Mosa NEW MAGIC WELD User Manual
NEW MAGIC WELD
222629003 - GB1 1 0 8
18/11/08 22262M00
preparato da UPT
approvato da DITE
ENGLISH
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
Quality system
M
01
REV.4-03/12
UNI EN ISO 9001 : 2008
10/10/02 M01-GB
MOSA has certied its quality system according
to UNI EN ISO 9001:2008 to ensure a constant,
highquality of its products. This certication covers
thedesign, production and servicing of engine drivenwelders and generating sets.
The certifying institute, ICIM, which is a member
ofthe International Certication Network IQNet,
awarded the ofcial approval to MOSA after anexamination of its operations at the head ofce
andplant in Cusago (MI), Italy.
This certication 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 ofcial 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 conrm 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
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
Copyright GE_, MS_, TS_, EAS
M
1.01
© MOSA 1.0-10/02
ATTENTION
© All rights are reserved to said 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.
➠
The reproduction and total or partial use, in 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
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).
INFORMATION
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.
☞
In case you do not 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.
☞
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.
INFORMATION OF GENERAL TYPE
In the 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.
Notes GE_, MS_, TS_, EAS_
M
1-1
© MOSA 1.0-10/02
☞
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 modifications
to parts and accessories, without putting this
manual uptodate immediately.
10/10/02 M 1-1 GB
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.
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
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 inamability point is very low.
!!!
!
!
!
These headings refer to information which will assis you
in the correct use of the machine and/or accessories.
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.
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.
!
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
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