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Yeni Monomag 180 User Manual.cdr
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1. oe 10 T WELBING 5 5 rrr ka a RD BE an ves ea 11 4 1 ADJUSTING THE S K OUT iet esi coena t eee ec ml angle odd ATAR ak 11 4 2 WELDING PARAMETERS tir pep anda tere dl al alaya cae b 11 5 MAINTENANCE 5 2 12 PERIODIG MAINTENANCE 12 52NONPERIODICMAINTENANCE AKEE 12 5 3 2 13 yan EET 13 APPENDIX T SPARE PARTS L ST ei aa aaa laa ur 14 APPENDIX 2 ELECTRICAL D AGRAM is sesim saa pi lakin 15 Monomag 180 1 SAFETY RULES OBEY ALL THE SAFETY RULES STATED IN THE MANUALI 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
2. Besureall equipmentin the welding area is electromagnetically compatible Toreduce possible interference keep weld cables as short as possible close together and down low such asonthe 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 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 area PROTECTION RD 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 Ifyou will have along break after welding turn off the machine after cooler fan cooled the machine Monomag 180 5 TECHNICAL INFORMATION 1 TECHNICAL INFORMATION 1 1 GENERAL EXPLANATIONS Monomag 180 is a single phase step controlled constant voltage compact MIG MAG welding equipment to be used especially for intensive thin metal repair applications Any kind of metal can be welded with this machine if proper welding wire and gas is used For mild steel welding even under CO you can weld with low spatter and stable arc The concept of this machine is based on our industr
3. Arc Lengths 4 2 SELECTING THE VVELDING PARAMETERS 3 m m EL 4 1213211 E du elel elal el res 0 rf a e F 3 Monomag 180 11 MAINTENANCE AND TROUBLESHOOTING 5 MAINTENANCE AND TROUBLESHOOTING Strictly follow the instructions contained in safety rules while servicing the machine Before removing any screw on the machine for maintenance it should be disconnected from the mains and 10 seconds should be allowed for capacitor discharging 5 1 PERIODIC MAINTENANCE Once every three months Clean the labels on the Repair or replace the vvorn machine Repair or out welding cables replace the worn out EN Ep labels Check the isolation of the Clean and tighten weld gt gt torch electrod holder earth terminals pe clamp and their cables 25 5 9 Once 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 5 2 NONPERIODIC MAINTENANCE 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 acc
4. 4 Monomag 180 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 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 notto fall over attach itto the mobile machine orto the wall with a chain Ensurethatoperators easily reach the controls and connections on the machine inu OVERUSE CAN CAUSE OVERHEATING E 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 without the approval of manufacturer ARC WELDING CAN CAUSE INTERFERENCE 11 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
5. 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 EN ELECTRICAL SHOCK CAN BE FATAL h gt Installation procedure must comply with national electricity standards and other relevant regulations and ensure that installation is performed 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 not touch 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 SEVER
6. or cannot b adjusted Contact your authorized technical service Heater socket is not working Fuse is blown out F2 Change the fuse 5 4 FUSES F1 T Fan Protective gas pressure is not appropriate 0 8A F2 1A F CO Heater Socket F3 10A Wire Feeder Monomag 180 13 APPENDIX 1 SPARE PARTS LIST NO MATERIAL CODE DESIGNATION 1 A253200003 Gas Ventile 2 A300101005 Glass Fuse Fast 1A 3 A300101015 Glass Fuse Fast 10A 4 A300102003 Glass Fuse Delayed 800mA 5 A300190001 Glass Fuse Socket 6 A310310002 Signal Lamp Neon 240VAC 7 A310310004 Signal Lamp Neon 24VAC 8 A377100004 Mono phase Machine Socket 16A 240V 9 A410200003 Stone Resistor 11W 220 Ohm 10 A410801001 Carbon Potentiometer 0 5VV 11 A229500002 Wire Feeding Speed Adiustmend Knob 12 A430800000 LED 13 A490300004 Plastic Card Holder 14 A430901002 Diode Bridge 15 A314800102 Temperature Limiting Switch 16 K304400012 Control Transformer 17 A229900004 Wire Spool Support 18 A308010004 Changeover Switch 19 A250100003 Axial Aspirator 20 A430902004 Diode Bridge 21 K405000064 Electronic Board 22 A377900106 Welding Socket 23 K309002202 Wire Feeding System 24 K304500028 Choke Coil 25 K304000048 Main Transformer 26 K302200032 Primary Secondary Coil 27 A225220008 Swivel Plastic Wheel 28 A225222010 Plastic Wheel 29 A229102002 Bakelite U Arm 30 A229300006 Panel Cabinet Lock 31 A229200
7. 004 Hinge 14 Monomag 180 APPENDIX 2 ELECTRICAL DIAGRAM Pk1 BA q id 1 BR1 1 1 1 TR1 x n aq 1 7 2 4 10 6 1 gt gt pos 5 5 R1 R2 8 8 220R 1W 220R 1W 4 5 4 12 4 i 5 4 16 3 6 4 18 2 o o 7 4 8 1 I L o 24VDC 90VV F3 TR2 m sl lt 4 2 220VAC y VR1 275VAC al TRIGGER LL TH 5mm red led B GREEN NEON 17 D 220VAC WIRE SPEED 1k 15 Monomag 180 NOTES 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 02 02 2011 Made in T RK YE MAGMA MEKATRON K MAK NE SANAY VE T CARET A www magmaweld com
8. E BURNS 2 e Donottouch hot parts Allow cooling time before servicing e Ifneeded to hold hot parts use appropriate tool insulating gloves and fireproof clothes 2 Monomag 180 SAFETY RULES BREATHING VVELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH Inhaling fumes and gases over a long 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 orforced 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 i
9. USER MANUAL magmaweld MONOMAG 180 MIG MAG WELDING MACHINE MAGMA MEKATRON K MAK NE SANAY VE T CARET A CONTENTS SAFETY RULES adarr ER 2 1 TECHNIGAL INFORMATIONS eh oa sine K a nama m lan Sel lade 6 1 1 GENERAL EXPEANATIONS sacs atte tee yal tu ete et a i ln asly iz 6 1 2 COMPONENTS OF 180 6 TES DATA PLATE ia ai a dm lie nie re Ta neville 7 1 4 TECHNICAL SPEGIFICATIONS lets Dil ob t ei a er gest ees id 7 1 5 ACGGCESSORIES enne ER VEE uU tutte e eee 7 ap SE Hop 8 2 1 UPON REGEIBT AND GEAIMS s REO e o ee edad e Ea lak lili 8 2 2 INSTALLINGANDWORKINGRECCOMENDATIONS 8 2 4 WELDING CONNECTIONS Saime eyler le e Pad iie ea a e 9 24 1 Connectithe T reli 3 5 trato ee one rate 9 2 4 2 Connecting the Earth Cable to the Machine and to the Workpiece 9 2 4 3 Connect the Gas Cylinder t d tee E read OR ed bea 9 OPERATION SUE Citrate Pesce pat ea toate o teta ds s 10 3 1 2222 m 1 10 3 2 CHOOSING THE RIGHT FEED 5 10 3 3 LOADING THE SPOOL AND THREADING 2 10 3 4 ADJUSTING THE GAS ELOW s iiid de asalak a
10. ate with the pressure adiustment valve 22 For more information about gas adiustment check the following page Monomag 180 OPERATION 3 OPERATION 3 1 CONNECTING TO THE MAINS Before plugging your machine to the electrical line check if the correct voltage exists um While inserting the plug into the socket pay attention that main switch is positioned to OFF 0 3 2 CHOOSING THE RIGHT FEEDING ROLLS For steel and stainless steel wires use V shape rolls for flux cored wires use knurled V shape rolls for aluminium wires use U shape rolls If you need to change the wire feeding roll remove the screw 30 ofthe feeding roll Unlock the pressure assembly 28 by pulling down the spring knob 29 Figure 5 Wire Feeding Motor SWITCH ON the machine via power switch 1 and check if mains lamp 11 lights up and cooler fan works Remove the existing rolls and put in the rolls which you will use Both 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 screw 30 should be postioned and fastened 0 8 m 1 0 TN Figure 6 Wire Feeding Roll 3 3 MOUNTING THE SPOOL AND THREADING THE WIRE Figure 7 Placing the Wire Spool Remove the spool support nut 31 Place the MIG MAG wire spool 32 and screw t
11. bearings etc Se When the gas cylinder is placed on the machine immediately lock the chain to secure the cylinder if it is the stand alone then the cylinders should be secured to a wall by a chain The electrical socket behind the machine is for CO heater only it is not recommended to connect other devices Monomag 180 INSTALLATION 2 4 VVELDING CONNECTIONS 2 4 1 Connecting the Earth Cable to the VVorkpiece To increase the quality of welding earth clamp should be clamped tightly as close as possible to the vvelding area 2 4 2 Connecting the Gas Cylinder Figure 3 Connecting The Gas Cylinder 18 Gas Cylinder Safety Chain 23 Gas Hose 19 Gas Pressure Regulator 24 Flovvmeter 20 Gas Cylinder 25 Manometer 21 Gas Cylinder Valve 26 CO Heater 22 Pressure Adiustment Valve 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 Open the gas cylinder valve 20 few times in order to blow out any dirt or particles f CO is going to be used first connect the CO heater 26 and then connect the gas pressure regulator 19 to the gas cylinder 20 Connect one end of gas hose 23 to the gas supply inlet 6 at the back panel of the machine and connect the other end to the gas pressure regulator 19 e Figure 4 Connecting Gas to the Machine Set the gas flow r
12. he spool support nut 29 tightly 3 4 ADJUSTING THE GAS FLOW DO NOT ADJUST THE GAS FLOW DURING WIRE FEEDING Practical adjustment of the gas flow rate CO Ar MIX is 10 times ofthe diameter ofthe wire EXAMPLE Diameter ofthe wire 1 2 mm Gas flow rate 10 x 1 2 12 It min e GN HF P Figure 8 Threading the Wire Unlockthe pressure assembiy 28 by pulling down the spring knob 29 Figure 8 Take the wire from the wire spool by paying attention not to release it and thread the wire through the wire feeding rolls into the torch liner then pull down the pressure assembly 28 and lock the spring knob 29 For accurate gas flow rate adjustments use the following table Mild Steel and Metal 2 Flux Cored Flux Cored x 08 8 t min 8 t min 8 t min 7 g 0 9 9 It min 9 It min 9 It min 8 It min E 1 0 10 It min 10 It min 10 It min 9 It min 1 2 121t min 12 It min 12 It min 11 It min RS 200 MK RS 300 MK RS 400 MK VVELDING 4 VVELDING 4 1 ADJUSTING THE STICK OUT n order to obtain good vvelding characteristics stick out has to be adjusted according to the table which is afunction ofthe diameter ofthe wire Wire Free Wire 57577 Diameter d Length Short Arc Short Arc Globular Spray Arc 1 0 12d 12 Transfer Spray Arc 1 0 15d 15 Figure 15
13. ial 3 phase machines only the wire feeder is 2 wheel drive The machine is fan cooled and thermally protected against overheating 1 2 COMPONENTS OF MONOMAG 180 gmaweld 180 p Figure 1 Front View 1 ON OFF and Voltage Step Switch 10 2 Wire Feeding Speed Adjustment Knob 11 3 Torch Connector 12 4 Earth Clamp Socket 13 5 Welding Parameters Chart 14 6 Gas Supply Inlet 15 7 CO Heater Socket 220 VAC 16 8 Fuses 17 9 Mains Cable 18 D KKAT BU PR Z CO ISITICISI ND R KES NL KLE BA KA MAKSATLA KULLANMAYINIZ Figure 2 Back View Thermic Lamp Mains Lamp Lifting Eye Handle Swivel Wheel Braked Swivel Wheel Wheel Drum Feeding Gas Cylinder Safety Chain Monomag 180 TECHNICAL INFORMATION 1 3 DATA PLATE MAGMA MEKATRON K MAK NE SAN VE T C A Organize Sanayi B lgesi 5 K s m Manisa T RK YE MONOMAG 180 Der EN 60974 10 5 30A 16V 140A 21V ET poe Pox 39x w v ef ma soa 60a 14 29 vf ziv sv vv Single Phase Transformer Rectifier Horizontal Characteristics MIG MAG Welding Line Input 3 Phase Alternative Current Appropriate To Operate In Dangerous Work Area Direct Current Fuse Duty Cycle Open Circuit Voltage Line Voltage and Frequency Rated Welding Voltage 1 Input Current 1 Rated Welding Curren
14. n 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 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 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 Monomag 180 SAFETY RULES NOISE CAN DAMAGE HEARING 0 Noise from certain industrial processes or equipments damage hearing Wearapproved 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 bod
15. rce n Earth Cable Gas Hose User Manual 2 2 INSTALLATION AND WORKING RECOMMENDATIONS Use lifting eyes or fork lift to carry the machine DO NOT lift the machine together with the gas cylinder Transport and place the device on a firm and level ground so that it may not fall over The maximum permissible angle of inclination for transport and assembly is 10 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 Ensure that operators can easily reach the machine controls and connections Use suitable welding fume extraction systems Use breathing apparatus if there is a risk of inhaling in confined places Respect the duty cycles given at the 6 data plate Exceeding the duty cycles 2 frequently can damage the machine and this would void the warranty Do not use stronger fuses than those stated on the data 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
16. t IP 21 Protection Class 5 Input Power CL I Insulation Class Duty Cycle Temperature Time min 4 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 For example a welder with 6096 duty cycle must be rested 2 for 4 minutes after 6 minutes of continuous welding 1 1 4 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS UNIT VALUE Line Voltage 1 Phase 220 V 50 Hz Input Power 20 kVA 6 2 Recommended Line Fuse A 32 Input Current 20 A 28 Welding Current Range 30 140 Voltage Adjustment Steps Coarse x Fine 7 Rated Welding Current 2096 140 Dimensions LxwxH mm 888x455x870 Weight kg 79 Drive Roll Size V socket mm 0 6 0 8 VVire Feding Speed m min 1 17 Protection Class IP21 1 5 ACCESORRIES STANDARD ACCESORRIES PIECE Torch 1 Electrode Holder and Cable 1 Gas Hose 2m 1 Monomag 180 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 MEKATRONIK with the photocopy of shipping bill E mail servis magma com tr Fax 90 236 226 27 28 Standard pallet contains o Power Sou
17. umulated on the mechanism should be cleaned by a brush or dry air Contact tip and nozzle on the torch have to be cleaned regularly and changed if required Contacttips must be in good condition longer tips generally give better results 12 Monomag 180 MAINTENANCE AND TROUBLESHOOTING 5 3 BASIC TROUBLESHOOTING TROUBLE REASON REMEDY Machine does not work Electronic Card is out of order Contact your authorized technical service Fuse is blown out Change the fuse Wire feeder doesn t work 7 Electronic Card is out of order Contact your authorized technical service 77 75 bis appropnate Select the appropriate drive roll Wire feeder works but wire is ki vs i ou not fed Pressure in the pressure roll is the pressure roll not enough Contact tip size is wrong or t is Change the contact tip worn out P in th li 2 Adjust the pressure roll Trouble in welding operation ER Co heater fuse is blown out F3 Change the fuse Check the gas and its adiustment Contact the authorized service if the gas adiustment can not be made Fuse is blown out F1 Change the fuse Ventilator does not function Ventilator motor is out of order Contact your authorized technical service Machine works noisily Ventilator motor is out of order Contact your authorized technical service Welding current isn t stabilized Some diodes in the power pack ice and
18. y 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 NR WELDING CAN CAUSE FIRE OR EXPLOSION Never vveld nearflammable material Itmay cause fire or explosions Before starting to weld move flammables away or protect them with flame proof covers Do not weld 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 Forthat 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 5 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
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