magmaweld ID ECO Series Welding Inverter Machine User Manual

magmaweld ID ECO Series Welding Inverter Machine

Product Information

Specifications

• Model: ID ECO SERIES
• Manufacturer: Magma Mekatronik Makine Sanayi ve Ticaret A.
• Contact: (+90) 444 93 53, [email protected]

Product Usage Instructions

Safety Precautions
Be sure to follow all safety rules mentioned in the manual. The following safety symbols are used:

• ATTENTION: Indicates a potentially hazardous situation that could cause injury or damage. Take necessary precautions to prevent injuries or material losses.
• IMPORTANT: Specifies notifications and alerts on how to operate the machine.
• DANGER: Indicates a danger. Failure to avoid it may result in severe or fatal injuries.

Electric Shocks
Make certain that the installation procedures comply with national electrical standards and other relevant regulations. Ensure that the machine is installed by authorized persons to avoid electric shocks. Check that all connections are tight, clean, and dry. If any uninsulated cable is detected, repair or replace it immediately to prevent accidents. When any of the following electrically hazardous conditions are present, additional safety precautions are required:

• Fumes and Gases: Long-term inhalation of fumes and gases released from welding/cutting is very dangerous. Ensure proper ventilation in the work area. If ventilation is insufficient, increase it immediately and if the problem persists, stop the welding/cutting process completely. Install a system to expel fumes and gases accumulated in the workshop and use a suitable filtration system to avoid pollution during discharge.
• Materials Containing Hazardous Substances: When welding/cutting materials containing hazardous substances such as lead, cadmium, zinc, coated or painted materials, use masks that provide fresh air in addition to other precautions.
• Gas Leaks: Keep the main valves closed when gas cylinders are not in use and pay attention to possible gas leaks.
• Confined Spaces: Avoid welding/cutting in confined spaces as it can be dangerous for your health.

FAQ

• Q: Can I use this welding machine for cutting?
  A: No, this welding machine is specifically designed for MIG/MAG welding and not for cutting.

• Q: What should I do if I encounter an error code?
  A: Refer to the Troubleshooting section in the manual for information on error codes and their solutions. If the issue persists, contact authorized service personnel for assistance.

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.Ş.

SAFETY PRECAUTIONS

Be Sure To Follow All Safety Rules In This Manual!

Explanation Of Safety Information

• Safety symbols found in the manual are used to identify potential hazards.
• When any one of the safety symbols is 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.
• IMPORTANT Specifies notifications and alerts on how to operate the machine.
• DANGER Indicates a danger. In case if not avoided, severe or fatal injuries may occur.

Comprehending Safety Precautions

• Read the user manual, the label on the machine and the safety instructions carefully.
• 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 May Kill

• Make certain that the installation procedures comply with national electrical standards 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.
• Make sure all connections are tight, clean, and dry.
• Keep cables dry, free of oil and grease, and protected from hot metal and sparks.
• Bare wiring can kill. Check all cables frequently for possible damage. If a damaged or uninsulated cable is detected, repair or replace it immediately.
• Insulate the work clamp when not connected to the 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 the remote output control if present on the unit.
• Additional safety precautions are required when any of the following electrically hazardous conditions are present.
• in damp locations while wearing wet clothing, on metal structures such as floors, gratings, or scaffolds,
• when in cramped positions such as sitting, kneeling, or lying,
• and when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in the 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 Electric Shock

• Turn off the electric power.
• 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 it according to instructions.
• 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 Cause Injuries

• Keep away from the moving parts.
• 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 onto your feet.

Fumes and Gases May Be Harmful To Your Health

• Long-term inhalation of fumes and gases released from welding/cutting is very dangerous.
• 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, and 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 for products that require special ventilation should be read carefully. A suitable gas mask should be worn when necessary.

Arc Light May Damage Your Eyes and Skin

• Use a standard protective mask and a suitable glass filter to protect your eyes and face.
• Protect other naked parts of your body (arms, neck, ears, etc.) with suitable protective clothing from these rays.
• 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 icebound pipes. This operation performed with the welding/cutting machine causes an explosion, fire, or damage to your installation.

Sparks and Spattering Particles May Get Into the Eyes and Cause Damage

• Performing works such as welding/cutting, surface grinding, and brushing causes sparks and metal particles to splatter. Wear approved protective work goggles that have edge guards under the welding masks to prevent sustaining possible injuries.

Hot Parts May Cause Severe Burns

• Do not touch the hot parts with bare hands.
• 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 Damage To Your Hearing Ability

• The noise generated by some equipment and operations may damage your hearing ability.
• Wear approved personal ear protective equipment if the noise level is high.

Welding Wires Can Cause Injuries

• Do not point the torch towards any part of the body, other persons, or any metal while 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 May Cause Fire and Explosion

• Never perform welding/cutting work in places near flammable materials. There may be fire or explosions.
• Before starting the welding/cutting work, remove these materials from 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, 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 that 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 Performed by Unauthorized Persons To Machines and Apparatus May Cause Injuries

• Electrical equipment should not be repaired by unauthorized persons. Errors occurred if failed to do so may result in serious injury or death when using the equipment.
• The gas circuit elements operate under pressure; explosions may occur as a result of services 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.

Welding / Cutting in Small Sized and Confined Spaces

• In small-sized and confined spaces, make sure to perform welding/cutting operations, accompanied by another person.
• Avoid performing welding/cutting operations in such enclosed areas as much as possible.

Failure To Take Precautions During Transport May Cause Accidents

• Take all necessary precautions when moving the machine. The areas where the machine to be transported, parts to be used in transportation and the physical conditions and health of the person carrying out the transportation works should be suitable for the transportation process.
• 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 using 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 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 sure to carry gas cylinders separately.
• Remove all interconnections before transporting the welding/cutting equipment, each being separate, 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 Cause Injuries
Improper positioning of the power supply sources or other equipment can cause serious injury 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 onto 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 Machine Causes Overheating

• Allow the machine to cool down according to operation cycle rates.
• Reduce the current or operation cycle rate before starting the welding/cutting again.
• 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 Machine Causes Overheating

• This device is in group 2, class A in EMC tests according to TS EN 55011 standard.
• This class A device is not intended for use in residential areas where electrical power is supplied 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).
• Ensure that your welding and/or cutting machine has been installed and situated in its place according to the user manual.

Evaluation Of Electromagnetic Suitability Of The Work Area
According to article 5.2 of IEC 60974-9;
Before installing the welding / cutting equipment, the person in charge of the operation and / or the user must conduct an inspection of possible electromagnetic interference in the environment. 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 Interferance Reduction Methods

• The appliance must be connected to the electricity supply in the recommended manner by a competent person. If interference occurs, additional measures may be applied, such as filtering 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 (EMF)
The electrical current passing through any conductor generates zonal electric and magnetic fields (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,

The electrical current passing through any conductor generates zonal electric and magnetic fields (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,
• 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 the warranty form.

TECHNICAL INFORMATION

General Information
ECO SERIES is an easy-to-use three-phase industrial inverter MIG/MAG welding machine designed for heavy conditions. It provides fast and easy use with its user-friendly interface. It offers excellent welding characteristics with all solid and flux-cored wires. Welding voltage, and wire feed speed can be adjusted from the panel in front of the wire feeder. Welding voltage and current can be monitored through a digital display. Optimal welding parameters can be selected from the table located inside the wire feeding unit. There is an integrated gas cylinder platform and a 24 V electrical socket for the CO2 gas heater. It is cooled by a fan and has protection against overheating.

Machine Components

1. Left Display
2. Adjustment Pot
3. Torch Connection
4. On / Off Switch
5. Grounding Connection
6. Data Socket
7. Right Display
8. Adjustment Pot
9. Torch Cold Water Outlet
10. Torch Hot Water Inlet
11. Gas Output
12. Intermediate Package Torch Connection
13. Water Unit Led
14. Water Unit Cold Water Outlet
15.  Water Unit Hot Water Inlet
16. Water Unit
17. Heater Socket
18. Cooling System Connection
19. Gas Inlet
20. Mains Cable

Product Label

As defined in the standard EN 60974-1, the duty cycle rate includes a 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 (zone 1). However, the following 4 minutes should be kept idle for the machine to cool down (zone 2).

Technical Data

Accessories

INSTALLATION

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
• Workpiece clamp and cable
• 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

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 a better performance, place the machine at least 30 cm away from the 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, operate 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!

Mains Plug Connection

For your safety, never use the mains cord of the machine without a plug.

• No plug has been connected to the mains cable since there may different types of outlets available in plants, construction sites and workshops. A suitable plug must be connected by a qualified technican. Make sure that the grounding cable marked with and a yellow / green color is present.
• After connecting the plug to the cable, do not attach it to the outlet at this stage.

Water Cooling Unit (for MW Models)

• Unit the water cooling unit is used to cool the torch It is a closed circuit system consisting of radiator, fan, pump coolant reservoir.
• Connect the cold (blue) water hose to the cold water outlet on the water cooling system, and the hot (red) water hose to the hot water inlet on the water cooling system.
• Magmaweld welding machines come with Magmaweld coolant, which is produced to give the best performance. In case of lack of coolant, open the coolant reservoir cap and add Magmaweld coolant suitable for the temperature of the working environment. The coolant must be within the minimum and maximum values shown on the front panel of the unit.
• Different coolant or water should not be added. Different liquid additives can cause chemical reactions or different problems.
• Magmaweld is not responsible for the risks that may arise in case of adding different liquids. All warranty provisions will be void if different coolant or water is added to the Magmaweld coolant.
• If it is desired to use a different brand of coolant, the inside of the coolant tank should be completely empty and there should be no residue or liquid in it.
• It is not suitable to use the water-cooling units with welding machines other than manufactured by Magma Mekatronik Makine ve Sanayi Ticaret A.Ş. Water cooling units cannot be operated with external supply.
• There are 2 leds in front of the machine: The power led will light as soon as the machine is activated and the water-cooling unit led will light when the water unit is activated.
• As soon as the machine starts welding, the water circulation will start and after the welding is completed, the water-cooling unit led will remain on during the time set in the menu. In case of any air inlet or problem, the water will not be recirculated.

Dirty and lime (hard) waters reduce the operating life of the torch and the pump.
If the coolant is below the minimum value, there is a possibility of damage and malfunction for the pump and torch.

Connection of Interconnection Hose Package

• For easy transport of machines with hose package of 10 meters or longer, the wire feed unit and the interim package have been designed to be detachable. Both ends of the long hose packages are the same and the connections on the machine front must be made with the connectors and sockets on the back of the wire feeder.
• If interconnection hose package is 10 meters or longer, connect the wire feed unit with the hose package as follows.

Connecting the Gas Cylinder

• Use regulators and heaters that comply with international standards to work safely and achieve the best results. Make sure the size of the hose connection of the gas regulator you are using is 3/8 .
• Open the gas cylinder valve, keeping your head and face away from the outlet of the valve and keep it open for 5 seconds. By this means, possible sediment and impurities will be discharged.
• If the CO2 heater is to be used, first connect the CO2 heater to the gas cylinder. After connecting the gas regulator to the CO2 heater, insert the plug of the CO2 heater into the CO2 heater outlet on the back of the machine.
• If the CO2 heater will not be used, connect the gas regulator directly 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 to check that the tube is full and that there are no leaks in the gas flow path. If you hear a noise and/or detect a smell of gas as a leak indicator, examine your connections and eliminate leakage.

1. Gas Cylinder Valve

2. Gas Cylinder

3. CO2 Heater

4. Chain

5. CO2 Heater Energy Cable

6. Gas R egulator

7. Manomet er

8. Flowmeter

9. Flow Adjustment Valve

10. Gas Hose

OPERATION

User Interface

Connection to Mains
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.

• Start the machine with the on/off switch.
• Turn the machine off by turning the on / off switch back to off after hearing the fan noise and seeing the mains lamp is illuminated.

Placing The Wire Spool And Wire Feeding Process

• Unscrew the screw of the wire transport system by turning it. Slide the welding wire roller onto the wire carrier system shaft and re-tighten the screw.
• Tightening the screw of the wire transport system prevents the wire from being fed and may cause failures. If the screw has not been tightened adequately this can cause the wire spool to empty after a period of time when the wire feed has stopped. For this reason, do not connect the screw too tightly or too loosely.
• Pull and lower the pressure screw on the wire feed roller, which means bring the pressure rollers to idle position.
• Find and open the welding wire end from the wire spool and cut off the end with a side chisel.

If the end of the wire is missed, the wire can jump like a spring and damage you and others.

• Pass the wire through the wire entry slot without releasing the wire into the rollers and into the torch through the rollers.
• Pull the pressure adjustment screws towards you and release the pressure on the rollers 1.
• Turn the on/off switch to position “1” to start the machine 2.
• Remove the nozzle and the contact nozzle and press the trigger until the wire comes out from the tip of the torch, while observing that the welding wire roller rotates freely then push and release the trigger a few times to check for any loosening of the winding 3.
• Re-attach the nozzle and contact nozzle to the torch when the wire comes out from the tip of the torch 4.
• Drive the wire on a non-insulating material  5 such as wood and make the appropriate wire pressure adjustment  6 and cut the tip of the wire 7.

The following effects will occur if the pressure adjustment screw is overtightened, left loose or if the wrong wire feed roller is used.

• A: Suitable wire pressure and conduit dimensions.
• B: The wire is distorted since the pressure lever is too tight.
• C: The roller surface is deteriorated due to excessive pressure on the pressure lever.
• D: The conduit length of the roller is small for the wire used. Wire form is distorted.
• E: The conduit length of the roller is big for the wire used. The wire cannot be transmitted to the welding area.

Adjustment of Gas Flow
Make the gas adjustment and gas test by lifting the wire feed roller pressure lever!

• Adjust the gas flow with the flow control valve.

• Practical gas flow rate (CO₂, Ar, mixture) is 10 times of wire diameter.
  For example, if the wire diameter is 0.9 mm, the gas flow rate can be adjusted as 10 x 0.9 = 9 l / min.

• You can use the table on the side for more precise flow adjustment.

• After adjusting the gas flow, lift the thrust bearing arm and close the wire feed unit door.

Remote Control

Starting and Ending the Welding Process

• Determine the Coarse Adjustment “, Fine Adjustment” and Wire Feed Speed from the welding parameters table of your machine according to the diameter of the wire you will use, the type of gas you will use and the thickness of the material to be welded, and set your machine to these settings.
• You can start welding after making sure that you comply with all safety rules and take the necessary precautions.
• During welding, instantaneous welding voltage will be displayed in voltmeter and instantaneous welding current will be displayed in ammeter.
• When not welding, leave the torch in such a way that it does not touch the workpiece, the welding pliers, the hood of the machine and the trigger does not remain pressed.
• After you have finished working with the welding machine, allow the machine to cool down and turn the on / off switch to “0”. Unplug the machine and close the gas cylinder

Welding Parameters

• The welding parameters were obtained by horizontal welding with solid wire in laboratory conditions. Values may vary depending on the application and ambient conditions.

Machine Features

• 24-V Heater Output
  • With 24 Volt heater output, it ensures the prevention of the transformer failures whereas safety requirements are met.
• Smart Fan Control
  • The fan will not operate when the machine is in idle position with the smart fan control. The fan is activated when the machine reaches a certain temperature. This saves energy and reduces iron dust entering the machine.
• Smart Thermal Control
  • Smart thermal control ensures digital thermal control and fan control accordingly.
• Parameter Setting with Digital Interface
  • The parameters such as the initial gas, final gas, burn back control are easily adjusted via the digital interface.
• Magnet Compatibility
  • Source and media information is stored in real time form thanks to its magNET-ready structure. Some values can be read on the LCD panel on the machine front, while other information (Original Equipment Activity-OEE, Welding Parameters-WR, Quality, etc.) can be stored and monitored or reported on the magNET platform. (Optional)
• Operation with generators
  • Suitable for operation with generators. The kVA operating value should be determined by referring to the technical specifications.
• Voltage Protection
  • If the mains voltage is too high or too low, the machine automatically protects itself by giving an error code on the display. By this means, no damage is caused to the machine components and long life of the machine is ensured. After the ambient conditions have returned to normal, the machine functions will also be activated.

MAINTENANCE AND SERVICE

• Maintenance and repairs to the machine must be carried out by a qualified personnel. Our company will not be responsible for any accidents that may occur by unauthorized interventions.
• Parts that will be used during repair can be obtained from our authorized services. The use of original spare parts will extend the life of your machine and prevent performance losses.
• Always contact the manufacturer or an authorized service designated by the manufacturer.
• Never make interventions yourself. In this case the macufacturer warranty is no langer valid.
• Always comply with the applicable safety regulations during maintenance and repair.
• Before performing any work on the machine for repair, disconnect the machine’s power plug from the power supply and wait for 10 seconds for the capacitors to discharge.

Maintenance

• Every 3 Months
  • Do not remove the warning labels on the device. Replace the worn/torn labels with the new ones. Labels can be obtained from the authorized service.
  • Check your torch, clamps and cables. Pay attention to the connections and the durableness of the parts. Replace the damaged/defective parts with the new ones. Do not ever make additions to/repair the cables.
  • Ensure adequate space for ventilation.
  • Before starting welding, check the gas flow rate from the tip of the torch with a flow meter. If the gas flow is high or low, bring it to the appropriate level for the welding process.
• Every 6 Months
  • Clean and tighten fasteners such as bolts and nuts.
  • Check the lead of the electrode pliers and earth pliers.
  • Open the side covers of the machine and clean with low pressure dry air. Do not apply compressed air to electronic components at close range.
  • Periodically replace the water in the tank of the water cooling unit with fresh, hard water and protect it against freezing with antifreeze.
• 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.

Non-Periodic Maintenance

• The Wire Feeding Mechanism must be kept clean and the roller surfaces must not be lubricated.
• Always remove any deposits on the mechanism with dry air each time you replace a welding wire.
• The consumables on the torch should be cleaned regularly. It should be replaced if necessary. Make sure that these materials are original products for long-term use.

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

Error Codes

ANNEX

Spare Parts Lists
Power Source Spare Parts List

Wire Feeder Spare Parts List

Water Cooling Unit Spare Parts List

Connection Diagrams Block Diagram

Circuit Diagram

WARRANTY CARD

Please visit out website www.magmaweld.com/warranty- terms/wt for warranty terms.

Magma Mekatronik Makine Sanayi ve Ticaret A.Ş. Organize Sanayi Bölgesi, 5. Kısım 45030 Manisa, TÜRKİYE

01.12.2023
UM_IDECO_092023_122023_001_324
(+90) 444 93 53
magmaweld.com
[email protected]

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