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1. 1 Adjust the solenoid as shown on page M34 18 11 08 22262 GB mara D MISA trouble shooting NEW MAGIC WELD 40 2 1 MOSA REV 11 08 Problem Possible cause Solution Incorrect maximum voltage 1 Incorrect maximum engine 1 Adjust the maximum engine spe under no load conditions speed ed as shown on page M34 Engine always at idle speed 1 Faulty circuit 1 Replace Engine always at maximum 1 faulty circuit 1 Dirty petrol filter speed 2 Faulty solenoid dirty air filter 1 Engine dirty carburetor See engine instruction booklet Insufficient power during 1 alternator windings not all the outputs 3 Tor welding or generation 2 Check that the resistance of the solenoid winding is approximately 10 ohm Irregular or inconsistent wel insulated from earth welding which go to the chopper ding current bridge and 4 for auxiliary power which go to the circuit board Use a multimeter to check the insulation of the alternator 2 welding chopper bridge not 2 disconnect the 3 welding cables insulated from earth the and for welding the black wire and the connector which go to the circuit board Use a multimeter to check that the bridge is insulated from the earth 3 power cables not insulated 3 check that the cables inside the from earth aluminium casting are properly 4 faulty circuit insulated 4 Replace RESISTENCE OF WINDING AT 20 C Output in weld mode Between g
2. Esquema el ctrico MOSA 1 9 80 11 81 2222 ens ezues 2193 OTIPOTUNNOD o uoo equesezd ep TS YSON VPT N 13M 2IOVIN j esouMWWWJ dyu ATVLI IN ODWSNI 0600Z QU STC 9103euast euquen VS a 329 034 uorjeuruoueg abeg MOTTANOTIVIO ra 107985013 euorzeuiuoueq beg ea UOTTET7 DOW Ei Q3H OSSOH 5 der x MOVISIONAN MOVIZIOHAN 8 MOE s00z Y0 81 eueiisne po p nuod rep euorzejo Jd e oiuueuez eosseuddos ojuniBBy y Io E IN 90076077 80404 auoizdo y uuo o ns 0 e 6 ex ojeonuod a VIN3931 amp TN 90074060 uuoo ns e 6 onuod jeu M wyoyj ezuejsise W TN 900290272 euejsne poip nuod eyosn ojeyjesed ur Mz uuoyzz 220151591 ojuniBBy W TN 0076067 Ld ones ns Hro ezuennpui ojunibBy 3 TN 002022 MESTRE O V9LAOL 1 1 9 80 11 81 61 1 euoIzezzuojne ens ezues 12191 e o rjeoiunuioo IP OJSIAIP uoo ouBesip ejueseud eyeudoud 2668 ip tuwa e eAjesu IS VSOIN NEW MAGIC WELD
3. 000 63 24 High yield rutile electrodes for flat or front plane 100 100 000 70 position welding for d c and a c 110 110 000 77 27 High yield acid electrodes for flat or front plane 120 120 000 84 position welding for d c pole and a c 28 High yield basic electrodes for flat or front plane Table 1 position welding for d c inverse polarity 30 Extra high yield acid electrodes extra high 1 for all positions penetration if required for flat position welding only 2 for plane and verticl for d c pole and a c 3 for plane posotion only Table2 Table 3 10 10 08 M55GB D Dimensioni Abmessungen M MOSA dimensions Dimensiones NEW MAGIC WELD 53 OMOSA REv 0 11 08 CF Dimensions SD 375 2 O e ms d pe 430 610 402 a LO l 18 11 08 22262 1 ES gt D OSAS o MOSA REV O 11 08 E NEW MAGIC WELD 60 Legenda schema elettrico A Alternatore F Fusibile H Presa 230V monofase I Presa 110V monofase R Unit controllo saldatura T Regolatore corrente saldatura Y Ponte diodi saldatura F1 Elettromagnete acceleratore S2 Trasmettitore livello olio Pulsante stop G3 Bobina accensione H3 Candela accensione W6 Sensore di hall St
4. 7 Fuel can cause fires Use only with safety protections 15 advisable to use all protections while A shifting the machine Use only with safety protections It is advisable to use protections suitable for xd the different daily checking works and or of Exhaust gases maintenance Exhaust gases from the engine can kill Petrol vapours Petrol vapours cause fires and can seriously damage your health Moving parts Moving parts are dangerous Avoid touching any ES moving parts with your hands or fingers Never wear loose clothing which may get trapped by moving parts 18 11 08 22262 GB MISA Gs ADVICE ENGINE DRIVEN WELDER NEW MAGIC WELD 2 2 OMOSA _ REVO 11108 E MAGIC WELD 200 ADVICE BEFORE USE The operator of the welder is responsible for the security of the people who work with the welder and for those in the vicinity The security measures must satisfy the rules and regulations for engine driven welders The information given below is in addition to the local security norms Arc welders can be dangerous Protect yourself and others A DANGEROUS from any possible risks which may cause death or serious injury e m Do not touch any bare wires leads or contacts as they may be live and there is danger of electric shock which can cause death or serious burns The electrode and welding cables etc are live when the unit is operating m Do not touch any electrical parts
5. Take out of the envelope A the user s manual B 2 Fit the handle as shown in the instructions fitting screws and spanner are supplied 3 Read the user s manual B the plates fixed on the machine the data plate In case you should transport or move the machine keep to the instructions as per the figures Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s packaging and conform to local rules and regulations Only authorized persons involved in the transport of the machine should be in the area of movement 18 11 08 22262 GB D Es A OMOSA REV 0 06 07 CF CTM MW 6 11 Note Lift the machine and assemble the parts as shown the drawing The accessory cannot be removed from the machine and used separately actioned manually or following vehicles for the transport of loads or anyway for used different from the machine move ments AO 26 06 01 M6GB sare A O mM E A Set up for operation MOSA REV 0 11 08 NEW MAGIC WELD MAGIC WELD 200 LUBRICANT En Please refer to the motor operating manual for the recommended viscosity RECOMMENDED OIL MOSA recommends selecting AGIP engine oil Refer to the label on the motor for the recommended products Agip To check the oil level 1 Remove the oil fill tap 24 and
6. air to the inside of the motor A WARNING Do not use the machine if it is not in good technical condition The machine must be in good working order before being used Defects especially those which regard the safety of the machine must be repaired before using the machine Do not use without protective devices provided Removing or disabling protective devices on the machine is prohibited lOS 18 11 08 22262 GB MOS A o Engine starting NEW MAGIC WELD 26 OMOSA _ REVO 11108 E MAGIC WELD 200 check daily Lightly pull the start up knob 73 until meeting resistance then pull decisively DI cs ATTENTION A NOTE Allow the start up knob to re enter slowly avoiding having it knock against the motor and Do not alter the primary conditions of regula 9 thereby damaging the start up system tion and do not touch the sealed parts 1 Turn the fuel cock 87 to ON FUEL COCK STARTER GRIP 4 When the engine is started the machine re aches maximum engine speed immediately 4000 rpm for 6 7 seconds after which the engine speed automatically decreases to minimum 2000 rpm The minimum is set by the solenoid which acts on the accelerator 2 Switch the choke control 66 to CLOSE lever N B Do not use the air valve if the motor is hot Or the air temperature is too high 5 The engine reaches maximum speed only when current is drawn in welding or auxiliary CHOKE LEVE
7. flood 5 Please do not use the machine in weather 004 conditions which are beyond IP protection shown both in the data plate and on page named technical data in this same manual 10 101 Q 20 max 20 max 10 10 Maximum leaning of the machine in case of dislevel 18 11 08 22262 GB M 2 7 NEW MAGIC WELD Instalaci n D CD Installazione Luftzirkulation Installation rev o 11108 CF Installation MOSA 1 9 80 11 81 a OD UNPACKING AND TRANSPORT NEW MAGIC WELD 3 MOSA REV 0 11 08 A NOTE t Be sure that the lifting devices are correctly mounted ade quate for the weight of the machine with it s packaging and conforms to local rules and regulations O When receiving the goods make sure that the product has not suffered damage during the transport that there has not been rough handling or taking away of parts contained inside the packing or in the set In case you find damages rough handling or absence of AN parts envelopes manuals etc we advise you to inform immediately our Technical Service A amp For eliminating the packing materials the User must keep to the norms in force in his country 1 Take the machine C out of the shipment packing
8. single phase auxiliary generation symbol 1 IP protection grads for electric devices against acess to dangerous parts according to the IEC 529 norm Internal Protection kg kilogram mass K welding cables set kVA kilovolt ampere kW kilowatt engine power kWh kilowatt hour energy Lwa maximum acoustic power level according to the regulations in force mm millimeter length measure S symbol of EN 60974 1 T thermic switch V Volt 18 11 08 22262 GB MO S A Gs INSTALLATION AND ADVICE NEW MAGIC WELD 26 OMOSA _ 1108 E MAGIC WELD 200 INSTALLATION AND ADVICE BEFORE USE Check that the air gets changed completely and the hot air sent out does not come back inside the set so as to cause a dangerous increase of the temperature Use in open space air swept or vent exhaust gases which contain the deathly carbone oxyde far from the work area i Make sure that the machine does not move during the work block it possibly with tools and or devices made to this purpose MOVES OF THE MACHINE At any move check that the engine is off that there are no connections with cables which impede the moves POSITION PLACE OF THE MACHINE AND OR EQUIPMENTS Place the machine on a level surface at a distance of at least 1 5 m from buildings or other plants A ATTENTION For a safer use from the operator DO NOT fit the machine in locations with high risk of
9. tank or fuel tap closed 5 Dirty or faulty spark plug 6 Cold motor 7 Other causes 1 Chopper welding bridge broken 2 Faulty circuit 3 Faulty alternator 1 Fuse open 2 Auxiliary power diode bridge broken 3 Faulty circuit 4 Faulty alternator 1 Incorrect solenoid adjustment 1 Position switch to ON 2 Refill or top off 3 Replace 4 Refill the tank Open the fuel tap 5 Clean or check and eventually replace 6 Hold down the CHOKE button after start up for a longer period of time 7 Consult the motor Operating Ma nual 1 Use a multimeter to test that there are 3 Kohms between pins 1 2 if NOT replace the bridge 2 Replace 3 Disconnect the welding and auxiliary power cables Use a voltmeter to check that there is 48 Vac at the outputs in weld and approximately 170 Vac in the 230 V version and 90 Vac in the 110 V version Carry out the check when the engine idles discon nect one of the two wires to the solenoid 1 replace the fuse 10A retarded for version 230V 15A retarded for version 110V 2 Use a multimeter to check the 2 single phase diode bridges on the auxiliary power 3 Replace 4 Disconnect the welding and auxiliary power cables Use a voltmeter to check that there is 48 Vac at the outputs in weld and approximately 170 Vac in the 230 V version and 90 Vac in the 110 V version Carry out the check when the engine idles discon nect one of the two wires to the solenoid
10. 011870 CAP 12 6060070 DOWEL 13 6060050 DOWEL 14 222440543 KIT FOR ARC FORCE KNOB 15 307047250 SOCKET 110V 16A 16 259107241 SOCKET SCHUKO 16 230V 2P T Note Versione 230V Versione 110V fino a REV 2 11 05 Del 78 06 del 18 05 06 da REV 3 06 07 Del 78 06 del 18 05 06 4 8 13 Versione 110V Versione Schuko Note 230V version 110V version up to REV 2 11 05 Del 78 06 del 18 05 06 from REV 3 06 07 Del 78 06 del 18 05 06 4 8 13 110V version Schuko version 18 11 08 22262 1 CTM MW KA 222420130 18 MOSA REV 0 06 07 e 990 222421050 BARELLA PROTECTIVE FRAME 222421226 MANIGLIA DI SOLLEVAMENTO L FTING HANDLE 219861159 MANOPOLA 222422038 RONDELLA 222421170 RUOTA 222421051 PIEDE DI STAZIONAMENTO PARKING STAND 222421160 AXLE 6075020 PIN SPLIT 222421356 PIASTRA FISS BASAMENTO FIXING PLATE FOR BASE 222429359 SPINA DI SICUREZZA SAFETY PLUG 1 2 3 4 5 6 7 8 9 h o 29 06 01 KA MOSA GRUPPI ELETTROGENI MOTOSALDATRICI WWW MOSA IT MOSA div della BCS S p A Stabilimento di Viale Europa 59 20090 Cusago MI Italia Tel 39 0290352 1 Fax 39 0290390466 ama jas ISO 9001 2008 Cert 0192
11. 11 08 Technical data NEW MAGIC WELD D C WELDING Current range continuous 30 150A Open circuit voltage 40 65V Duty cycle 150 A 6095 D C GENERATION Single phase output max 2kW 230V 8 7A Single phase output continuous 1 6kW 230V 6 9A Single phase output max optional 1 5kW 110V 13 6 A Single phase output continuous optional 1 2 KW 110 V 10 9A ALTERNATOR Self excited self regulated brushless Type permanent magnet three phase Insulating class H ENGINE Mark Model HONDA GX 200 Type Cooling system Gasoline 4 stroke Air Cylinders Displacement 1 196 cm Output max 5 kW 6 8 HP Speed 4000 rpm Fuel consumption 313 g kWh Engine oil capacity 0 6 Starter recoil GENERAL SPECIFICATIONS Tank capacity 3 61 Running time at duty cycle 60 3 5 h Protection IP 23 Dimensions max on base Lxlxh 430x375x470 Weight dry 34 Kg Noise level 99 LWA 74 dB A 7 m Dimensions and weight are inclusive of all parts POWER Declared power according to ISO 3046 1 temperature 25 C 30 relative hummidity altitude 100 m above sea level It s admitted overload of 1096 each hour every 12 h In an approximative way one reduces of 1 every 100 m altitude and of 2 5 for every 5 C above 25 C ACOUSTIC POWER LEVEL ATTENTION The concrete risk due to the machine depends on the conditions in which it is used Therefore it is up to the end user and under his direct responsibility t
12. 8 Pi ces de rechange Pos Rev Cod Descr Note 1 222406020 VENTOLA CENTRIFUGA FAN 2 222403047 ASSIEME MOZZO ROTORE HUB SHAFT ASSY 3 222413025 STATORE AVVOLTO 230 VAC STATOR 230V Versione 230V 230V version 3a 222403025 STATORE AVVOLTO 110 VAC STATOR 110V Versione 110V 110V version 4 222418263 PIASTRINA FERMA CAVI 5 1270040 PONTE DIODI DIODE BRIDGE 35A800V Versione 110V 110V version 5a 1270070 PONTE DIODI DIODE BRIDGE Versione 230V 230V version 6 222422200 MOTORE HONDA GX200T EPA HONDA ENGINE GX200T 7 102011270 TAPPO MANIGLIA STOPPER HANDLE 8 222401226 MANIGLIA DI SOLLEVAMENTO LIFTING HANDLE 9 222509800 SCHEDA SALDATURA MAGIC WELD WELDING PCB 10 222405400 PONTE CHOPPER WELDING PCB 11 222405107 SENSORE DI HALL 250A HALL SENSOR 12 222408065 GRIGLIA USCITA ARIA AIR OUTLET GRID 13 222403040 CARTER ATT MOTORE ALTERN LAV BOX 14 222409050 ELETTROMAGNETE ECONOMIZZATORE ECONOMIZER SOLENOID 15 222402244 MORSETTO PER FUNE COMANDO COMMAND WIRE CLAMP 16 222409101 SUPPORTO ELETTROMAGNETE SOLENOID BRACKET 17 222434126 LAMIERA PROTEZIONE REATTORE REACTOR PROTECTION 18 222401035 ANTIVIBRANTE D 25x30 VIBRATION DAMPER 19 222402038 RONDELLA DISTANZIALE WASHER 20 222411050 BASE SUPPORTO MOTORE ALTERN BASE 21 222434100 REATTORE DI LIVELLO REACTOR 22 222402199 SQUAD SUPP LEVA COMAN GAS MOT COMPL ENGINE GAS LEVER BRACKET 23 222408460 FILO RIGIDO COMANDO ACCELER ACCELERATOR WIRE 24 222402230 AS
13. EU Version ico iagram ic d CD Schema elettr Electr REv 0 11 08 Esquema el ctrico MOSA MOSA ai d 090 S 10 N 9281009 resoqurnwny d A enodd 20908 0000 E E Y pri us Geb Dover deo li U SII 98 19101200951 Beachy 5 Z z welbeig bunim gt v ESA anana 19 36 Heg ika gl 3 MOTENOTM W Tay 758 38 qay ossou y TN 90079081 eueysne quod rep euorzejoid e ojueuaz e1ossexddos aun Y XOVISIONSN 8 TN l 90076081 euejsne uod eyasn ojo ered ul ep 920191917 juni g Big ERA TN 40076062 d eJ0jeuuoo ns pri ezuegnpui ojunibby 0 N9LINOEZ lo us Eri Gi i z ar W ala A la sees gt 2 02 a MEI Es A o spare PARTS LIST 1 EEE MOSA 1 0 03 00 MOSA guarantees that any request for spare parts will be satisfied To keep the machine in full working order when replacement of MOSA spare parts is required always ask for genuine parts only 0 The requested data are to be fou
14. NEW MAGIC WELD 222629003 GB ENGLISH 18 11 08 22262M00 preparato da UPT approvato da DITE lt gt M OSA DESCRIPTION OF THE MACHINE NEW MAGIC WELD 0 MOSA REV 0 11 08 The Engine Driven Welder is a block with an engine an aluminium casting and a front panel Inside the casting there are all electrical components of the machine a permanent magnet alternator a high frequency chopper diode bridge an electronic control board and an electromagnet Main features e D C welding current 150A 60 e Continuous regulation of the welding current with Chopper Technology e Suitable for basic and rutile electrodes Areactance for cellulose electrodes is available as an option e Antistick function small arc force e Continuous auxiliary output 1600 W 230 Vdc max power 2000 W e Auto idle function e Weight 34 Kg Regulation knob for welding current Auxiliary output Welding sockets 4 Kc Fuse for auxiliary output Electrical components of the machine e Permanent magnet alternator the alternator has 2 galvanically separated windings one for welding and the other for the auxiliary output e Auto idle solenoid an electromagnet inside the aluminium casting is supplied at no load only and forces the engine speed at minimum 2000 rpm When the load is present welding or auxiliary output the electromagnet is not supplied any more and the engine speed goes to the maximum 4000 r
15. O 9001 2008 Cert 0192 UNI EN ISO 9001 2008 MOSA has certified its quality system according to UNI EN ISO 9001 2008 to ensure a constant highquality of its products This certification covers thedesign production and servicing of engine dri venwelders and generating sets The certifying institute ICIM which is a member ofthe International Certification Network IQNet awarded the official approval to MOSA after an examination of its operations at the head office andplant in Cusago MI Italy This certification is not a point of arrival but a pledgeon the part of the entire company to maintain a levelof quality of both its products and services whichwill continue to satisfy the needs of its clients aswell as to improve the transparency and thecom munications regarding all the company s activesin accordance with the official procedures and inhar mony with the MOSA Manual of Quality www icim it CERTIFICATO n CERTIFICATE No 0192 6 SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITA DI WE HEREBY CERTIFY THAT THE QUALITY MANAGEMENT SYSTEM OPERATED BY BCS S p A UNITA OPERATIVE OPERATIVE UNITS Sede e Unit Operativa Viale Mazzini 161 20081 Abbiategrasso MI Unit Operative Via Valbrina 17 19 42045 Luzzara RE Viale Europa 59 20090 Cusago MI Italia CONFORME ALLA NORMA IS IN COMPLIANCE WITH THE STANDARD UNI EN ISO 9001 2008 PERLE SEGUENTI ATTIVITA FOR THE FOLLOWING ACTIVI
16. R power mode ENGINE SWITCH 18 11 08 22262 GB MOSA REV 0 11 08 IT CD M D SA Stopping the engine NEW MAGIC WELD MAGIC WELD 200 t Before stopping the engine it is compulsory Disconnect or close any power load connected to the system s auxiliary generation Interrupt welding Fo To shut down the motor For shut down the motor in case of emergency turn the motor switch 28 to OFF In normal conditions wait for the engine to reach minimum speed automatically 6 7 seconds after the load has been excluded Turn the engine in these conditions for a few minutes so that it can cool down and then turn the engine switch 28 to OFF ENGINE SWITCH Turn the fuel valve to the OFF position FUEL VALVE 18 11 08 22262 GB D Comandi F gt Commandes M MOSA controls NEW MAGIC WELD 3 REv 0 11 08 CE Mandos 9 Prese di saldatura Welding sockets Prises de soudage Tomas de soldadura Prese di saldatura Welding sockets Prises de soudage Tomas de soldadura Presa di messa a terra Earth terminal Prise de mise terre Toma de puesta a tierra Presa di corrente in c c d c socket Prises de courant en c c Toma de corriente en c c Filtro aria motore Engine air filter Filtre air moteur Filtro aire motor Asta livello olio motore Oil level dipstick Jauge niveau huile moteur Aguja nivel ac
17. SIEME LEVA COMANDO GAS MOT ENGINE GAS LEVER 25 208029104 COLONNETTA SPACER 18 11 08 22262 1 D Ricambi Ersatzteile AG SA Spare parts Tabla de recambios NEW MAGIC WELD 2 MosA rev o 11108 Pi ces de rechange 0 2301 Version 2301 Schuko Version 18 11 08 22262 1 AG NEW MAGIC WELD 2 1 D Ricambi CD Ersatzteile M O SA GB Spare parts Tabla de recambios MOSA_ REv 0 11 08 Pi ces de rechange ID Pos Rev Cod Descr 1 1291180 FUSIBILE 1a 1291090 FUSIBILE 2 103011320 PORTA FUSIBILE 2 873789045 PORTA FUSIBILE 3 307017240 PRESA 220V 16A 4 270009701 POTENZ LINEARE A FILO 5Kohm 5 102301310 PRESA DI SALDATURA 4 6 102044400 PRESA DI SALDATURA 7 222427020 FRONTALE 8 1018090 ANELLO OR 9 107799349 BUSSOLA MANOP POT REG UN SALD 10 207409751 MANOPOLA REGOLAZ CORR SALDAT 11 107011870 TAPPO 12 6060070 GRANO FILETTATO E 1 M4X8 13 6060050 GRANO M 4X4 UNI 5923 R45H 14 222440543 KIT MANOPOLA ARCO SALD COMPL 15 307047250 PRESA 110V 16A 16 259107241 PRESA SCHUKO 16A 230V 2P T Pos Rev Cod Descr 1 1291180 FUSE 1a 1291090 FUSE 2 103011320 HOLDER FUSE 2 873789045 HOLDER FUSE 3 307017240 EEC SOCKET 16A 220V 2P T 4 270009701 POTENTIOMETER 5 102301310 WELDING SOCKET 6 102044400 WELDING SOCKET 7 222427020 FRONT PANEL 8 1018090 O RING 9 107799349 SLEEVE 10 207409751 KNOB WELDING CURRENT REGULAT 11 107
18. TIES EA 18 Progettazione produzione ed assistenza di trattori macchine per agricoltura e manutenzione del verde motosaldatrici e gruppi elettrogeni Design production and servicing of tractors agricultural and green maintenance machines engine driven welders and generating sets Manuale dela Qualit per applcabilt dei requis dell norma di riferimento Refer to Qualty Manual for details of application to reference standard requirements sistem digestione per la qualit delle aziende management systems i presente certificato soggetto al rispetto el regolamento per la certificazione dei The use and the valdy of this certificate shall sas the requirements of the rules for the certification of company Data emissione First issue 30 05 1994 Emissione corrente Data di scadenza Expiring date 05 03 2015 Current issue 06 03 2012 ACCREDIA The advantages for MOSA clients are Constant quality of products and services at thehigh level which the client expects Continuous efforts to improve the products andtheir performance at competitive conditions Competent support in the solution of problems Information and training in the correct applicatio nand use of the products to assure the security ofthe operator and protect the environment Regular inspections by ICIM to confirm that the requirements of the company s quality systemand ISO 9001 are being respected All these
19. advantages are guaranteed by the CER TIFICATE OF QUALITY SYSTEM No 0192 issued by ICIM S p A Milano Italy www icim it 10 10 02 M01 GB D OSA o mex NEW MAGIC WELD MOSA 0 11 08 M 01 M 1 01 M 1 1 M1 4 M2 M 2 1 M 2 2 M 2 3 M 2 6 M 2 7 M3 M 25 M 26 M 27 M 31 M 34 M 37 M 40 2 M 43 M 45 M 51 M 55 M 53 M 60 M 61 RI HT QUALITY SYSTEM COPYRIGHT NOTES CE MARK ADVICE SYMBOLS ADVICE ENGINE DRIVEN WELDER SYMBOLS ABBREVIATIONS LEGEND INSTALLATION AND ADVICE INSTALLATION UNPACKING AND TRANSPORT SET UP FOR OPERATION ENGINE STARTING STOPPING THE ENGINE CONTROLS USE AS A WELDER USE AS A GENERATOR TROUBLE SHOOTING MAINTENANCE STORAGE CUST OFF TECHNICAL DATA RECOMMENDED ELECTRODES DIMENSIONS ELECTRICAL SYSTEM LEGENDE ELECTRICAL SYSTEM SPARE PARTS LIST SPARE PARTS REQUEST FOR ORDER SPARE PARTS 18 11 08 22262 GB MOSA Copyright MOSA 1 0 10 02 C GE MS TS EAS N ATTENTION This use and maintenance manual is an important part of the machines in question The assistance and maintenance personel must keep said manual at disposal as well as that for the engine and alternator if the machine is synchronous and all other documentation about the machine We advise you to pay attention to the pages concerning the security see page M1 1 MOSA All rights are reserved to sai
20. ca della massima corrente di saldatura e eventualmente procedere ad una sua taratura nel se guente modo Lasciare fissato il frontale solo con la vite centrale inferiore e non stringerla in modo che il frontale nella sua parte superiore rimanga staccato di circa 7 8 cm Ruotare il trimmer sulla scheda tutto in senso antiorario Porre i dip switch secondo la figura Verificare che al minimo del potenziometro corrisponda il minimo della manopola Porre la manopola di saldatura al minimo e avviare il motore Lasciare che la macchina vada al minimo poi fare un corto circuito tra il e tramite i cavi di saldatura Ruotar e la manopola di saldatura al massimo Ruotare lentamente il trimmer in senso orario affinch la corrente di saldatura arrivi a 140A Every time either the board or the current sensor is changed it is necessary to check the max welding current and if it is the case to set it as follows Keep the front panel fixed with its lower central screw and don t tight it so that the front panel in its upper part can have a gap of 7 8 cm Rotate the trimmer on the board fully anticlockwise Put the dip switch as drawing Dip switch Check that to the minimum of the potentiometer corrisponds the minimum of the knob Put the welding knob to the minimum and start the engine Let the machine idle then shortcircuit between the and welding sockets through the welding cables Rotate the welding knob to the maximum Slowly rota
21. clean the dip stick 23 2 Insert the dip stick into the oil filler without screwing it in 3 Ifthe oil level is low fill with recommended oil up to the top of the oil filler Oil fill tap dip stick Upper oil level MOTORS WITH OIL ALERT DEVICE The Oil Alert system is designed to prevent dama ge to the motor due to an insufficient quantity of oil in the cup This system automatically shuts off the motor before the oil level falls below the safety limit If the motor does not start up again after shutting itself off check the oil level ry FUEL N ATTENTION y Gasoline is highly flammable Refuel with motor shut off in a flat surfaced well venti l lated area Do not refuel in the presence M of flames Avoid spilling fuel Any eventual spilled fuel and fumes are flammable Clean any dispersions of fuel before starting up the motor A Fill the tank with gasoline for automobiles prefe rably lead free or with low lead content in order to reduce deposits in the combustion chamber to a minimum For further details on the type of gasoline to use see the motor operating manual supplied Do not fill the tank completely leave a space of approx 10 mm between the fuel level and the wall of the tank to allow for expansion AIR FILTER Check that the dry air filter is correctly installed and that there are no leaks around the filter which could lead to infiltrations of non filtered
22. d Company It is a property logo of MOSA division of B C S S p A All other possible logos contained in the documentation are registered by the respective owners im The reproduction and total or partial use any form and or with any means of the documentation is allowed to nobody without a written permission by MOSA division of B C S S p A To this aim is reminded the protection of the author s right and the rights connected to the creation and design for communication as provided by the laws in force in the matter In no case MOSA division of B C S S p A will be held responsible for any damaga direct or indirect in relation with the use of the given information MOSA division of B C S S p A does not take any responsibility about the shown information on firms or individuals but keeps the right to refuse services or information publication which it judges discutible unright or illegal 10 10 02 M1 01 GB D M MOSA 0 Notes GE MS TS EAS 1 1 OMOSA 1 0 10 02 CF INFORMATION INFORMATION OF GENERAL TYPE Dear Customer We wish to thank you for having bought from MOSA a high quality set Our sections for Technical Service and Spare Parts will work at best to help you if it were necessary To this purpose we advise you for all control and overhaul operations to turn to the nearest authorized Service Centre where you will obtain a prompt and specialized intervention us In case you do n
23. e getting rid of the various components of the machine must be made accordingly to rules in force of law a o local rules Particular attention must be paid when getting rid of lubricating oils inflamable liquids such as fuel The machine user is responsible for the obser vance of the norms concerning the environment conditions with regard to the elimination of the machine being cust off and of all its compon ents In case the machine should be cust off without any previous disassembly it is however com pulsory to remove tank fuel engine lubricating oil NOTE MOSA is involved with custing off the machine only for the second hand ones when not reparable This of course after authorization 69 9X9 A AA 18 11 08 22262 GB MUSA RECOMMENDED ELECTRODES in accordance with A W S Standard MS TS 55 OMOSA 1 0 10 03 The information here below are to be intended only as indicative since the above norm is much larger For further details please see the specific norms and or the manufacturers of the product to be used in the welding process RUTILE ELECTRODES E 6013 Easily removable fluid slag suitable foe welding in all position Rutile electrodes weld in d c with both polarities electrode holder at or and in a c Suitable for soft steels R 38 45 kg mm Also for soft steels of lower quality BASIC ELECTRODES E 7015 Basic electrrodes wels onlu in d c with inverse polarity on the elec
24. eite motor Tappo caricamento olio motore Engine oil reservoir cap Bouchon remplissage huile moteur Tap n llenado aceite motor Tappo serbatoio Fuel tank cap Bouchon r servoir Tap n dep sito Silenziatore di scarico Muffler Silencieux d chappement Silenciador de descarga Comando stop Stop control Commande stop Mando stop Tappo scarico olio motore Oil drain tap Bouchon d charge huile moteur Tap n vaciado aceite motor Comando choke Choke button Bouton Choke Pulsador Choke Comando manuale avviamento Starting push button Commande manuelle d marrage Mando manual arranque Rubinetto carburante Fuel cock Robinet de l essence Grifo de combustible Fusibile Fuse Fusible Fisible Regolatore corrente di saldatura Welding current regulator R gulateur courant soudage Regulador corr de soldadura 18 11 08 22262 1 mara D MOSA Use as a welder MOSA REV 0 11 08 NEW MAGIC WELD A WARNING personnel is forbidden are the control panel at the front the endo Areas for which access by non authorized thermic motor discharge CONNECT WELDING CABLES Insert the welding cable plugs completely in the sockets turning clockwise to lock them in place Connect the earth cla the PUSH AND TWIST and the electrode holder to the positive r Pay attention to the two polarities on the welding circuit which must not come into electrical contact with each other Carefully tighten the outpu
25. for any reason the machine must be operated while working on it be careful not to touch rotating parts hot surfaces live wires etc which may be unprotected Remove protective guards only when necessary to perform maintenance and replace them immediately after the main tenance is completed MONG Use suitable tools and wear suitable clothes can injure Do not modify the machine without prior authorization hurt you DRY AIR FILTER Replace the air filter cartridge every 200 hours under normal conditions and every 100 hours in dusty environments PERMANENT MAGNET ALTERNATOR No maintenance is necessary as the alternator has no brushes or slip rings and there are no devices for regulation of the output WARNING LABELS AND DECALS Check warning labels and decals once a year and replaced if missing or unreadable CABLES AND CONNECTIONS Periodically check the condition of the cables and tighten the connections N IMPORTANT When carrying out maintenance operations be careful to avoid polluting the environment with the materials used during maintenance Follow all local health and safety regulations 099 18 11 08 22262 GB T 1 MUSA STORAGE cust OFF MOSA REV 0 11 08 NEW MAGIC WELD MAGIC WELD 200 t Have qualified personnel prepare the ma chine for the cust off STORAGE In case the machine will not be used for more than 30 days it sho
26. gs plug sockets and appliances should be in good condition and correctly wired and connected All earthing wi res qhere used must be continuous Extension corde with three wires should be used except for double insulated appliances The frame of the unit should not be connec ted to the general mass of earth by an earth spike or by any other means but should be isolated from earth Note in line with current practice a floating auxiliary power system is used The auxiliary power windings are not connected to the fra me hence a residual current device is not required If the generator is used to feed more complex circuits or used in special environments for example building sites it is obligatory to interpose between the socket and the loads a small distribution panel complete with electrical safeties foreseen by regulatory norms in force in matters of electrical installation gt 9 18 11 08 22262 GB MISA troubie shooting NEW MAGIC WELD 40 2 MOSA REV 0 11 08 Problem Possible cause Solution The motor does not start up or starts up and then stops immediately No current under no load conditions in weld mode No current under no load conditions in auxiliary power mode Incorrect minimum voltage under no load conditions 1 Engine switch 28 at position OFF 2 Lack of or insufficient oil in the motor 3 Faulty motor stopping device oil alert 4 Lack of fuel in
27. he envelope given together with the machine and or set you will find the manual for Use Maintenance and Spare Parts the manual for use of the engine and the tools if included in the equipment the guarantee in the countries where it is prescribed by law Our products have been designed for the use of generation for welding electric and hydraulic system ANY OTHER DIFFERENT USE NOT INCLUDED IN THE ONE INDICATED relieves MOSA from the risks which could happen or anyway from that which was agreed when selling the machine MOSA excludes any responsibility for damages to the machine to the things or to persons in this case Our products are made in conformity with the safety norms in force for which it is advisable to use all these devices or information so that the use does not bring damage to persons or things While working it is advisable to keep to the personal safety norms in force in the countries to which the product is destined clothing work tools etc Do not modify for any motive parts of the machine fastenings holes electric or mechanical devices others if not duly authorized in writing by MOSA the responsibility coming from any potential intervention will fall on the executioner as in fact he becomes maker of the machine t Notice this manual does not engage MOSA who keeps the faculty apart the essential characteristics of the model here described and illustrated to bring betterments and modificati
28. nd on the data plate located on the machine structure quite visible and easy to consult When ordering the spare parts it is recom mended to indicate O MNOSA Europa 59 20090 CUSAGO MI ITALY AS Tel 39 02 90352 1 fax 39 02 90390466 TS 0000 GE 1 serial number 2 model of welder and or generating set 4 n position 3 0 n table 5 quantity MOSA si A 1e 13 a mE 21 22 23 ABBREVIATIONS AND SYMBOLS EV When ordering specify the engine type and the auxiliary voltage ER Engine with recoil starter only ES Engine with electric starter only VE E A S version only QM When ordering specify the length in meters VS Special version only SR By request only 14 12 986Q16M31 22 03 00 R1GB NEW MAGIC WELD Tabla de recambios D CD Ersatzteile de rechange ces REv 0 11 08 Pi CD Ricambi O CA Spare parts MOSA 29222 80 11 81 230V version 5 110V version 5a 5192 N 27 4 y y 9 Cy Ey EY s 22 230V Version 3 110V Version 3a CD Ersatzteile AG MOSA o spare parts Tabla de recambios NEW MAGIC WELD 5 1 OMOSA REV 0 11 0
29. o make a correct evaluation of the same risk and to adopt specific precautions for instance adopting a I P D Individual Protection Device Acoustic Noise Level Lwa Measure Unit dB A it stands for acoustic noise released in a certain delay of time This is not submitted to the distance of measurement Acoustic Pressure Lp Measure Unit dB A it measures the pressure originated by sound waves emission Its value changes in proportion to the distance of measurement The here below table shows examples of acoustic pressure Lp at different distances from a machine with Acoustic Noise Level Lwa of 95 dB A Lp a 1 meter 95 dB A 8 dB A 87 dB A Lp a 7 meters 95 dB A 25 dB A 70 dB A Lp a 4 meters 95 dB A 20 dB A 75 dB A Lp a 10 meters 95 dB A 28 dB A 67 dB A when with acoustic noise values indicates that the device respects noise emission limits 18 11 08 22262 GB MOSA apvice NEW MAGIC WELD 2 OMOSA REVO 1108 E MAGIC WELD 200 AN The installation and the general advice concerning the operations are finalized to the correct use of the ma chine in the place where it is used as generator group and or welder Advice to the User about the safety te The information contained in the manual can be changed without notice Potential damages caused in relation to the use of these instructions will not be considered because these are only indicative Remember tha
30. ody non flamable protective clothers 2 Avoid inhaling fumes by providing a ventilation system if not possible use an approved air breather WF Do not work in closed areas where there is no fresh air flow Do not use the welder to defrost thaw pipes Use ear protections if the noise level is high 18 11 08 22262 GB SQUAD MOS o 5 ABBREVIATIONS LEGEND NEW MAGIC WELD 2 3 MOSA REV 0 11 08 e 5 CONS Conformity S E i EN 60974 1 Single phase Users Information Various CE ound power conformity 1 manual news conformity Equipment and optional Engine H RE Cn Gasoline Air Manual Engine shut engine cooling recoil down oil Genera tion 1 CEE 1 Schuko Permanent magnet Fuse Socket Socket Ground con alternator 230 110 48V EEC 230V Schuko nection point e was OW LO D control A Welding with Welding cur D C Plus Minus control covered rent electr electrode regulation Various gt GS 1 Standard Options on Maintenance Central equipment request Time lifting eye Optionals Welding cables C temperature Celsius grades A Ampere B pretrol C A c a alternating current C C c c direct current cc cm volume CE European norm conformity CF special for pipe welding D GFI F Fuse g kwh grams kilowatt hour engine consumption GMP permanent magnet alternator Hz frequency I
31. ons to parts and accessories without putting this manual uptodate immediately 10 10 02 M 1 1 GB M MUSA o ce mark 1 4 it OMOSA REV 4 10 07 Any of our product is labelled with CE marking attesting its conformity to appliable directives and also the fulfillment of safety requirements of the product itself the list of these directives is part of the declaration of conformity included in any machine standard equipment Here below the adopted symbol CE marking is clearly readable and unerasable and it can be either part of the data plate A or placed as a sticker near the data plate B B 9 gt Vie Europa 59 20090 CUSAGO MI ITALY o AN te 39 02903521 fax 39 0290390486 Vie Europa 69 20090 CUSAGO IM ITALY http wwwmosait infoemosait M l 0 tS AN tel 39 02903521 fax 39 0290390466 CL httpwww mosa it e mail infoemosa it N T SY OTE a xv 3 E e Ea pan Hal Jesse A ne POS OL nea O Furthermore on each model it is shown the noise level value the symbol used is the following O ba dB war The indication is shown in a clear readable and indeleble way a sticker 10 10 02 M1 4 GB CD M Es A technical data NEW MAGIC WELD 1 5 MOSA 0
32. operates perfectly STOP Read absolutely and be duly attentive HIGH VOLTAGE Attention High Voltage There can be parts in voltage dangerous to touch The non observance of the advice implies life danger FIRE Danger of flame or fire If the advice is not respected fires can happen HEAT Hot surfaces If the advice is not respected burns or damage to things can be caused EXPLOSION Explosive material or danger of explosion in general If the advice is not respected there can be explosions WATER Danger of shortcircuit If the advice is not respected fires or damage to persons can be caused SMOKING The cigarette can cause fire or explosion If the advice is not respected fires or explosions can be caused WRENCH Use of the tools If the advice is not respected damage can be caused to things and even to persons ACCES FORBIDDEN to non authorizad peap le 8 P PP PG Use only with safety clothing Ma It is compulsory to use the personal pro Dy 774 tection means given in equipment Use with safe materials only Never use water to put out fires on electrical equipment Use only with non inserted voltage It is prohibited to make interventions before having disinserted the voltage No smoking It is prohibited to smoke while filling the tank with fuel Do not refuel Do not refuel when the engine is hot NI S Switch off the engine prior to refuelling Fire B 7
33. or the electrode while standing in water or with wet hands feet or clothes m nsulate yourself from the work surface while welding Use carpets or other insulating materials to avoid physical contact with the work surface and the floor not wind cables around the body im Always wear dry insulating glovers without holes and body protection Estimate possible electromagnetic problems in the work area taking into account the following indi cations m Telephonic wirings and or of communication check wirings and so on in the immediate vicinity mb Radio and television receptors and transmettors m Computer and other checking devices m Critical devices for safety and or for industrial checks iP apol who for instance use pace maker hearing aid for deaf or something and else im Devices used for rating and measuring m The immunity of other devices in the operation area of the welder Make sure that other used devices are compatible If it is the case provide other additional measures of protection m The daily duration of the welding time ult is forbidden to weld in rooms containing explosive gases M m Keep flamable material away from the welding area not weld on containers which contain flamable material 9 nue VA E TA 4 Do not weld near refuelling areas m Do not weld on easily flamable surfaces AE m Protect face and eyes protective mask with suitable dark lens and side screens B ears and b
34. ot profit on these Services and some parts are replaced please ask and be sure that are used exclusively original MOSA parts this to guarantee that the performances and the initial safety prescribed by the norms in force are re established rz The use of non original spare parts will cancel immediately any guarantee and Technical Ser vice obligation from MOSA NOTES ABOUT THE MANUAL Before actioning the machine please read this manual attentively Follow the instructions contained in it in this way you will avoid inconveniences due to negligence mistakes or incorrect maintenance The manual is for qualified personnel who knows the rules about safety and health installation and use of sets movable as well as fixed You must remember that in case you have difficulties for use or installation or others our Technical Service is always at your disposal for explanations or interventions The manual for Use Maintenance and Spare Parts is an integrant part of the product It must be kept with care during all the life of the product In case the machine and or the set should be yielded to another user this manual must also given to him Do not damage it do not take parts away do not tear pages and keep it in places protected from dampness and heat You must take into account that some figures contained in it want only to identify the described parts and therefore might not correspond to the machine in your possession In t
35. pm It remains at this speed until current is drawn when set to weld or auxiliary power When set to weld mode the machine reaches maximum engine speed as soon as there is mi nimum contact between the tip of the electrode and the piece to be welded and also when setto generation drawing a minimum of 250 300 W The machine returns to minimum 6 7 seconds later if power is not drawn during welding or generation Checking and adjusting idling speed Check idling speed when COLD When the engine is switched on it reaches ma ximum speed after 6 7 seconds it decreases automatically to idle Check the speed when the engine idles The idling speed corresponds to 33 35 Vdc only for Italy 42 45 Vdc at the welding sockets or the equivalent at 2000 2200 rpm Minimum welding voltage TOO LOW From Fig 1 proceed as follows when the machine idles engine cold Keep pin A locked 8 mm spanner and un screw nut B 7 mm spanner Again with pin A locked turn nut C clockwi se 7 mm spanner 1 3 mm The more it is extended the more the idle speed increases Tighten nut B on pin A and check the idling speed Minimum welding voltage TOO HIGH From Fig 1 proceed as follows When the machine idles engine cold tKeep pin A locked 8 mm spanner and un screw nut B 1 3 mm 7 mm spanner Again with pin Alocked turn nut C anticlockwi se 7 mm spanner until nut B touches pin A Tighten nut B against pin A and check that the idling
36. pm rated open circuit e High frequency chopper diode bridge it regulates the welding current using the Chopper Techno logy which chops the welding D C current at high frequency e Hall sensor it measures with high precision the welding current and it s completely isolated from the welding circuit e Reactance for cellulose electrodes optional e PWM control board this single board controls the welding process the auxiliary current and the elec tromagnet for the engine accelerator Three integrated circuits PWM type Pulse Width Modulation have been used The use of these PWM s not only for the welding control but also for the supply control of the electromagnet reduces to the minimum the wasted power on the electromagnet m e D C chopped auxiliary output the auxiliary output is chopped every 50 msec in order to prevent 3 damages to switches of hand tools due to arcing This special D C auxiliary is suitable not only for amp universal hand tools with brushes but also for those with electronic speed control In this case the limit is that these tools can run at the maximum speed only without possibility of speed regulation D Quality system M 01 REV 4 03 12 x X ax AX THE INTERNATIONAL CERTIFICATION NETWORK CERTIFICATE CISQ ICIM hereby certify that the organization BCS S p A Head Office and Operative Unit Viale Mazzini 161 1 20081 Abbiategrasso MI Operative Unit
37. reen black cable Between green red cable Between black red cable Auxiliary power outputs 230 Vdc Between the black cables R S Cable Y is connected to the centro Between the black cables R T stella of the three phase circuit Between the black cables S T Auxiliary power outputs 110Vdc Between the black cables R S Cable Y is connected to cable T Between the black cables Between the black cables S T 18 11 08 22262 GB D MAINTENANCE NEW MAGIC WELD M MAGIC WELD 200 lified personnel MAINTENANCE OF THE MACHINE Maintenance refers to all operations regarding the control and replacement of mechanical and electrical parts subject to wear In addition it refers to the control and topping up or replace ment of fluids such as fuel oil and the regular cleaning of the machine Repairs refers to the substitution of worn or damaged parts and repairs should be carried out by Authorized Service Centres Refer to the Engine Manufacturer s Manual for the maintenance instructions for the engine Periodic maintenance should be performed according to the schedule shown in this manual On a regular basis check that there are no obstructions in the aspiration exhaust ducts of the alternator the engine or the housing which could restrict the flow of cooling air N ATTENTION Maintenance and repair work should only be done by qua Stop the engine before doing any work on the machine If
38. romlaufplan Referenzliste A Generator F Sicherung H Steckdose 230V 1 phasig Steckdose 110V 1 phasig R Steuerplatine SchweiBstrom T SchweiBstromregler Y Diodenbr cke SchweiBstrom Fi Elektromagnet Motordrehzahl 52 Olstandssensor F3 Taste Stopp G3 Z ndspule H3 Z ndkerze W6 Hall Sensor Electrical system legende Alternator Fuse 230V 1phase socket 110V 1 phase socket Welding control PCB Welding current regulator Welding diode bridge F1 Acceleration solenoid 2 Oil level transmitter F3 Stop push button G3 Ignition coil H3 Spark plug W6 Hall sensor Leyenda esquema el ctrico Alternador Fusible Toma 230V monof sica Toma 110V monof sica Unidad control soldadura lt 410 Puente diodos soldadura F1 Electromagnetismo acelerador 52 Captador nivel aceite F3 Pulsador stop G3 Bobina encendido H3 Buj a encendido W6 Sensor de entrada Regulador corriente soldadura Legende des schemas electriques A Alternateur F Fusible H Prise 230V monophas Prise 110V monophas R Unite contr le soudage T R gulateur courant de soudage Y Pont diodes soudage F1 Electro aimant acc l rateur S2 Transmetteur niveau huile F3 Bouton stop G3 Bobine allumage H3 Bougie allumage W6 Senseur de hall 18 11 08 22262 I 61 NEW MAGIC WELD 110V version ico iagram ic d CD Schema elettr Electr A o REv 0 11 08
39. s Via Valbrina 17 19 1 42045 Luzzara RE Viale Europa 59 20090 Cusago MI for the following field of activities Design production and servicing of tractors agricultural and green maintenance machines engine driven welders and generating sets has implemented and maintains a Quality Management System which fulfills the requirements of the following standard ISO 9001 2008 Issued on 2012 03 06 Validity date 2015 03 05 Registration Number T 3722 Gianrenzo Prati E3Net 2 Michael Drechsel President of IONET President of CISO 1QNet Partners AENOR Spain AFNOR Certification France AIB Vingotte International Belgium ANCE Mexico APCER Portugal CCC Cyprus CISQ CQC China China CQS Czech Republic Cro Cert Croatia DOS Holding GmbH Germany DS Denmark ELOT Greece FCAV Brazil FONDONORMA Venezuela ICONTEC Colombia IMNC Mexico INNORPI Tunisia Inspecta Certification Finland IRAM Argentina JQA Japan KFQ Korea MSZT Hungary Nemko AS Norway NSAI Ireland PCBC Poland Quality Austria Austria RR Russia SII Israel SIQ Slovenia SIRIM QAS International Malaysia SQS Switzerland SRAC Romania TEST St Petersburg Russia TSE Turkey YUQS Serbia IQNet is represented in the USA by AFNOR Certification CISQ DQS Holding GmbH and NSAI Inc The list of IQNet partners is valid at the time of issue of this certificate Updated information is available under www ignet certification com A Net 5 ICIM IS
40. speed is correct Adjusting the maximum engine speed To check that the maximum engine speed is correct simply measure the welding voltage under no load conditions at maximum engine speed which must be 49 51 V only for Italy 66 68 Vdc Turn screw A to adjust the engine speed Fig 2 Turning the screw clockwise increases the idling speed screwing it anticlockwise decreases the maximum engine speed FIG 2 18 11 08 22262 GB MOS checking and adjusting the maximum welding current NEW MAGIC WELD MOSA REV 0 11 08 M dal frontale dal solenoide from frontal from solenoid c ES 8 N t O 11 o o o o 1 9 g ber 12 2 25 s O oO o o MORICI S Sj D 9 e i med cr S rc Su RH Ri 2 5 3 8 0 c A CE E JE O FE gt RIT Ru T 1 S2 i m 2 OFF ex A A A a Dip switch TT lt taratura corrente max di sald dall alternatore dai ponti ausiliari welding max current adjustment from alternator from aux bridges Tutte le volte che viene sostituita o la scheda o il sensore di corrente necessario procedere ad una verifi
41. t cables to the bushings if loose they can cause problems of overheating and damage the bushings cables etc Make certain the grounding pincer is connec ted as near as possible to the work station ADJUSTING THE WELDING CURRENT The welding current is regulated by turning knob continuously If set to the minimum turned fully in an anticlockwise direction it provides a current of approximately 30 A if set to the maximum turned fully in a clockwise direction it gives a maximum current of approximately 150A RECOMMENDED ELECTRODES All the electrodes on the market can be used however for cellulose electrodes we recom mend Magic Weld with added reactor N ATTENTION To reduce the risk of electromagnetic interfe rence keep the welding cable length short and keep them on or near the ground If possible welding operations should not be done near sensitive electronic devices If interference continues to occur adopt additional measures shift the group use shielded cables line filters shield the entire work area If the above solutions do not suffice consult our Technical Servicing Department 18 11 08 22262 GB Use as a welder M NEW MAGIC WELD 34 1 AUTO IDLE Operation When the engine is switched on it immediately reaches a maximum speed of 4000 rpm for ap proximately 6 7 seconds for easy start up after which it automatically decreases and idles at 2000 r
42. t the non observance of the indications reported by us might cause damage to persons or things It is understood that local dispositions and or laws must be respected This heading warns of an immediate danger for persons A DANGEROUS as well for things Not following the advice can result in serious injury or death This heading warns of situations which could result in WARNING injury for persons or damage to things To this advice can appear a danger for persons as well A CAUTION as for things for which can appear situations bringing material damage to things A IMPORTANT These headings refer to information which will assis you the correct use of the machine and or accessories A ATTENTION FIRST AID In case the operator shold be sprayed by accident from corrosive liquids a o hot toxic gas or whatever event which may cause serious injuries or death predispose the first aid in accordance with the ruling labour accident standards or of local instructions Skin contact Wash with water and soap Eyes contact Irrigate with plenty of water if the irritation persists contact a specialist Ingestion Do not induce vomit as to avoid the intake of vomit into the lungs send for a doctor Suction of liquids you suppose that vomit has entered the lungs as in case of spontaneous vomit take from lungs the subject to the hospital with the utmos
43. t urgency Inhalation n case of exposure to high concentration of vapours take immediately to a non polluted zone the person involved FIRE PREVENTION In case the working zone for whatsoever cause goes on fire with flames liable to cause severe wounds or death follow the first aid as described by the ruling norms or local ones EXTINCTION MEANS Appropriated Carbonate anhydride or carbon dioxyde powder foam nebulized water Not to be used Avoid the use of water jets Other indications Cover eventual shedding not on fire with foam or sand use water jets to cool off the surfaces close to the fire Particular protection Wear an autorespiratory mask when heavy smoke is present Useful warnings Avoid by appropriate means to have oil sprays over metallic hot surfaces or over electric contacts switches plugs etc In case of oil sprinkling from pressure circuits keep in mind that the inflamability point is very low 18 11 08 22262 GB MOSA 5 REV 0 11 08 NEW MAGIC WELD MAGIC WELD 200 2 1 SYMBOLS IN THIS MANUAL The symbols used in this manual are designed to call your attention to important aspects of the operation of the machine as well as potential hazards and dangers for persons and things This symbol is used to draw your attention to the fact that the welder is being used correctly and that the machine or equipment used
44. te the trimmer clockwise so that the welding current reaches 140 A 18 11 08 22262 GB MOS o parallel engine driven welder NEW MAGIC 343 MOSA REV 0 11 08 How to put two machines in parallel from the front panels of the machines connect the two positives welding sockets between themselves and the two negative welding sockets bethween themselves To effect the connection ask for the accessory K2X150 ATTENTION use fit cables and tight at the connection point How to proceed start the machine putting the two welding handles T in the wanted position half of the total current put in parallel with the right cables proceed with welding 18 11 08 22262 GB sa D MOSA Use as a generator AA A MOSA REV 0 11 08 NEW MAGIC WELD N WARNING unit to the public mains and or another electrical power source Areas for which access by non authorized personnel is forbidden are the control panel at the front the endo thermic motor discharge It is absolutely forbidden to connect the GENERATION IN C C CONTINUOUS CUR RENT WITH MICRO INTERRUPTION Machines with three pin outlets for auxiliary supply have at each outlet isolated active and neutral sockets and an earth socket Only the earth socket is bonded to the frame of the machine For your safety all auxiliary equipment exten sion cords appliance cords plu
45. trode holder there are also types for a c Suitable for impure carbon steels Weld in all position HIGH YIELD BASIC ELECTRODES E 7018 The iron contained in the coating increases the quality of metal added Good mechanical properties Weld in all position Electrode holder at inverse polarity WId deposit of nice aspect also vertical Workable high yield Suitable for steels with high contens of sulphur impurities CELLULOSIC ELECTRODES E 6010 Cellulosic electrodes weld only in d c with polarity electrode holder ground clamp Special for steels run on pipes with R max 55 kg mm Weld in all position volatile slag ELECTRODES IDENTIFICATION ACCORDING TO A W S STANDARDS 2 L 2 digits type of coating and electric power conditions see table 3 1 digits welding positions see table 2 E N Descrizione dd 10 Cellulose electrodes for d c see table 1 11 Cellulose electrodes for a c symbol for 12 Rutile electrode for d c Coated 13 Rutile electrode for a c electrode 14 High yield rutile electrodes 15 Basic electrodes for d c Number Strenght 16 Basic electrodes for c a Kg mm 18 High yield basic electrodes for d c inverse polarity 60 60 000 42 20 Acid electrodes for flat or front position welding for 70 000 9 d c pole and for a c 80 80 000 56 y 90 90
46. uld be stored in a suitable area where it is protected from the elements to prevent rusting corrosion and other damage to the machine ENGINE Run the engine until it stops from lack of fuel For long periods of storage refer to the engine manufacturer s manual Clean the machine carefully Cover the machine with a plastic cover and store in a dry place In case of necessity for first aid and fire preven tion see page M2 A IMPORTANT In the storage or cust off operations avoid that polluting substances liquids exhausted lt a oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place CUST OFF As cust off we intend all operations to be made at utilizer s care at the end of the use of the machine This comprises the dismantling of the machine the subdivision of the several components for a further reutilization or for getting rid of them the eventual packing and transportation of the eliminated parts up to their delivery to the store or to the bureau encharged to the cust off or to the storage office etc The several operations concerning the cust off involve the manipulation of fluids potentially dangerous such as lubricating oil The dismantling of metallic parts liable to cau se injuries or wounds must be made wearing heavy gloves and using suitable tools Th

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