installed by authorized persons.
Make sure all connections are tight, clean, and dry. If an uninsulated cable is detected, repair or replace it immediately. When any of the following electrically hazardous conditions are present, additional safety precautions are required:

Use appropriate equipment for electrically hazardous conditions
Ensure proper ventilation to prevent the inhalation of fumes and gases released from welding/cutting
Use a suitable filtration system to avoid polluting the environment during discharge
Use masks that provide fresh air when welding materials such as cadmium, zinc, coated or painted materials
Keep gas cylinders’ main valves closed when not in use and pay attention to possible gas leaks
Avoid welding in confined spaces

Installation
Before installation, ensure that the machine’s components are complete and that there is no damage during transportation. Follow the delivery control procedures outlined in the user manual.
The machine should be installed and operated by authorized persons. Ensure that the welding connections, grounding clamp, gas connections, and torch connection and consumable changes are
appropriately connected.

Operation
The megaMIG welding machine has a user-friendly interface that allows for easy operation and control. The menu structure is outlined in the user manual. The machine can be connected to mains using the procedures outlined in the manual. Wire reels can be selected and replaced using the instructions provided. The wire spool and wire feeding process can be performed by following the guidelines provided in the manual. Gas flow can be set using the procedures outlined in the manual.

Maintenance and Service
Maintenance of the megaMIG welding machine should be performed regularly to ensure optimal performance. The user manual outlines periodic and non-periodic maintenance procedures. Troubleshooting procedures and error codes are also provided in case of any issues with the machine.

Annex
The user manual includes a spare part list, fine settings in the wire feed unit, and connection diagrams in the annex section.

USER MANUAL megaMIG

(+90) 444 93 53 magmaweld.com info@magmaweld.com

(+90) 538 927 12 62

All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without the prior written
authorisation of Magma Mekatronik Makine Sanayi ve Ticaret A.. Magma Mekatronik may modify the information and the images without any prior notice.
Tüm haklari saklidir. Magma Mekatronik Makine Sanayi ve Ticaret A..’nin yazili izni olmaksizin bu dokümanin tamaminin ya da bir bölümünün kopyalanmasi yasaktir. Magma Mekatronik önceden haber vermeksizin bilgilerde ve resimlerde deiiklik yapilabilir.

megaMIG

3
MIG / MAG WELDING MACHINE EN POSTE DE SOUDAGE MIG/MAG FR MIG/MAG RU MIG / MAG KAYNAK MAKNES TRwww.magmaweld.com

megaMIG

Safety Precautions

SAFETY PRECAUTIONS

EN Be Sure To Follow All Safety Rules In This Manual!

Explanation Of Safety · Safety symbols found in the manual are used to identify potential hazards. Information · When any one of the safety symbols are seen in this manual, it must be understood that there is a risk of injury and the following instructions should be read carefully to avoid potential hazards. · The possessor of the machine is responsible for preventing unauthorized persons from accessing the equipment. · Persons using the machine must be experienced or fully trained in welding / cutting they have to read the user manual before operation and follow the safety instructions.
Explanation Of Safety Symbols ATTENTION Indicates a potentially hazardous situation that could cause injury or damage. In case if no precaution is taken, it may cause injuries or material losses / damages.
IMPORTANT Specifies notifications and alerts on how to operate the machine.
DANGER Indicates a serious danger. In case if not avoided, severe or fatal injuries may occur.

Comprehending Safety · Read the user manual, the label on the machine and the safety instructions carefully. Precautions · Make sure that the warning labels on the machine are in good condition. Replace missing and damaged labels. · Learn how to operate the machine, how to make the checks in a correct manner. · Use your machine in suitable working environments. · Improper changes made in your machine will negatively affect the safe operation and its longevity. · The manufacturer is not responsible for the consequences resulting from the operation of the device beyond the specified conditions.

Electric Shocks Make certain that the installation procedures comply with national electrical standards May Kill and other relevant regulations, and ensure that the machine is installed by authorized persons.
· Wear dry and sturdy insulated gloves and working apron. Never use wet or damaged gloves and working aprons.
· Wear flame-resistant protective clothing against the risk of burning. The clothing used by the operator must be protective against sparks, splashing and arc radiation.
· Do not work alone. In case of a danger make sure you have someone for help in your working environment.
· Do not touch the electrode with the bare hand. Do not allow the electrode holder or electrode to come in contact with any other person or any grounded object.
· Never touch parts that carry electricity. · Never touch the electrode if you are in contact with the electrode attached to the work surface,
floor or another machine. · By isolating yourself from the work surface and the floor, you can protect yourself from possible
electric shocks. Use a non-flammable, electrically insulating, dry and undamaged insulation material that is large enough to cut off the operator’s contact with the work surface. · Do not connect more than one electrode to the electrode holder. · Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. · Check the torch before operating the machine. Make sure the torch and its cables are in good condition. Always replace a damaged, worn torch. · Do not touch electrode holders connected to two machines at the same time since double open-circuit voltage will be present. · Keep the machine turned off and disconnect cables when not in use. · Before repairing the machine, remove all power connections and / or connector plugs or turn off the machine. · Be careful when using a long mains cable.

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6 Safety Precautions

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Make sure all connections are tight, clean, and dry.

· Keep cables dry, free of oil and grease, and protected from hot metal and sparks.

EN

· Bare wiring can kill. Check all cables frequently for possible damage. If a damaged or an

uninsulated cable is detected, repair or replace it immediately.

· Insulate work clamp when not connected to workpiece to prevent contact with any metal

object.

· Make sure that the grounding of the power line is properly connected.

· Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling.

· Use AC output ONLY if required for the welding process.

· If AC output is required, use remote output control if present on unit.

Additional safety precautions are required when any of the following electrically hazardous

conditions are present :

· in damp locations or while wearing wet clothing,

· on metal structures such as floors, gratings, or scaffolds,

· when in cramped positions such as sitting, kneeling, or lying,

· when there is a high risk of unavoidable or accidental contact with the workpiece or ground.

For these conditions, use the following equipment in order presented:

· Semiautomatic DC constant voltage (CV) MIG welding machine,

· DC manual MMA welding machine,

· DC or AC welding machine with reduced open-circuit voltage (VRD), if available.

Procedures for · Turn off the electric power. Electric Shock · Use non- conducting material, such as dry wood, to free the victim from contact with live parts
or wires. · Call for emergency services.
If you have first aid training; · If the victim is not breathing, Administer cardiopulmonary resuscitation (CPR) immediately
after breaking contact with the electrical source. Continue CPR (cardiac massage) until breathing starts or until help arrives. · Where an automatic electronic defibrillator (AED) is available, use according to ins tructions. · Treat an electrical burn as a thermal burn by applying sterile, cold (iced) compresses. Prevent contamination, and cover with a clean, dry dressing.

Moving Parts May · Keep away from the moving parts. Cause Injuries · Keep all protective devices such as covers, panels, flaps, etc., of machinery and equipment closed and in locked position. · Wear metal toe shoes against the possibility of heavy objects falling on to your feet.

Fumes and Gases May Be Harmful To

Long-term inhalation of fumes and gases released from welding / cutting is very dangerous.

Your Health · Burning sensations and irritations in the eyes, nose and throat are signs of inadequate

ventilation. In such a case, immediately boost the ventilation of the work area, and if the

problem persists, stop the welding / cutting process completely.

· Create a natural or artificial ventilation system in the work area.

· Use a suitable fume extraction system where welding / cutting works are being carried out. If

necessary, install a system that can expel fumes and gases accumulated in the entire workshop.

Use a suitable filtration system to avoid polluting the environment during discharge.

· If you are working in narrow and confined spaces or if you are welding lead, beryllium,

cadmium, zinc, coated or painted materials, use masks that provide fresh air in addition to the

above precautions.

· If the gas tanks are grouped in a separate zone, ensure that they are well ventilated, keep the

main valves closed when gas cylinders are not in use, pay attention to possible gas leaks.

· Shielding gases such as argon are denser than air and can be inhaled instead of air if used in

confined spaces. This is dangerous for your health as well.

· Do not perform welding / cutting operations in the presence of chlorinated hydrocarbon vapors

released during lubrication or painting operations.

· Some welded / cut parts require special ventilation. The safety rules of products that require

special ventilation should be read carefully. A suitable gas mask should be worn when

necessary.

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Safety Precautions 7

Arc Light May Damage · Use a standard protective mask and a suitable glass filter to protect your eyes and face.

Your Eyes and Skin · Protect other naked parts of your body (arms, neck, ears, etc.) with suitable protective clothing

from these rays.

EN

· Enclose your work area with flame-resistant folding screens and hang warning signs at eye level

so that people around you will not sustain injuries from arc rays and hot metals.

· This machine is not used for heating of icebound pipes. This operation performed with the

welding / cutting machine causes explosion, fire or damage to your installation.

Sparks and Spattering · Performing works such as welding / cutting, surface grinding, and brushing cause sparks and Particles May Get metal particles to splatter. Wear approved protective work goggles which have edge guards
Into Eyes and Cause under the welding masks to prevent sustaining possible injuries. Damage

Hot Parts May Cause · Do not touch the hot parts with bare hands. Severe Burns · Wait until the time required for the machine to cool down before working on its parts. · If you need to hold hot parts, use suitable tools, welding / cutting gloves with high-level thermal insulation and fire-resistant clothes.
Noise May Cause · The noise generated by some equipment and operations may damage your hearing ability. Damage To Your · Wear approved personal ear protective equipment if the noise level is high. Hearing Ability

Welding Wires Can · Do not point the torch towards any part of the body, other persons, or any metal while Cause Injuries unwrapping the welding / cutting wire. · When welding wire is run manually from the roller especially in thin diameters the wire can slip out of your hand, like a spring or can cause damage to you or other people around, therefore you must protect your eyes and face while working on this.
Welding Operations · Never perform welding / cutting work in places near flammable materials. There may be fire or May Cause Fire and explosions.
Explosion · Before starting the welding / cutting work, remove these materials form the environment or cover them with protective covers to prevent combustions and flaring.
· National and international special rules apply in these areas.
· Do not apply welding / cutting operations into completely closed tanks or pipes. · Before welding to tanks and closed containers, open them, completely empty them, and clean
them. Pay the greatest attention possible to the welding / cutting operations you will perform in such places. · Do not weld in tanks and pipes which might have previously contained substances that may cause explosions, fires or other reactions. · Welding / cutting equipment heats up. For this reason, do not place it on surfaces that could easily burn or be damaged !
· Sparks and splashing parts may cause a fire. For this reason, keep materials such as fire extinguishers tubes, water, and sand in easily accessible places.
· Use holding valves, gas regulators and valves on flammable, explosive and compressed gas circuits. Make sure that they are periodically inspected and pay attention that they run reliably.
Maintenance Work · Electrical equipment should not be repaired by unauthorized persons. Performed by Unauthorized Errors occurred if failed to do so may result in serious injury or death when using the
Persons To Machines equipment. and Apparatus May · The gas circuit elements operate under pressure; explosions may occur as a result of services
Cause Injuries provided by unauthorized persons, users may sustain serious injuries. · It is recommended to perform technical maintenance of the machine and its auxiliary units at least once a year.

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8 Safety Precautions

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Welding / Cutting in · In small-sized and confined spaces, absolutely make sure to perform welding / cutting

EN

Small Sized and operations, accompanied by another person. Confined Spaces · Avoid performing welding / cutting operations in such enclosed areas as much as possible.

Failure To Take · Take all necessary precautions when moving the machine. The areas where the machine to be Precautions During transported, parts to be used in transportation and the physical conditions and health of the Transport May Cause person carrying out the transportation works should be suitable for the transportation process.
Accidents · Some machines are extremely heavy; therefore, make sure that the necessary environmental safety measures are taken when changing their places.
· If the machine is to be used on a platform, it must be checked that this platform has suitable load bearing limits.
· If it is to be transported by means of a haulage vehicle (transport trolley, forklift etc.), make sure of the durableness of the vehicle, and the connection points (carrying suspenders, straps, bolts, nuts, wheels, etc.) that connect the machine to this vehicle.
· If the machine will be carried manually, make sure the durableness of the machine apparatuses (carrying suspenders, straps, etc.) and connections.
· Observe the International Labor Organization’s rules on carriage weights and the transport regulations in force in your country in order to ensure the necessary transport conditions.
· Always use handles or carrying rings when relocating the power-supply sources. Never pull from torches, cables or hoses. Be absolutely sure to carry gas cylinders separately.
· Remove all interconnections before transporting the welding / cutting equipment, each being separately, lift and transport small ones using its handles, and the big ones from its handling rings or by using appropriate haulage equipment, such as forklifts.
Falling Parts May Improper positioning of the power-supply sources or other equipment can cause serious injury Cause Injuries to persons and physical damage to other objects.
· Place your machine on the floor and platforms with a maximum tilt of 10° so that it does not fall or tip over. Choose places that do not interfere with the flow of materials, where there is no risk of tripping over on cables and hoses; yet, large, easily ventilatable, dust-free areas. To prevent gas cylinders from tipping over, on machines with a gas platform suitable for the tanks, fix the tanks on to the platform; in stationary usage applications, fix them to the wall with a chain in a way that they would not tip over for sure.
· Allow operators to easily access settings and connections on the machine.
Excessive Use Of The · Allow the machine to cool down according to operation cycle rates. Machine Causes · Reduce the current or operation cycle rate before starting the welding / cutting again. Overheating · Do not block the fronts of air vents of the machines. · Do not put filters that do not have manufacturer approvals into the machine’s ventilation ports.

Excessive Use Of The · This device is in group 2, class A in EMC tests according to TS EN 55011 standard. Machine Causes · This class A device is not intended for use in residential areas where electrical power is supplied Overheating from a low-voltage power supply. There may be potential difficulties in providing electromagnetic compatibility due to radio frequency interference transmitted and emitted in such places.
This device is not compliant with IEC 61000 -3-12. In case if it is desired to be connected to the low voltage network used in the home, the installer to make the electrical connection or the person who will use the machine must be aware that the machine has been connected in such a manner; in this case the responsibility belongs to the user.
· Make sure that the work area complies with electromagnetic compatibility (EMC). Electromagnetic interferences during welding / cutting operations may cause undesired effects on your electronic devices and network; and the effects of these interferences that may occur during these operations are under the responsibility of the user.
· If there is any interference, to ensure compliance; extra measures may be taken, such as the use of short cables, use of shielded (armored) cables, transportation of the welding machine to another location, removal of cables from the affected device and / or area, use of filters or taking the work area under protection in terms of EMC.
· To avoid possible EMC damage, make sure to perform your welding / cutting operations as far away from your sensitive electronic devices as possible (100 m).

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Safety Precautions 9

· Ensure that your welding and/or cutting machine has been installed and situated in its place according to the user manual. EN
Evaluation Of According to article 5.2 of IEC 60974-9; Electromagnetic Before installing the welding / cutting equipment, the person in charge of the operation and / or Suitability Of The the user must conduct an inspection of possible electromagnetic interference in the environment.
Work Area Aspects indicated below has to be taken into consideration; a) Other supply cables, control cables, signal and telephone cables, above and below the welding / cutting machine and its equipment, b) Radio and television transmitters and receivers, c) Computer and other control hardware, d) Critical safety equipment, e.g. protection of industrial equipment, e) Medical apparatus for people in the vicinity, e.g. pacemakers and hearing aids, f) Equipment used for measuring or calibration, g) Immunity of other equipment in the environment. The user must ensure that the other equipment in use in the environment is compatible. This may require additional protection measures. h) Considering the time during which the welding / cutting operations or other activities take place during the day, the boundaries of the investigation area can be expanded according to the size of the building, the structure of the building and other activities that are being performed in the building. In addition to the evaluation of the field, evaluation of device installations may also be necessary for solving the interfering effect. In case if deemed necessary, on-site measurements can also be used to confirm the efficiency of mitigation measures. (Source: IEC 60974-9).

Electromagnetic · The appliance must be connected to the electricity supply in the recommended manner by a Interferance competent person. If interference occurs, additional measures may be applied, such as filtering
Reduction Methods the network. The supply of the fixed-mounted arc welding equipment must be made in a metal tube or with an equivalent shielded cable. The housing of the power supply must be connected and a good electrical contact between these two structures has to be provided.
· The recommended routine maintenance of the appliance must be carried out. All covers on the body of the machine must be closed and / or locked when the device is in use. Any changes, other than the standard settings without the written approval of the manufacturer, cannot be modified on the appliance. Otherwise, the user is responsible for any consequences that may possibly occur.
· Welding / cutting cables should be kept as short as possible. They must move along the floor of the work area, in a side by side manner. Welding / cutting cables should not be wound in any way.
· A magnetic field is generated on the machine during welding / cutting. This may cause the machine to pull metal parts on to itself. To avoid this attraction, make sure that the metal materials are at a safe distance or fixed. The operator must be insulated from all these interconnected metal materials.
· In cases where the workpiece cannot be connected to the ground due to electrical safety, or because of its size and position (for example, in building marine vessel bodies or in steel construction manufacturing), a connection between the workpiece and the grounding may reduce emissions in some cases, it should be kept in mind that grounding of the workpiece may cause users to sustain injuries or other electrical equipment in the environment to break down. In cases where necessary, the workpiece and the grounding connection can be made as a direct connection, but in some countries where direct connection is not permissible, the connection can be established using appropriate capacity elements in accordance with local regulations and ordinances.
· Screening and shielding of other devices and cables in the work area can prevent aliasing effects. Screening of the entire welding / cutting area can be evaluated for some specific applications.
Electromagnetic Field The electrical current passing through any conductor generates zonal electric and magnetic fields (EMF) (EMF). All operators must follow the following procedures to minimize the risk of exposure to EMF; · In the name of reducing the magnetic field, the welding / cutting cables must be assembled and secured as far as possible with the joining materials (tape, cable ties etc.). · The operator’s body and head should be kept as far away from the welding / cutting machine and cables as possible,

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10 Safety Precautions

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The electrical current passing through any conductor generates zonal electric and magnetic fields

(EMF).

EN

All operators must follow the following procedures to minimize the risk of exposure to EMF;

· In the name of reducing the magnetic field, the welding / cutting cables must be assembled and

secured as far as possible with the joining materials (tape, cable ties etc.).

· The operator’s body and head should be kept as far away from the welding / cutting machine

and cables as possible,

· Welding / cutting and electric cables should not be wrapped around the body of the machine in

any way,

· The body of the machine should not get caught between the welding / cutting cables. The source

cables must be kept away from the body of the machine, both being placed side by side,

· The return cable must be connected to the workpiece as close as possible to the work area,

· The welding / cutting machine should not rest against the power unit, ensconce on it and not

work too close to it,

· Welding / cutting work should not be performed when carrying the wire supply unit or power

unit.

EMF may also disrupt the operation of medical implants (materials placed inside the body), such

as pacemakers. Protective measures should be taken for people who carry medical implants. For

example, access limitation may be imposed for passers-by, or individual risk assessments may be

conducted for welders. Risk assessment should be conducted and recommendations should be

made by a medical professional for users who carry medical implants.

Protection · Do not expose the machine to rain, prevent the machine from splashing water or pressurized steam.

Energy Efficiency · Choose the welding / cutting method and welding machine for the welding work you are to perform.
· Select the welding / cutting current and/or voltage to match the material and thickness you are going to weld.
· If you have to wait for a long time before you start your welding / cutting work, turn off the machine after the fan has cooled it down. Our machines with smart fan control will turn off on their own.
Waste Procedure · This device is not domestic waste. It must be directed to recycling within the framework of the European Union directive and national laws.
· Obtain information from your dealer and authorized persons about the waste management of your used machines.
WARRANTY FORM

Please visit our website www.magmaweld.com/warranty-form/wr for warranty form.

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Technical Information 11

TECHNICAL INFORMATION

EN

1.1 General Information

megaMIG is a single-phase, compact MIG / MAG welding machine with an inverter structure, designed for light fabrication, repair / maintenance, automotive, steel construction etc. applications. Any metal can be welded with this machine, when the suitable welding wire and shielding gas are used. The machine is fan-cooled and thermally protected against overheating. megaMIG has a multi-process structure, in addition to MIG / MAG welding, Lift TIG and MMA welding can also be performed.

1.2 Machine Components

1

11

13

2

3

4 5
7

8

6

9

14

10 12

Figure 1: megaMIG

1- Digital Display

8- Welding and Ground Cable Socket (+)

2- Digital Display

9- Welding and Ground Cable Socket (-)

3- Adjustment Pot

10- Trigger Control Socket

4- Torch Socket with Remote Control 11- On/Off Switch

5- Spool Gun Torch Socket

12- Gas Inlet

6- Torch Connection

13- Mains Cable

7- Fan

14- Drum Wire Connection

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Technical Information

EN

1.3 Product Label

Duty Cycle Temperature (C°)

megaMIG

X U0 U1 U2 I1 I2 S1 IP21S

Single Phase Transformer Rectifier MIG/MAG Welding MMA Welding Direct Current Mains Input 1-Phase Alternating Current Suitable for Operation at Hazardous Environments Duty Cycle Open Circuit Voltage Mains Voltage and Frequency Rated Welding Voltage Rated Mains Current Rated Welding Current Rated Power Protection Class

6 min.

4 min.

6 min.

4 min.

6 min.

4 min.

Time (min.)

As defined in the standard EN 60974-1, the duty cycle rate includes a time period of 10 minutes. For example, if a machine specified as 250A at %60 is to be operated at 250A, the machine can weld / cut without interruption in the first 6 minutes of the 10 minutes period (zone 1). However, the following 4 minutes should be kept idle for the machine cool down (zone 2).

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1.4 Technical Data
TECHNICAL DATA Mains Voltage (1-phase 50-60 Hz)
Rated Power Welding Current Range Rated Welding Current
Open Circuit Voltage Dimensions (l x w x h) Weight (Torch Excluded)
Protection Class
1.5 Accessories
STANDARD ACCESSORIES Workpiece Clamp and Cable
Gas Hose MIG / MAG CO Accessory Set MIG/MAG Mix/Argon Accessory Set * Must be verified during order.
OPTIONAL ACCESSORIES Lava MIG 25 (3 m) Air Cooled MIG Torch
Gas Regulator (CO2) Gas Regulator (Mix)
CO2 Heater (24V) Spool Gun

UNIT V
kVA ADC ADC VDC mm kg
QTY 1 1 1 1
QTY 1 1 1 1 1

Technical Information 13
EN megaMIG
230 8.2 30 – 200 200 75 561 x 212 x 447 19.5 IP 21S
PRODUCT CODE 7905212503 (25 mm² – 3 m)
7907000002 7920000510 7920000515
PRODUCT CODE 7120020003 7020001005 7020001004 7020009003 7121018006

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14 Installation

megaMIG

EN

INSTALLATION

2.1 Delivery Control

Make sure that all the materials you have ordered have been received. If any material is missing or damaged,

contact your place of purchase immediately.

The standard box includes the following;

· Welding machine and connected mains cable

· Warranty certificate

· Workpiece clamp and cable

· User manual

· Gas hose

· Welding Wire

In case of a damaged delivery, record a report, take a picture of the damage and report to the transport

company together with a photocopy of the delivery note. If the problem persists, contact the customer service.

Symbols and their meanings on the device Welding may be dangerous. For welding should ensure proper working conditions, and the authorized person should take necessary precautions. Specialists are responsible for the machine and have to be equipped with the necessary equipment and those who are not relevant should be kept away from the welding area. This device is not compatible with IEC 61000-3-12. If it is desired to connect to the low voltage mains used in homes, it is essential that the installer or the person who will operate the machine to make the electrical connection must have the information on the machine’s connectivity. In this case, the person who will perform the installation or the operator will assume responsibility.
The safety symbols and warning notes on the device and in the operating instructions must be observed and the labels must not be removed.

Grids are intended for ventilation. The openings should not be covered to provide good cooling and no foreign objects should be inserted.

2.2 Installation and Operation Recommendations
· Lifting rings or forklifts should be used to move the machine. Do not lift the machine with the gas cylinder. Place the power supply on a hard, level, smooth surface where it will not fall or tip over.
· For better performance, place the machine at least 30 cm away from surrounding objects. Pay attention to overheating, dust and moisture near the machine. Do not operate the machine under direct sunlight. If the ambient temperature exceeds 40°C, use the machine at a lower current or a lower operating cycle.
· Avoid welding outdoors in windy and rainy weather circumstances. If welding is necessary in such cases, protect the welding area and the welding machine with a curtain and canopy.
· When positioning the machine, make sure that materials such as walls, curtains, boards do not prevent easy access to the machine’s controls and connections.
· If you weld indoors, use a suitable fume extraction system. Use breathing apparatus if there is a risk of inhaling welding fumes and gas in confined spaces.
· Observe the operating cycle rates specified on the product label. Suspending operating cycle rates can damage the machine and this may invalidate the warranty.
· The supply cable must comply with the specified fuse value. · Tighten the ground wire as close as possible to the workpiece. Do not allow the welding current to pass
through equipment other than the welding cables such as the machine itself, gas cylinder, chain and roller bearing. · When the gas cylinder is placed on the machine, secure the gas cylinder by connecting the chain immediately. If you will not place the gas cylinder on the machine, secure the gas cylinder to the wall with a chain. · The electrical outlet on the back of the machine is for the C02 heater. Never connect a device to the C02 outlet other than the C02 heater !

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Installation 15

2.3 Welding Connections

EN

2.3.1 Connecting Grounding Clamp to Workpiece
· As standard use you must connect your grounding clamp to the negative (-) polarity plug and welding polarity cable to the positive (+) plug.
· Some wire types can weld at negative polarities. In that case please connect your grounding clamp to the positive (+) plug and the welding cable to the negative (-) pole.
· Connect the grounding clamp firmly to the workpiece as close to the area to be welded as possible.

2.3.2 Gas Connections

· Install the gas cylinders in an upright position by securing them to stationary support to prevent falling or

tipping.

· Use regulators and heaters that comply with standards to ensure safe work and achieve the best results.

· Make sure that the gas regulator you will use is tightly connected to the hose.

· Open the gas cylinder valve by keeping your head and face away from the cylinder valve outlet and keep it open for 5 seconds. As a result, all sediment and dirt will be flushed out.
· If a CO heater is to be used, first connect the CO heater to the gas cylinder. After connecting the gas regulator to the CO heater, plug the CO heater into the CO heater’s socket on the back of the machine.
· If the CO heater is not used, connect the gas regulator to the gas cylinder. · Connect one end of the tube hose to the gas regulator and tighten the clamp. Connect the other end to the gas

inlet at the back of the machine and tighten the nut.

· Open the gas cylinder valve and check that the cylinder is full and there are no leaks in the gas port. If you

hear a sound and/or smell gas to indicate a leak, inspect your connections and remove the leak.

4

1- Chain

6- Gas Hose

9

2- Gas Regulator

7- Flow meter

8 27

3- Gas Cylinder

8- Manometer

4- Gas Cylinder Valve

9- CO2 Heater

5- Flow Adjustment Valve 10- CO2 Heater Energy Cable

3

5

1

6

10

Figure 2 : Gas Cylinder – Heater – Regulator Connections

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USER MANUAL

16 Installation

megaMIG

EN

2.3.3 Torch Connection and Consumable Changes

· The connector is a Euro connect type. All Euro connect model

standard and spoolgun torches are compatible with your machine.

Some wires can weld at negative polarity. For reversing polarities

on your machine, plug your pole connection to the negative (-)

plug and grounding clamp to the positive (+) plug.

· Insert the torch into the torch connector and screw its nut tightly.

Nut of Torch

Spool Gun Connection (Connector)

Figure 3 : Connecting the Torch

SPOOL GUN MOTOR –

LP-16-C07PE-02-001 – 7

SPOOL GUN TRIGGER 1 SPOOL GUN MOTOR +
SPOOL GUN TRIGGER 2 LP-16-C07PE-02-001 – 3 LP-16-C07PE-02-001 – 4

LP-16-C07PE-02-001 – 1 LP-16-C07PE-02-001 – 6 LP-16-C07PE-02-001 – 2 LP-16-C07PE-02-001 – 4 LP-16-C07PE-02-001 – 3

· Check if the liner and the contact tip is matching with the diameter of the welding wire. If it is needed, change the liner and the contact tip.
· To change the liner; remove the nozzle, the contact tip and the adaptor respectively.

Contact Tip

Nozzle

Adapter

· Unscrew the liner’s nut which is on the torch connector side and remove the liner existing in torch. After inserting the new lider into the torch, screw its nut tightly.

Figure 4 : Removing the Nozzle, the Contact Tip and the Adapter
Nut of Liner
Liner

Figure 5 : Removing the Liner and Installing the New Liner

· Cut off the stick out of the liner with a side cutter. Be sure that head of the liner is smooth.
· Reassemble the adaptor, the contact tip and the nozzle respectively with help of an appropriate hand tool.

Figure 6 : Cutting off the Liner Stick Out and Reassembling the Torch

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Operation 17

OPERATION

EN

3.1 User Interface

1

3

2

4

5

6

1-) DIGITAL DISPLAY
Allows monitoring of Ampere / Wire Feed Speed and Function settings.

2-) DIGITAL DISPLAY
Allows monitoring of voltage and function settings.

3-) FUNCTION SELECTION

By pressing once, the menu is accessed and each press gives access to the next function. With the help of the adjustment button, the relevant function is adjusted.

PrE

Pre-Gas Pre-gas time is set.
Setting Range · 0.1 – 10 sec. Before starting the welding for the specified time, gas comes in and then the welding starts. It provides protection of the welding pool when the welding starts.

PoS

Post-Gas Post-gas time is set.
Setting Range · 0 – 9.9 sec. After the end of the welding for the specified time, gas comes and the welding ends. It provides protection of the welding pool at the end of the welding.

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USER MANUAL

18 Operation

megaMIG

EN

bub

Burn Back Burnback adjustment is made.
Setting Range

· + 25 – 25

If the value seen on the screen is “+” in backburning, the wire will come forward for the

specified time, if the value on the screen is “-“, the wire will continue to burn back for the

specified time. When the welding process is completed, it prevents the welding wire from

sticking to the contact nozzle.

Ont

On Time In spot mode, the time that the weld is active (time to weld) is set. During this period, the welding will continue, and at the end of this time, the welding will terminate.
Setting Range · 0.2-10 sec.

OFt

Off Time In spot mode, the time that the weld will be on hold time (welding is not carried out) is set. Welding will stop during the set time, and will start again at the end of this time.
Setting Range · 0.2-10 sec.

SoS

Soft Start Soft start setting is made.
Setting Range · On – Off When starting to weld, the wire speed gradually increases from low speed to the set speed. In this way, knocks and splashes at the beginning of the welding are prevented.

Crt

Crater Crater function setting is made.
Setting Range · On – Off It is the filling process to prevent cracks that will occur at the end of welding. When the crater is active, the welding current is reduced with a certain linearity at the end of the welding and the welding ends.

4-) WELDING MODE SELECTION
Welding mode is selected. Each press of the button will switch between the lines in the relevant column. The corresponding led will turn on when the welding mode is selected.
Setting Range
· MMA
· LIFT TIG
· MIG / MAG

5-) ADJUSTMENT POT
Selected parameters are adjusted by turning it left and right. It returns to the main page when the adjustment pot is pressed on the function page. It switches between the right/left screen when the adjustment pot is pressed once on the main page. E.g.; When MIG mode is selected, wire speed is adjusted from the left digital display and voltage from the right digital display. When the adjustment pot is pressed once, it switches between screens. On the screen to be adjusted, the led in the lower right corner flashes and shows which screen you are on. If the flashing led is on the left screen, the wire speed is adjusted. If the flashing led is on the right screen, the voltage is adjusted. Only current adjustment is made in MMA-LIFT TIG modes. The flashing led will be on the left screen. Even if you press the adjustment pot once, it will not switch to the right screen.

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Operation

6-) TRIGGER MODE SELECTION

EN

Trigger mode selection will be made. Each time the button is pressed, the other trigger mode is switched.

Setting Range

· 2 Trigger

· 4 Trigger

· Spot (Pnt)

Press the Trigger

Hold the Trigger Pressed

Release Trigger

2 TRIGGER MODE

When the torch trigger is pressed, welding starts and the trigger will be held pressed until the welding ends. Releasing the trigger will end the welding.

Welding Start

Welding Termination

· Press and hold the torch trigger.

· Release the pressed torch trigger.

· Shielding gas flow starts as long as the pre-gas period. · The wire feed motor will stop.

· At the end of the pre-gas period, the wire feed motor runs · The arc extinguishes after the set burn-back time.

at a slow speed.

· The process ends after the final gas period.

· Welding current increases when the workpiece is reached.

PrG : Initial Gas Time I : Welding Current PoG : Final Gas Time

4 TRIGGER MODE

When the torch trigger is pressed and released once, welding starts and there is no need to hold it pressed until the welding ends. Pressing and releasing the trigger again will end the welding process.

Welding Start

Welding Termination

· Press and hold the torch trigger.

· Release the pressed torch trigger.

· Shielding gas flow starts as long as the pre-gas period.

· The wire feed motor will stop.

· At the end of the pre-gas period, the wire feed motor runs at · The arc extinguishes after the set burn-back time.

a slow speed.

· The process ends after the final gas period.

· Welding current increases when the workpiece is reached.

· Release the pressed torch trigger and the welding will

continue.

PrG : Initial Gas Time I : Welding Current PoG : Final Gas Time

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USER MANUAL

20 Operation

megaMIG

EN Spot Mode (Pnt)
Welding starts as soon as the trigger is pressed, welds for the specified time period and waits for the off time period and continues as long as it is kept pressed. Welding will end when the trigger is terminated. If the
tailstock is selected in trigger mode, On Time and Off Time times, welding and waiting times are determined.

3.2 Menu Structure

Functions that are either on or off according to the modes are as shown in the table below.

Parameter Pre-Gas Time

Value Range 0.1 – 10 sec.

Factory Setting 1 sec.

Position 2 MIG

Position 4 MIG

Current Scale

30 – 200 A

Upper Current

200 A

Lower Current

30 A

Final Gas Time

0.1 – 10 sec.

1 sec.

Burnback Time

0.1 – 5 sec.

0 – 1 sec.

Spot Welding Active Time (On Time) 0.2 – 10 sec.

1 sec.

Spot Welding Passive Time (Off Time) 0.2 – 10 sec.

1 sec.

Spot Welding MIG

3.3 Remote Control

With a torch with suitable properties and a connector, you can also change your wire speed / welding voltage

through the torch without going near your machine. Connect the remote control torch socket.

Socket connections are as follows:

Remote Control Torch Socket Front View

Torch Control – Brown Torch Control – Black Torch Control – Red Torch Control – White Torch Control – Green

A378000110 – 1 A378000110 – 2 A378000110 – 4 A378000110 – 5 A378000110 – 3

A

2

1

B

A378000110

Button

Position

1

You can reduce your wire speed to the minimum tolerance value (-10%). Setting Range : 0.5 m/min

2

You can increase your wire speed up to the maximum tolerance value (+10%). Setting Range : 0.5 m/min

A

You can increase your welding voltage up to the maximum tolerance value (+10%). Setting Range : 0.5 V

B

You can reduce your welding voltage up to the minimum tolerance value (-10). Setting Range : 0.5 V

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Operation 21

3.4 Connecting to Mains

EN

Check the mains voltage before connecting the machine to the mains.

When inserting the plug into the mains socket, ensure that on/off switch is in the “O” position.

· Turn on the machine with the on/off switch. · After hearing the fan sound and seeing that the mains lamp is on, turn off the machine by turning the on / off
switch to the “0” position.

3.5 Selection and Replacement of Wire Reels

· Open the cover of the wire feed section. The wire feeding system with 2 reels can be seen.

4

1- Motor

2- Euro Connector

3

1

3- Thrust Bearing Arm

4- Thrust Bearings

5- Wire Feed Reels

6- T. F. Reels Screws

2

6

5

Figure 7 : Wire Feed System · Use wire feed reels suitable for the material and diameter of the welding wire to be used. Use wire feed rollers
with V groove for steel and stainless steel, serrated V groove for flux cored wire, and U groove for aluminum. · When replacing the wire feed reels, pull the thrust bearing arm, and lift the thrust bearings, then unscrew the
wire feed reels screws and remove the reels.
0.8 mm
Both sides of the reels are marked according to the wire diameter. Place the reels on the flange so that the side with wire diameter facing towards you.

· After placing the reels to be used, tighten the screws, lower the thrust bearings, and lift the thrust bearing lever and lock it on the thrust bearings.

Figure 8 : Removing Wire Feed Reels
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Figure 9 : Placing Wire Feed Reels
USER MANUAL

22 Operation

megaMIG

EN

3.6 Placing the Wire Spool and Wire Feeding Process

· Unscrew the wire holder system screw. Insert the welding wire reel to the wire transport system shaft and re-screw the screw.

c
b Tightening the wire transport system screw too tightly may prevent the wire from feeding and cause malfunctions. Tightening the screw too loose may cause the wire basket to move freely and wire to get kinked when the wire feed is stopped. Therefore, tighten the screw neither too tight nor too loose.
a
Figure 10 : Placing Wire Basket · Pull down on the thrust bearing arm on the wire feed reel, which means setting thrust bearing free.
· Remove the welding wire from the wire basket, hold the wire tightly and cut the end with diagonal pliers.

If the wire slips from your hands, the wire may hurt you or other people in the vicinity. · Hold the wire tightly and pass it through the wire inlet to the reels and over the rollers into the torch.

Figure 11 : Feeding Wire to Reel
· Push thrust bearings and lift thrust bearing arm . · Turn the on/off switch to “1” position to turn on the machine . · Press the trigger until the wire comes out of the torch tip, meanwhile observe that the welding wire reel turns
smoothly press and release the trigger several times to check if the winding is not loose . · If the wire is loose and/or rewinding is observed, tighten the wire holder system screw slightly. · When the wire comes out of the torch tip, reattach the nozzle and contact tip to the torch . · Adjust wire thrust adjustment by sliding the wire onto a board and cut the wire end .

USER MANUAL

BOARD

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megaMIG

Operation 23

A: Proper wire thrust and channel size B: The thrust bearing arm is tightened too tightly; the shape of the wire is distorted.

EN

C: The thrust bearing arm is tightened too tightly; the surface of the reel is distorted.

D: The channel length of the reel is too short for the wire used. The shape of the wire is distorted.

E: The channel length of the reel is too long for the wire used. The wire cannot be driven to the welding area.

Figure 12 : Thrust Adjustment and Reel Selection Faults

3.7 Setting Gas Flow

Perform the gas adjustment and gas test by lowering the thrust bearing arm of the wire feed reel!

· Adjust the gas flow with the flow control valve. · Practical gas flow rate (CO, Ar, mixture) is 10
times the wire diameter. For example, if the wire diameter is 1.0 mm, the gas flow rate can be adjusted as 1.0 x 10 = 10 lt./min.

Diameter (mm)

Mild Steel and
Metal Cored 0.8 8 lt/min 1.0 10 lt/min 1.2 12 lt/min

Flux Cored
7 lt/min 9 lt/min 11 lt/min

Stainless Steel
8 lt/min 10 lt/min 12 lt/min

Aluminium
8 lt/min 10 lt/min 12 lt/min

· You can use the table on the side for more precise Note: Recommended values in standard conditions.

flow adjustment.

· After adjusting the gas flow, lift the thrust bearing

arm and close the wire feed unit door.

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USER MANUAL

24 Maintenance and Service

megaMIG

EN

MAINTENANCE AND SERVICE

· Maintenance and repairs to the machine must be carried out by qualified persons. Magmaweld is not responsible for accidents that may occur as a result of interventions by unauthorized persons.
· You can obtain the parts to be used in the repairs from our authorized services. The use of original spare parts will extend the life of your machine and prevent performance losses.
· Always contact Magmaweld or an authorized service specified by Magmaweld. · All warranty provisions will become void due to any interference not authorized by Magmaweld within the
warranty period. · Make sure you comply with the applicable safety rules during maintenance and repair works. · Disconnect the machine’s plugs from the mains before carrying out any repairs and wait for 10 seconds for
the capacitors to discharge.

4.1 Maintenance

Every 3 Months
· Do not remove the warning labels on the device. Replace worn/torn labels with new ones. You can obtain the labels from the authorized service.
· Check your pliers and cables. Pay attention to the connections and soundness of the parts.
· Replace damaged / defective parts with new ones. Never add/repair cables. · Make sure there is enough space for ventilation.

Every 6 Months

· Clean and tighten the connecting parts such as bolts and nuts.

· Check the electrode holder and ground clamp cables.

or

· Open the side covers of the machine and clean it with low pressure dry air.

· Do not apply compressed air from close distance to electronic components.

4.2 Non-Periodic Maintenance
· Wire Feeding Mechanism should be kept clean and roller surfaces should never be greased. Residues accumulated on the mechanism should always be cleaned by dry air at every welding wire change.
· The consumables on the torch should be cleaned regularly. If necessary, they should be replaced. Make sure that these materials are original products for ensuring long-term use.
NOTE: The above mentioned periods are the maximum ones that should be applied if no problems are encountered in your device. Depending on the work load and contamination of your work environment, you can repeat the above processes more frequently.

Never operate the machine when covers are open.

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Maintenance and Service 25

4.3 Troubleshooting

EN

The following tables contain possible errors to be encountered and their solutions.

Failure

Reason

Solution

· The machine is not connected to the mains, or the plug is not connected

· Make sure that the machine is plugged in

Machine is not operating

· The mains connections are not correct
· The power supply fuses, mains cable or plug are problematic

· Check whether the mains connections are correct
· Check the power supply fuses, mains cable and plug

· The fuse has blown

· Check the fuse

· Contactor failure

· Check the contactor

Wire feed motor failure

· The fuse has blown · Electronic card failure

· Check the fuse · Contact the authorized service

The wire feed motor is operating, but the wire is not moving further

· Wire feed rollers were not chosen · Select the appropriate wire feed

to fit the wire diameter

roller

· The pressure on the wire feed rollers is too minimal

· Adjust the pressure roller

· There is a problem in the

· Make sure that the grounding

connection of grounding clamps clamps of the machine is

of the machine

connected to the workpiece

· Cables and connection points are worn out

· Make sure that the cables are secure and that the connection points are not worn

Welding quality is not good

· Parameter and process selection are not correct
· Gas flow is not open aor faulty
· Welding torch is damaged

· Make sure that the parameter and process selection are correct. Follow the steps below according to the process you have selected
· Check that the gas flow is open, ensuring that the flow is correct
· Make sure the welding torch is secure

· Consumables were selected incorrectly or damaged

· Appropriate consumables should be selected and the consumables on the torch must be cleaned regularly. Improperly selected or worn consumables should be replaced

· The pressure adjustment of the · Pressure roller settings must be

rollers is not correct

made correctly

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USER MANUAL

26 Maintenance and Service

megaMIG

EN

Failure

Reason

Fan is not operating

· The fuse has blown · Fan motor failure

Machine operates noisily

· Contactor failure

Unstable and / or non-adjustable welding current

· Diode group failure

Heater outlet is not operating

· The fuse has blown

Solution · Check the fuse · Contact the authorized service · Contact the authorized service
· Contact the authorized service
· Check the fuse. Contact the authorized service

4.4 Error Codes

Error Code
E01
E02 E03 E04 E05 E06

Error

Cause

· The duty cycle of your machine may have been exceeded

Thermal Protection (Primary)

· Fan may not be working
· The front of the air inlet-outlet ducts may be blocked

· The machine working environment may be too hot

Mains Voltage Low

· Mains voltage may have decreased

Mains Voltage High

· Mains voltage may have increased

Current / Voltage Reading Error

· There may be a hardware error

Temperature Sensor Reading Error

· There may be a hardware error

Water Cooling · There may be an error in the water

Unit Error

cooling unit

Solution
· Allow the machine to cool down by waiting for a while. If the fault disappears, try to use the machine at lower amperage values
· If the problem continues, contact the authorized service
· Check visually whether the fan is working or not
· If the problem continues, contact the authorized service
· Open the front of the air ducts · If the problem continues, contact the
authorized service
· Make sure that the working environment of the machine is not excessively hot or stuffy
· If the problem continues, contact the authorized service
· Check the mains connection cables and the voltage. Make sure the correct voltage input is provided. If the mains voltage is normal, contact the authorized service
· Check the mains connection cables and the voltage. Make sure the correct voltage input is provided. If the mains voltage is normal, contact the authorized service
· Contact the authorized service
· Contact the authorized service
· Check water cooling unit connector and torch inlets/outlets
· Make sure there is water circulation · If the problem continues, contact the
authorized service

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Maintenance and Service 27

Error Code

Error

Cause

Solution

EN

E07

E08

System Error · There may be a hardware error

· Contact the authorized service

E09

E10

Torch Connection · The torch or torch connections

Error

may be faulty

· Check torch and torch connections · If the problem continues, contact the
authorized service

E11

System Error · There may be a hardware error

· Contact the authorized service

E12

· Check wire basket, reel / reel press

E13

Wire Feeder Error

· There may be an error in wire feeding

and torch connections · If the problem continues, contact the

authorized service

E14

System Error · There may be a hardware error

· Contact the authorized service

E15

Remote Control Communication
Error

· There may be an error in the remote control connections

· Check remote control connections · If the problem continues, contact the
authorized service

E16

E17

System Error · There may be a hardware error

· Contact the authorized service

E18

· The duty cycle of your machine may have been exceeded

· Allow the machine to cool down by waiting for a while. If the fault disappears, try to use the machine at lower amperage values
· If the problem continues, contact the authorized service

· Visually check if the fan is working

· Fan may not be working

· If the problem continues, contact the

Thermal

authorized service

E19

Protection

(Secondary)

· The front of the air inlet – outlet ducts may be blocked

· Unblock the front of the air ducts · If the problem continues, contact the
authorized service

· The machine working environment may be too hot or stuffy

· Make sure that the working environment of the machine is not excessively hot or stuffy
· If the problem continues, contact the authorized service

E20

E21

System Error · There may be a hardware error

· Contact the authorized service

E22

E23

E26

Inlet Pressure Low

· Inlet pressure may be low

· Check your air / gas connections, make sure that the inlet pressure is appropriate. If the inlet pressure is normal, contact the authorized service

· Make sure that the torch shield is

E27

Torch Shield Not · Torch shield may not be installed or

correctly fitted to the machine

Installed

properly fitted

· If the problem continues, contact the

authorized service

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USER MANUAL

28 Maintenance and Service

megaMIG

EN Error Code E28 E29
E30 E31

Error System Error

Cause · There may be a hardware error

DC Busbar Voltage Low

· Mains voltage may have decreased

DC Busbar Voltage High

· Mains voltage may have increased

System Error · There may be a hardware error

Solution
· Contact the authorized service
· Check the mains connection cables and the voltage. Make sure the correct voltage input is providevd. If the mains voltage is normal, contact the authorized service
· Check the mains connection cables and the voltage. Make sure the correct voltage input is provided. If the mains voltage is normal, contact the authorized service
· Contact the authorized service

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ANNEX
5.1 Spare Parts Lists

1 2 3 4
5
6
NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

10
9
11 12
13
8 7
DEFINITION Panel Label Potency Button Torch Control Cable Installation Cable Plastic Case Welding Socket Electronic Card E309A-4 V1.1 Power Transformer Electronic Card E309A-1 V1.2 DACO Choke Coil Electric Switch Plastic Sleeve Quick Coupling Wire Carr. Mac. System Processed Wire Feeding System Electric Switch Electronic Card E309A-2 V1.1

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Annex 29
EN
17
16
15
14
megaMIG K109900175 A229500005 K301300118 K301825105 Y522000124 A377900104 Y524000051 A366000036 Y524000052 A421050008 A310100011 A376400016 A245700004 A229900006 K309003216 A310100010 Y524000050
USER MANUAL

30 Annex

megaMIG

EN

5.2 Fine Settings in the Wire Feeding Unit

1- Free Wire Feed Button : As long as the button is pressed, the wire feed operation is performed, the gas valve won’t work. This button can be used to feed the wire to the torch.
2- Free Gas Button : As long as the button is kept pressed, gas flow is provided but wire would not feed. This button can be used to change the gas in the system after the gas change.

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5.3 Connection Diagrams Block Diagram

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Front Panel Gas

Welding Torch Control Line
Output Filter

Supply Voltage

Control Unit

Control Line

L

Wire Feeding Unit

Hall Effect

N

Line Filter

Primary Rectifier

Capacitors

IGBT Module

High Frequency Transformer Secondary Rectifier

Output Choke

Solenoid Valve Welding Torch Workpiece

Annex 31 EN

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PFC COIL

POWER TRANSFORMER
MOTOR ENCODER CABLE

BAG LIGHTING BAG LIGHTING
(A357000017-1 SPIR 2 CM CLOSE TO E309A-2)
TORCH CONTROL CONNECTOR CABLE CONNECTION (A357000017-1 SPIR 7 CM CLOSE TO E309A-1)

BACK VIEW BACK VIEW

(A357000017-1 SPIR 2 CM CLOSE TO E309A-1) SPOOL GUN CONNECTOR CABLE CONNECTION

CHOKE COIL
MOTOR EURO CONNECTOR

GROUND
NEUTRAL PHASE

(A357000017-2 SPIR 5 CM CLOSE TO E309A-1) POWER SWITCH-1 POWER SWITCH-1b
(A357000017-2 SPIR 4 CM CLOSE TO E309A-1)
POWER SWITCH-2 POWER SWITCH-2a

(A357000008-2 SPIR)

GROUND CONNECTION

SWITCH-1A SWITCH-2A
SWITCH-1 SWITCH-2
(A357000017-2 SPIR 7 CM CLOSE TO E309A-1) TRIGGER TRIGGER

(A357000017-2 SPIR 2 CM CLOSE TO E309A-1) MOTOR MOTOR +
(A357000017-1 SPIR 2 CM CLOSE TO E309A-1) VALVE VALVE

32 Annex
EN Circuit Diagram

megaMIG

USER MANUAL

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PFC COIL

POWER TRANSFORMER
MOTOR ENCODER CABLE

BAG LIGHTING
BAG LIGHTING
(A357000017-1 SPIR 2 CM CLOSE TO E309A-2)
TORCH CONTROL CONNECTOR CABLE CONNECTION (A357000017-1 SPIR 7 CM CLOSE TO E309A-1)

BACK VIEW BACK VIEW

(A357000017-1 SPIR 2 CM CLOSE TO E309A-1) SPOOL GUN CONNECTOR CABLE CONNECTION

CHOKE COIL
MOTOR EURO CONNECTOR

GROUND
NEUTRAL PHASE

(A357000017-2 SPIR 5 CM CLOSE TO E309A-1) POWER SWITCH-1 POWER SWITCH-1b
(A357000017-2 SPIR 4 CM CLOSE TO E309A-1) POWER SWITCH-2 POWER SWITCH-2a

(A357000008-2 SPIR)

GROUND CONNECTION

SWITCH-1A SWITCH-2A
SWITCH-1 SWITCH-2
(A357000017-2 SPIR 7 CM CLOSE TO E309A-1) TRIGGER TRIGGER

(A357000017-2 SPIR 2 CM CLOSE TO E309A-1) MOTOR MOTOR +

(A357000017-1 SPIR 2 CM CLOSE TO E309A-1)
VALVE VALVE

Annex 33 EN

megaMIG