Magmaweld TD 355 Welding Rectifier User Manual

Magmaweld TD 355 Welding Rectifier

SAFETY PRECAUTIONS

Be Sure To Follow All Safety Rules In This Manual!

Explanation Of Safety Information

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

Explanation Of Safety Symbols

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

Comprehending Safety Precautions

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

Electric Shocks May Kill

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

• Wear dry and sturdy insulated gloves and working apron. Never use wet or damaged gloves and working aprons.
• Wear flame-resistant protective clothing against the risk of burning. The clothing used by the operator must be protective against sparks, splashing and arc radiation.
• Do not work alone. In case of a danger make sure you have someone for help in your working environment.
• Do not touch the electrode with the bare hand. Do not allow the electrode holder or electrode to come in contact with any other person or any grounded object.
• Never touch parts that carry electricity.
• Never touch the electrode if you are in contact with the electrode attached to the work surface, floor or another machine.
• By isolating yourself from the work surface and the floor, you can protect yourself from possible electric shocks. Use a non-flammable, electrically insulating, dry and undamaged insulation material that is large enough to cut off the operator’s contact with the work surface.
• Do not connect more than one electrode to the electrode holder.
• Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
• Check the torch before operating the machine. Make sure the torch and its cables are in good condition. Always replace a damaged, worn torch.
• Do not touch electrode holders connected to two machines at the same time since double open-circuit voltage will be present.
• Keep the machine turned off and disconnect cables when not in use.
• Before repairing the machine, remove all power connections and / or connector plugs or turn off the machine.
• Be careful when using a long mains cable.

Safety Precautions

• Make sure all connections are tight, clean, and dry.
• Keep cables dry, free of oil and grease, and protected from hot metal and sparks.
• Bare wiring can kill. Check all cables frequently for possible damage. If a damaged or an uninsulated cable is detected, repair or replace it immediately.
• Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
• Make sure that the grounding of the power line is properly connected.
• Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling.
• Use AC output ONLY if required for the welding process.
• If AC output is required, use remote output control if present on unit.
• Additional safety precautions are required when any of the following electrically hazardous conditions are present :
• in damp locations or while wearing wet clothing,
• on metal structures such as floors, gratings, or scaffolds,
• when in cramped positions such as sitting, kneeling, or lying,
• when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented:
• Semiautomatic DC constant voltage (CV) MIG welding machine,
• DC manual MMA welding machine,
• DC or AC welding machine with reduced open-circuit voltage (VRD), if available.

Procedures for  Electric Shock

• Turn off the electric power.
• Use non-conducting material, such as dry wood, to free the victim from contact with live parts or wires.
• Call for emergency services.
• If you have first aid training;
• If the victim is not breathing, Administer cardiopulmonary resuscitation (CPR) immediately after breaking contact with the electrical source. Continue CPR (cardiac massage) until breathing starts or until help arrives.
• Where an automatic electronic defibrillator (AED) is available, use according to ins tructions.
• Treat an electrical burn as a thermal burn by applying sterile, cold (iced) compresses. Prevent contamination, and cover with a clean, dry dressing.

Moving Parts May Cause Injuries

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

Fumes and Gases May Be Harmful To Your Health

• Long-term inhalation of fumes and gases released from welding / cutting is very dangerous.
• Burning sensations and irritations in the eyes, nose and throat are signs of inadequate ventilation. In such a case, immediately boost the ventilation of the work area, and if the problem persists, stop the welding / cutting process completely.
• Create a natural or artificial ventilation system in the work area.
• Use a suitable fume extraction system where welding / cutting works are being carried out. If necessary, install a system that can expel fumes and gases accumulated in the entire workshop. 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.

Arc Light May Damage Your Eyes and Skin

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

Sparks and Spattering Particles May Get Into Eyes and Cause Damage

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

Hot Parts May Cause Severe Burns

• Do not touch the hot parts with bare hands.
• Wait until the time required for the machine to cool down before working on its parts.
• 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 Hearing Ability

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

Welding Wires Can Cause Injuries

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

Welding Operations May Cause Fire and Explosion

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

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

Welding / Cutting in Small Sized and Confined Spaces

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

Failure To Take Precautions During Transport May Cause Accidents

• Take all necessary precautions when moving the machine. The areas where the machine to be transported, parts to be used in transportation and the physical conditions and health of the person carrying out the transportation works should be suitable for the transportation process.
• Some machines are extremely heavy; therefore, make sure that the necessary environmental safety measures are taken when changing their places.
• If the machine is to be used on a platform, it must be checked that this platform has suitable load bearing limits.
• If it is to be transported by means of a haulage vehicle (transport trolley, forklift etc.), make sure of the durableness of the vehicle, and the connection points (carrying suspenders, straps, bolts, nuts, wheels, etc.) that connect the machine to this vehicle.
• If the machine will be carried manually, make sure the durableness of the machine apparatuses (carrying suspenders, straps, etc.) and connections.
• Observe the International Labor Organization’s rules on carriage weights and the transport regulations in force in your country in order to ensure the necessary transport conditions.
• Always use handles or carrying rings when relocating the power-supply sources. Never pull from torches, cables or hoses. Be absolutely sure to carry gas cylinders separately.
• Remove all interconnections before transporting the welding / cutting equipment, each being separately, lift and transport small ones using its handles, and the big ones from its handling rings or by using appropriate haulage equipment, such as forklifts.

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.

TECHNICAL INFORMATION

General Information

TD 355 is a moving-coil welding machine, designed to weld all type of coated electrodes from 2.0 to 5.0 mm. Excellent welding performance with cellulosic electrodes. The equipment is very easy to use, current adjustment is made by just turning the lever in front of the machine clockwise or counter clockwise and adjusted value of the current is observed by the scale on the machine. Although it is not an electrically efficient machine, due to its very simple concept, it is down time 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.  Current Adjustment Indicator
3.  Wheel
4.  Welding Cable Sockets (+ and -)
5.  Current Adjustment Lever
6.  Handle
7.  Lifting Eye

**Product Label

**

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).

Technical Data

Accessories

INSTALLATION

Delivery Control

• Make sure that all the materials you have ordered have been received. If any material is missing or damaged, contact your place of purchase immediately.
• The standard box includes the following;
• Welding machine and connected mains cable
• Workpiece clamp and cable
• Electrode clamps and cable
• 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.

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.
• Observe the duty cycle rates specified on the product label. Exceeding duty cycle rates can damage the machine and this may invalidate the warranty.
• Use the fuse that is compliant with your system.
• Secure the ground cable as close as possible to the welding area.
• Do not allow the welding current to pass through equipment other than the welding cables.
• Secure the gas cylinder to the wall with a chain.
• The welding cables and the mains cable must not be wrapped in the machine housing during operation.

Mains Plug Connection

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

• No plug has been connected to the mains cable since there may different types of outlets available in plants, construction sites and workshops. A suitable plug must be connected by
  a qualified technican. Make sure that the grounding cable marked with and a yellow / green color is present.

• after connecting the plug to the cable, do not attach it to the outlet at this stage.

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.

Welding Connections

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

Welding Adjustments

• By turning the current adjustment lever clockwise, current is increased. Approximate value of the adjusted current can be read on the corrent adjustment indicator.
• The machine is ready to weld.
• Below table is given as a reference for current adjustment of mild steel electrodes, please refer to the electrode manufacturer’s recommendations.
  Diameter (mm)| Rutile| Basic| Cellulosic
  ---|---|---|---
  2.0| 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
  5.0| 200-240 A| 200-250 A| 160-200 A

MAINTENANCE AND SERVICE

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

Maintenance

Daily Maintenance

• Do not remove the warning labels on the device. Replace the worn/torn labels with the new ones. Labels can be obtained from the authorized service.
• Check your torch, clamps and cables. Pay attention to the connections and the durableness of the parts. Replace the damaged/defective parts with the new ones. Do not ever make additions to/repair the cables.
• Ensure adequate space for ventilation.
• Before starting welding, check the gas flow rate from the tip of the torch with a flow meter. If the gas flow is high or low, bring it to the appropriate level for the welding process.

Every 6 Months

• Clean and tighten fasteners such as bolts and nuts.
• Check the electrode clamp and grounding clamp cables.
• Open the side covers of the machine and clean with low pressure dry air. Do not apply compressed air to electronic components at close distance.
• Check the socket to which the power supply plug of the machine is connected. If there is any looseness in the power cable connection points of the socket, remove such looseness. If there is an arc or expansion in the socket slots, replace them with new ones.
• Check the power supply plug of the machine. If there is any looseness in the power or cable connection points in the electricity plug, remove such looseness. If there is an arc or deformation at the ends of the plug, replace it with a new one.
• NOTE: The above mentioned periods are the maximum ones that should be applied if no problems are encountered in your device. Depending on the work load and contamination of your work environment, you can repeat the above processes more frequently.

Troubleshooting

Machine does not work

| •  Phase failure

•  No neutral line

•  Fuse blown out

Welding current is low

| •  Phase failure

•  Diode unit breakdown

•  Primary or secondary coil born down

Fan is out of order

| •  Fan supply voltage phase failure

•  Fan motor break down

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

ANNEX

Spare Parts List

Electrical Diagram

Documents / Resources

| Magmaweld TD 355 Welding Rectifier [pdf] User Manual
TD 355 Welding Rectifier, TD 355, Welding Rectifier
---|---
| Magmaweld TD 355 Welding Rectifier [pdf] User Manual
TD 355 Welding Rectifier, TD 355, Welding Rectifier

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