Magmaweld ID 250 T DC PULSE TIG Welding Inverter User Manual

: June 1, 2024
: magmaweld

Table of Contents

Magmaweld ID 250 T DC PULSE TIG Welding Inverter
Product Information
Product Usage Instructions
FAQs
SAFETY PRECAUTIONS
TECHNICAL INFORMATION
TECHNICAL DATA
OPTIONAL ACCESSORIES
INSTALLATION
Operation
MAINTENANCE AND SERVICE
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Download This Manual (PDF format)

Magmaweld ID 250 T DC PULSE TIG Welding Inverter

Magmaweld-ID-250-T-DC-PULSE-TIG-Welding-Inverter-image

Product Information

Specifications:

Model: ID 250 – 300 T DC PULSE / TW DC PULSE
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. Explanation of safety symbols:

ATTENTION: Indicates potentially hazardous situations that could cause injury or damage if no precautions are taken.
IMPORTANT: Specifies notifications and alerts on how to operate the machine.
DANGER: Indicates serious danger that may lead to severe or fatal injuries if not avoided.

Electric Shocks:

Ensure installation procedures comply with national electrical standards and regulations. Machine should be installed by authorized persons.

Fumes and Gases:

Long-term inhalation of fumes and gases released from welding/cutting is dangerous. Ensure proper ventilation in the work area. Use suitable filtration systems to avoid environmental pollution.

Additional Safety Precautions:

Make sure all connections are tight, clean, and dry. Repair or replace any detected uninsulated cables immediately. Take additional safety precautions in electrically hazardous conditions.

Operation

User Interface:

The user interface provides access to various welding processes and settings.

TIG Cycle:

Understand the TIG welding cycle for efficient operation.

Maintenance and Service:

Regular maintenance is essential for optimal performance. Refer to the manual for maintenance schedules and error code troubleshooting.

FAQs

Q: How often should I perform maintenance on the welding machine?
- A: Regular maintenance should be performed as per the guidelines provided in the manual. Non-periodic maintenance should be done whenever required.
Q: What should I do in case of an error code?
- A: Refer to the manual for a list of error codes and their explanations. Follow the instructions to troubleshoot and resolve the issue.

“`

USER MANUAL
ID 250 T DC PULSE ID 300 T DC PULSE ID 250 TW DC PULSE ID 300 TW DC PULSE

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

(+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.

ID 250 – 300 T DC PULSE / TW DC PULSE

3
TIG WELDING INVERTER EN POSTE DE SOUDAGE TIG FR TIG RU TIG KAYNAK NVERTÖRÜ TR

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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USER MANUAL

6 Safety Precautions

ID 250 – 300 T DC PULSE / TW DC PULSE

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.

USER MANUAL

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ID 250 – 300 T DC PULSE / TW DC PULSE

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

ID 250 – 300 T DC PULSE / TW DC PULSE

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).

USER MANUAL

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ID 250 – 300 T DC PULSE / TW DC PULSE

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

ID 250 – 300 T DC PULSE / TW DC PULSE

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.

USER MANUAL

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ID 250 – 300 T DC PULSE / TW DC PULSE

Technical Information 11

TECHNICAL INFORMATION

EN

1.1 General Information
ID 250 T DC PULSE, ID 300 T DC PULSE, ID 250 TW DC PULSE and ID 300 TW DC PULSE are inverter type, 3-phase Pulse DC TIG and MMA welding machine. It is designed for TIG welding of other metals except aluminum and MMA welding up to 5 mm diameter. It features advanced professional TIG controls such as HF ignition, touch start, pregas, upslope, pulse, downslope, postgas, and crater filling. Rutile, Basic and Cellulosic options are available in MMA mode. In TIG mode, 10 work programs can be stored in memory and can be selected according to the job, giving the opportunity to regain exactly the same weld. All welding parameters can be adjusted via the control panel and monitored via digital displays. It can also be used with a generator that will provide the appropriate power and frequency. It can also be used with welding cables up to 25 meters long. The machine is fan cooled and thermally protected against overheating.

1.2 Machine Components

1

9

11

2

6 10

12

3

7

4

8

5

Figure 1 : ID 250 T DC PULSE

1- Torch Strap

7- Torch Control Connections

2- Control Panel

8- Earth Cable and Welding Cable Socket (-)

3- Pedal Control Connections

9- Gas Input

4- Earth Cable and Welding Cable Socket (+) 10- Remote Connection Input

5- Gas Output

11- Power Switch

6- Parameter Adjustment Pot

12- Line Cable Inlet

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12 Technical Information EN
1
2 3
4

5 11 12

ID 250 – 300 T DC PULSE / TW DC PULSE
14 15

6 7 13 8

9 10

Figure 2 : ID 250 TW DC PULSE

1- Control Panel 2- Pedal Control Socket 3- Welding and Ground Cable Socket (+) 4- Water Unit 5- Parameter Adjustment Pot 6- Trigger Control Socket 7- Welding and Ground Cable Socket (-) 8- Gas Output

9- Water Unit Hot Water Inlet 10- Water Unit Cold Water Outlet 11- Gas Inlet 12- Remote Connection Input 13- Water Unit Energy Socket 14- On / Off Switch 15- Line Cable Inlet

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1.3 Product Label

Technical Information 13 EN

Duty Cycle Temperature (C°)

Three Phase Transformer Rectifier TIG Welding MMA Welding Direct Current Vertical Characteristic Mains Input 3-Phase Alternating Current Suitable for Operation at Hazardous Environments

X U0 U1 U2 I1 I2 S1 IP21S

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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14 Technical Information

EN

1.4 Technical Data

TECHNICAL DATA

Mains Voltage (3-phase 50-60 Hz)

Rated Power (MMA)

Rated Power (TIG)

Welding Current Range

Rated Welding Current

Open Circuit Voltage

Stick Electrode Diameter Range

Tungsten Electrode Diameter Range

Dimensions (l x w x h)

Weight

Protection Class

UNIT V
kVA kVA ADC ADC VDC mm mm mm kg

ID 250 – 300 T DC PULSE / TW DC PULSE

ID 250 T DC PULSE ID 250 TW DC PULSE
400 13 (%35) 9.5 (%35)
5 – 250 250 (%35)
85 1.60 – 4.00 1.00 – 2.40 598 x 252 x 661
22.5 IP 21S

ID 300 T DC PULSE ID 300 TW DC PULSE
400 16.1 (%30) 12.3 (%30)
5 – 300 300 (%30)
85 1.60 – 5.00 1.00 – 2.40 598 x 252 x 661
22.5 IP 21S

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ID 250 – 300 T DC PULSE / TW DC PULSE

Technical Information 15

1.5 Accessories

EN

ID 250 T DC PULSE

STANDARD ACCESSORIES

QTY

ID 250 TW DC PULSE

Workpiece Clamp and Cable

1 7905212503 (25 mm² – 3 m)

Gas Hose

1

7907000002

Lava TIG 26 (4 m) Air Cooled TIG Torch*

1

7110018004

Lava TIG 18W (4 m) Water Cooled TIG Torch*

1

7110038004

Torch selection is according to the cooling type of the machine.

ID 300 T DC PULSE ID 300 TW DC PULSE 7905212503 (25 mm² – 3 m)
7907000002
7110018004
7110038004

OPTIONAL ACCESSORIES

Electrode Clamp and Cable
Lava TIG 26 (8 m) Air Cooled TIG Torch
Lava TIG 18W (8 m) Water Cooled TIG Torch
Water Cooling Unit (CST 60i)
Foot Pedal (On / Off)
Foot Pedal (Current Adjustable)
Torch Control Tools (2 Button / 4 Button)
Transport Trolley (4 Wheels)
Gas Regulator (Argon)
TIG Accessory Set Air Cooled (Torch + Regulator)
Water Cooled TIG Accessory Set (Torch + Regulator)

ID 250 T DC PULSE

QTY

ID 250 TW DC PULSE

ID 300 T DC PULSE ID 300 TW DC PULSE

1 7906202503 (25 mm² – 3 m) 7906202503 (25 mm² – 3 m)

1

7110018008

1

7110038008

1

7910005250

1

7910000120

1

7910000140

7910005250 7910000120 7910000140

1 7910000003 / 7910000004 7910000003 / 7910000004

1

7910000200

1

7020001004

7910000200 7020001004

1

7910000510

1

7910000530

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USER MANUAL

16 Installation

ID 250 – 300 T DC PULSE / TW DC PULSE

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.

Scope of supply;

· Welding machine and connected mains cable

· Warranty certificate

· Workpiece clamp and cable

· Torch

· 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. 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.
· 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 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 in confined spaces.
· When positioning the machine, make sure that materials such as walls, curtains, panels, etc. do not impede easy access to the controls and connections of the machine.
· 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. · The welding cables and the mains cable must not be wrapped in the machine housing during operation. · When the gas cylinder is placed on the machine, immediately fasten the chain to secure the gas cylinder. If you
do not place the gas cylinder on the machine, fasten it to the wall with a chain

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ID 250 – 300 T DC PULSE / TW DC PULSE

Installation 17

2.3 Mains Plug Connection

EN

For your safety, never use the mains cable 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 electrician.
· Make sure that the grounding cable is present. · After connecting the plug to the cable, do not attach it to the outlet at this stage.
2.4 Connection to Mains

When plugging the power plug into the outlet, make sure that the on/off switch is set to “0”.

· Support should be received from authorized persons (qualified electricians, etc.). Check the phase voltage before connecting the machine to the mains. The plug must be plugged to the outlet once it is observed to be correct.
· Turn the coarse on/off switch to position “1” to start the machine. Make sure that the indicators and leds on the control panel are lit and the cooling fan is operating.
· Turn the machine off by turning the on / off switch back to the “0” position.

2.5 Connections for TIG Welding

Check for the correct 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.

Tungsten Electrode Recommended TIG Diameter (mm) Welding Current

1.6

30-130

2.0

45-180

2.4

70-240

2.5.1 Torch Connections
· Insert the TIG torch’s plug into the negative pole welding socket and tighten it by turning to the right. Attach the torch trigger connector that came with the machine to the trigger control cables of the torch. Then connect the connector to the trigger control socket.
· Connect the gas hose of the torch to the gas outlet. · In water-cooled models, connect the cold “blue” hose of the torch to the cold water outlet on the machine, and
the hot “red” hose to the hot water inlet on the machine.

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18 Installation

ID 250 – 300 T DC PULSE / TW DC PULSE

EN

2.5.2 Gas Connections

· Secure the argon gas cylinder (a) with a chain. · Use safe high quality regulators (b) and heaters approved by the standards to work safely and achieve the best
results. · Keep the gas cylinder valve (c) open for a while, so that possible sediment and particles are discharged. · Connect the gas regulator to the gas cylinder, making sure that the thread on the gas outlet of the gas cylinder
and the nut of the regulator overlap. · Connect one end of the cylinder hose (d) to the gas regulator and the other end to the gas inlet at the rear of the
machine and turn on the gas cylinder valve. · Adjust the flow rate with the flow regulating valve (e). · Make sure the connections are free of leakages.

This welding machine can carry 10/20 Liter gas cylinders. Using larger sizes may cause the gas cylinder and welding machine to tip over. When you place the gas cylinder on the
machine, immediately fix the gas cylinder by connecting the chain. If you will not place the gas cylinder on the machine, fasten it to the wall with a chain.

c

Electrode

Nozzle

Welding

Diameter Diameter

Current

Gas Flow

b

(mm)

(ADC)

(lt/sec)

1.0

6.3

30-70

6-8

a

1.6

9.5

30-150

6-8

e

d

Figure 3 : Gas Connections
2.5.3 Trigger and Pedal System Socket Connections
· The terminals 4 and 5 must be connected to the trigger control socket.

(1) Soldering direction has been taken as the reference.
· TIG Torch Connection; the trigger should be connected to the control socket with the terminals 1-2-3-4-5 as shown.

(2) Soldering direction has been taken as the reference.
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ID 250 – 300 T DC PULSE / TW DC PULSE

Installation 19

· Adjustable Pedal Connection; It should be secured to the pedal socket with the ends 3-4-5-6.

EN

(3) Soldering direction has been taken as the reference.
2.5.4 Grounding Clamps Connections
· Insert the grounding clamps cable plug (a) into the positive terminal socket and tighten it by turning right.
· To improve the welding quality, firmly connect the grounding pliers (b) to the workpiece as close as possible to the welding area.

a
b
Figure 4 : Grounding Clamps Connections
2.5.5 Installation of Torch Consumables
· The ceramic gas nozzle (5) and the tungsten electrode (1) must be selected according to the operating current and the shape of the workpiece. Accordingly, the diameters of the clamp (3) and the clamp holder (4) must match with the diameter of the tungsten electrode.
· Remove the clamping cap (2). · Remove the existing electrode from the electrode clamp and match the diameter of the new tungsten electrode. · Secure the collect to the torch. · Secure the clamping cap firmly head firmly.
1

3 4 5
Figure 5 : Installation of Torch Consumables
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USER MANUAL

20 Installation

ID 250 – 300 T DC PULSE / TW DC PULSE

EN

2.6 Connections for (MMA) Welding

Check for the correct 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.
· Connect the electrode clamp cable plug (c) and the grounding clamp cable plug (a) to the welding and ground
cable sockets according to the electrode to be used and the polarity recommended by the electrode manufacturer. · To improve the welding quality, firmly connect the grounding pliers (b) to the workpiece as close as possible to
the welding area.

Covered “mm”
2.0

Recommended Welding Current

Rutile Alkaline Cellulosic

40-60 A

–

2.5

60-90 A 60-90 A 60-100 A

3.25

100-140 A 100-130 A 70-130 A

4.0

140-180 A 140-180 A 120-170 A

c

b

a

2.7 Water Cooling Unit (for Water Cooled 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.
If your machine has a water cooling unit; · 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.. Water cooling units cannot be operated with external supply.

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ID 250 – 300 T DC PULSE / TW DC PULSE
OPERATION
3.1 User Interface

Operation 21 EN

1

Parameter Adjustment Pot It is used to set the welding parameters to the desired value.

Digital Display 2 It shows the numerical value of the selected welding parameter and the current value during welding.
It also shows error message in case of error.

Program Selection Button

It is used to select one of 10 work programs covering all parameter settings in TIG modes. Thanks to

3

the programs, the adjusted parameters are kept in the memory of the machine and can be used for repetitive jobs, selected by the user. The last settings made for the selected program number will be

saved automatically, no further action is required for recording. In addition, while still in TIG modes,

it allows to switch to the cooling time setting when pressed for 3 seconds.

Digital Program Display 4 Shows the program number selected with the program selection button. It also shows the letter C
when setting the cooling time.

Welding Mode Selector Button

It is used to select one of the MMA welding, HF ignition TIG welding and Touch Start TIG welding

modes.

5

6 Led lights up when MMA welding mode is selected. 7 Led lights up when HF ignition TIG welding mode is selected. In this mode, when the electrode is

approached without touching the workpiece, the arc starts with a voltage jump over the gas.

8 Led lights up when Touch Start TIG welding mode is selected. In this mode, arc starts when the

electrode touches the workpiece and is pulled.

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USER MANUAL

Operation

ID 250 – 300 T DC PULSE / TW DC PULSE

EN

Trigger Mode and Electrode Type Selection Button

While in TIG welding modes; It is used to select one of the 2-Position, 4-Position, Tailstock Position

modes.

When 2-position is selected, led 10 lights up.

When 4-position is selected, led 11 lights up.

9 When the tailstock position is selected, led 12 lights up.

While in MMA mode; It is used to select one of the rutile, basic, cellulosic electrode modes. When the rutile electrode is selected, led 10 lights up. When the basic electrode is selected, led 11 lights up. When cellulosic electrode is selected, led 12 lights up.
Button is for selecting flat DC TIG / PULSE DC TIG 13 Led 14 lights when flat DC TIG is selected and led 15 lights when PULSE DC TIG is selected.
When PULSE DC TIG is selected, its led 15 lights.
TIG Parameters Selection Buttons It is used to select the TIG parameter to be adjusted. After the related TIG parameter’s led is on, the parameter is adjusted to the desired value with the parameter setting button. You can set the following TIG parameters: 18 Pre-Gas Flow Time Led 19 Starting Current Led 20 Up-Slope Time Led 16-17 21 Main Current Led 22 Base Current Led 23 Pulse Duty Cycle Led 24 Pulse Frequency Led 25 Down Slope Time Led 26 Final Current Led 27 Pos-Gas Flow Time Led 28 Spot Welding Time Led

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3.2 TIG Cycle

** Spot Welding Time
Pulse Frequency

Pulse (Width)

Operation 23 EN

Higher Current

Pre-Gas

Initial Current

Start Ramp

Lower Current

End Ramp

Final Current

Final Gas

3.3 Menu Structure

The statuses of the functions on or off according to the modes are as follows.

Parameter Pre-Gas Flow Time

ID 250 T DC PULSE ID 250 TW DC PULSE

ID 300 T DC PULSE ID 300 TW DC PULSE

Factory Setting

LED

MMA Welding

0-10 sec.

0 – 5 sec.

18

Start Current

5 – 250 A

5 – 300 A

30 A

19

Up-Slope Time

0.1-10 sec.

1 sec.

20

Main Current

5 – 250 A

5 – 300 A

85 A

21

Base Current

5 – 250 A

5 – 300 A

40 A

22

Pulse Cycle Rate

%1 – %99

% 50

23

Frequency

0.1 – 2000 Hz

75 Hz

24

Down-Slope Time

0.1 – 10 sec.

1 sec.

25

Final Current

5 – 250 A

5 – 300 A

30 A

26

Post-Gas Flow Time

0-20 sec.

0.1 sec.

27

Spot Welding Time

0-20 sec.

2 sec.

28

Water Cooler Time

1 – 20

3 min.

3.3.1 TIG Welding Process

In HF Start TIG mode, a high ignition voltage is present at the torch. Never touch the tungsten electrode or parts conducting welding current when the device is switched on.

· 10 jobs programs including complete parameter settings can be stored and run for repeated jobs. · In the first use, all parameters of all programs are in factory settings which are shown in the table. · Push the program selection button. For selecting a previously adjusted program or changing its parameters. · Push the welding mode selection button for selecting Touch-Lift TIG of HF start TIG. · Push the 2 Stroke – 4 Stroke – Spot Welding Selection Button for selecting the appropriate mode for the work. · Use TIG parameter selection button (13-14) to change the welding parameters.When the led, which belongs
to the parameter you will change is turned on,adjust the parameter by turning the parameter adjustment button. · Latest adjusted parameter values will be saved automatically. There is no need to do anything else for saving the settings.

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USER MANUAL

24 Operation

EN

3.3.2 Usage of the TIG Welding Trigger

ID 250 – 300 T DC PULSE / TW DC PULSE

Press the Trigger

Hold the Trigger Pressed

Release Trigger

2 Stroke TIG Trigger

· Push the torch trigger and do not release your finger. Current starts with start current after pre gas-flow period and increases according to the up- slope time adjustment and reaches to value of the main current.
· Welding goes on with the main current as long as the torch trigger is kept pushed. After releasing the trigger, current decreases according to down-slope time adjustment and reaches to final current, after post gas-flow period the operation ends.

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

4 Stroke TIG Trigger
· When torch trigger is pushed, following the pre-gas flow, initial current starts and when the trigger is released the currrent ramp leads to the welding current. If DC PULSE mode is selected, according to the adjusted frequency, welding current oscillates between this reached welding current and the base current. If the trigger will be pushed and released more than 1 second, current decreases according to down-ramp adjustment, reaches to the final current, after post gas, welding ends.
· Base current is generally used for repairing and cooling during welding and crater filling at the finishing of the welding beads. Either during DC or during Pulsed DC welding if the trigger is pushed and released less than 1 second, DC base current will be on. If the trigger will be pushed less than 1 second, welder will go back to the existing welding mode and parameters, but if the trigger will be pushed and released more than 1 second, welding will be finished by following the down-ramp, final current and post-gas.
PrG : Initial Gas Time I : Welding Current PoG : Final Gas Time

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Operation 25

Spot TIG Trigger

EN

· When the torch trigger is pushed, main current starts immediately and goes on as long as the torch trigger is

kept pushed.

· Welding goes on during spot welding time. After spot welding time is over, current stops immediately.

Flat DC / Pulse DC

· For using welding modes (2-stroke, 4-stroke, Spot Welding) in Flat DC mode, select Flat DC mode by button, its led will be on. In this mode, only main current is used and it is simply adjusted by the multifunctional pot.
· For using welding modes (2-stroke, 4-stroke, Spot Welding) in Pulse DC mode, select Pulse DC mode by button , its led will be on. In this case, main current, base current and the Pulse frequency should be adjusted by the multifunction pot. Welding current changes between main current and base current in the adjusted Pulse frequency.

Electrode Diameter
(mm)
1.6

Recommended TIG Welding Current
(A)
15 – 130

2.0

45 – 180

2.4

70 – 240

3.3.3 MMA Welding Process
· Push the welding mode selection button. For selecting the MMA welding mode. Stick electrode welding led lights.
· Adjust the current via current adjustment knob. · Below table can be used as a rough referance for mild steel electrodes. For exact parameters, please refer to
the electrode manufacturer recommendations.

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USER MANUAL

26 Maintenance and Service

ID 250 – 300 T DC PULSE / TW DC PULSE

EN

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
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.

or

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.

4.2 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.
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Maintenance and Service 27

4.3 Error Codes

EN

Error Code ERR-T1 E02 E04 E08

Error
Thermal Error

Cause
· Machine is overheated because of high ambient temperature of exceeding duty cycle

Power Module · Error/Errors may exist in any

Error

electronic card

Mains Voltage High

· Mains voltage may have increased

Mains Voltage Low

· Mains voltage may have decreased

Solution
· Let the machine on for a while in order to cool down itself with the cooling fan. After is cools enough, you can go on welding
· Switch off and switch on. If the error still exists, check the mains voltage whether it is within the range of 340V-420V or not. If the error still exists, 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

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28 Annex

EN

ANNEX

5.1 Spare Part List

ID 250 – 300 T DC PULSE / TW DC PULSE

NO

DEFINITION

1

Welding Socket

2 Electronic Card E202A-CN2

3 Electronic Card E202A-CN1

4

Quick Caplin

5

Quick Caplin – Blue

6

Quick Caplin – Red

7

Water Pump

8

HF Transformer

9

Fan

10 Electronic Card E202A-3 PFC

11 Electronic Card E202A-7A

12 Electronic Card E202A-7B

13

Fan

14

Relay

15

Gas Valve

16

Pacco Switch

17

Radiator

18

Water Tank

19 Electronic Card E202A-4B

20 Electronic Card E202A-FLT5

21 Electronic Card E110A-3

22 Electronic Card E202A-11B

23

Choke Coil

24 Electronic Card E202A-13

USER MANUAL

ID 250 T DC PULSE
A377900106 K405000202 K405000201 A245700006
A366700012 K405000151 K405000246 K405000198 K250200018 A312100014 A253006019 A308030004 K405000196 K405000227 K405000263 K405000194 K304500115 K405000195

ID 250 TW DC PULSE
A377900106 K405000202 K405000201 A245700006 A245700002 A245700003 A240000006 A366700012 A250001007 K405000151 K405000246 K405000198 K250200018 A312100012 A253006019 A308030004 A260000008 A249000005 K405000196 K405000227 K405000263 K405000194 K304500115 K405000195

ID 300 T DC PULSE
A377900106 K405000202 K405000201 A245700006
A366700012 K405000151 K405000245 K405000200 K250200018 A312100014 A253006019 A308030004 K405000196 K405000227 K405000263 K405000194 K304500115 K405000195

ID 300 TW DC PULSE
A377900106 K405000202 K405000201 A245700006 A245700002 A245700003 A240000006 A366700012 A250001007 K405000151 K405000245 K405000200 K250200018 A312100012 A253006019 A308030004 A260000008 A249000005 K405000196 K405000227 K405000263 K405000194 K304500115 K405000195

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ID 250 – 300 T DC PULSE / TW DC PULSE
5.2 Connection Diagrams Block Diagram ID 250 T DC PULSE ID 250 TW DC PULSE

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Solenoid Valve

HF Control Unit

Front Panel

Supply Voltage

Control Unit

Current Feedback

Output Voltage Feedback

R

S