Magmaweld RS 200 M MIG-MAG Welding Machine User Manual

: June 1, 2024
: magmaweld

Table of Contents

Magmaweld RS 200 M MIG-MAG Welding Machine
Product Information
Product Usage Instructions
FAQs
SAFETY PRECAUTIONS
TECHNICAL INFORMATION
TECHNICAL DATA
INSTALLATION
OPERATION
MAINTENANCE AND SERVICE
PRODUCT INFORMATION
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Magmaweld RS 200 M MIG-MAG Welding Machine

Magmaweld-RS-200-M-MIG-MAG-Welding-Machine-image

Product Information

Specifications

Models: RS 200 M, RS 250 M, RS 300 M
Product Type: MIG/MAG Welding Machine
Contact: (+90) 444 93 53, [email protected]
All rights reserved by Magma Mekatronik Makine Sanayi ve Ticaret A.

Product Usage Instructions

Safety Precautions

Be sure to follow all safety rules mentioned in the manual. Pay
attention to safety symbols and warnings.

Technical Information

General Information: Contains machine components and product label details.

Technical Data: Includes specifications and accessories information.

Installation

Check delivery contents, follow installation recommendations, connect mains plug, welding connections, and gas connections.

Operation

Connect to mains power, prepare and connect the torch, adjust wire feed rollers, place wire spool, adjust gas flow, use trigger modes, start and end welding process, set welding parameters.

Maintenance and Service

Regular maintenance, troubleshooting guide, fuse replacement, error codes interpretation.

Annex

Details on fine settings in the wire feed unit, spare parts lists, connection diagrams.

FAQs

Q: How to troubleshoot common issues with the welding machine?
- A: Refer to the troubleshooting section in the user manual for detailed steps to identify and resolve common problems.
Q: What should I do if I encounter an error code while using the machine?
- A: Check the error code section in the manual to understand the issue and take necessary actions as advised.

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

RS 200 M / RS 250 M / RS 300 M

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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RS 200 M / RS 250 M / RS 300 M

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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USER MANUAL

8 Safety Precautions

RS 200 M / RS 250 M / RS 300 M

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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RS 200 M / RS 250 M / RS 300 M

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

RS 200 M / RS 250 M / RS 300 M

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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RS 200 M / RS 250 M / RS 300 M

Technical Information 11

TECHNICAL INFORMATION

EN

1.1 General Information
RS 200 M, RS 250 M and RS 300 M are 3 phase step controlled, Constant Voltage industrial MIG/MAG machines to weld all types of solid and flux cored wires in any kind of fabrication and erection. The machine is fan cooled and thermally protected against over heating. The welding voltage adjustment ranges are, for 200 model 14 steps between 17-36 V, for 250 models 21 steps between 20-51 V, for 300 models 21 steps between 19 – 44 V. Wire feeding unit is a robust 4 wheel drive system which is designed as a separate box from the power source in order to cover larger work areas. It contains a wire feeding motor-gearbox assembly, an electronic control card and a gas valve, therefore this unit should be handled carefully at site. The wheels under the box are for the ease of the welder to move the box as he welds, but the box shouldn’t be pulled across the work area by the torch. Even though you can manufacture with these machines in a big range of current scale all day long, model 200 is optimized for 0.8 mm, 250 for 1.0mm and 300 for 1.0 mm heavy-duty applications.

1.2 Machine Components

16-a

16-b

7

8

16-c

1

9

18

10

16

2

11

3

12

13

17

19

20

4

14

21

5

22

6

23

24 15

Figure 1 : RS 300 M Front and Back View

1- Torch Connector

15- Wheel

2- Thin Adjustment Switch

16- Wire Feeder Harness

3- On / Off and Coarse Adjustment Switch 16-a Welding Current Plug

4- Wire Feed Unit Connector 5- Gas Outlet

16-b Wire Feed Unit Control Cable 16-c Gas Hose

6- Welding Current Plug Socket 7- Trigger Mode Switch

17- Mains Cable 18- Drum Feeding Wire Inlet

8- Wire Speed Adjustment Button 9- Turn Table

19- Insurance Group 20- CO2 Heater Socket

10- Handle 11- Lifting Eye

21- Gas Inlet 22- Gas Cylinder Security Chain

12- Voltmeter 13- Ammeter

23- Fan Output 24- Gas Cylinder Transport Platform

14- Workpiece Cable Socket (-)

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12 Technical Information

EN

1.3 Product Label

RS 200 M / RS 250 M / RS 300 M

Three Phase Transformer Rectifier Horizontal Characteristic MIG/MAG Welding Direct Current Mains Input 3-Phase Alternating Current Suitable for Operation at Hazardous Environments
Duty Cycle Temperature (C°)

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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RS 200 M / RS 250 M / RS 300 M
1.4 Technical Data
TECHNICAL DATA Mains Voltage (3-Phase 50-60 Hz)
Rated Power Welding Current Range Rated Welding Current
Open Circuit Voltage Voltage Adjustment and Number of Levels
Dimensions (l x w x h) Weight
Protection Class
TECHNICAL DATA Mains Voltage (3-Phase 50-60 Hz)
Rated Power Welding Current Range Rated Welding Current
Open Circuit Voltage Voltage Adjustment and Number of Levels
Dimensions (l x w x h) Weight
Protection Class

TECHNICAL DATA

Mains Voltage (3-Phase 50-60 Hz)
Rated Power Welding Current Range Rated Welding Current
Open Circuit Voltage Voltage Adjustment and Number of Levels
Dimensions (l x w x h) Weight
Protection Class

UNIT V
kVA ADC ADC VDC mm mm kg
UNIT V
kVA ADC ADC VDC mm mm kg
UNIT V
kVA ADC ADC VDC mm mm kg

Technical Information 13
EN
RS 200 M 400
8.3 (%23) 40 – 240
240 17 – 36 2 x 7 865 x 510 x 780
101 IP 21
RS 250 M 400
10 (%40) 57 – 250
250 19.7 – 51
3 x 7 865 x 510 x 780
101 IP 21
RS 300 M 400
13.8 (%40) 40 – 300 300 19 – 44 3 x 7
865 x 510 x 780 101 IP 21

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14 Technical Information

EN

1.5 Accessories

STANDARD ACCESSORIES

QTY

Workpiece Clamp and Cable

1

Gas Hose

1

MIG / MAG CO Accessory Set*

1

MIG/MAG Mix/Argon Accessory Set*

1

STANDARD ACCESSORIES

QTY

Workpiece Clamp and Cable

1

Gas Hose

1

MIG / MAG CO Accessory Set*

1

MIG/MAG Mix/Argon Accessory Set*

1

STANDARD ACCESSORIES

QTY

Workpiece Clamp and Cable

1

Gas Hose

1

MIG / MAG CO Accessory Set*

1

MIG/MAG Mix/Argon Accessory Set*

1

Should be verified during ordering.

RS 200 M / RS 250 M / RS 300 M
RS 200 M 7905212505 (25 mm² – 5 m)
7907000002 7920000510 7920000515
RS 250 M 7905212505 (25 mm² – 5 m)
7907000002 7920000520 7920000525
RS 300 M 7905212505 (25 mm² – 5 m)
7907000002 7920000530 7920000535

USER MANUAL

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RS 200 M / RS 250 M / RS 300 M

OPTIONAL ACCESSORIES

QTY

CO2 Heater

1

Gas Regulator (CO2)

1

Gas Regulator (Mix)

1

Lava MIG 25 (3 m) Air Cooled MIG Torch

1

OPTIONAL ACCESSORIES

QTY

CO2 Heater

1

Gas Regulator (CO2)

1

Gas Regulator (Mix)

1

Lava MIG 25 (3 m) Air Cooled MIG Torch

1

Lava MIG 35 (3 m) Air Cooled MIG Torch

1

OPTIONAL ACCESSORIES

QTY

CO2 Heater

1

Gas Regulator (CO2)

1

Gas Regulator (Mix)

1

Lava MIG 35 (3 m) Air Cooled MIG Torch

1

Technical Information 15

RS 200 M

EN

7020009002

7020001005

7020001004

7120025003

RS 250 M 7020009002 7020001005 7020001004 7120025003 7120035003

RS 300 M 7020009002 7020001005 7020001004 7120035003

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16 Installation

RS 200 M / RS 250 M / RS 300 M

EN

INSTALLATION

2.1 Delivery Control

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

contact your place of purchase immediately.

The standard box includes the following;

· Welding machine and connected mains cable

· Warranty certificate

· Workpiece clamp and cable

· User manual

· Gas hose

· Welding Wire

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

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

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

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Installation 17

2.3 Mains Plug Connection

EN

For your safety, never use the mains cord of the machine without a plug.
· No plug has been connected to the mains cable since there may different types of outlets available in plants, construction sites and workshops. A suitable plug must be connected by a qualified technican. Make sure that the grounding cable marked with and a yellow / green color is present.
· After connecting the plug to the cable, do not attach it to the outlet at this stage.
2.4 Welding Connections
2.4.1 Connections of the Wire Feeder
· Place the wire feeder on to the turn table on the machine. · Connect the blue gas hose to gas outlet bush in front of the power source. · Connect the control cable to the control socket in front of the power source. · Connect the welding plug into the welding cable connection outlet in front of the power source.
Be sure that the connections are fastened tightly. Loose or incorrect fastening may cause overheating or gas leakage.

2.4.2 Grounding Pliers Connections

· Grounding cable sockets with different inductance values

allow welding with lower spatter in a wide current range.

Socket for low current and small wire diameters socket,

for high current and large wire diameters

or

socket should be preferred.

· Connect the grounding pliers wire to one of the grounding wire

sockets on the machine and tighten by turning it to the right.

· To improve the welding quality, firmly connect the grounding

pliers to the workpiece as close as possible to the welding

area.

16-a 16-b 16-c

Figure 2 : Intermediate Pack and Grounding Pliers Connections

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18 Installation

RS 200 M / RS 250 M / RS 300 M

EN

2.4.3 Connections for Long Harness

· Machines with harness longer than 5 meter have detachable harness and wire feeding connection in order to

lift easier. Both ends of the harness are the same, therefore sockets and connectors must be connected to the

wire feeding unit same as the connections to the front side of the machine.

· If your machine has harness longer than 5 meter, connect the harness to the wire feeding unit as seen below.

16-c 16-b 16-a

Figure 3 : Long Harness Connections

2.4.4 Gas Connections

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

1

3

1- Gas Cylinder Valve 2- Gas Cylinder

6- Gas Regulator 7- Manometer

7 68

3- CO2 Heater 4- Chain

8- Flowmeter 9- Flow Adjustment Valve

5- CO2 Heater Energy Cable 10- Gas Hose

2

9

4

10

5

Figure 4 : Gas Cylinder – Heater – Regulator Connections

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Operation 19

OPERATION

EN

3.1 Connection to Mains

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

· Check the 3-phase with a voltmeter before connecting the machine to the mains. After detecting that each phase is 400V (± 40V), attach the plug into the wall outlet.
· Start the machine with the on / off switch. · Turn the machine off by turning the switch back to the “0” position
after hearing the fan sound and seeing the ammeter and voltmeter lights are on.

Figure 5 : Mains Connection

3.2 Preparation and Connection of the Torch

· Use the torch according to the capacity of your machine and the welding you will perform.
· Make sure that the diameters of the spiral and contact nozzle inside the torch match the diameter of the welding wire you will use. Replace the spiral and contact nozzle if necessary.
· To change the spiral, remove the nozzle, contact nozzle and adapter respectively.

Contact Tip

Nozzle

Adapter

Figure 6 : Separation of Nozzle and Contact Nozzle from the Torch

· Afterwards, remove the spiral nut on the torch connector side with a wrench and extend the torch so that it is in flat position and remove the spiral inside the torch.
· After inserting the new spiral into the torch, install and firmly tighten the spiral nut.

Nut of Liner Liner

Figure 7 : Removal and Installation of Spiral

· Cut the excess of the spiral from the torch head with a side chisel at the point where the gas distributor (contact nozzle holder) immediately ends as shown on the right, so that there is no gap between the spiral and the contact nozzle. File the cut point to make it blunt and burr free.

Figure 8 : Cutting the Spiral Extension

· Attach it to torch torch connector and tighten the nut tightly.

Torch Nut

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Figure 9 : Torch Connection
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20 Operation

RS 200 M / RS 250 M / RS 300 M

EN

3.3 Selection and Replacement of Wire Feed Rollers

· Open the cover of the wire feed part. You will see the four-roller wire feed system.

3

1

5

4

2 6

6 5

1- Engine 2- Euro Connector 3- Pressure Roller Handle 4- Pressure Rollers 5- Wire Feed Rollers 6- WF Roller Screws

Figure 10 : Wire Feed System

· Use wire feed rollers suitable for the material and diameter of the welding wire you will use. Use V-grooved wire feed rollers for steel and stainless steel, corrugated V-grooves for cored wires and U corrugated ones for aluminum.
· If you need to replace the wire feed rollers, pull the pressure roller lever toward your side and after lifting the pressure rollers, remove the wire feed roller screws and remove the existing rollers.

Figure 11 : Wire Feed Roller Removal
0.8 mm
Both sides of the rollers are marked according to the wire diameter used. Place the rollers on the flange so that the wire diameter value you will use will be on the side facing your side.

· After inserting the rollers, you will use, re-insert the screws and lower the pressure rollers and lock the pressure roller lever onto the rollers.

Figure 12 : Wire Feed Roller Placement

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3.4 Placing the Wire Spool and Wire Feeding Process

· Unscrew the screw of the wire transport system by turning it.

Insert the welding wire roller parallel to the wire ground and

always from the bottom to the wire transport system shaft and

re-tighten the screw.

b

Operation 21 EN
c

a Figure 13 : Placement of Wire Spool Over-tightening the nut will prevent the wire from feeding and may cause failures. Under-tightening of the nut may cause the roller to be released at the time wire feed is stopped and mixed after a while. For this reason, do not connect the nut too tightly or too loosely. · Pull and lower the pressure lever on the wire feed rollers, which means bring the pressure rollers to idle position. · Remove the welding wire from the point where the roller is connected and cut off the end with a side chisel.
If the end of the wire is missed, the wire can jump like a spring and damage you and others.
· Pass the wire through the wire entry slot without releasing the wire into the rollers and into the torch through the rollers.
Figure 14 : Feeding the Wire to Rollers

BOARD
· Press the pressure rollers and lift the pressure lever . · Turn the on/off switch to position “1” to start the machine . · Press the trigger until the wire comes out from the tip of the torch, while observing that the welding wire
roller rotates freely then push and release the trigger a few times to check for any loosening of the winding . If loosening and/or backwinding is observed, tighten the screw of the wire bearing system. · Re-attach the nozzle and contact nozzle to the torch when the wire comes out from the tip of the torch . · Drive the wire on a board and make the appropriate wire pressure adjustment and cut the tip of the wire .

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22 Operation

RS 200 M / RS 250 M / RS 300 M

EN

A: Suitable wire pressure and conduit dimensions B: The wire is distorted since the pressure lever is too tight.

C: The roller surface is deteriorated due to excessive pressure on the pressure lever.

D: The conduit length of the roller is small for the wire used. The shape of the wire is distorted.

E: The conduit length of the roller is big for the wire used. The wire cannot be transmitted to the welding area.

Figure 15 : Pressure Setting and Roller Selection Mistakes
3.5 Adjustment of Gas Flow

Make the gas adjustment and gas test by lifting the wire feed roller pressure lever!

Diameter (mm)

· Adjust the gas flow with the flow control valve. · Practical gas flow rate (CO, Ar, mixture) is 10 times
of wire diameter. For example, if the wire diameter is 0.9 mm, the gas flow rate can be adjusted as 10 x 0.9 = 9 l/min. · You can use the table on the side for more precise

Mild Steel and
Metal Cored 0.8 8 lt/min
0.9 9 lt/min
1.0 10 lt/min

Flux Cored
7 lt/min 8 lt/min 9 lt/min

Stainless Steel
8 lt/min 9 lt/min 10 lt/min

Aluminium
8 lt/min 9 lt/min 10 lt/min

flow adjustment.

1.2 12 lt/min 11 lt/min 12 lt/min 12 lt/min

· After adjusting the gas flow, lift the thrust bearing

1.6 16 lt/min 15 lt/min 16 lt/min 16 lt/min

arm and close the wire feed unit door.

Note: Recommended values in standard conditions.

3.6 Using Trigger Modes

· The trigger mode switch selects 2-position, 4-position or pnt position. · The 2-position operates as shown in Figure 16. · The 4-position operates as shown in Figure 17. The 4-position provides ease of use for the welder in
long-term and automatic welding operations. · In the pnt mode, the welding starts at the moment the trigger is pressed, the welding continues until the set
time period is on and stands by as long as the off-time period. The process continues in this manner until the trigger is released and the welding stops as soon as the trigger is released.

1

2

1

2

3

4

Switch is triggered Switch is released Switch is triggered Switch is released

Gas starts instantly Current starts instantly Wire feeding starts after pre gas

Wire stops instantly Current stops after burn back Gas stops after post gas

Gas starts instantly

Gas goes on

Current starts instantly Current goes on

Wire feeding starts

Wire goes on

after pre gas

Switch is triggered Switch is released

Gas goes on Current goes on Wire goes on

Wire stops instantly Current stops after burn back Gas stops after post gas

Figure 16 : Using the 2-Position

Figure 17 : Using the 4-Position

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3.7 Starting and Ending the Welding Process

Operation 23 EN

Figure 18 : Welding Connections
· Determine the Coarse Adjustment “, Fine Adjustment” and Wire Feed Speed from the welding parameters table of your machine according to the diameter of the wire you will use, the type of gas you will use and the thickness of the material to be welded, and set your machine to these settings.

Wire Diameter

Material Thickness

Coarse Adjustment Range

Fine Adjustment

Wire Feeding Speed

Current
Voltage
· You can start welding after making sure that you comply with all safety rules and take the necessary precautions.
· During welding, instantaneous welding voltage will be displayed in voltmeter and instantaneous welding current will be displayed in ammeter.

When not welding, leave the torch in such a way that it does not touch the workpiece, the welding pliers, the hood of the machine and the trigger does not remain pressed.

· After you have finished working with the welding machine, allow the machine to cool down and turn the on / off switch to “0”. Unplug the machine and close the gas cylinder.

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24 Operation

RS 200 M / RS 250 M / RS 300 M

EN

3.8 Welding Parameters

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

RS 200 M

RS 250 M

RS 300 M

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Maintenance and Service 25

MAINTENANCE AND SERVICE

EN

· 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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26 Maintenance and Service

RS 200 M / RS 250 M / RS 300 M

EN

4.3 Troubleshooting

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

Failure

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

Solution
· Make sure that the machine is plugged in

Machine is not operating

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

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

· The fuse has blown

· Check the fuse

· Contactor failure

· Check the contactor

Wire feed motor failure

· The fuse has blown · Electronic card failure

· Check the fuse · Contact the authorized service

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

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

to fit the wire diameter

roller

· The pressure on the wire feed rollers is too minimal

· Adjust the pressure roller

· There is a problem in the

· Make sure that the grounding

connection of grounding clamps clamps of the machine is

of the machine

connected to the workpiece

· Cables and connection points are worn out

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

Welding quality is not good

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

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

· Consumables were selected incorrectly or damaged

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

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

rollers is not correct

made correctly

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Maintenance and Service 27

Failure

Reason

Fan is not operating

· The fuse has blown · Fan motor failure

Machine operates noisily

· Contactor failure

Unstable and / or non-adjustable welding current

· Diode group failure

Heater outlet is not operating

· The fuse has blown

Solution

EN

· Check the fuse

· Contact the authorized service

· Check the fuse. Contact the authorized service

4.4 Fuses
Fuse F1 F2 F3 F4

Amperage 10 A 1 A 1 A 1 A

Feature Fast
Delayed Fast Fast

Protected Circuir Motor and Card of the Wire Feeder
Cooler Fan CO2 Heater Card of Voltmeter / Ampermeter

4.5 Error Codes

Error Code Err

Error
Thermal Protection
Water Cooling Unit Error

Cause

Solution

· Allow the machine to cool down by

waiting for a while. If the fault

· The uptime of your machine may have disappears, try to use the machine at

been exceeded

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

· There may be an error in the water cooling unit

· Check water cooling unit connector and torch inlets/outlets
· Make sure there is water circulation · If the problem continues, contact the
authorized service

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28 Annex

RS 200 M / RS 250 M / RS 300 M

EN

ANNEX

5.1 Fine Settings in the Wire Feed Unit
You can make fine adjustments through panel which is above wire feeder. 1- Soft Start Switch : While the switch is ON, the wire is fed at a slow speed until it touches to the work piece. Then, wire feeding goes on at the adjusted speed. While the switch is OFF, wire feeding starts at the adjusted speed. 2- Free Wire Feeding Button : The wire is fed as long as you push this button, but the gas ventile does not work. You can use this function for inserting the wire to the torch. 3- Post-Gas Adjustment Trimmer : In order to increase the post-gas time, rotate the trimmer clockwise with a slot screwdriver. In order to decrease the post-gas time, rotate the trimmer counter-clockwise. Post-gas time can be adjusted in a range of 0 – 3 sec. 4- Pre-Gas Adjustment Trimmer : In order to increase the pre-gas time, rotate the trimmer clockwise with a slot screwdriver. In order to decrease the pre-gas time, rotate the trimmer counter-clockwise. Pre-gas time can be adjusted in a range of 0 – 3 sec. 5- Burn Back Adjustment Trimmer : In order to increase the burn back time, rotate the trimmer clockwise with a slot screwdriver. In order to decrease the burn back time, rotate the trimmer counter-clockwise. Burn back time can be adjusted in a range of 0 – 1 sec.

1 2

3 4 5

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5.2 Spare Parts Lists Power Source Spare Parts List

23

1

4

5

8
67 9 10 11 12 13

Annex 29 EN

16

14

15

17 18 19

20 21

23

5

22

24

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30 Annex

EN NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

DEFINITION Glass Fuse Socket Monophase Socket Machine
Connector Electronic Card RS Filter
Gas Fitting EMC Filter Connector Turn Table Cooler Fan Main Transformer Diode Group Hall Effect Sensor Ampermeter Voltmeter Card Plastic Wheel Control Transformer Primary-Secondary Coil Plastic Swivel Wheel Shock Coil Plastic Swivel Wheel Welding Socket Pacco Switch Pacco Switch Switch Button Connector

RS 200 M / RS 250 M / RS 300 M

RS 200 M A300190001 A377100004 A378002002 K405000224 A256006069 K405000902 A311000016 K090200002 A250001003 K304000052 A430901009 A834000001 K405000018 A225222010 K304400024 K302200040 A225220106 K304500032 A225222010 A377900106 A308031008 A308031010 A308900004 A378002002

RS 250 M A300190001 A377100004 A378002002 K405000224 A256006069 K405000902 A311000025 K090200002 A250001003 K304000055 A430901010 A834000001 K405000018 A225222010 K304400024 K302200046 A225220106 K304500039 A225222010 A377900106 A308032022 A308032020 A308900004 A378002002

RS 300 M A300190001 A377100004 A378002002 K405000224 A256006069 K405000902 A311000025 K090200002 A250001003 K304000062 A430901010 A834000001 K405000018 A225222010 K304400024 K302200050 A225220106 K304500040 A225222010 A377900106 A308032022 A308032020 A308900004 A378002002

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Wire Feeder Spare Parts List

Annex 31
EN 38

27

28

26 29
25

NO

DEFINITION

25

Cover Lock

26

Hinge

27

Wire Carr. Mac. System 3 – Way Connection

28

Sheet Fixed Wheels

29

Wire Feed System

30

Quick Coupling Red

31

Quick Coupling Blue

32

Sheet Metal Swivel Wheel

33

Latch Button

34

Potency Button

35

Potentiometer

36

Gas Valve

37

Electronic Card E301A

38

Bakelite U-Arm

37
36
35 34 33
32
31 30
MATERIAL CODE RS 200 M – RS 250 M – RS 300 M
A229300006 A229200005 A229900003 A225101004 K309002210 A245700003 A245700002 A225100004 A310030002 A229500002 A410810004 A253006014 K405000351 A229102002

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USER MANUAL

EN

32 Annex

5.3 Connection Diagrams

Block Diagram

USER MANUAL

Control Transformer

Solenoid Valve Gas
Control Unit

R

Welding Torch

S