eng RS 200 MK - RS 300 MK - R
Contents
1. 17 Diode Bridge 160A Diode Bridge 240A Diode Bridge 350A A430901009 A430901010 A430901011 18 Main Transformer RS 300 Main Transformer RS 300 Main Transformer RS 400 K304000052 K304000060 304000064 19 Prim Secondary RS 200 Prim Secondary RS 300 Prim Secondary RS 400 K302200040 K302200048 K302200056 20 Axial Aspirator Cooling Ventilator Cooling Ventilator A250100003 A250200003 A250200003 21 Glass Fuse Socket 20x5mm A300190001 A300190001 A300190001 22 Mono phase Machine Socket 16A 240V A377100004 A377100004 A377100004 23 Gas Ventile 24 VDC A253200001 A253200001 A253200001 24 Hinge A229200004 A229200004 A229200004 25 Panel Cabinet Lock A229300006 A229300006 A229300006 26 Bakalite U Arm A229102002 A229102002 A229102002 27 Eye Bolt M10 281000010 A281000010 A281000010 28 Swivel Plastic Wheel 100x35 A225220008 A225220008 A225220008 29 Swivel Plastic Wheel Braked 100x35 A225220106 A225220106 A225220106 30 Plastic Wheel 250x50x20 A225222010 A225222010 A225222010 31 Ampermeter Voltmeter Card E901A K405000016 K405000016 K405000016 RS 200 MK RS 300 MK RS 400 MK 21 APPENDIX 5 ELECTRICAL DIAGRAM FOR RS 200 MK Ha OVASL LHL ZHL LHL 21914 RS 200 RS 300 MK RS 400 222. Es rafal A pepe eo pap ea RS 200 MK RS 300 MK RS 400 20 APPENDIX 4 SPARE PARTS LIST FOR RS 200 RS 300 RS 400 MK RS 200 MK RS 300 MK RS 400 MK APPENDIX 4 SPARE PARTS LIST FOR RS 200 RS 300 RS 400 MK DESIGNATION MATERIAL CODE RS 200 MK RS 300 MK RS 400 MK 1 Changeover Switch 1 10 Changeover Switch 0 3 Changeover Switch 0 4 A308033106 A308033112 A308033114 2 Changeover Switch 1 7 A308033108 A308033108 A308033108 3 Wire Feeding Speed Adjustmend Knob A229500002 A229500002 A229500002 4 Potentiometer 10K A410801004 A410801004 A410801004 5 Welding Socket 35 70 A377900106 A377900106 A377900106 6 Switch For 2 4 Function Selection A310030002 A310030002 A310030002 9 Electronic Board ES212 K405000032 K405000032 K405000032 10 EMC Filter A490400001 A490400001 A490400001 11 Contactor 24VAC 16A Contactor 24VAC 16A Contactor 24VAC 25A 11000016 A311000016 A311000025 12 Control Transformer 500VA K304400024 K304400024 K304400024 13 Wire Feeding System K309002210 K309002210 K309002210 15 Wire Coil Support A229900004 A229900004 A229900004 Impedance Coil RS 200 Impedance Coil RS 300 Impedance Coil RS 400 K304500032 K304500040 K304500044
3. APPENDIX 6 ELECTRICAL DIAGRAM FOR RS 300 MK 9 8 19 E yol hal z IZIH s pi 3 1 8L yz 23 RS 200 RS 300 RS 400 APPENDIX 7 ELECTRICAL DIAGRAM FOR RS 400 MK cil EM LK vioe3 e v yu I A y C C L A OWASL E 21653 9 TA a CZ 15 5 6 bd 44 0 02 LHL Lua ZHL 141 9 4 a 7 DUI a d t eb q liz IWG RS 200 MK RS 300 MK RS 400 MK 24 FACTORY e Organize Sanayi B lgesi 5 K s m 5503 Sokak No 1 MAN SA 90 236 226 27 00 90 236 226 27 28 OWM 10 1011e 01 11 10 2010 Made in Turkey MAGMA MEKATRON K MAK NE SANAY VE T CARET A www magmaweld com
4. 14 3 5 SETTINGS FOR ALUMINUM 14 RS 200 RS 300 RS 400 4 MAINTENANCE 2 15 PERIODIC MAINTENANCE 15 4 2 15 4 3 BASIC TROUBLESHOOTING crea fttt ipee BA aaa 16 APPENDIX APPENDIX 1 WELDING PARAMETERS CHART FOR RS 200 2 17 APPENDIX 2 WELDING PARAMETERS CHART FOR RS 300 18 APPENDIX 3 WELDING PARAMETERS CHART FOR RS 400 19 APPENDIX 4 SPARE PARTS LIST FOR RS 200 MK RS 300 MK RS 400 20 APPENDIX 5 ELECTRICAL DIAGRAM FOR RS 200 MK 22 APPENDIX 6 ELECTRICAL DIAGRAM FOR RS 300 23 APPENDIX 7 ELECTRICAL DIAGRAM FOR RS 400 24 2 RS 200 MK RS 300 MK RS 400 MK SAFETY RULES ELECTRICAL SHOCK COULD BE FATAL A Installation procedure must comply with national electricity standards and other relevant regulations and ensure that installation is performed by gualified persons VVear dry hole free insulating gloves and body protection Do not touch electrode with bare hand Do not wear
5. wet damaged gloves and body protection Do not touch live electrical parts Never touch electrode vvhile in contact vvith vvorking surface ground or another electrode vvhich is connected to a different machine Protect yourself from electric shock by insulating yourself from vvork and ground Use non flammable dry insulating material if possible or use dry rubber mats dry wood or plywood or other dry insulating material big enough to cover your full area of contact with the work or ground and watch for fire Never connect up more than 1 electrodes or wires to the machine Turn off the machine when in use Disconnect input plug or power before working on machine Frequently inspect input power cord for damage or bare wiring repair or replace cord immediately if damaged Be sure input ground wire is properly connected to a ground terminal in disconnect box or receptacle BREATHING WELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH Inhaling fumes gases over along period of time generated during welding is dangerous and forbidden Irritation of the eyes nose and throat are symptoms of inadequate ventilation Take immediate steps to improve ventilation Do not continue welding if symptoms persist Install a natural or forced air ventilation system in the work area Install an adequate ventilation system in the welding and cutting area if needed install a system that can remove the fume and vapor a
6. 00 MK RS 300 MK RS 400 MK TECHNICAL INFORMATIONS UNIT ETTM RS 300 MK RS 400 MK 1 4 TECHNICAL SPECIFICATIONS Line Voltage 3 Phases 50 Hz V 380 380 380 Input Power 60 kVA 4 6 9 9 14 5 Input Current 60 A 7 15 22 Recommended Line Fuse A 3x16 3x16 3x32 Open Circuit Voltage Vpc 17 36 19 44 18 5 45 Welding Current Range 40 240 40 300 45 400 Rated Welding Current 160 250 350 Voltage Adjustment Steps Coarse x Fine 1x10 3x7 4x7 Dimensions LxWxH mm 890x460x950 890x510x950 890x510x950 Weight kg 90 95 116 Protection Class IP21 IP21 IP21 Drive Roll Size socket mm 0 6 0 8 0 8 1 0 1 0 1 2 Wire Feding Speed m dk 2 20 2 20 1 20 Trigger Control 2 4 2 4 2 4 1 5 ACCESSORIES RS200MK RS300MK RS 400 MK Earth Clamp and Cable 25mm 3m KM96013 KM96013 Earth Clamp and Cable 35mm 3m KM96023 Gas Hose D400202 D400202 D400202 CO Heater A259009002 A259009002 A259009002 Gas Pressure Regulator Ar CO A259001002 A259001002 A259001002 Torch MBG 25 AK 3 230A 9660 5290022205 5290022205 Torch MBG 25 AK 4 230A 60 5290022206 5290022206 5 Torch MBG 36 KD 3 320A 9660 5290022304 Torch MBG 36 KD 4 320A 60 5 5290022305 RS 200 RS 300 MK RS 400 INSTALLATION 2 INSTALLATION 2 1 UPON RECEIPT AND CLAIMS Be sure that you have received all the items that you have ordered In case of any items are missing or damaged contact your supplier
7. 16 300 29 V f l 300A 250A 200A E EN U2 29V 27V 24V 13 2kVA 9 9kVA 7 9 kVA X Duty Cycle Uo Open Circuit Voltage U1 Line Voltage and Frequency U2 Rated Welding Voltage For more information about Duty Cycle check page 10 Output voltage of the RS 200 MK can be adjusted through 10 steps between 16 26V output voltage of the RS 300 MK can be adjusted through 21 steps between 16 29V and output voltage of the RS 400 MK can be adjusted through 28 steps between 16 34V Wire feeding system is in the same cabinet so the machine occupies less space and it can be put into service faster than the separate wire feeder models RS 400 MK is a very good selection for medium thickness metal welding where mix gases and argon are used therefore it is a very good choice for stainless steel and aluminium MIG welding MAGMA MEKATRONIK MAKINE SAN VE TIC A S EN 60974 1 Organize Sanayi B lgesi 5 K s m Manisa T RK YE EN 60974 10 EF 45A 16V 400A 34V x 19 V l2 400A 350A 270A Uz 34V 31 5V 27 5V 11 All All A T32A 28 22 15 x 0 3 Phase Transformer Rectifier Horizontal Characteristics 4 MIG MAG Welding D D Line Input 3 Phase Alternative Current 5 Appropriate Operate In Dangerous Work Area Direct Current Fuse Input Current 12 Rated Welding Current 21 Protection Class 51 Input Power Insulation Class RS 2
8. NICAL SPECIFICATIONS vives arm alim 9 1 5 5 5 9 2 et a lak Sok nel aaa N iin ates 10 2 1 UPON REGEIPT AND CLAIMS alla alan n Ye Maa deu a da small 10 2 2 WORK AREA CE 10 2 3 2222 11 2 4 INSTALLATION OF THE 1 12 2 4 1 Connect The Machine To Power Sup LL 12 2 4 2 Connect The Torch o 12 2 4 3 Connect The Earth Cable To The 1580 11116 12 2 4 4 Connect The Earth 00 4 aaa 12 2 4 5 Connect The Gas Cylinder rensei LA AHA 13 2 4 6 Thread The Welding Wire 5 io eiii ecd emendo eee et tarea tee Pea p ud MEER Cu E ec 13 g USAGE INFORMA T O N ER anl laik Balear 14 3A ADJUSTING THE GAS EE OW payla Hz 14 3 2 ALIGNING DRIVE ROLLS FOR APPROPRIATEWIRE 2 14 3 3 5522 14 3 4 THE FUNCTIONS OF THE 2 4 9 5
9. TENANCE Wire feeding rolls and the surrounding parts should be kept clean and the surface of the drive rolls should definitely not be lubricated Each time the wire is replaced the dirt accumulated on the mechanism must be cleaned with dry air Contact tip and nozzle on the torch have to be cleaned regularly and changed if required Contact tips must be in good condition longer tips generally give better results RS 200 MK RS 300 MK RS 400 MK 15 AND TROUBLESHOOTING 4 3 BASIC TROUBLESHOOTING TROUBLE REASON REMEDY Fuse is blown out F1 Change the fuse Machine does not work Contactor is out of order 5 Contact your authorized technical service Electronic Card is out of order Wire feeder doesn t work Torch Fuse is blown out F1 Change the fuse doesn t perform the triggering Electronic card is out of order Contact your authorized technical service The drive roll is not appropriate PM for the wire diameter Select the appropriate drive roll Wire feeder works but wire is not fed Pressure in the pressure roll is Adjust the pressure roll as explained in not enough the Section 2 4 6 Contact tip size is wrong or it is Pressure in the pressure roll is Adjust the pressure roll as explained in not enough the Section 2 4 6 Trouble in welding operation heater fuse is blown out F3 Change the fuse Check the
10. USER MANUAL 1 magmaweld RS 200 MK RS 300 MK RS 400 MK MIG MAG WELDING MACHINE MAGMA MEKATRONIK MAKINE SANAYI VE TICARET A S eld com SAFETY RULES unti tte eet terdum discuss 3 VN IDENTIFYING SAFETY INFORMATION These symbols are being used to identify potential risks When seen a safety symbol in the manual it must be understood that there is an injury risk and following instructions must be read carefully to avoid potential risks While welding keep the third persons and especially the children away from the work area m UNDERSTANDING THE SAFETY WARNINGS Read carefully the manual and the labels and the safety warnings on the machine Make sure that warning labels positioned on your machine are in good order Renew the damaged and the missing labels Learn to operate the machine and how to make the controls properly Operate your machine in convenient work areas Improper modifications affect the safety of your machine negatively and shorten its lifetime 7 1 1 INFORMATIONS belalar ke RR RR 8 1 1 05 EXPLANAT ONS tenen anna 8 1 2 APPEIGATION AREA eas 4 54405484 8 teet bei 8 1 3 tu et ead atn it el a eet pala em 8 1 4 TECH
11. ain the switch is triggered and released the operation ends Steel torch liner has be replaced with a teflon liner Longer and larger inner diameter contact tips should be used RS 200 MK RS 300 MK RS 400 MK AND TROUBLESHOOTING 4 MAINTENANCE AND TROUBLESHOOTING must be disconnected from the electric lines and enough time should be allowed for capacitor discharging During maintenance pay attention to the moving parts in the machine such as ventilator wire feeding motor rolls and e 8 lt wire spool 4 1 PERIODIC MAINTENANCE ri Before removing any screw the machine for maintenance power supply ES Once every three months Clean the labels on the 4 machine Repair or E replace the worn out labels Clean and tighten weld Check torch electrod terminals a holder earth clamp and their cables 5 2 m Repair or replace the worn out welding cables 7 gi every six months Open the covers of the machine and clean with dry air NOTE The above recommended maintenence periods are indicative according to our general experience these may vary from work shop to work shop and the conditions of the welding site DO NOT CONNECT THE MAINS ELECTRIC BEFORE CLOSING THE CABINET PANELS 4 2 NONPERIODIC MAIN
12. arks and flying metal To preventiniuries wear appropriate safety glasses with side shields even under your welding helmet NOISE CAN DAMAGE HEARING Noise from certain industrial processes or equipments can damage hearing Wearapproved ear protection if noise level is high HOT PARTS CAN CAUSE SEVERE BURNS Donottouch hot parts Allow cooling time before servicing Ifneeded to hold hot parts use appropriate tool insulating gloves and fireproof clothes MOVING PARTS CAN CAUSE INJURY Keepaway from moving parts Keepall doors panels and guards closed and secured Wear shoes with metal protection over the fingers WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS While welding and cutting in small confined places always have a trained watchperson nearby Avoid working in such confined places 4 RS 200 MK RS 300 MK RS 400 MK SAFETY RULES WELDING WIRE MAY CAUSE INJURY af Do not point the torch toward any part of ahuman body other persons or any type of metal when unwinding welding wire While extracting the wire from the spool by hand it may spring suddenly and injure you or a nearby person protect especially your eyes and face Make sure that there is no one close WELDING CAN CAUSE FIRE OR EXPLOSION Never weld near flammable material It may cause fire or explosions Before starting to weld move flammables away or protect them with flame proof covers Do not we
13. ccumulated in the entire work area to prevent pollution use adequate filtration in discharge In the event of welding in small confined places or welding lead beryllium cadmium zinc zinc coated or painted materials also wear a fresh air supplied respirator in addition to the above mentioned rules Always have a trained watchperson nearby while working in small confined places Avoid working in such confined places if possible If gas cylinders are grouped in a different area make sure that it is a well ventilated area When not being used turn off the main cylinder valve and watch out for gas leakage Shielding gasses such as argon is denser than air and when being used in confined places can be inhaled in place of air and this is dangerous for your health Do not perform welding operations near chlorinated hydrocarbon vapors produced by degreasing or painting RS 200 RS 300 RS 400 MK 3 SAFETY RULES ARC RAYS CAN BURN EYES AND SKIN Use adequate welding helmet with correct shade of filter 4 or 13 considering TS 379 to protect your eyes and face Protect open parts of your body arms neck and ears from arc rays by adequate protective clothing To protect others by arc rays and hot metals surround the working area with flame proof curtains which are higher than eye level and put up warning boards FLYING METALS CAN INJURE EYES sur Welding wire brushing and grinding cause sp
14. ce on firm and level ground so that it may not fall over The maximum permissible angle of inclination for transport and assembly is 10 If the cylinder is placed on the machine lock the chain to secure the tube if not be sure that gas cylinder is chained vertically to a wall This machine is protected electronically against overloading Do not use stronger fuses than those stated on the type plate ofthe device Ensure that the earth clamp has good and direct contact near the welding location Do not direct welding current over chains ball bearings steel cables protection conductors etc Otherwise they may melt Ensure that operators can easily reach the machine controls and equipment connections Use lifting eyes for lifting the machine Do not lift the machine by using a fork lift or a similar vehicle The electrical socket behind machine is only for heating CO2 Do not use it for any other purpose Maximum permissible heat for thermal safety 6 min 4 min 6 min 4 min 6 min 4 min Time min Duty cycle defines the percentage of welding time out of a period of 10 minutes ata given current For example a 250A welder with a 60 duty cycle must be rested 2 for 4 minutes after 6 minutes of continuous welding 1 If the unit overheats thermostats will open and welding will stop Wait for the unit to cool down In this case ambient temperature might be over 40 C therefore either reduce the current or work with lower duty
15. chine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work STATIC ESD CAN DAMAGE PC BOARDS Puton grounded wrist strap before handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards PROTECTION Donotexpose the welding machine to rain protect from water drops and vapour LIFETIME e The lifetime determined by Ministry of Industry and Trade is 10 years OBEY ALL THE SAFETY RULES STATED IN THE MANUAL 6 RS 200 MK RS 300 MK RS 400 MK ELECTROMAGNETIC COMPATIBILITY EMC ELECTROMAGNETIC EMISSION All electrical equipment generates small amounts of electromagnetic emission due to current transferring in the equipment Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect not only welding machines but also many kinds of electrical equipment radio and TV reception numerical controlled machines telephone systems computers etc Welding and cutting machines have been designed to work for professional and industrial use for other applications to contact the manufacturers The user is responsible for installing and using the w
16. cycle Exceeding duty cycle can damage unit and void warranty RS 200 MK RS 300 MK RS 400 MK 2 3 COMPONENTS OF THE INSTALLATION of step switches steps and earth cable connections are different RS 200 MK has one step switch with 14 steps 2x7 RS 300 MK has 2 step switches with 21 steps 3x7 RS 400 MK has 2 step RS 200 MK RS 300 and RS 400 MK have the same components But number switches with 28 steps 4x7 Besides both RS 200 MK and RS 300 MK have one earth cable connection 7 when RS 400 MK has 2 earth cable connections 7 Q magmaweld RS 400 MK m Figure 1 Front View Line Voltage amp Coarse Step Switch Fine Step Switch Wire Feeding Speed Adjustment Knob Switch For 2 4 Function Selection Digital Voltmeter Digital Ampermeter Earth Cable Connection Torch Connection Welding Parameters Chart BEN RS 200 RS 300 RS 400 a 10 11 12 13 14 15 16 17 18 Figure 2 Back View Mains Cable Electrical Socket for Heater Gas Supply Inlet Fuses Drum Feeding Handle Lifting Eye Swivel Wheel Wheel 11 INSTALLATION 2 4 INSTALLATION OF THE MACHINE 2 4 1 Connect The Machine To Power Supply Before plugging your machine to the electrical line check carefully the 3 live phase neutral and earth connections are present The connection of line cable to the machi
17. ding bench or the workpiece Do not place the earth clamp on the welding machine or the gas cylinder otherwise the welding current will be carried via the protective conductors and it will destroy these Figure 7 Incorrect Connection of Earth Clamp RS 200 MK RS 300 MK RS 400 MK INSTALLATION 2 4 5 Connect The Gas Cylinder 12 Figure 8 Connecting Gas Hose The Machine Connect one end of gas hose 24 to the machine gas supply inlet 12 The other end is for connecting the hose to pressure regulator Figure 8 Figure 9 Connecting The Gas Cylinder 19 Pressure Regulator 23 Pressure Adj Valve 20 Gas Cylinder 24 Gas Hose 21 Gas Cylinder Valve 25 Flowmeter 22 Chain 26 Manometer After placing the gas cylinder on its platform fasten it with the chain To operate safely and get best results use approved gas regulators and heaters Briefly open the gas cylinder valve 21 several times in order to blow out any dirt and particles present Connect the pressure regulator 19 to the shielding gas cylinder 36 Screw the gas hose 24 pressure regulator 19 and open the shielding gas cylinder 20 Set the gas quantity with the pressure adjustment valve 29 For more information about gas adjustment check the following page RS 200 RS 300 RS 400 2 4 6 Thread The Welding Wire To avoid any problems during operation this part has t
18. elding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the welding the welding circuit in other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Extra precaution may be required when the welding power source is used in a domestic establishment Special measures shall be taken to achieve compliance with welding power source including HF frequency for arc ignition and stabilizing it may be required use of shielded cables and in any case to resolve the particular implementation e g with robot computer and any other electrical and electronic equipment connected to welding power source to call the technical assistance of the manufacturer Before installing the weldin
19. g cables in the shape of 8 and taping together reduce emission Connect earth clamp to workpiece as close to the weld as possible But the user should be control whether this situation damage to people and equipment or not RS 200 MK RS 300 MK RS 400 MK 7 TECHNICAL INFORMATIONS 1 TECHNICAL INFORMATIONS 1 1 GENERAL EXPLANATIONS RS 200 MK RS 300 MK and RS 400 MK welding machines are three phase constant voltage compact type MIG MAG welding machines The power supply is forced cooled and protected against overheating by a thermostat Allthe controls are placed on the front panel Running gear and cylinder rack are factory installed for better mobility in the workshop 1 2 APPLICATION AREA RS 200 MK is for welding thin steel stainless steel and aluminium sections 24 hours 7 days RS 300 MK is thin metal manufacturer s choice due to its high 60 duty cycle Also this machine could be used at the repair shops up to medium thicknesses This is an easy oparated simple cost efficient and long life machine 1 3 DATA PLATE MAGMA MEKATRONIK MAKINE SAN VE TIC A S EN 60974 1 Organize Sanayi B lgesi 5 K s m Manisa T RK YE EN 60974 10 0 40A 16 240 26 V f Uo l 2404 160A 125A 25 17 36 Uz 26V 23V 21V 1 167 5 MAGMA MEKATRON K MAK NE SAN VE T C A EN 60974 1 Organize Sanayi B lgesi 5 K s m Manisa T RK YE EN 60974 10 DP 40A
20. g equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account if needed arrange the working hours that not coincide with those Other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment Radio and television transmitters and receivers Computer and other control equipment Safety critical equipment Presence of heart beat regulators heart cells hearing devices or etc nearby Equipment used for calibration or measurement The immunity of other equipmentin the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures Welding equipment should be connected to the mains supply according to the manufacturer s recommendations OERLIKON welding machines are filtered against emission according to standards If interference still occurs it may be necessary to take additional precautions such as filtering of the mains supply The welding equipment should be routinely maintained according to the manufacturer s recommendations The welding equipment should not be modified without the approval of manufacturer The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Power cables and signal cables should be kept separately Keepin
21. gas and its adjustment Protect t Contact the authorized service if the gas ppropriate 4 adjustment not be made Fuse is blown out F3 Change the fuse Ventilator does not function Ventilator motor is out of order Contact your authorized technical service Machine works noisily Contactor is out of order Contact your authorized technical service Welding current isn t stabilized Some diodes in the power pack Contact your authorized technical service and or cannot be adjusted are out of order Heater socket is not working Fuse is blown out Change the fuse Voltmeter or ampermeter Fuse is blown out F4 Change the fuse is not working Electronic card is out of order Change the fuse 16 RS 200 MK RS 300 MK RS 400 MK APPENDIX 1 WELDING PARAMETERS CHART FOR RS 200 Ar CO 80 20 5 hasl sis ln S A ei N 5 4 z sed RS 200 RS 300 RS 400 APPENDIX 2 WELDING PARAMETERS CHART FOR RS 300 MK Ar CO 80 20 gt _ SSS SCR Lv 0 1 0 mm A ehe 1 2 mm RS 200 MK RS 300 MK RS 400 MK APPENDIX 3 WELDING PARAMETERS CHART FOR RS 400 MK 80 20 Tel lsizir A er 21 12 22 hele
22. h sides of the rolls are labeled according to appropriate wire diameter Rolls must be inserted into the flange in such a way that appropriate diameter of the wire to be feeded is seen from outside After installing the rolls the screws should be positioned and fastened 3 3 ADJUSTING THE FREE WIRE LENGTH Short Arc Globular Transfer Figure 14 Arc Lengths Spray Arc 3 4 THE FUNCTIONS OF THE 2 4 SWITCH This switch 13 is also called 2 4 switch indicating the number of torch switch strokes Mode 2 1 When operating at mode 2 once the switch is triggered wire feeding and current starts and when itis released the operation ends 3 5 SETTINGS FOR ALUMINUM WELDING Argon must be used as protective gas In this case the gas heater is necessary Wire feeding rolls has to be replaced with U groove rolls Less pressure should be applied on the feeding rolls than steel 14 Figure 13 Wire Feeding Roll In order to obtain good welding characteristics free wire length has to be adjusted by the following instructions The diameter of the wire and the distance between the nozzle and the contact tip is important Wire ll Free Wire 715 Length 1 0 10d 10 Short Arc Globular Transfer 12 1 Spray Arc 1 0 15d 15 Mode 4 Mode 4 gives more comfort to the welder for long welding operations and automatic applications when the switch is triggered and released the welding starts when ag
23. immediately In the event of damaged or missing delivery draw up record take a photo and report it to the shipping agency and MAGMA MEKATRONIK with the photocopy of shipping bill MAGMAMEKATRONIK 90 236226 27 28 2 2 WORK AREA Make sure that your line voltage is 3 Phase 380V 50Hz and you have a neutral and earth line present at your work place In order to cool down the machine and have an efficient work keep the machine at least 30 cm away from the surrounding objects Do not place any heat source as oven to front side of the machine where the cooling air is taken from Welding machine must not be effected of heat directly Do not place the machine in small and narrow places Beware of excessive dust and dirt Keep your machine away from wet and humid places Do not operate the machine under direct sunlight rain and wind Machines should be operated on lower capacities when ambient air temperature exceeds 40 C Please use a suitable exhaust system for gases and cutting vapours Use breathing apparatus if there is a risk of inhaling any welding or cutting vapours Avoid welding where air flow is high Protect the welding area with curtains or mobile screens Duty Cycle Temperature C Be sure that none of the following 5 items are missing in the box Power Source and attached line cable Earth Clamp and Cable Gas Hose Certificate of Warranty UserManual Transport and place the devi
24. ld on and cut closed tubes or pipes Before welding on closed containers open and clear them entirely Welding operations on these parts must be performed with the utmost caution Never weld containers or pipes containing or which have contained substances that could give rise to explosions Welding equipments warms up so never position them on flammable surfaces Welding sparks can cause fire For that reason keep extinguishing means such as fire extinguishers water and sand easy reach Have and maintain security valves regulators and other valves on the flammable explosive and compressed gas circuits in good condition by periodical controls used for welding and cutting operations FALLING UNIT CAN CAUSE INJURY Wrong positioned power source or other equipment may cause serious injury to persons or damage to objects While repositioning the power source always carry by using the lifting eye Never pull cable hose or torch Always carry the gas cylinders separately Before carrying the welding and cutting equipment disassemble all the connections between and separately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriate vehicles like forklifts Install your machine on flat platforms having maximum 10 slope that it does not fall over Install it on well ventilated non confined places away from the dust also avoiding the risk of falling caused by cables and hoses For gas c
25. ne is made in the factory Connection to the main lines is made by the end user It has to be performed by gualified electricians or by the people trained in this area 380V 50 60 Hz For RS 200 MK RS 300 MK and RS 400 Mk 4x2 5mm 5mt line cables have been used Earth cable has been labeled as is seen in the following figure Figure 3 Earth Cable Yellow Green AW gt Figure 3 Line Cable Unexpected results may occur if a mistake is made in the network connection While inserting the plug into the socket pay attention that main switch is positioned at 0 Now turn the switch to 1 and observe at noise of cooling fan and monitor the open circuit welding voltage on the voltmeter 2 4 2 Connect The Torch Make sure that liner and contact tip match with diameter of welding wire Insert the torch in to the torch connector 11 as seen in the figure Figure 4 Torch Torch Connector Figure 4 Connecting The Torch 2 4 3 Connect The Earth Cable To The Machine magmaweld Figure 5 Connection Of Earth Cable To The Machine Connect the earth cable to the work piece connetion 7 Figure 6 Connecting The Earth Clamp Mount the earth clamp in the immediate vicinity of the welding point such that the welding current cannot find its own way via machine components ball bearings or electrical circuits Connect the earth clamp firmly to the wel
26. o be understood correctly Inappropriate and incomplete operation may result in poor welding quality and harm the torch this kind of failures are out of warranty Ensure that the diameters of the drive rolls correct Raise the pressure assembly of the drive rolls flange TN Torch 1 Figure 10 Pressure Assembly Open Torch Connector Thread the wire to the torch through the guides into the liner Closeandtighten pressure assembiy Wire Guide Figure 11 Pressure Assembly Closed Turn on the machine by adjusting the switch for coarse tuning 1 to the position 1 While pushing the trigger of the torch wait until the wire comes out of the torch tip 13 USAGE INFORMATION 3 USAGE INFORMATION 3 1 ADJUSTING THE GAS FLOW DO NOT ADJUST THE GAS FLOW DURING WIRE FEEDING The indicators on the regulator at the tube side shows the pressure in Bar and the other shows the flow rate l min Appropriate gas flow rate must be between 8 and 10 times of the diameter of the wire in use The practical ratio is 10 EXAMPLE Diameter of the wire 1 2 mm Gas flow rate 10 x 1 2 12 25 Flowmeter 26 Manometer Figure 12 Pressure Regulator 3 2 ALIGNING DRIVE ROLLS FOR APPROPRIATEWIRE DIAMETER Always control the rolls on the flange for compatibility with diameter of the wire because alignment problems are out of warranty Bot
27. ylinders notto fall over attach itto the mobile machine orto the wall with a chain Ensure that operators easily reach the controls and connections on the machine RS 200 MK RS 300 MK RS 400 MK 5 SAFETY RULES MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES Electrical devices should not be repaired by unqualified persons Improper repairs can cause serious injuries or even death during applications The components of the gas circuit works under pressure The service given by unqualified persons may cause explosions and operators can be injured seriously m OVERUSE CAN CAUSE OVERHEATING Allowcooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Donotblock airflow to unit Donotfilter airflow to unit without the approval of manufacturer ARC WELDING CAN CAUSE INTERFERENCE K Electromagnetic energy arising during welding and cutting operations can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor To avoid possible EMC damages locate welding operation as far as possible 100 meters from any sensitive electronic equipment Be sure this welding ma
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