USER MANUAL
WELDING RECTIFIER
www.magmaweld.com
RA 300 E
RA 400 E
RA 650 E
CONTENTS
SAFETY RULES
1. TECHNICAL INFORMATION
1.1 GENERAL EXPLANATIONS
1.2 COMPONENTS OF RA 300 E / RA 400 E / RA 650 E
1.3 DATA PLATE
1.4 TECHNICAL SPECIFICATIONS
1.5 ACCESORRIES
2. INSTALLATION
2.1 UPON RECEIPT AND CLAIMS
2.2 WORKING CONDITIONS
2.3 ELECTRIC PLUG CONNECTION
2.4 CONNECTIONS FOR MMA WELDING
2.5 CONNECTIONS FOR TIG WELDING
3. OPERATION
3.1 CONNECTING TO THE MAINS
3.2 WELDING ADJUSTMENTS
3.2.1 Welding Adjustments
3.2.2 Remote Control (Optional)
4. MAINTENANCE AND TROUBLESHOOTING
4.1 MAINTENANCE
4.2 TROUBLESHOOTING
APPENDIX 1: SPARE PARTS LIST FOR RA 300 E / RA 400 E / RA 650 E
APPENDIX 2: ELECTRICAL DIAGRAM FOR RA 300 E / RA 400 / RA 650 E
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1RA 300 E / RA 400 E / RA 650 E
RA 300 E / RA 400 E / RA 650 E2
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.
Learn to operate the machine and how to make the controls properly.
Operate your machine in convenient work areas. Improper modifications affect the safety of your machine
negatively and shorten its lifetime.
SAFETY RULES
ELECTRICAL SHOCK C FATALAN BE
Installation procedure must comply with national electricity standards and other relevant
regulations and ensure that installation is performed by qualified persons.
Wear dry insulatinggloves 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
free of damage
.
.
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 electrode to the .one electrode holder
Turnoff the machine, when not in use
Disconnect input plug or power before working on machine.
Frequently inspect input power cord for damage or bare wiring - repair or replace
cord immediately if damaged.
Be sure ground
.
swtich off the the
that the machine is properly ed.
HOT PARTS CAN CAUSE SEVERE BURNS
Do not touch hot parts
Allow cooling time before servicing
hot parts, use appropriate tool, insulating gloves and fireproof clothes.
.
.
If needed to hold
OBEY ALL THE SAFETY RULES
STATED IN THE MANUAL!
3
RA 300 E / RA 400 E / RA 650 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 .
Irritation of the eyes, nose and throat are symptoms of inadequate ventilation. Take
immediate steps to improve ventilation. Do not continue welding if symptoms persist
Install a natural or forced air ventilation system in the work area
Install an adequate ventilation system in the welding and cutting area, if needed
install a system that can remove the fume and vapor 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 insuch confinedplaces if possible
If gas cylinders are grouped in a different area, make sure that it is a well-ventilated
area. When not being used, turn off the main cylinder valve and watch out for gas
leakage
Shielding gasses such as argon is denser than air and when being used in confined
places, can be inhaled is dangerous for health
Do not perform welding operations near chlorinated hydrocarbon vapors produced
by degreasing or painting
.
.
.
.
.
.
it which .
.
ARC RAYS CAN BURN EYES AND SKIN
Use adequate welding helmet withcorrect shade offilter (4or 13 consideringEN 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 & FLYING METALS CAN INJURE EYES
Welding, wire brushingand grindingcause sparks and flying metal.
Toprevent injurieswear appropriate safety glasses with side shields even under your welding helmet .
MOVING PARTS CAN CAUSE INJURY
Keep away from moving parts
Keep all doors, panels, and guards closed and secured
Wear shoes withmetal protectionover the fingers.
.
.
RA 300 E / RA 400 E / RA 650 E4
SAFETY RULES
NOISE CAN DAMAGE HEARING
Noise from certain industrial processes or equipments can damage hearing.
Wear approved earprotection ifnoise 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 insuch confinedplaces..
WELDING CAN CAUSE FIRE OR EXPLOSION
Never weld near flammable material. It may cause fire or explosions.
Before starting to weld, move flammables away or protect them with flame-proof
covers.
Do not 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. For that reason, keep extinguishing means, such as
fire extinguishers, water and sand easy reach
security valves, regulators and other valves on flammable, explosive
and compressed gas circuits in good condition
which are to .
Keep , used
, .
WELDING WIRE MAY CAUSE INJURY
Do not point the torch toward anypart 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.
.
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..
5
RA 300 E / RA 400 E / RA 650 E
FALLING UNIT CAN CAUSE INJURY
Wrong positioned power source or other equipment may cause serious injury to persons or damage
to objects.
While repositioning the power source always carry by using the lifting eye. Never pull cable, hose or torch.
Always carry the gas cylinders separately
Before carrying the welding and cutting equipment, disassemble all the connections between and
separately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriate
vehicles like forklifts
Install your machine on flat platforms having maximum 10 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.
.
.
° slope
.
SAFETY RULES
OVERUSE CAN CAUSE OVERHEATING
Allow cooling period; follow rated duty cycle
Reduce current or reduce duty cycle before starting to weld again
Do not block airflow t unit.
Do not filter airflow to unit without the approval of manufacturer
.
.
hrough the
.
ARC WELDING CAN CAUSE INTERFERENCE
Electromagnetic energy arising during welding and cuttingoperations can interfere withsensitive electronic
equipment such as microprocessors, computers, and computer-driven equipment such as robots
Be sure all equipment in the welding area is electromagnetically compatible
To reduce possible interference,keep weld cables as short as possible, close together, and downlow, 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 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
.
.
.
.
.
.
Donot exposethe welding machine to rain, protect from water drops and vapour.
PROTECTION
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.
If you will have a long break after welding, turn off the machine after cooler fan cooled the machine.
TECHNICAL INFORMATION
1. TECHNICAL INFORMATION
1.1 GENERAL EXPLANATIONS
1.2 COMPONENTS OF RA 300 E / RA 400 E / RA 650 E
1
7
2
8
3
9
4
Power Switch (Changeover Switch)
Mains LED
HOT START Current Knob
Handles
V/A Digital Meter
Rutile/Basic/Cellulosic Selection Switch
Welding And Earth Cable Outlets
Current Adjustment Knob
5
6
10
11
12
Lifting Eyes
Thermal LProtection ED
ARC FORCE Adjustment Knob
Welding Carbon Gouging Selection Switch/
Figure 1: ineComponents of the Mach
3
4
5
7
10
11
12
RA 650 E
1
2
9
8
6
RA300E, RA400E and RA650E are t yristor (SCR) controlled welding machines, designed to weld all type of
coated electrodes from 2mm, 300 model up to 5 mm, 400 & 650 models up to 6mm, while 400 model can
carbon gauge up to 6mm, 650 model can carbon gauge up to 10mm. For RA650E, cellulosic welding at low
currents is not recommended. Since 300 & 400 models can go as low as 20 Amps, their cellulosic welding
behavior is excellent and if a proper TIG starting unit is connected, they can perform as a DC TIG welder as
well. These units can be grouped as 4, 6,8 or 9machines in a rack,for large constructionsites like shipbuilding
etc.
Due to th ristor (SCR) and electronic close loop control technology, current is adjusted precisely by a
potentiometer, 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. Also due to this technology, pre-adjusted current stays
stable even during mains fluctuations or if additional welding cables are used. Electrical efficiency of these
machines are 70%.
Even though there is a certain level of electronics is involved in this machine, the PCB is protected in a
separate cabinet inside of the machine against dust and corrosion. With its telescopic arms and big wheels it
can be pulled easily across the working area especially at outdoor welding sites. Also stepless remote current
controlling is possible as an option.
These machines are fan cooled and thermally protected against overheating and phase failures.
h
y
RA 300 E / RA 400 E / RA 650 E6
10 A / 20,4 V - 300A / 32 V
X
25 % 60 % 100 %
190 A 150 A
28 V
22 V
CL.I. H
U V
380
50 Hz
1
S1
IP 22
I A
20
1 I A
15
1I A
30
1
13 kVA
10 kVA
S
T 32 A
U V
66
0
I2
U2
3R
300 A
32 V
20 kVA
3R
RA 00E3
Seri No :
EN 60974-1
EN 60974-10
Organize Sanayi Bölgesi 5.K s m Manisa-TÜRK YEı ı İ
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
20 A / 21 V - 650A / 46 V
X
35 % 60 % 100 %
500 A 385 A
40 V
35 V
CL.I. H
U V
380
50 Hz
1
S1
IP 22
I A
52
1 I A
40
1I A
68
1
19 kVA
14 kVA
S
T 80 A
U V
68
0
I2
U2
3R
650 A
46 V
25 kVA
3R
RA 0E65
Seri No :
EN 60974-1
EN 60974-10
Organize Sanayi Bölgesi 5.K s m Manisa-TÜRK YEı ı İ
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
20 A / 20,4 V - 400A / 36 V
X
35 % 60 % 100 %
305 A 235 A
32 V
29 V
CL.I. H
U V
380
50 Hz
1
S1
IP 22
I A
29
1 I A
22
1I A
38
1
19 kVA
14 kVA
S
T 40 A
U V
58
0
I2
U2
3R
400 A
36 V
25 kVA
3R
RA 00E4
Seri No :
EN 60974-1
EN 60974-10
Organize Sanayi Bölgesi 5.K s m Manisa-TÜRK YEı ı İ
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
X :Duty Cycle*
U :Open Circuit Voltage
U :Line Voltage and Frequency
U :Rated Welding Voltage
I :Input Current
I :Rated Welding Current
IP 21 :Protection Class
S :Input Power
CL.I. :Insulation Class
0
1
2
1
2
1
3 Phase Transformer Rectifier
Descending Characteristics
St
Line Input 3 Phase Alternative Current
Direct Current
Appropriate For Dangerous Work Area
ick Electrode Welding
*Duty Cycle
1 2
Temperature ( C)°
Time (min.)
6 min. 6 min. 6 min.4 min. 4 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°C). For example, a welder with 60% duty cycle must be rested (2) for 4 minutes,
after 6 minutes of continuous welding (1).
1.3 DATA PLATE
TECHNICAL INFORMATION
7RA 300 E / RA 400 E / RA 650 E
1.4 TECHNICAL SPECIFICATIONS
TECHNICAL INFORMATION
1.5 ACCESSORIES
UNIT
TECHNICAL SPECIFICATIONS
RA 400 E RA 650 E
380
25
38
3x40
58
20 - 400
400
6
950x660x640
173.5
IP22
2 - 5
V
kVA
A
A
V
A
A
mm
mm
kg
mm
DC
DC
DC
380V
45
68
3x80
68
20 - 650
650
9
950x660x640
208
IP22
2 - 6
RA 300 E
380
20
30
3x32
66
10 - 300
300
-
950x660x640
155
IP22
2 - 4
Line Voltage (3 Phases 50 Hz)
Input Power (35%)
Input Current (35%)
Recommended Line Fuses
Welding Current Range
Open Circuit Voltage
Rated Welding Current (35%)
Carbon Gouging
Dimensions (LxWxH)
Weight
Protection Class
Electrode Diameter
RA 400 E RA 650 E
Electrode Holder and Cable
Electrode Holder and Cable
(35mm - 5m)
(70mm - 5m)
(35mm - 5m)
(70mm - 5m)
2
2
2
2
Earth Clamp and Cable
Earth Clamp and Cable
Remote Control Box With 10m Cable
Remote Control Box With 20m Cable
Remote Control Box With 50m Cable
RA 300 E
-
-
-
-
-
-
STANDARD ACCESSORIES
OPTIONAL ACCESSORIES
K301000405
K301100403
K301400210
K301400220
K301400250
K301000605
K301100603
K301400310
K301400320
K301400350
K301000405
K301100403
K301400210
K301400220
K301400250
RA 300 E / RA 400 E / RA 650 E8
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 missingor
damaged, contact your supplier immediately.
In the event of damaged or missing delivery,
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
draw
up a record, take a photo of the damage and
report
ú
ú
ú
ú
Standard pallet contains:
Power Source
H Cable
Earth Clamp Cable
User Manual
Electrode older
2. INSTALLATION
2.2 INSTALLATION AND WORKING RECOMMENDATIONS
• Use lifting eyes or fork-lift to carry the machine.
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 40ºC.
• 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.
• 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
data plate.
• Ensure that the earth clamp is tightly connected as
close as possibleto thewelding 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.
• Use suitable welding fume extraction systems.
Use breathing apparatus if there is a risk ofinhaling
in confined places.
9
RA 300 E / RA 400 E / RA 650 E
INSTALLATION
2.3 ELECTRIC PLUG CONNECTION
Figure 2: Electric Plug Connection
According to the polarity of the electrode to be
used, i s into the appropriate
outlet them clock-wise
nsert welding cable
and tighten by turning .( )10
Connect the earth clamp tightly to the workpiece
as close as possible to the welding area.
Install the Argon gas regulator onto the Argon gas
cylinder.
C gas hose of the torch the
regulator
onnect the to gas
.
2.4 MMA WELDING CONNECTIONS
Figure 5: Connecting Gas Cylinder
TIG torch with a valve should be
used.
Connect TIG orch
to the negative
of the machine.
the t power
cable outlet and
the earth cable to the positive
outlet (1 )0
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
INSERTIT INTO THE SOCKETATTHIS STAGE.
Figure 4: TIG Welding Connections
RA 300 E / RA 400 E / RA 650 E10
2.5 TIG WELDING CONNECTIONS
Figure 3: MMA Welding Connections
RA 650 E
OPERATION
3. OPERATION
Before plugging your machine to the electrical line
check carefully the 3 phase with a voltmeter and then
insert the plug into the socket.
SWITCH ON the machine via power switch .
Observe the fan noise and illumination of the mains
LED and V/Adigital meters .
(1)
(8) (5)
While inserting the plug into the
socket, pay attention that main
switch is positioned to “OFF” “0”.
3.1 CONNECTING TO THE MAINS
3.2 WELDING ADJUSTMENTS
Select via the selection switch the type of the
electrode
(6)
(rutile/basic/cellulosic) to be used.
For carbon gauging, selection switch
Welding current isadjusted via current adjustment
knob and the adjusted current value can be
observed from the ammeter . Below table can
be used as a rough reference for mild steel
electrodes. For exact parameters, please refer to
the electrode manufacturer's recommendations.
(7)
.
(4)
(5)
toggle the
downwards
For better ignition turn the HOT START knob
clock-wise. If theadjustment is not correct, arc can
burn through the workpiece
ARC FORCE is useful for electrodes which have
tendency to stick into the weld poolduring welding.
Turning the knob clock-wise will decrease the
tendency to stick.
Start welding and observe welding current (A) and
voltage (V) by V/Ameters .
(2)
(3)
(5)
6
7
4
5
Diameter Rutile Basic
Cellulosic
2.0
2.5
3.25
4.0
5.0
6.0
40-60 A
60-90 A 60-90 A 60-100 A
100-140 A 100-130 A 70-130 A
140-180 A 140-180 A 120-170 A
200-240 A 200-250 A 160-200 A
260-320 A
-- --
----
11RA 300 E / RA 400 E / RA 650 E
It is possible to connect a remote control box via
long control cable as long as it is necessary. In this
case, appropriate control socket must be installed
onto the front panel by a certified Magma Service.
connector is
by
When the remote control connected
to the machine, ampere adjustment knob on the
machine is disabled automatically and current
adjustment is made the remote control.
3.2.2 Remote Control (Optional)
3.2.1 Welding Adjustments
Figure 6: Mains Connection
Figure 2: Electric Plug Connection
Figure 7: Control Panel
4.2 TROUBLESHOOTING
4. MAINTENANCE AND TROUBLESHOOTING
MAINTENANCE AND TROUBLESHOOTING
TROUBLE
Machine does not work.
Welding current is low.
Fan is out of order.
Phase failure
No neutral line
Fuse blown out
Phase failure
Diode breakdown
Aprimary or secondary coil burn down
Fan supply voltage phase failure
Fan motor break down
[REMEDY] REASON
Before removing any screw on the machine for maintenance, power
supply must be disconnected from the electric lines and 10 seconds
should be allowed for capacitor discharging.
4.1 MAINTENANCE
Clean the labels on the
machine, replace the worn
out labels.
Repair or replacethe worn
out welding cables.
Clean and tighten weld the
terminals.
Check the isolation of the
electrode holder, earth
clamp and their cables.
ONCE IN EVERY 3 MONTHS
ONCE IN EVERY 6 MONTHS
Open the covers of the
machine and clean with
dry air.
NOTE: The above recommended maintenance periods are indicative, these may vary according to the
work shop conditions.
DO NOT PLUG THE MAINS ELECTRIC CABLE BEFORE CLOSING ALL THE
CABINET PANELS.
OR
RA 300 E / RA 400 E / RA 650 E12
SPARE PARTS LIST FOR RA 300 E / RA 400 E / RA 650 E
APPENDIX 1
NO
MATERIAL CODE
DESIGNATION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Rheostat 250W
Carbon Potentiometer
Welding Socket (T) 35-70
Electronic Board - E101A
Ammeter-Voltmeter Board - E901A
Rectifier
Cooling Fan SF-350
Changeover Switch
Body
Impedance Coil
Plastic Wheel 300x50x20
Main Transformer
Primary-Secondary Spool
Knob - Small
Knob - Big
Potentiometer - 10K
Mains LED (N733)-220VAC
Thermal Protection LED (N733)-24VAC
Switch 2 Position 1 Pole
EMC Filter
Glass Fuse Socket 20x5mm
Glass Fuse Delayed 1 A
Capacitor - 100 NF / 250V
Temperature Limiting Switch 125 Degrees
Hall Effect Sensor
RA 300 E RA 400 E RA 650 E
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
20
9
9
A410500002
A410801003
A377900106
K405000068
K405000016
A430902001
A250200002
A308033102
K100200003
K304500012
A225222012
K304000024
K302200004
A229500001
A229500002
A410801004
A310310002
A310310004
A310100006
A490400001
A300190001
A300102005
A420000003
A314800102
A830900004
A410500002
A410801003
A377900106
K405000068
K405000016
A430902002
A250200002
A308033102
K100200003
K304500016
A225222012
K304000016
K302200016
A229500001
A229500002
A410801004
A310310002
A310310004
A310100006
A490400001
A300190001
A300102005
A420000003
A314800102
A830900008
A410500002
A410801001
A377900106
K405000068
K405000016
A430902003
A250200002
A308034102
K100200003
K304500024
A225222012
K304000032
K302200024
A229500001
A229500002
A410801004
A310310002
A310310004
A310100006
A490400001
A300190001
A300102005
A420000003
A314800102
A830900016
13
RA 300 E / RA 400 E / RA 650 E
ELECTRICAL DIAGRAM FOR RA 300 E / RA 400 E / RA 650E
APPENDIX 2
A
B
P1
P2
P3
OFF For Rutile and Basic, On For Cellulosic Electrode
OFF For Carbon Electrode
Current Regulator
Arc Force
Hot Start
RA 300 E / RA 400 E / RA 650 E14
+90 236 226 27 00
+90 236 226 27 28
FACTORY
Made in TÜRKİYE
Organize Sanayi Bölgesi 5.Kısım 5503. Sokak No:1 MANİSA
www.magmaweld.com
OWM 02.07.2011
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