ID 250 E User Manual.cdr - Magmaweld Welding and Cutting
Contents
1. NO DESIGNATION MATERIAL CODE 1 Main Body K101111010 2 Right Cover K101115010 3 Left Cover K101116010 4 Upper Cover K101118010 5 nformation Sticker ID 250 E A909000037 6 Control Panel Sticker K109900026 7 Changeover Switch A308030004 8 Plastic Gland PG16 A376400016 9 Welding Socket A377900106 10 Knob Big A229500002 11 Knob Small A229500001 12 Cooling Fan A250200007 13 Rubber Foot A229400010 14 Handle Fixer A229102005 15 Handle K103009003 16 Electronic Card E202A 5 K405000118 17 Control Transformer A366100004 18 Electronic Card E202A 3 K405000116 19 Electronic Card E202A 1 K405000114 20 Electronic Card E202A FLT K405000119 21 Povver Transformer A366000007 22 Electronic Card E202A 2 K405000115 23 Electronic Card E202A 4 K405000117 24 Choke Coil K304500114 25 Capacitor DC Link A420300014 ID 250 E 15 FACTORY e Organize Sanayi B lgesi 5 Kisim Yalgin Ozaras Caddesi No 1 45030 MAN SA 444 93 53 90 236 226 27 28 OWM 04 10 2012 Made in TURKIYE MAGMA MEKATRON K MAK NE SANAY VE T CARET A www magmaweld com2. MEKATRONIK with the photocopy of shipping bill E mail servis magma com tr Fax 90 236 226 27 28 For a better performance keep the machine at least 30 cm away from the surrounding objects Beware of excessive heat dust and humidity around the machine Try not to operate the machine under direct sunlight Machines should be operated on lower capacities when ambient air temperature exceeds 40 C Avoid welding at outdoors where it is windy and rainy if this is a must protect the welding area with curtains mobile screens or tents Use suitable welding fume extraction systems Use breathing apparatus if there is a risk of inhaling in confined places 2 3 ELECTRIC PLUG CONNECTION For your own safety do not use the mains cable of the machine without a plug Since mains connection sockets may vary from factory to factory an appropriate plug must be installed to the built in mains cable of the machine by qualified electricians Please observe that the earth cable is in yellow green colour and labeled as After installing the electric plug DO NOT INSERT IT INTO THE SOCKET AT THIS STAGE Standard pallet contains 2 Power Source Earth Cable Electrod Holder User Manual 2 2 INSTALLATION AND WORKING RECOMMENDATIONS Respect the duty cycles given at the data plate Exceeding the duty cycles frequently can damage the machine and this would void the warranty Do not use stronger fuses than those stated on the da
3. 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 cylinders not to fall over attach it to the mobile machine or to the wall with a chain Ensure that operators easily reach the controls and connections on the machine inu OVERUSE CAN CAUSE OVERHEATING b Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block airflow through the unit Donotfilter airflow to unit withoutthe approval of manufacturer m ARC WELDING CAN CAUSE INTERFERENCE 121 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 e Be sure all equipment in the welding area is electromagnetically compatible e 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 machine is installed and grounded according to this manual If int
4. stick electrode welding mode Stick electrode welding LED 13 ligths Adjust the current via current adjustment knob 7 Below table can be used as a rough reference for mild steel electrodes For exact parameters please refer to the electrode manufacturer s recommendations Cellulosic 2 0 40 60 A 2 9 60 90 A 60 90 A 60 100 A 3 25 100 140A 100 130 A 70 130 A 4 0 140 180A 140 180A 120 170A 5 0 200 240 A 200 250 A 160 200 A 3 4 TOUCH SCRATCH TIG VVELDING Push the vvelding mode selection button 10 for selecting Touch Scratch TIG welding mode Touch Scratch welding LED 14 lights Adjust the current via current adjustment knob 7 3 5 REMOTE CONTROL OPTIONAL It is possible to connect wireless or cable remote control unit In this case appropriate control socket must be installed onto the back cover by a certified Magma Service 3 6 ERROR MESSAGES CODE ERROR POSSIBLE REASON Thermal Error Machine is overheated because of high ambient temperature or exceeding duty cycle For better ignition turn the HOT START knob 11 clock wise Welding arc can drill the metal when it is very thin and hot start is high ARC FORCE is useful for electrodes which have tendency to stick into the weld pool during welding Turning the knob 12 clock wise will decrease the tendency to stick If ARC FORCE is adjusted too high spatter increases Start welding You can observe welding current A and voltage V by current displ
5. USER MANUAL magmaweld D 250 E DC INVERTER ARC WELDING MACHINE MAGMA MEKATRON K MAKINE SANAY VE T CARET A CONTENTS SAFETY RULES semaisi varana a Baya an l a 2 T e Ee ya N e 6 1 1 GENERAL EXPEANATIONS trien alin dn quae la span ttr mee yan da ran a Fe eva LR dd Ge 6 1 2 COMPONENTS OF THE MACHINE coc rene ten tit eet papa Lese ey rte Roue re to ep sanada 6 1 3 DATA 4530 0757 7 1 4 TECHNICAL SPECIFIGAT IONS naa erdt in tene ne aa in a yan ten rne en Fere E cd etos 7 1SAGGESSO RRIES usunne lekmann erd andet 7 2 INSTALLATION Sas aaa akan layla ba ani dala aaa l ak 8 2 1 UPON 8 2 2 INSTALLING AND WORKING 1 5 8 2 9 ELECTRIC PLUG CONNECTION kaviar kinini betae red drake ctas doi ada ga denen 8 2 4 CONNECTIONS FOR MMA 1 9 2 5 CONNECTIONS FOR TOUCH SCRATCH TIG 9 3s OPERATION EE odalar ces 10 CONNECTING TO THE MAINS unntakene Sisi 10 3 2 CONTROL PANEL 7 10 SP MMA WELDING 30000 11 3 4 TOUCH SCRATCH TIG WEED ING tete e eiu ee Anu aa ana eta alama SNR ERR ERE 11 3 5 REMOTE CONTROL OPTIONAL iv titu ie
6. 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 which are easy to reach Keep security valves regulators and other valves used on flammable explosive and compressed gas circuits in good condition MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES x e Electrical devices should not be repaired by unqualified persons Improper repairs can cause serious injuries or even death during applications e The components of the gas circuit works under pressure The service given by unqualified persons may cause explosions and operators can be injured seriously 4 ID 250 E SAFETY RULES EZ FALLING UNIT CAN CAUSE INJURY A 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
7. ated Welding Voltage z 1 Input Current U 380V 20 213 1 Rated Welding Current m wee Ce re S Input Power Duty Cycle Temperature C Time min 3 5 min Duty cycle defines the percentage of welding time out of a period of 10 minutes at a given current and ambient temperature standard is 40 C For example a welder with 250A at 35 duty cycle must be rested 2 for 6 5 minutes after 3 5 minutes of continuous welding 1 1 4 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS UNIT VALUE Line Voltage 3 Phase Vac 380 Input Power 35 kVA 13 5 Rated Input Current 35 A 20 5 Power Factor 0 97 Open Circuit Voltage Vpc 75 Welding Current Range Apc 5 250 Rated Welding Current 9635 Apc 250 Fuse A 32 Delayed Protection Class IP23S Cooling Method Air Dimensions LxWxH mm 576x250x462 Weight kg 21 5 Standards and Approvals 1 5 ACCESSORIES CE EN60974 1 EN60974 10 STANDARD ACCESSORIES PIECE PRODUCT CODE Electrode Holder and Cable 25mm 3mt Earth Clamp and Cable 25mm 3mt ID 250 E 1 K301000303 1 K301100303 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 item is missing or damaged contact your supplier immediately In the event of damaged or missing delivery draw up a record take a photo of the damage and report it to the shipping agency and MAGMA
8. ay 8 and voltage display 9 Start welding You can observe welding current A and voltage V by current display 8 and voltage display 9 When the remote control connector is connected to the machine ampere adjustment knob on the machine is disabled automatically and current adjustment is made by the remote control POSSIBLE REMEDY Let the machine on for a while in order to cool down itself with the cooling fan After it cools enough you can go on welding Power Module Error Error errors may exist in any electronic card Switch off and switch on If the error still exists Check the mains voltage whether it is within the range of 340V 420V or not If the error still exists contact to your authorized technical service Overvoltage Mains voltage is too high Check the mains voltage whether it is within the range of 340V 420V or not If the error still exists contact to your authorized technical service Undervoltage Mains voltage is too low ID 250 E Check the mains voltage whether it is within the range of 340V 420V or not If the error still exists contact to your authorized technical service 11 MAINTENANCE 4 MAINTENANCE Strictly follow the instructions contained in safety rules while servicing the machine Before removing any screw on the machine for maintenance power supply must be disconnected from the electric lines and enough time should be allowed for capacitor d
9. d by qualified persons Wear dry insulating gloves free of damage and body protection Do not touch electrode with bare hand Do not wear wet or damaged gloves and body protection Do nottouch live electrical parts Never touch electrode while in contact with working surface ground or another electrode which is connected to a different machine Protect yourself from electric shock by insulating yourself from work 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 more than one electrode to the electrode holder Turn off the machine when not in use Disconnect input plug or swtich off the power before working on the machine Frequently inspect input power cord for damage or bare wiring repair or replace cord immediately if damaged Be sure that the machine is properly grounded HOT PARTS CAN CAUSE SEVERE BURNS zf e Do nottouch hot parts Allow cooling time before servicing e fneeded to hold hot parts use appropriate tool insulating gloves and fireproof clothes 2 ID 250 E SAFETY RULES BREATHING WELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH Inhaling fumes and gases over a long period of time generated during welding is dangerous and forbidden my Irritation of the eyes nose and throat are s
10. erference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area PROTECTION po Donotexpose the welding machine to rain protect from water drops and vapour ENERGY EFFICIENCY Choose appropriate welding method and welding machine for your work Choose appropriate welding current and welding voltage for the material and its thickness e If you will have a long break after welding turn off the machine after cooler fan cooled the machine ID 250 E 5 TECHNICAL INFORMATION 1 TECHNICAL INFORMATION 1 1 GENERAL EXPLANATIONS ID 250 E is an inverter type portable tri phase DC MMA vvelding machine designed to weld stick electrodes up to 5 0 mm Due to descending characteristics of the inverter technology it provides stable arc and good re striking performance Initial striking ability of the electrodes can be improved via Hot Start potentiometer and certain electrodes like basic electrodes which have tendency to short circuit and stick to the weld pool could be avoided by adjusting the Arc Force potentiometer It can be used as a Touch Scratch DC TIG welder if a TIG torch with a valve is connected The electric consumption is approximately 1096 less than the silicon controlled rectifier equipments and 2596 less than the magnetically controlled equipments ID 250 E can also be used with long welding cables up to 25 mt Plus wireles
11. is positioned to 0 Before plugging your machine to the electrical line check with a voltmeter the correct voltages indicated at the plate of the machine and then insertthe plug into the socket SWITCH ON the machine via ON OFF switch 2 Observe that the illumination of hte displays and LEDs are visible and the sound of the cooler fan is hearable 11 13 A N Pet Start mi 4 ay 14 CN wu B 12 i 1 IN N 10 l Arc Force ID 250 E Figure 7 Control Panel 7 Current Adjustment Knob is used for adjusting the welding current in a range of 5 250A 8 Current Display displays the welding current during welding displays the adjusted current when the machine doesn t weld 9 Voltage Display displays the open circuit voltage and the welding voltage during welding 10 Welding Mode Selection Button is used for selecting either stick electrode welding mode or touch scratch TIG welding mode 11 Hot Start Adjustment Knob is used for a better ignition in stick electrode welding 12 Arc Force Adjustment Knob is used for reducing the electrode s tendecy to stick into the weld pool during welding 13 Stick Electrode Welding LED lights when stick electrode welding mode is selected 14 Touch Scratch TIG Welding LED lights when touch scratch TIG welding mode is selected ID 250 E OPERATION 3 3 MMA WELDING Push the welding mode selection button 10 for selecting the
12. ischarging 3 1 PERIODIC MAINTENANCE ONCE IN EVERY 3 MONTHS Clean the labels on the machine replace the worn out labels Repair or replace the worn out welding cables ESLA Clean and tighten the weld terminals E VG ER ONCE IN EVERY 6 MONTHS Open the covers of the machine and clean with dry air Check isolation of the eff electrode holder earth clamp and their cables NOTE The above recommended maintenence periods are indicative these may vary according to the work shop conditions 4 2 NONPERIODIC MAINTENANCE 12 generally give better results 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 ID 250 E APPENDIX 1 ELECTRICAL DIAGRAM 19943 JOWUOJSUEIL To ure 1109 4049 YNO S LOH ow UUOJSUELL uang G WZ0Z3 Im id JeuuojJsueJ Jojuo2 1244 Ped zol p pose MONA 13 ID 250 E APPENDIX 2 SPARE PARTS LIST 0 KD T 8 AAA YAMA ARYA O44 2 GGG PI GLY 77 10 10 LOD GOD HA 12 HAT 9 YD Z gt Y Y 777 all A cU 9 z 25 gt n 43 14 ID 250 E APPENDIX 2 SPARE PARTS LIST
13. nt da a aya c Bam agree a a 11 3 0 ERROR MESSAGES iy aras m 11 EE 12 4 4 MAINTENANCE 0000706 12 4 2 NONPERIODIG MA NTENANCE 12 APPENDIX 1 ELECTRICAL DIAGRAM beder an 13 APPENDIX 2 SPARE PARTS LIST Ra R k l tx tien gel Pcr pa v xeu ea ck cd dd trea ib 14 ID 250 E 1 SAFETY RULES OBEY ALL THE SAFETY RULES STATED IN THE MANUAL 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 UNDERSTANDING THE SAFETY WARNINGS Read carefully the manual and the labels and the safety warnings on the machine Make sure that the warning labels positioned on your machine are in good order Renew the damaged and the missing labels Learntooperate 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 ELECTRICAL SHOCK CAN BE FATAL Installation procedure must comply with national electricity standards and other relevant regulations andensure that installation is performe
14. otect 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 SPARKS amp FLYING METALS CAN INJURE EYES Welding wire brushing and grinding cause sparks and flying metal Topreventinjuries wear appropriate safety glasses with side shields even under your welding helmet MOVING PARTS CAN CAUSE INJURY Keepaway from moving parts Keepall doors panels and guards closed and secured e Wear shoes with metal protection over the fingers ID 250 E SAFETY RULES NOISE CAN DAMAGE HEARING 88 e Noise from certain industrial processes or equipments can damage hearing e Wear approved ear protection if noise level is high 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 WELDING WIRE MAY CAUSE INJURY Do not point the torch toward any part of a human 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 NA WELDING CAN CAUSE FIRE OR EXPLOSION Wy 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 weld on
15. s and cable remote control options are possible The machine is fan cooled and thermally protected against over heating For more information about TIG welding check page 9 1 2 COMPONENTS OF THE MACHINE E ee fosse tf 2 42 94 OA magmaweld ID 250 E 10 1 Ey ENE EN A NE XN NN NN 2 NC NE NA NS NN NN 1 Figure 1 Front and Back View 1 Mains Cable Inlet 7 Current Adjustment Knob 2 ON OFF Switch 8 Current Display 3 Remote Control Connector Inlet 9 Voltage Display 4 Earth Cable and Welding Cable Socket 10 Welding Mode Selection Button 5 Earth Cable and Welding Cable Socket 11 Hot Start Adjustment Knob 6 Handle 12 Arc Force Adjustment Knob 6 ID 250 E TECHNICAL INFORMATION 1 3 DATA PLATE R SHG Single Phase Static Frequency Converter MAGMA MEKATRONIK MAK NE SAN VE T C A Transformer Rectifier Organize Sanayi B lgesi 5 Kisim Manisa T RK YE E Manual Metal Arc Welding Sela 0 Pis EN 60974 1 EN 60974 10 eee Directeuren 5A 10V 250A 30V A Descending Characteristics 100 ye Line Input 3 Phase Alternating Current b 250A 193A 148A sl Appropriate To Operate In Dangerous Work Area E U 27 7V 25 9V X Duty Cycle u 75v 1 20 5A 1454 NA U Open Circuit Voltage 5 13 5kVA 10 3kVA 7 6kVA U Line Voltage U R
16. ta plate Ensure that the earth clamp is tightly connected as close as possible to the welding location Do not let welding current flow through any media other than welding cables e g over the machine itself gas tubes chains ball bearings etc Figure 2 Electric Plug Connection ID 250 E INSTALLATION 2 4 CONNECTIONS FOR MMA WELDING According to the polarity of the electrode to be used insert welding cables into the appropriate outlet 4 and 5 and tighten them by turning clock wise Connect the earth clamp tightly to the workpiece as close as possible to the welding area Figure 3 MMA Welding Connections 2 5 CONNECTIONS FOR TOUCH SCRATCH TIG WELDING TIG torch with a valve should be Install the Argon gas regulator onto the Argon gas used cylinder Connect the TIG torch power Connect the gas hose of the torch to the gas cable to the negative outlet 5 regulator and the earth cable to the positive outlet 4 of the machine Figure 5 Connecting Gas Cylinder Diameter of Diameter of Welding Electrode Nozzle Current mm mm 1 0 6 3 15 70 1 6 9 5 30 150 6 8 Figure 4 TIG Welding Connections ID 250 E 9 OPERATION 3 OPERATION 3 1 CONNECTING TO THE MAINS Figure 6 Mains Connection 3 2 CONTROL PANEL 8 7 9 magmaweld M E PE While inserting the plug into the socket pay attention that ON OFF switch
17. ymptoms 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 accumulated 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 it can be inhaled which is dangerous for health Do not perform welding operations near chlorinated hydrocarbon vapors produced by degreasing or painting ARC RAYS CAN BURN EYES AND SKIN Use adequate welding helmet with correct shade of filter 4 or 13 considering EN 379 to protect your eyes and face Protect open parts of your body arms neck and ears from arc rays by adequate protective clothing e To pr
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