magmaweld proSTICK 200i Welding and Cutting Machines User Manual

DC WELDING INVERTER
USER MANUAL

proSTICK 200i

(+90) 444 93 53
magmaweld.com
[email protected]
(+90) 538 927 12 62

proSTICK 200i Welding and Cutting Machines

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.
Magma Mekatronik may modify the information and the images without any prior notice.

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 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 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  devicebeyondthespecifiedconditions.

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.

• Wearflame-resistantprotectiveclothingagainsttheriskofburning.Theclothingusedbythe  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, floororanothermachine.

• Byisolatingyourselffromtheworksurfaceandthefloor,youcanprotectyourselffrompossible electricshocks.Useanon-flammable,electricallyinsulating,dryandundamagedinsulation  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.

• Clampworkcablewithgoodmetal-to-metalcontacttoworkpieceorworktableasneartheweld  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-circuitvoltagewillbepresent.

• 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 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 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 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 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 on to 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.

Useasuitablefiltrationsystemtoavoidpollutingtheenvironmentduringdischarge.

• 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  confinedspaces.Thisisdangerousforyourhealthaswell.

• 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.

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.

• Encloseyourworkareawithflame-resistantfoldingscreensandhangwarningsignsateyelevel 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/cuttingmachinecausesexplosion,fireordamagetoyourinstallation.

Sparks and Spattering Particles May Get Into Eyes and Cause Damage

• Performing works such as welding / cutting, surface grinding, and brushing cause sparks and metal particles to splatter. Wear approved protective work goggles which 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.

• Ifyouneedtoholdhotparts,usesuitabletools,welding/cuttinggloveswithhigh-levelthermal insulationandfire-resistantclothes.

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

• Neverperformwelding/cuttingworkinplacesnearflammablematerials.Theremaybefireor  explosions.

• Before starting the welding / cutting work, remove these materials form the environment or cover themwithprotectivecoverstopreventcombustionsandflaring.

• 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 causeexplosions,firesorotherreactions.

• 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, absolutely 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 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 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 on to the platform; in stationary usage applications, fix them to the wall with a chain ina 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 fromalow-voltagepowersupply.Theremaybepotentialdifficultiesinprovidingelectromagnetic  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 anotherlocation,removalofcablesfromtheaffecteddeviceand/orarea,useoffiltersortaking 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 competentperson.Ifinterferenceoccurs,additionalmeasuresmaybeapplied,suchasfiltering thenetwork.Thesupplyofthefixed- mountedarcweldingequipmentmustbemadeinametal 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 modifiedontheappliance.Otherwise,theuserisresponsibleforanyconsequencesthatmay  possibly occur.

• Welding/cuttingcablesshouldbekeptasshortaspossible.Theymustmovealongthefloorof  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 materialsareatasafedistanceorfixed.Theoperatormustbeinsulatedfromallthese  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.Screeningoftheentirewelding/cuttingareacanbeevaluatedforsomespecific  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 warranty form.

TECHNICAL INFORMATION

1.1 General Information
proSTICK 200i is an easy to carry welding machine with direct current output, produced with single phase inverter technology. It has outstanding cellulosic performance and can burn all types of electrodes up to 5 mm. Excellent welding performance is achieved  with the advanced software features. Since proSTICK 200i may operate between 185 VAC and 250 VAC at 50 / 60 Hz mains voltage, it will not be a affected by fluctuations in the mains voltage and will operate perfectly with generators.

1.2 Machine Components

1- Spot (Punta) Mode Led
2- Cellulosic Mode Led
3- MMA Mode Led
4- Welding Mode Selection Key
5- Arc Force Setting Button
6- Hot Start Setting Button
7- Earth Cable and Welding Cable Socket (-) 8- Handle
9- Voltage Led| 10- Current Led
11- TIG Mode Led
12- Digital Display
13- Current Adjustment Button
14- VRD Led
15- Earth Cable and Welding Cable Socket (+)
16- Supply Cable Input
17- Fan
18- On / Off Switch
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1.3 Product Label

| Single Phase Transformer Rectifier
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| Single Phase Transformer Rectifier
| Direct Current
| Vertical Characteristic
| 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

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).

1.4 Technical Data

1.5 Accessories

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
• Workpiece clamp and cable
• Electrode clamps and cable
• Strap Belt
• Warranty certificate
• User manual

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. Proper working conditions should be ensured and necessary precautions should  be taken. 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.
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| 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 has information on the machine’s connectivity. In this case the responsibility will be assumed by  the person who will perform the installation or by the operator.
| 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 in order to provide good cooling and no foreign objects should be inserted.

2.2 Installation and Operation Recommendations

• 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.

• Donotoperatethemachineunderdirectsunlight.Iftheambienttemperatureexceeds40°C,operatethe  machine at a lower current or a lower duty 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. If you weld indoors, use a suitable fume extraction system. Use  breathing apparatus if there is a risk of inhaling welding fumes and gas inconfinedspaces.

• Observe the duty cycle rates specified on the product label. Exceeding duty cycle rates can damage the  machine and this may invalidate the warranty.

• Use the fuse that is compliant with your system.

• Secure the ground cable as close as possible to the welding area.

• Do not allow the welding current to pass through equipment other than the welding cables.

• Secure the gas cylinder to the wall with a chain.

• The welding cables and the mains cable must not be wrapped in the machine housing during operation.

2.3 Connections for MMA Welding
Check the mains voltage before connecting the machine to the mains.
When plugging the power plug into the outlet, make sure that the power switch is set to “0” in the turned-off position.

• SWITCH ON the machine via power switch and check if power led lights up and cooler fan works.

• According to the polarity of the electrode to be used, insert welding cables into the appropriate socket and tightenthembyturningclock-wise.

• Connect the earth clamp tightly to the workpiece as close as possible to the welding area.

• Adjust the desired current and the machine is ready to weld.

• Below table is given as a reference for current adjustment of mild steel electrodes, please refer to the  electrode manufacturer’s recommendations.

2.4 Connections for TIG Welding
Check the mains voltage before connecting the machine to the mains.
When plugging the power plug into the outlet, make sure that the power switch is set to “0” in the turned-off position.

• Start the machine with the on/off switch and check whether the Leds are on and the cooling fan is working.
• TIG torch with a valve should be used.
• Connect the TIG torch power cable to the negative welding socket and the earth cable to the positive welding socket of the machine.
• Install the Argon gas regulator onto the Argon gas cylinder.
• Connect the gas hose of the torch to the gas regulator.
• Adjust the desired current and the machine is ready to weld.

OPERATION

3.1 User Interface

| Current Setting Button
• Welding current is set between 5-200A in all welding modes with the current adjustment knob. The value set by turning left  and right will be monitored on the  digital display.
•  You can switch between the current and voltage values at the time of welding or in idle  position by pressing the current  adjustment button.
•  Switch to the VRD menu by pressing the current adjustment button for 3 seconds.
VRD menu is described under the VRD section.
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| Digital Display
•  Welding current, welding voltage and other parameters can be monitored.
| Welding Mode Selection Key
• Used for selecting one of MMA-CEL-SPOT-TIG welding modes. Press the button once to  switch to the other welding mode.  The led of the selected mode will be lit.
| MMA Mode
•  MMA mode is selected by using the Menu button and the relevant led will light when  this mode is selected. MMA mode  should be selected when welding of rutile and basic  electrodes is desired.
| Cellulosic Electrode Mode
• Cel mode is selected by using the Menu button and the relevant led will light when  this mode is selected. If cellulosic electrode  welding will be done, welding connections  must be made correctly and CELL mode should be selected.
| Spot Welding Mode
•  The SPOT (Punta) mode is selected by using the Menu button, the relevant led will light when this mode is selected.
•  Developed for users who do short welding works.
•  Welding is terminated when the welding voltage is above 35 V
•  This mode should be selected when shorter welding length (rupture) is desired.
| TIG Welding Mode
•  TIG mode is selected by using the Menu button and the relevant led will light when  this mode is selected. When TIG welding  is required, the welding connections and  parameter selections must be set correctly.
| Arc Force Setting
•  Arc Force increases the welding current and prevents arc interruption based on the  welding voltage if the welded electrode  has a tendency to adhere.
• It is set between 0-100% with the help of the pot.
•  The set value cannot exceed the maximum current of the machine.
For example, if the main current is 150 A and the Arc force is set to 100%, the current  of the machine will not be 300A and the  maximum current of the machine will be 200 A
• Arc Force setting is not active in the TIG mode
| Hot Start Setting
•  When electrode welding is started, high current is supplied for 1 second up to two  times the welding current set with the Hot  Start function to ignite the electrode more  easily. The “Hot Start” value set at the time of the initial welding will be added to the   main current as much as the percentage of the main current.
•  The set value cannot exceed the maximum current of the machine.
• For example, if the main current is 150 A and the Hot start is set to 100%, the current  of the machine will not be 300A and the  maximum current of the machine will be 200 A.
•  The output current will return to the set current at the end of “Hot Start” period and  easy ignition is provided.
Not active in TIG mode
| VRD Function
• Occupational safety requirements are fulfilled with the VRD function where the  security measures are high.
•  It should be ensured that the supply voltage is below 12 Volts when idle.
•  The VRD menu is accessed using the current setting pot.
•  VRD menu will open by pressing the current setting pot for 3 seconds.
Set the “on/off “ state by turning the current adjustment pot to the left and right.
•  When “on” is shown on the digital display, the VRD mode will be on and the VRD led  will be lit, and when “o “ is shown , the  VRD mode and the VRD LED will be o .
• If you want to exit the VRD menu, press the current setting pot once to return to the  main menu.

3.2 Machine Features

Smart Fan

• The internal temperature of the machine is continuously measured.
• The cooling fan speed is increased or decreased according to the measured temperature.
• Fan is stopped completely under 30°C.
• The amount of dust entering the machine is reduced by this function. As the machine life is prolonged, energy is saved.
• The fan provides continuous cooling performance during welding.

Smart Performance

• Thanks to the intelligent performance control, the welding parameters of the machine are continuously  monitored and analyzed.

• If compulsory conditions occur, the machine switches to the protection mode in order to extend its life and  protect itself against malfunctions.

• This protection is indicated by a thermal led warning on the machine panel.

• The machine is reactivated after 2 minutes of safe time.

Voltage Protection

• If the mains voltage is above 275 V, the machine automatically protects itself by giving an E03 fault on the  display. By this means, no damage is caused to the machine components and long life of the machine is ensured.

• The same applies for low voltage. If the mains voltage is below 160 V, the machine protects itself by giving an  E02 error.

• After the ambient conditions have returned to normal, the machine functions will also be activated.

Smart Start

• Tungsten provides arc ease in TIG welding by heating the electrode.

Lift TIG

• Lift TIG function allows TIG to be made without damaging the Tungsten tip while rubbing it.

Anti Stick

• Anti-Stick feature to prevent the electrode from sticking.

Protection

• Displayed as E03 error.

• Machine functions will be activated when the phases are corrected.

Operation With Generators

• Suitable for operation with generators. The kVA operating value should be determined by referring to the technicalspecifications.

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.

4.1 Maintenance

Daily Maintenance

• 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 electrode clamp and grounding clamp cables.
• Open the side covers of the machine and clean with low pressure dry air. Do not apply compressed air to electronic components at close distance.
• Check the socket to which the power supply plug of the machine is connected. If there is any looseness in the power cable connection points of the socket, remove such looseness. If there is an arc or expansion in the socket slots, replace them with new ones.
• Check the power supply plug of the machine. If there is any looseness in the power cable connection points in the electricity plug, remove such looseness. If there is an arc or deformation at the ends of the plug, replace it with a new one.

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.

**** 4.2 Troubleshooting

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

power
•  Check that the mains connections are correct
•  Check the mains power supply fuses, mains cable and its plug
•  Check the on / off operating switch
•  If you have made all the checks and if the problem still persists, please contact the authorized service center
The machine welds poorly| •  Make sure that the machine’s grounding pliers are connected to the  workpiece
•  Make sure that the cables are secure and that the connection points are not worn
•  Make sure that the parameter and process selection are correct
•  According to the process you have chosen, follow the steps below:
1- Check the pole that the electrode must be connected and the  current value that must be set on the machine
2- Check that the gas flow is open, ensuring that the flow is accurate
3- Make sure that the tungsten tip is clean
4- Make sure the durableness of the welding torch
5- If you have made all the checks, if the problem still persists, please contact the authorized service center

4.3 Error Codes

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
| | • Fan may not be working| • Check visually whether the fan is  working or not
• If the problem continues, contact the  authorized  service
| | • The front of the air inlet-outlet ducts  may be blocked| • Open 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
E02| Mains Voltage Low| • Mains voltage may have decreased| • 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
E03| | • Mains voltage may have increased| • 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
E05| | • There may be a hardware error| • Contact the authorized service

5.1 Spare Parts List

5.2 Connection Diagrams
Block Diagram

Circuit Diagram

WARRANTY CARD

PRODUCT INFORMATION

Model|
Serial Number|
MANUFACTURER
Name| MAGMA MEKATRONİK MAKİNE SANAYİ VE TİCARET A.Ş.
Address| Organize Sanayi Bölgesi 5. Kısım MANİSA
Phone / E-mail| +90 236 226 27 00 / [email protected]
PURCHASE INFORMATION
Dealer Name|
City / Country|
Phone / E-mail|
Purchase Date|
CUSTOMER INFORMATION
Company Name|
City / Country|
Phone / E-mail|
Contact Name|
SERVICE INFORMATION (if applicable)
Company Name|
Technician’s Name|
Commissioning Date
(Warranty Start Date)|

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

DECLARATION OF CONFORMITY

Company
Magma Mekatronik Makine Sanayi ve Ticaret A.5.
Organize Sanayi Bélgesi 5, Kisim Yal¢in Ozaras Caddesi No;1 45030 Manisa / TURKIYE
Factory
Magma Mekatronik Makine Sanayi ve Ticaret A.S.
Organize Sanayi Bélgesi 5, Kisim Yalcin Ozaras Caddesi No:1 45030 Manisa / TURKIYE
The Product
Appropriate for professional and industrial usage.
PROSTICK 200) 200Amp (%14) Shielded metal arc welding machine
Date of assessment
03.09.2019
European Standard
EN IEC 60974- 1:2018 , EN 60974-10:2014+A1:2015
Meet the requirements of the European Directive
EMC Directive 2014/30/EU – LVD Directive 2014/35/EU
Magma Mekatronik Makine Industry and Trade Co. We declare that the above mentioned products comply with the standard. This declaration will loose its validity in case of modification on the welding machine without our written authorization.

Date of issue /Yayin Tarihi
Manisa – 12.10.2021
Baris Ozgiir TUGGAN
R &D Manager

Magma Mekatronik Makine Sanayi ve Ticaret A.Ş.
Organize Sanayi Bölgesi, 5. Kısım 45030 Manisa, TÜRKİYE
01.11.2023
UM_PROS_112022_112023_002_128
(+90) 444 93 53
magmaweld.com
[email protected]

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