Magmaweld GL 600 Welding Inverter User Manual

USER MANUAL
KULLANIM KILAVUZU
GL 451 – GL 600 WELDING INVERTER

All rights reserved. It is prohibited to reproduce this documentation or any part thereof, without the prior written authorization of Magma Mekatronik Makine Sanayi ve Ticaret A.Ş.
Magma Mekatronik may modify the information and the images without any prior notice.

SAFETY P3RECAUTIONS

Be Sure To Follow All Safety Rules In This Manual!

Explanation Of Safety Information

• Safety symbols found in the manual are used to identify potential hazards.
• When any one of the safety symbols is seen in this manual, it must be understood that there is a risk of injury and the following instructions should be read carefully to avoid potential hazards.
• The possessor of the machine is responsible for preventing unauthorized persons from accessing the equipment.
• Persons using the machine must be experienced or fully trained in welding; they have to read the user manual before operation and follow the safety instructions.

Explanation Of Safety Symbols

ATTENTION
Indicates a potentially hazardous situation that could cause injury or damage. In case if no precaution is taken, it may cause injuries or material losses/damages.
IMPORTANT
Specifies notifications and alerts on how to operate the machine.
DANGER
Indicates a serious danger. In case if not avoided, severe or fatal injuries may occur.

Comprehending Safety Precautions

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

Electric Shocks
May Kill
Make certain that the installation procedures comply with national electrical standards and other relevant regulations, and ensure that the machine is installed by authorized persons.

| • Wear dry and sturdy insulated gloves and a working apron. Never use wet or damaged gloves and working aprons.
• Do not work alone. In case of 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.
• Do not touch electrode holders connected to two welding machines at the same time since the double open-circuit voltage will be present.

• Keep the machine turned off and disconnect cables when not in use.

• Before repairing the machine, remove all power connections and/or connector plugs or turn off the machine.

• Be careful when using a long mains cable.

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

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

• Bare wiring can kill. Check all cables frequently for possible damage. If a damaged or an uninsulated cable is detected, repair or replace it immediately.

• Insulate the work clamp when not connected to the workpiece to prevent contact with any metal object.

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

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

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

• If AC output is required, use remote output control if present on the unit.
  Additional safety precautions are required when any of the following electrically hazardous conditions are present:

• in damp locations 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 the order presented:

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

• DC manual MMA welding machine,

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

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Procedures for Electric Shock

• Turn off the electric power.
• Use non-conducting material, such as dry wood, to free the victim from contact with live parts or wires.
• Call for emergency services.

If you have first aid training;

• If the victim is not breathing, Administer cardiopulmonary resuscitation (CPR) immediately after breaking contact with the electrical source. Continue CPR (cardiac massage) until breathing starts or until help arrives.
• Where an automatic electronic defibrillator (AED) is available, use it according to instructions.
• Treat an electrical burn as a thermal burn by applying sterile, cold (iced) compresses.
  Prevent contamination, and cover with a clean, dry dressing.

Moving Parts May
Cause Injuries

• Keep away from the moving parts.
• Keep all protective devices such as covers, panels, flaps, etc., of machinery and equipment closed and in the locked position.
• Wear metal toe shoes against the possibility of heavy objects falling onto your feet.

Fumes and Gases
May Be Harmful To
Your Health

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

| • Burning sensations and irritations in the eyes, nose, and throat are signs of inadequate ventilation. In such a case, immediately boost the ventilation of the work area, and if the problem persists, stop the welding process completely.
• Create a natural or artificial ventilation system in the work area.
• Use a suitable fume extraction system where welding and 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 operations in the presence of chlorinated hydrocarbon vapors released during lubrication or painting operations.
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ArcLight May Damage Your Eyes and Skin

• Use a suitable protective mask and glass filter (4 to 13 according to EN 379) suitable for that to protect your eyes and face.
• Protect other naked parts of your body (arms, neck, ears, etc.) with suitable protective clothing from these rays.
• Enclose your work area with flame-resistant folding screens and hang warning signs at eye level so that people around you will not sustain injuries from arc rays and hot metals.
• This machine is not used for heating of icebound pipes. This operation performed with the welding machine causes an explosion, fire or damage to your installation.

Sparks and Spattering Particles  May Get Into Eyes and Cause Damage

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

Hot Parts May Cause
Severe Burns

• Do not touch the hot parts with bare hands.
• Wait until the time required for the machine to cool down before working on its parts.
• If you need to hold hot parts, use suitable tools, welding gloves with high-level thermal insulation and fire-resistant clothes.

Noise May Cause
Damage To Your Hearing Ability

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

Welding Wires Can Cause Injuries

• Do not point the torch towards any part of the body, other persons, or any metal while unwrapping the welding wire.
• When welding wire is run manually from the roller, especially in thin diameters the wire can slip out of your hand, like a spring or can cause damage to you or other people around, therefore you must protect your eyes and face while working on this.

Welding Operations
May Cause Fire and Explosion

• Never perform welding work in places near flammable materials. There may be fire or explosions.
• Before starting the welding 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 or 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 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 equipment heats up. For this reason, do not place it on surfaces that could easily burn or be damaged!
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| • Welding sparks can 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.
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Maintenance Work
Performed by Unauthorized
Persons To Machines and Apparatus May Cause Injuries

• Electrical equipment should not be repaired by unauthorized persons. Errors that occurred if failed to do so may result in serious injury or death when using the equipment.
• The gas circuit elements operate under pressure; explosions may occur as a result of services provided by unauthorized persons, and users may sustain serious injuries.
• It is recommended to perform technical maintenance of the machine and its auxiliary units at least once a year.

Welding In Small Sized and Confined Spaces

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

Failure To Take
Precautions During
Transport May Cause
Accidents

• Take all necessary precautions when moving the machine. The areas where the machine is to be transported, the parts to be used in transportation and the physical conditions and health of the person carrying out the transportation works should be suitable for the transportation process.
• Some machines are extremely heavy; therefore, make sure that the necessary environmental safety measures are taken when changing their places.
• If the welding 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 durability 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 and cutting equipment, each being separate, lift and transport small ones using their handles, and the big ones from their handling rings or by using appropriate haulage equipment, such as forklifts.

Falling Parts May
Cause Injuries

Improper positioning of the power-supply sources or other equipment can cause serious injury to persons and physical damage to other objects.

• Place your machine on the floor and platforms with a maximum tilt of 10° so that it does not fall or tip over. Choose places that do not interfere with the flow of materials, where there is no risk of tripping over cables and hoses; yet, large, easily ventilatable, dust-free areas. To prevent gas cylinders from tipping over, on machines with a gas platform suitable for the tanks, fix the tanks onto the platform; in stationary usage applications, fix them to the wall with a chain in a way that they would not tip over for sure.
• Allow operators to easily access settings and connections on the machine.

Excessive Use Of The
Machine Causes
Overheating

• This device is in group 2, class A in EMC tests according to TS EN 55011 standard.

• This class A device is not intended for use in residential areas where electrical power is supplied from a low-voltage power supply. There may be potential difficulties in providing electromagnetic compatibility due to radio frequency interference transmitted and emitted in such places.
  This device is not compliant with IEC 61000 -3-12. In case if it is desired to be connected to the low voltage network used in the home, the installer to make the electrical connection or the person who will use the machine must be aware that the machine has been connected in such a manner; in this case the responsibility belongs to the user.

• Make sure that the work area complies with electromagnetic compatibility (EMC). Electromagnetic interferences during welding or 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 operations as far away from your sensitive electronic devices as possible (100m).

• Ensure that your welding and/or cutting machine has been installed and situated in its place according to the user manual.

Evaluation Of Electromagnetic
According to article 5.2 of IEC 60974-9;
Suitability Of The Work Area

Before installing the welding and cutting equipment, the person in charge of the operation and/or the user must conduct an inspection of possible electromagnetic interference in the environment. The aspects indicated below has to be taken into consideration;
a) Other supply cables, control cables, signal and telephone cables, above and below the welding 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 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 Interference
Reduction Methods

• The appliance must be connected to the electricity supply in the recommended manner by a competent person. If interference occurs, additional measures may be applied, such as filtering the network. The supply of the fixed-mounted arc welding equipment must be made in a metal tube or with an equivalent shielded cable. The housing of the power supply must be connected and 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 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 cables should not be wound in any way.
• A magnetic field is generated on the machine during welding. This may cause the machine to pull metal parts onto 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 a 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 area can be evaluated for some specific applications.

Arc Welding May Cause
Electromagnetic
Field (EMF)

The electrical current passing through any conductor generates zonal electric and magnetic fields (EMF).
All welders must follow the following procedures to minimize the risk of exposure to EMF from the welding circuit;

• In the name of reducing the magnetic field, the welding cables must be assembled and secured as far as possible with the joining materials (tape, cable ties etc.).
• The welder’s/worker’s body and head should be kept as far away from the welding machine and cables as possible,
• Welding 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 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 welded area,
• The welding machine should not rest against the power unit, ensconce on it and not work too close to it,
•  Welding work should not be performed when carrying the welding wire supply unit or welding 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 limitations 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 method and welding machine for the welding work you are to perform.
• Select the welding 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 work, turn off the machine after the fan has cooled it down. Our machines (our products) 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.

TECHNICAL INFORMATION

General Information

GL 451 / GL 600 is a moving magnetic-core type welding machine, designed to weld all type of coated electrodes from 2.0 to 6.0 mm. It has excellent welding performance with cellulosic electrodes and carbon gauging, for GL 451 up to 8.0 mm, for GL 600 up to 10 mm is possible.
The equipment is very easy to use, current adjustment is made by just turning the lever on top of the machine clockwise or counterclockwise and the adjusted value of the current is observed by the scale in front of the machine. Although it is not an electrically efficient machine, due to its very simple concept, its downtime and operation costs are very low.
Since there is no electronics involved, the machine can perform great at dusty, humid, corrosive, very hot and very cold environments. With its telescopic arms and big wheels, it can be pulled easily across the working area, especially at outdoor welding sites.
The machine is fan-cooled and thermally protected against overheating and phase failures.

Machine Components

1. Power Switch
2. Welding Cable Sockets (+ and -)
3. Current Adjustment Lever
4. Current Adjustment Indicator
5. Lifting Eye
6. Handle
7. Wheel

Product Label

| Three Phase Transformer Rectifier
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| Covered Electrode Welding
| Direct Current
| Vertical Characteristic
| Mains Input-3 Phase Alternating Current
| Suitable for operation at hazardous environments
X| Duty Cycle
Uo| Open Circuit Voltage
U1| Line Voltage and Frequency
U2| Rated Welding Voltage
I1| Input Current
I2| Rated Welding Current
IP225| Protection Class

As defined in the standard EN 60974-1, the operating 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 without interruption in the first 6 minutes of the 10-minute period(zone 1). However, the following 4 minutes should be kept idle for the machine to cool down (zone 2).

 Technical Data

Accessories

INSTALLATION

Delivery Control

Make sure you have received your order in full. If any material is missing or damaged, contact your place of purchase immediately.
The standard box includes the following;

• Power Source
• Electrode Holder Cable
• Earth Clamp Cable

User Manual
In the case of damaged delivery, draw up a record, 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 customer service.

Symbols and their meanings on the device;

The welding process is 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. Irrelevant persons 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.

Installation And Operation Recommendations

• Necessary precautions should be taken during the transportation of the machine. Do not lift the machine with the gas cylınder. Place the power supply on a hard, level and level surface where it will not fall or tip over.
• For better performance, place the machine at least 30 cm away from surrounding objects. Pay attention to overheating, dust and moisture around the machine. Do not operate the machine in direct sunlight. When the ambient temperature exceeds 40°C, operate the machine at a lower current or at a lower cycle rate.
• Avoid welding with wind and rain outdoors. If welding is required in such cases, protect the welding area and the welding machine with curtains and awnings.
• 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.
• If welding inside, use a suitable smoke extraction system. Use breathing apparatus if there is a risk of inhaling welding fumes and gas indoors.
• Observe the duty cycle rates specified on the product label. Frequent exceeding duty cycle rates can damage the machine and void the warranty.
• Use the appropriate fuse for your system.
• Connect the ground wire as close to the welding area as possible. Do not allow welding current to pass through elements other than welding cables, eg the machine itself, the gas cylinder, the chain, the bearing.
• 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.
• The electrical outlet on the back of the machine is for the CO₂ heater. NEVER connect a device other than a CO₂ heater to the CO₂ socket!

 Mains Plug Connection

For your safety, never use the main cable of the machine without a plug.

• Since main connection sockets may vary from factory to factory, an appropriate plug must be installed o the built-in mains cable of the machine by qualified electricians.  Please observe that the earth cable is in yellow/green color and label led as.
• After installing the electric plug, DO NOT INSERT IT INTO THE SOCKET AT THIS STAGE.

Connecting To The Mains

When inserting the plug into the wall socket, the machine Makes sure it is in the “0” position.

• Check the 3-phase with a voltmeter before connecting the machine to the mains. After detecting that each phase is 400V (± 40V), plug in the plug.
• Switch on the machine with the On / Off switch.
• Turn off the machine by turning the switch back to the “0” position after hearing the fan noise and seeing the voltmeter and ammeter light on.

 Welding Connections

• According to the electrode to be used, insert the welding cables, with correct polarity into the welding and earth cable sockets (2) and tighten them by turning clockwise.
•  Connect the earth clamp tightly to the workpiece as close as possible to the welding area.

Welding Adjustments

• By turning the current adjustment lever (3) clockwise, the current is increased (Figure 5). The approximate value of the adjusted current can be read on the correct adjustment indicator (4).
•  The machine is ready to weld.
• The below table is given as a reference for the current adjustment of mild steel electrodes, please refer to the electrode manufacturer’s recommendations.

MAINTENANCE AND SERVICE

• Strictly follow the instructions contained in safety rules while servicing the machine.
• Before removing any screw on the machine for maintenance, the power supply must be disconnected from the electric lines and enough time should be allowed for capacitor discharging.

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 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.

Every 6 Months

• Clean and tighten fasteners such as bolts and nuts.
• Check the electrode clamp and grounding clamp cables.
• Open the side covers of the machine and clean with low-pressure dry air. Do not apply compressed air to electronic components at a close distance

NOTE: The above-mentioned periods are the maximum ones that should be applied if no problems are encountered in your device.
Depending on the workload and contamination of your work environment, you can repeat the above processes more frequently.

Never operate the machine when covers are open.

Troubleshooting

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

•No neutral line
•Fuse blew out
The welding current is low.| •Phase failure
•Diode unit breakdown
•Primary or secondary coil born down
The fan is out of order.| •Fan supply voltage phase failure
•Fan motor breaks down

ANNEX 1 – SPARE PARTS LIST

ANNEX 2 – CIRCUIT CHART

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