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NEW MAGIC WELD
User Manual
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Mosa NEW MAGIC WELD User Manual

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Page 1
NEW MAGIC WELD
222629003 - GB1 1 0 8
18/11/08 22262M00 preparato da UPT approvato da DITE
ENGLISH
Page 2
Page 3
DESCRIPTION OF THE MACHINE
M
0
© MOSA REV.0 - 11/08
18/11/08 22262-GB
The Engine Driven Welder is a block with an engine, an aluminium casting and a front panel. Inside the c
asting 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:
• D.C. welding current 150A @ 60%
• Continuous regulation of the welding current with "Chopper Technology"
• Suitable for basic and rutile electrodes. A reactance for cellulose electrodes is available as an option
• Antistick function (small arc force)
• Continuous auxiliary output 1600 W/ 230 Vdc (max. power 2000 W)
• Auto idle function
• Weight 34 Kg.
Electrical components of the machine:
• Permanent magnet alternator: the alternator has 2 galvanically separated windings, one for welding and the other for the auxiliary output.
• 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 rpm rated open circuit).
• High frequency chopper diode bridge: it regulates the welding current using the “Chopper Techno­logy”, which chops the welding D.C. current at high frequency.
• Hall sensor: it measures with high precision the welding current and it’s completely isolated from the welding circuit.
• Reactance for cellulose electrodes (optional).
• 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.
• D.C. chopped auxiliary output: the auxiliary output is chopped every 50 msec. in order to prevent damages to switches of hand tools due to arcing. This special D.C. auxiliary is suitable not only for 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.
Auxiliary output
Fuse for auxiliary output
Welding sockets
Regulation knob for welding current
NEW MAGIC WELD
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Quality system
M
01
REV.4-03/12
UNI EN ISO 9001 : 2008
10/10/02 M01-GB
MOSA has certied its quality system according to UNI EN ISO 9001:2008 to ensure a constant, highquality of its products. This certication covers thedesign, production and servicing of engine dri­venwelders and generating sets.
The certifying institute, ICIM, which is a member ofthe International Certication Network IQNet, awarded the ofcial approval to MOSA after an­examination of its operations at the head ofce andplant in Cusago (MI), Italy.
This certication 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 thecom­munications regarding all the company’s activesin accordance with the ofcial procedures and inhar­mony with the MOSA Manual of Quality.
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 applicatio­nand use of the products to assure the security ofthe operator and protect the environment;
· Regular inspections by ICIM to conrm that the­requirements of the company’s quality systemand ISO 9001 are being respected.
All these advantages are guaranteed by the CER­TIFICATE OF QUALITY SYSTEM No.0192 issued by ICIM S.p.A. - Milano (Italy ) - www.icim.it
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INDEX NEW MAGIC WELD
M
1
© MOSA REV.0 - 11/08
18/11/08 22262-GB
M 01 QUALITY SYSTEM M 1.01 COPYRIGHT M 1.1 NOTES M 1.4 CE MARK M 2 ADVICE M 2.1 SYMBOLS M 2.2 ADVICE ENGINE DRIVEN WELDER M 2.3 SYMBOLS - ABBREVIATIONS LEGEND M 2.6 INSTALLATION AND ADVICE M 2.7 INSTALLATION M 3 UNPACKING AND TRANSPORT M 25 SET-UP FOR OPERATION M 26 ENGINE STARTING M 27 STOPPING THE ENGINE M 31 CONTROLS M 34... USE AS A WELDER M 37 USE AS A GENERATOR M 40.2... TROUBLE-SHOOTING M 43 MAINTENANCE M 45 STORAGE - CUST OFF M 51 TECHNICAL DATA M 55 RECOMMENDED ELECTRODES M 53 DIMENSIONS M 60 ELECTRICAL SYSTEM LEGENDE M 61-….. ELECTRICAL SYSTEM
R1 SPARE PARTS LIST AG... SPARE PARTS R1.1 REQUEST FOR ORDER SPARE PARTS
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CE MARK
M
1.4
© MOSA REV.4-10/07
10/10/02 M1-4 GB
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)
A
B
Furthermore, on each model it is shown the noise level value; the symbol used is the following:
The indication is shown in a clear, readable and indeleble way on a sticker.
Page 10
18/11/08 22262-GB
Technical data
M
1.5
© MOSA REV.0 - 11/08
Technical data NEW MAGIC WELD
D.C. WELDING
Current range, continuous 30 - 150A Open circuit voltage 40-65V Duty cycle 150 A - 60%
D.C. GENERATION
Single-phase output (max) 2 kW / 230 V / 8.7 A Single-phase output (continuous) 1.6 kW / 230 V / 6.9 A Single-phase output (max) (optional) 1.5 kW / 110 V / 13.6 A Single-phase output (continuous) (optional) 1.2 kW / 110 V / 10.9 A
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
3
Output max 5 kW (6.8 HP) Speed 4000 rpm Fuel consumption 313 g/kWh Engine oil capacity 0.6 l Starter recoil
GENERAL SPECIFICATIONS
Tank capacity 3.6 l 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.
NEW MAGIC WELD
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 10% 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 to 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)
PLEASE NOTE: the symbol when with acoustic noise values, indicates that the device respects noise emission limits according to 2000/14/CE directive.
2000/ 14 / CE
Page 11
ADVICE NEW MAGIC WELD
MAGIC WELD 200
M
2
© MOSA REV.0 - 11/08
18/11/08 22262-GB
ATTENTION
NOTE
IMPORTANT
CAUTION
WARNING
DANGEROUS
☞ 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 rst aid in accordance with the ruling labour accident standards or of local instructions.
☞ FIRE PREVENTION. In case the working zone,for whatsoever cause goes on re with ames liable to
cause severe wounds or death, follow the rst aid as described by the ruling norms or local ones.
This heading warns of an immediate danger for persons as well for things. Not following the advice can result in serious injury or death.
This heading warns of situations which could result in injury for persons or damage to things.
To this advice can appear a danger for persons as well as for things, for which can appear situations bringing material damage to things.
The installation and the general advice concerning the operations, are nalized to the correct use of the ma­chine, in the place where it is used as generator group and/or welder.
!
- Advice to the User about the safety:
N.B.: 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 that 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.
Skin contact Eyes contact Ingestion Suction of liquids from lungs Inhalation
Wash with water and soap Irrigate with plenty of water, if the irritation persists contact a specialist Do not induce vomit as to avoid the intake of vomit into the lungs, send for a doctor If you suppose that vomit has entered the lungs (as in case of spontaneous vomit) take the subject to the hospital with the utmost urgency In case of exposure to high concentration of vapours take immediately to a non polluted zone the person involved
Appropriated Not to be used Other indications
Particular protection Useful warnings
EXTINCTION MEANS
Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water Avoid the use of water jets Cover eventual shedding not on re with foam or sand, use water jets to cool off the surfaces close to the re Wear an autorespiratory mask when heavy smoke is present 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 inamability point is very low.
!!!
!
!
!
These headings refer to information which will assis you in the correct use of the machine and/or accessories.
Page 12
SYMBOLS NEW MAGIC WELD
MAGIC WELD 200
M
2.1
© MOSA REV.0 - 11/08
18/11/08 22262-GB
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 ame or re. If the advice is not respected res 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 res or damage to persons can be caused.
SMOKING - The cigarette can cause re or explosion. If the advice is not respected res 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 peap­le.
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 operates perfectly.
Use only with safety clothing -
It is compulsory to use the personal pro­tection means given in equipment.
Use with safe materials only -
Never use water to put out res 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 lling the tank with fuel.
Do not refuel -
Do not refuel when the engine is hot.
Switch off the engine prior to refuelling.
Fire -
Fuel can cause res.
Use only with safety protections -
It is advisable to use all protections while shifting the machine.
Use only with safety protections -
It is advisable to use protections suitable for the different daily checking works.and/or of maintenance.
Exhaust gases -
Exhaust gases from the engine can kill.
Petrol vapours -
Petrol vapours cause res and can seriously damage your health.
Moving parts -
Moving parts are dangerous. Avoid touching any moving parts with your hands or ngers. Never wear loose clothing which may get trapped by
moving parts.
Page 13
ADVICE ENGINE DRIVEN WELDER NEW MAGIC WELD
MAGIC WELD 200
M
2.2
© MOSA REV.0 - 11/08
18/11/08 22262-GB
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.
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.
Do not touch any electrical parts or the electrode while standing in water or with wet hands,
feet or clothes.
Insulate yourself from the work surface while welding. Use carpets or other insulating materials
to avoid physical contact with the work surface and the oor.
Do not wind cables around the body.Always wear dry, insulating glovers, without holes, and body protection.
Estimate possible electromagnetic problems in the work area taking into account the following indi­cations:
Telephonic wirings and/or of communication, check wirings and so on, in the immediate vicinity.Radio and television receptors and transmettors.Computer and other checking devices.Critical devices for safety and/or for industrial checks.Peapol who, for instance, use pace-maker, hearing-aid for deaf or something and else.Devices used for rating and measuring.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.
The daily duration of the welding time.It is forbidden to weld in rooms containing explosive gases.
Keep amable material away from the welding area.
Do not weld on containers which contain amable material.Do not weld near refuelling areas.Do not weld on easily amable surfaces.Protect face and eyes (protective mask with suitable dark lens and side screens),
ears and body (non-amable protective clothers).
☞
Avoid inhaling fumes by providing a ventilation system or, if not possible, use an approved air breather
☞
Do not work in closed areas where there is no fresh air ow.
☞
Do not use the welder to defrost (thaw) pipes.
☞
Use ear protections if the noise level is high.
DANGEROUS
Arc welders can be dangerous. Protect yourself and others from any possible risks which may cause death or serious injury.
!
Page 14
SYMBOLS - ABBREVIATIONS LEGEND
NEW MAGIC WELDM2.3
© MOSA REV.0 - 11/08
18/11/08 22262-GB
Equipment and optional
Permanent magnet
alternator
Gene ra­tion
2000 / 14 / CE
+
-
~
°C: temperature Celsius grades A: Ampere B: pretrol C.A.(c.a.): alternating current C.C.(c.c.): direct current cc: cm³ (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: 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
PAR 600
Single-phase
1 ~
Engine
Welding control
Optionals
Conformity
CE
EEC
Sound power
conformity
EN 60974-1
conformity
Various
news
Information
Users'
manual
Air
cooling
Socket
230/110/48V EEC
Welding cur-
rent electr.
regulation
Gasoline
engine
Manual
recoil
Arc
control
Fuse
Welding with
covered
electrode
Socket
230V Schuko
Ground con­nection point
Engine shut
down (oil)
A.C.
Plus MinusD.C.
Options on
request
Standard
equipment
Maintenance
Time
Central
lifting eye
Welding
cables
Various
Page 15
INSTALLATION AND ADVICE NEW MAGIC WELD
MAGIC WELD 200
M
2.6
© MOSA REV.0 - 11/08
18/11/08 22262-GB
INSTALLATION AND ADVICE BEFORE USE
☞ Use in open space, air swept or vent exhaust gases,
which contain the deathly carbone oxyde, far from the work area.
POSITION
Place the machine on a level surface at a distance of at least 1,5 m from buildings or other plants.
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.
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.
PLACE OF THE MACHINE AND/OR EQUIPMENTS
10°
10°
= 20° max
10°
10°
= 20° max
1,5 m
1,5 m
1,5 m
GAS DI SCARICO
Maximum leaning of the machine (in case of dislevel)
EXHAUST OUTPUT
ATTENTION
!
For a safer use from the operator DO NOT t the machine in locations with high risk of ood Please do not use the machine in weather conditions which are beyond IP protection shown both in the data plate and on page named “technical data” in this same manual.
Page 16
NEW MAGIC WELDM2.7
© MOSA REV.O-11/08
18/11/08 22262-I
Installazione Installation Installation
Luftzirkulation Instalación
Page 17
UNPACKING AND TRANSPORT NEW MAGIC WELD
M
3
© MOSA REV.0 - 11/08
18/11/08 22262-GB
NOTE
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. 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 nd damages, rough handling or absence of parts (envelopes, manuals, etc.), we advise you to inform
immediately our Technical Service.
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. Take out of the envelope (A) the user’s manual (B).
2) Fit the handle as shown in the instructions (tting: screws and spanner are supplied).
3) Read: the user’s manual (B), the plates xed on the machine, the data plate.
2
B
A
1
C
In case you should transport or move the machine, keep to the instructions as per the gures. 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.
!
Page 18
ASSEMBLY
CTM-MW
© MOSA REV.0-06/07
M
6.11
26/06/01 M6GB
Note
: Lift the machine and assemble the parts as shown in the drawing
The CTM 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 move­ments.
ATTENTION
Page 19
Set-up for operation
M
25
© MOSA REV.0 - 11/08
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LUBRICANT
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.
To check the oil level:
1. Remove the oil-ll tap (24) and clean the dip-stick (23).
2. Insert the dip-stick into the oil ller without screwing it in.
3. If the oil level is low, ll with recommended oil up to the top of the oil ller
Oil ll tap / dip-stick
Upper oil level
MOTORS WITH OIL ALERT DEVICE
The “Oil Alert” system is designed to prevent dama­ge to the motor due to an insufcient 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.
FUEL
ATTENTION
!
Gasoline is highly ammable. Refuel with motor shut off in a at surfaced well-venti­lated area. Do not refuel in the presence of ames. Avoid spilling fuel.
Any eventual spilled fuel and fumes are ammable. Clean any dispersions of fuel before starting up the motor.
AIR FILTER
Check that the dry air lter is correctly installed and that there are no leaks around the lter which could lead to inltrations of non-ltered air to the inside of the motor.
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.
!
NEW MAGIC WELD MAGIC WELD 200
Fill the tank with gasoline for automobiles (prefe­rably 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 ll the tank completely; leave a space of approx. 10 mm between the fuel level and the wall of the tank to allow for expansion.
Page 20
Engine starting
M
26
© MOSA REV.0 - 11/08
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check daily
Do not alter the primary conditions of regula­tion and do not touch the sealed parts.
NOTE
!
1. Turn the fuel cock (87) to ON.
FUEL COCK
2. Switch the choke control (66) to CLOSE
N.B.: Do not use the air valve if the motor is hot
or the air temperature is too high.
CHOKE LEVER
CLOSE
CLOSE
3. Turn the engine switch (28) to the ON position
ENGINE SWITCH
STARTER GRIP
Lightly pull the start-up knob (73) until meeting resistance, then pull decisively.
ATTENTION:
Allow the start-up knob to re-enter slowly, avoiding having it knock against the motor and thereby damaging the start-up system.
4. When the engine is started the machine re­aches 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 lever.
5. The engine reaches maximum speed only when current is drawn in welding or auxiliary power mode.
NEW MAGIC WELD MAGIC WELD 200
Page 21
Stopping the engine
© MOSA REV.0 - 11/08
18/11/08 22262-GB
Before stopping the engine it is compulsory:
- Disconnect or close any power load connected to the system’s auxiliary generation.
- Interrupt welding.
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.
Turn the fuel valve to the OFF position.
ENGINE SWITCH
FUEL VALVE
NEW MAGIC WELD MAGIC WELD 200
M
27
Page 22
Comandi Controls Mandos© MOSA REV.O-11/08
18/11/08 22262-I
Commandes
Pos. Descrizione Description Description
9 10 12 15 22 23 24 26 27 28 31 66 73 87
F
T
Tomas de soldadura (+) Tomas de soldadura (-) Toma de puesta a tierra Toma de corriente en c.c Filtro aire motor Aguja nivel aceite motor Tapón llenado aceite motor Tapón depósito Silenciador de descarga Mando stop Tapón vaciado aceite motor Pulsador Choke Mando manual arranque Grifo de combustible Fisible Regulador corr. de soldadura
Welding sockets (+) Welding sockets (-) Earth terminal d.c. socket Engine air filter Oil level dipstick Engine oil reservoir cap Fuel tank cap Muffler Stop control Oil drain tap Choke button Starting push button Fuel cock Fuse Welding current regulator
Prises de soudage (+) Prises de soudage (-) Prise de mise à terre Prises de courant en c.c. Filtre air moteur Jauge niveau huile moteur Bouchon remplissage huile moteur Bouchon réservoir Silencieux d’échappement Commande stop Bouchon décharge huile moteur Bouton Choke Commande manuelle démarrage Robinet de l'essence Fusible Régulateur courant soudage
Prese di saldatura (+) Prese di saldatura (-) Presa di messa a terra Presa di corrente in c.c. Filtro aria motore Asta livello olio motore Tappo caricamento olio motore Tappo serbatoio Silenziatore di scarico Comando stop Tappo scarico olio motore Comando choke Comando manuale avviamento Rubinetto carburante Fusibile Regolatore corrente di saldatura
Descripción
F
M
31
F15 T 910
12
22 27 26
73
31
23-24
28
87
66
NEW MAGIC WELD
Page 23
Use as a welder
M
34
© MOSA REV.0 - 11/08
18/11/08 22262-GB
Areas for which access by non-authorized personnel is forbidden are:
- the control panel (at the front) - the endo­thermic motor discharge.
WARNING
!
PUSH AND TWIST
CONNECT WELDING CABLES
Insert the welding cable plugs completely in the sockets, turning clockwise to lock them in place. Connect the earth clamp to the negative pole
and the electrode holder to the positive.
Pay attention to the two polarities on the
welding circuit, which must not come into electrical contact with each other.
- Carefully tighten the output cables to the bushings; if loose, they can cause problems of overheating and damage the bushings, cables, etc.
- Make certain the grounding pincer is connec­ted as near as possible to the work station.
ATTENTION
!
To reduce the risk of electromagnetic interfe­rence, 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 lters, shield the entire work area. If the above solutions do not sufce, consult our Technical Servicing Department.
ADJUSTING THE WELDING CURRENT
The welding current is regulated by turning knob “T” 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 recom­mend Magic Weld with added reactor.
NEW MAGIC WELD
Page 24
Use as a welder
© MOSA REV.0 - 11/08
18/11/08 22262-GB
AUTO IDLE
Operation
When the engine is switched on it immediately reaches a maximum speed of 4000 rpm for ap­proximately 6/7 seconds for easy start up, after which it automatically decreases and idles at 2000 rpm. 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 mi­nimum contact between the tip of the electrode and the piece to be welded and also when set to 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 A locked, 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 speed is correct.
Adjusting the maximum engine speed
FIG. 1
FIG. 2
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.
M
34.1
NEW MAGIC WELD
Page 25
Checking and adjusting the maximum welding current
© MOSA REV.0 - 11/08
18/11/08 22262-GB
dal ponte chopper
from chopper welding bridge
dal sensore di corrente
from current sensor
taratura corrente max. di sald. (*) welding max. current adjustment (*)
dall'alternatore from alternator
dai ponti ausiliari from aux. bridges
dal frontale from frontal
dal solenoide from solenoid
NEW MAGIC WELD
M
34.2
Sol. 1
Sol. 2
Si
Su
Ri
Ru
Y
Ti
Tu
2
1
14
13 7
8
1
2
11
12
2
1
Y
T
R
S
S
R
T
ON
OFF
*) Tutte le volte che viene sostituita o la scheda o il sensore di corrente è necessario procedere ad una verica della massima corrente di saldatura e eventualmente procedere ad una sua taratura nel se­guente modo:
- Lasciare ssato 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 gura
- Vericare 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 afnché 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 xed 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
- 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 rotate the trimmer clockwise so that the welding current reaches 140 A.
Dip switch
Dip switch
Dip switch
Page 26
Parallel engine driven welder
M
34.3
© 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 t 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
NEW MAGIC WELD
Page 27
Use as a generator
© MOSA REV.0 - 11/08
18/11/08 22262-GB
WARNING
!
GENERATION IN C.C. (CONTINUOUS CUR­RENT 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, exten­sion cords, appliance cords, plugs, plug sockets and appliances should be in good condition and correctly wired and connected. All earthing wi­res, 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 connec­ted 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 oating auxiliary power system is used. The auxiliary power windings are not connected to the fra­me, 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.
It is absolutely forbidden to connect the 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 endo­thermic motor discharge.
M
37
NEW MAGIC WELD
Page 28
Trouble-shooting
© MOSA REV.0 - 11/08
18/11/08 22262-GB
The motor does not start up, or starts up and then stops immediately
1) Engine switch (28) at position OFF
2) Lack of or insufcient oil in the motor
3) Faulty motor stopping device (oil-alert)
4) Lack of fuel in tank or fuel tap closed
5) Dirty or faulty spark plug
6) Cold motor
7) Other causes
1) Position switch to ON
2) Rell or top off
3) Replace
4) Rell 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 Ma­nual.
Problem Possible cause Solution
No current under no-load conditions in weld mode No current under no-load
conditions in auxiliary power mode Incorrect minimum voltage
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 (discon­nect one of the two wires to the solenoid)
1) Chopper welding bridge broken
2) Faulty circuit
3) Faulty alternator
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 (discon­nect one of the two wires to the solenoid).
1) Fuse open
2) Auxiliary power diode bridge broken
3) Faulty circuit
4) Faulty alternator
under no-load conditions 1) Adjust the solenoid as shown on
page M34.
1) Incorrect solenoid adjustment
M
40.2
NEW MAGIC WELD
Page 29
Trouble-shooting
© MOSA REV.0 - 11/08
18/11/08 22262-GB
M
40.2.
1
Problem Possible cause Solution
RESISTENCE OF WINDING AT 20°C
Ω (ohm)
NOTE
Output in weld mode Between green / black cable Between green / red cable Between black / red cable
0,030 0,030 0,030
All cables of the same colour are connected in parallel
Auxiliary power outputs 230 Vdc Between the black cables: R / S Between the black cables: R / T Between the black cables: S / T
1,2 1,2 1,2
Auxiliary power outputs 110Vdc Between the black cables: R / S Between the black cables: R / T Between the black cables: S / T
1,0 1,0 1,0
Cable Y is connected to the centro stella of the three phase circuit
Cable Y is connected to cable T
1) Adjust the maximum engine spe­ed as shown on page M34.
Incorrect maximum voltage under no-load conditions
Engine always at idle speed
1) Replace
Engine always at maximum speed
1) Incorrect maximum engine speed
1) Faulty circuit
1) Replace;
2) Check that the resistance of the solenoid winding is approximately 10 ohm.
Insufficient power during welding or generation
1) Dirty petrol lter,
dirty air lter, dirty carburetor. See engine instruction booklet.
1) Disconnect all the outputs; 3 for
1) faulty circuit
2) Faulty solenoid
1) Engine
1) a lt er na to r w in di ng s n o t
Irregular or inconsistent wel­ding current
insulated from earth
2) welding chopper bridge not insulated from earth
3) power cables not insulated from earth
4) faulty circuit
welding which go to the chopper bridge and 4 for auxiliary power which go to the circuit board. Use a multimeter to check the insulation of the alternator;
2) disconnect the 3 welding cables, 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) check that the cables inside the aluminium casting, are properly insulated;
4) Replace
NEW MAGIC WELD
Page 30
MAINTENANCE
© MOSA REV.0 - 11/08
18/11/08 22262-GB
!
!
• Maintenance and repair work should only be done by qua­lied personnel.
• Stop the engine before doing any work on the machine. If 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 main­tenance is completed.
• Use suitable tools and wear suitable clothes.
• Do not modify the machine without prior authorization
ATTENTION
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.
IMPORTANT
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 replace­ment of uids 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 ow of cooling air.
DRY AIR FILTER
Replace the air lter 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.
HOT surface
can
hurt you
MOVING
PARTS
can injure
M
43
NEW MAGIC WELD MAGIC WELD 200
Page 31
STORAGE - CUST OFF
© MOSA REV.0 - 11/08
18/11/08 22262-GB
M
45
Have qualied personnel prepare the ma- chine for the cust-off.
STORAGE
In case the machine will not be used for more than 30 days, it should 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.
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 ofce, etc.
The several operations concerning the cust off, involve the manipulation of uids potentially dangerous such as: lubricating oil.
The dismantling of metallic parts liable to cau­se injuries or wounds, must be made wearing heavy gloves and using suitable tools.
The 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, inamable liquids such as fuel.
The machine user is responsible for the obser­vance of the norms concerning the environment conditions with regard to the elimination of the machine being cust off and of all its compon­ents.
In case the machine should be cust off without any previous disassembly it is however com­pulsory 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.
In case of necessity for rst aid and re preven­tion, see page M2.
In the storage or cust-off operations avoid that polluting substances, liquids, exhausted
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.
!
IMPORTANT
NEW MAGIC WELD MAGIC WELD 200
Page 32
RECOMMENDED ELECTRODES (In accordance with A.W.S Standard)
MS_, TS_
M
55
© MOSA 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/mm2 . Also for soft steels of lower quality.
BASIC ELECTRODES: E 7015
Basic electrrodes wels onlu in d.c. with inverse polarity (+ on the electrode 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). Wld 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/mm2. Weld in all position. volatile slag.
ELECTRODES IDENTIFICATION ACCORDING TO A.W.S. STANDARDS
EX XY Z
2 digits: type of coating and electric power conditions. (see table 3)
1 digits: welding positions. (see table 2)
2÷3 digits: tesile strenght of the weld deposit. (see table 1)
symbol for
"Coated
electrode"
10 Cellulose electrodes for d.c. 11 Cellulose electrodes for a.c. 12 Rutile electrode for d.c. 13 Rutile electrode for a.c. 14 High yield rutile electrodes 15 Basic electrodes for d.c. 16 Basic electrodes for c.a. 18 High yield basic electrodes for d.c. (inverse polarity) 20 Acid electrodes for flat or front position welding for
d.c. (- pole) and for a.c.
24 High yield rutile electrodes for flat or front plane
position welding for d.c. and a.c.
27 High yield acid electrodes for flat or front plane
position welding for d.c. (- pole) and a.c..
28 High yield basic electrodes for flat or front plane
position welding for d.c. (inverse polarity)
30 Extra high yield acid electrodes, extra high
penetration if required, for flat position welding only for d.c. (- pole) and a.c.
N° Descrizione
Number
Strenght
K.s.l. Kg/mm
2
60 70 80
90 100 110 120
60.000
70.000
80.000
90.000
100.000
110.000
120.000
42 49 56 63 70 77
84
for all positions for plane and verticl for plane posotion only
1 2 3
Table 1
Table 2 Table 3
10/10/03 M55GB
Page 33
© MOSA REV.O-11/08
18/11/08 22262-I
M
53
Dimensioni Dimensions Dimensions
Abmessungen Dimensiones
375
430
470
510
854
610 402
~
566
NEW MAGIC WELD
Page 34
18/11/08 22262-I
NEW MAGIC WELD
M
60
© MOSA REV.O-11/08
A : Alternatore F : Fusibile H : Presa 230V monofase I : Presa 110V monofase R : Unità controllo saldatura T : Regolatore corrente saldatura Y : Ponte diodi saldatura F1 : Elettromagnete acceleratore S2 : Trasmettitore livello olio F3 : Pulsante stop G3 : Bobina accensione H3 : Candela accensione W6 : Sensore di hall
Legenda schema elettrico Electrical system legende Legende des schemas electriques
Stromlaufplan-Referenzliste Leyenda esquema eléctrico
A: Alternator F: Fuse H: 230V 1phase socket I: 110V 1-phase socket R: Welding control PCB T: Welding current regulator Y: Welding diode bridge F1: Acceleration solenoid S2: Oil level transmitter F3: Stop push-button G3: Ignition coil H3: Spark plug W6: Hall sensor
A : Alternateur F : Fusible H : Prise 230V monophasé I : Prise 110V monophasé R : Unite contrôle soudage T : Régulateur courant de soudage Y : Pont diodes soudage F1 : Electro-aimant accélérateur S2 : Transmetteur niveau huile F3 : Bouton stop G3 : Bobine allumage H3 : Bougie allumage W6: Senseur de hall
A Generator
F Sicherung H Steckdose 230V 1-phasig I Steckdose 110V 1-phasig R Steuerplatine Schweißstrom T Schweißstromregler Y Diodenbrücke Schweißstrom F1 Elektromagnet Motordrehzahl S2 Ölstandssensor
F3 Taste Stopp G3 Zündspule H3 Zündkerze W6 Hall-Sensor
A :Alternador F :Fusible H :Toma 230V monofásica I :Toma 110V monofásica R :Unidad control soldadura T :Regulador corriente soldadura Y :Puente diodos soldadura F1 :Electromagnetismo acelerador S2 :Captador nivel aceite F3 :Pulsador stop G3 :Bobina encendido H3 :Bujía encendido W6 :Sensor de entrada
Page 35
18/11/08 22262-I
Schema elettrico Electric diagram Esquema eléctrico
NEW MAGIC WELD (110V version)
M
61
© MOSA REV.O-11/08
20090-CUSAGO (MI)-ITALY
http://www.mosa.it
MAGIC WELD
Wiring Diagram 22263.prg
22240.S.060-F
Leporace N.
2
Approvato:
Esp.
Data Dis. Appr.
Modifica
Denominazione:
Macchina:
Data:
Progetto:
di n°
Pag.n°
2
Date Appr.
Approved:
Project:
Denomination:
Machine:
Modification
Date:
Da Pag.
Alla Pag.
To Page
From Page
Designer:
of n°
Desi.
Dis. n°:
Exp.
Page n°
Dwg. n°:
Disegnatore:
La MOSA si riserva a termini di legge la proprieta' del presente disegno con divieto di riprodurlo o comunicarlo a terzi senza sua autorizzazione.
02.07.2004
-
+
KEY COLOR
LEGENDA COLORI
NERO/BLACK
(R)
ROSSO/RED
(B)
(B)
Y
T
S
R
(B)
GIALLO/YELLOW
(B)
(Y)(B)(Y)
(Y)
(B)
(Y)
(B)
(B)
(Y)
(BL)
(BL)
BLU/BLUE
(Y)
(R)
(B)
(B)
(R)
(BL)
+
-
~
~
~
-
+
Z
3~
GS
A
W6
Y
F1
S2G3H3
ONOFF
F3
P1
P3
P2
Sol. 1
Sol. 2
Si
Su
Ri
Ru
Tu
Ti
Y
1
2
3
4
5
6
7
8
9
10
11
12
R
T
A
18.04.2005 N.L.
T
(R)
(B)
S
R
+
-
+
-
F
15A
110V/16A
I
Aggiunto soppressore (Zenamic) a pr
otezione dei ponti diodi ausiliaria.
B Aggiunto ponticello tra pin9e10suc onn. P1 (opzione Arc- Force). 22.03.2006 N.L.
(BL)
N.L.
C
03.04.2006
1Kohm/¼W
Aggiunto resistenza 1Kohm/¼W nel pontic
ellotrapin9e10suconn. P1.
22Kohm/2W
D
27.06.2006 N.L.
Aggiunto resistenza 22Kohm/2W in parallelo uscita ponti diodi ausilaria.
10µH
Aggiunto induttanza 10µH su cavo
1 connettore P1. 23.05.2007 N.L.
E
Aggiunto reattore(W)F
27.10.2008 N.L.
W
Page 36
18/11/08 22262-I
Schema elettrico Electric diagram Esquema eléctrico
NEW MAGIC WELD (EU Version)
M
61.1
© MOSA REV.O-11/08
20090-CUSAGO (MI)-ITALY
http://www.mosa.it
MAGIC WELD
Wiring Diagram
22243.prg
22243.S.060-C
Leporace N.
2
Approvato:
Esp.
Data
Dis.
Appr.
Modifica
Denominazione:
Macchina:
Data:
Progetto:
di n°
Pag.n°
2
Date
Appr.
Approved:
Project:
Denomination:
Machine:
Modification
Date:
Da Pag.
Alla Pag.
To Page
From Page
Designer:
of n°
Desi.
Dis. n°:
Exp.
Page n°
Dwg. n°:
Disegnatore:
La MOSA si riserva a termini di legge la proprieta' del presente disegno con divieto di riprodurlo o comunicarlo a terzi senza sua autorizzazione.
-
+
T
(R)
(B)
KEY COLOR
LEGENDA COLORI
NERO/BLACK
(R)
ROSSO/RED
(B)
(B)
Y
T
S
R
S
R
(B)
GIALLO/YELLOW
(B)
(Y)(B)(Y)
(Y)
(B)
(Y)
(B)
(B)
(Y)
(BL)
(BL)
BLU/BLUE
(BL)
(Y)
(R)
(B)
(B)
(R)
-
+
Z
3~
GS
A
W
+
-
+
-
F
10A
230V/16A
H
W6
Y
F1
S2G3H3
ONOFF
F3
P1
P3
P2
Sol. 1
Sol. 2
Si
Su
Ri
Ru
Tu
Ti
Y
1
2
3
4
5
6
7
8
9
10
11
12
R
A
18.04.2005 N.L.
Aggiunto soppressore (Zenamic) a protezione dei ponti diodi ausiliaria.
02.07.2004
2x15Kohm/2W
N.L.
B Aggiunto n° 2 resistenze da 15Kohm/2W in parallelo uscita ponti diodi ausilaria.
19.09.2006
10µH
C Aggiunto induttanza 10µH su cavo 1 connettore P1.
23.05.2007 N.L.
Page 37
SPARE PARTS LIST
R
1
© MOSA 1.0-03/00
MOSA guarantees that any request for spare parts will be satised.
To keep the machine in full working order, when replacement of MOSA spare parts is required, always ask for genuine parts only.
When ordering the spare parts, it is recom­mended to indicate:
1) Y serial number
2) Y model of welder and/or generating set
3) u n. table
4) u n. position
5) quantity
14/12/986Q16M31
TAVOLA RICAMBI - SPARE PARTS - PIECES DE RECHANGE - ERSATZTEILE
ON
OFF
START
*
VE
NULLEITERAUFMASSE NULVERBONDENMETMASSA
NEUTROCONECTADOAMASA
NEUTRERACCORDEAUBATI
NEUTRALBONDEDTOFRAME
NEUTROCOLLEGATOAMASSA
*
65
60
Hz A
10
50
15
55
500
300
V
ST
RS
0
200
100
TR
0
h
HOURMETER
I
0
EA
1
25
20
125
1-3 13
18
17 16
20-21-22
12
21-22-23
14
11
8
2
19
15
4-5-6
EA
1
12
50 Hz
50 Hz
3
EA
1
4
12
TS 0000 GE
V.le Europa,59 - 20090 CUSAGO (MI) ITALY
Tel. +39-02 90352.1 - fax +39-02 90390466
0987654321
TYPE SERIAL N°
22/03/00 R1GB
The requested data are to be found on the data
plate located on the machine structure, quite visible and easy to consult.
Y
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
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Ricambi Spare parts Piéces de rechange
Ersatzteile Tabla de recambios
AG
NEW MAGIC WELD 5
1
2
(230V Version)
(110V Version)
3
3a
4
6
5 5a
(110V version)
(230V version)
7
8
9
10
11
12
13
14
15
16
17
18
20
23
24
22
19
21
25
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NEW MAGIC WELD
AG
5.1
Ricambi Spare parts Piéces de rechange
Ersatzteile Tabla de recambios
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 ASSIEME LEVA COMANDO GAS MOT. / ENGINE GAS LEVER
25 208029104 COLONNETTA / SPACER
Page 40
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© MOSA REV.O-11/08
NEW MAGIC WELD
AG
2
Ricambi Spare parts Piéces de rechange
Ersatzteile Tabla de recambios
110I Version
230I Schuko Version
15
16
230I Version
123 4* 567
8*
9*
10*
11*
12*
13*
(*) 14
FUSE
10
20
30
40
50
60
70
1a
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© MOSA REV.O-11/08
NEW MAGIC WELD
AG
2.1
Ricambi Spare parts Piéces de rechange
Ersatzteile Tabla de recambios
Pos. Rev. Cod. Descr. Note
1 1291180 FUSIBILE Versione 230V
1a 1291090 FUSIBILE Versione 110V
2 103011320 PORTA FUSIBILE fino a REV.2-11/05 Del. 78/06 del 18/05/06 2 873789045 PORTA FUSIBILE da REV.3-06/07 Del.78/06 del 18/05/06 3 307017240 PRESA 220V 16A 4 270009701 POTENZ. LINEARE A FILO 5Kohm (*) 5 102301310 PRESA DI SALDATURA (+) 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.I.M4X8 (*) 13 6060050 GRANO M 4X4 UNI 5923 R45H (*) 14 222440543 KIT MANOPOLA ARCO SALD. COMPL, (* 4+8÷13) 15 307047250 PRESA 110V 16A Versione 110V 16 259107241 PRESA SCHUKO 16A 230V - 2P+T Versione Schuko
Pos. Rev. Cod. Descr. Note
1 1291180 FUSE 230V version 1a 1291090 FUSE 110V version
2 103011320 HOLDER, FUSE up to REV.2-11/05 Del. 78/06 del 18/05/06
2 873789045 HOLDER, FUSE from REV.3-06/07 Del.78/06 del 18/05/06
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 107011870 CAP (*) 12 6060070 DOWEL (*) 13 6060050 DOWEL (*) 14 222440543 KIT FOR ARC FORCE KNOB (*4+8÷13) 15 307047250 SOCKET 110V 16A 110V version 16 259107241 SOCKET SCHUKO 16A 230V 2P+T Schuko version
Page 42
© MOSA REV.0-06/07
29/06/01 KA
CTM-MW 222420130
KA 18
1
2
3
4
5
6
7
8
9
10
Pos. Rev. Cod. Descr. Descr. Note
1 222421050 BARELLA
PROTECTIVE FRAME
2 222421226 MANIGLIA DI SOLLEVAMENTO
LIFTING HANDLE
3 219861159 MANOPOLA
KNOB
4 222422038 RONDELLA
WASHER
5 222421170 RUOTA
WHEEL
6 222421051 PIEDE DI STAZIONAMENTO
PARKING STAND
7 222421160 ASSALE
AXLE
8 6075020 COPIGLIA
PIN, SPLIT
9 222421356 PIASTRA FISS. BASAMENTO
FIXING PLATE FOR BASE
10 222429359 SPINA DI SICUREZZA
SAFETY PLUG
Page 43
Page 44
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Stabilimento di Viale Europa, 59
20090 Cusago (MI) Italia
Tel. + 39 - 0290352.1
Fax + 39 - 0290390466
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