USE AND MAINTENANCE MANUAL MAGIC WELD 200 YD MAGIC WELD 200 YDE M A D E I N I T A L Y Codice Code Codigo Kodezahl 222719003 Edizione Edition Edición Ausgabe 02.
I GB F MAGIC WELD 200 YD - YDE DESCRIPTION OF THE MACHINE M 0 REV.0-02/14 The MAGIC WELD engine driven welder is a unit which ensures the dual function as: a) a current source for are welding b) current generator for generating auxiliary Unit meant for industrial and professional use. Powered by an endothermic engine; it is composed of various parts such as: engine, alternator, electric and electronic controls, the fairing at a protective structure.
M Quality system 01 REV.4-03/12 UNI EN ISO 9001 : 2008 The certifying institute, ICIM, which is a member ofthe International Certification Network IQNet, awarded the official approval to MOSA after anexamination of its operations at the head office andplant in Cusago (MI), Italy.
Index M0 M 01 M 1.01 M 1.1 M 1.4 M1.4.1 M 1.5 M 1.6 M2 M 2.1 M 2.2 M 2.6 M 2.7 M3 M 6.21 M 6.22 M 20 M 21 M 22 M 31 M 34... M 34.3 M 37 M 38.10 M 38.12 M 39.6 M 40... M 43 M 45 M 55 M 60 M 61-….. MAGIC WELD 200 YD - YDE M 1 REV.
M 1.01 Copyright REV.0-10/02 ! ATTENTION This use and maintenance manual is an important part of the machines in question. The assistance and maintenance personel must keep said manual at disposal, as well as that for the engine and alternator (if the machine is synchronous) and all other documentation about the machine. We advise you to pay attention to the pages concerning the security (see page M1.1). All rights are reserved to said Company. It is a property logo of MOSA division of B.C.S. S.p.
Notes M 1-1 REV.1-03/14 INFORMATION Dear Customer, We wish to thank you for having bought 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.
M 1.4 CE MARK REV.7-02/14 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. TYPE SERIAL N° Made in UE-ITALY TYPE/N° VOLTAGE(V) POWER(W) Hz G P.F. I.
I GB F Dichiarazione conformità Declaration of conformity Déclaration de conformité Konformitätserklärung Declaración de conformidad Declaração de conformidade BCS S.p.A. M 1.4.1 REV.2-10/13 Stabilimento di Cusago, 20090 (Mi) - Italia V.le Europa 59 Tel.
I GB F Technical data M 1.5 MAGIC WELD 200 YD - YDE REV.0-02/14 Technical data A.C.
Technical data M 1.6 MAGIC WELD 200 YD - YDE REV.0-02/14 D.C. WELDING Current range, continuous Open circuit voltage Duty cycle 20 - 200A 65V 200 A - 60% OUTPUT CARACTERISTIC SIMULTANEOUS UTILIZATION FACTORS WELDING CURRENT >150A 125A 100A 75A 50A 0A POWER GENERATION 230 Vac 0 kVA 0.8 kVA 1.5 kVA 2.1 kVA 2.5 kVA 3 kVA POWER GENERATION 115 Vac 0 kVA 0.5 kVA 1 kVA 1.3 kVA 1.5 kVA 1.
M 2 WARNINGS REV.1-02/14 The installation and general warnings regarding operations are aimed achieving correct use of the machine and/or apparatus in the place where it is used as a genset and/or motor welder. - Advice to the User about the safety: + NB: The information contained in the manual can be changed without notice. Any damage caused in connection with the use of these instructions shall not be considered as they are only indicative.
M 2-1 SYMBOLS AND SAFETY PRECAUTIONS REV.2-06/10 STOP - Read absolutely and be duly attentive Read and pay due attention ! GENERAL ADVICE - If the advice is not respected damage can happen to persons or things. HIGH VOLTAGE - Attention High Voltage. There can be parts in voltage, dangerous to touch. The non observance of the advice implies life danger. FIRE - Danger of flame or fire. If the advice is not respected fires can happen. HEAT - Hot surfaces.
SYMBOL © MOSA TS_, DSP_ M 2.2 1.0-05/04 ARC WELDING HAZARDS Electric shock from welding electrode or wiring can kill. Wear dry, hole-free insulating gloves and body protection. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Do not touch live electrical parts. Wet or confined spaces, or if their is una danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit.
SIMBOLI E AVVERTENZE RELATIVE ALLA SICUREZZA TS_, DSP_ © MOSA M 2.2.1 1.0-05/04 ENGINE HAZARDS Fuel can cause fire or explosion. = STOP engine before fueling. DO NOT fuel a hot engine. Stop engine and let it cool off before checking or adding fuel. Hot parts can cause severe burns. Do not touch not welder with bare hand. If handling is needed, use proper tools and/ or wear heavy, insulated welding gloves to prevent burns. Allow cooling period before handing parts or working on gun or torch.
M 2.6 INSTALLATION AND ADVICE REV.1-06/07 INSTALLATION AND ADVICE BEFORE USE GASOLINE ENGINES + Use in open space, air swept or vent exhaust gases, which contain the deathly carbone oxyde, far from the work area. 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. 1,5 m DIESEL ENGINES + Use in open space, air swept or vent exhaust gases far from the work area.
Luftzirkulation Instalación MAGIC WELD 200 YD - YDE M 2.7 REV.
Luftzirkulation Instalación MAGIC WELD 200 YD - YDE M 2.7.1 REV.
M 3 UNPACKING REV.1-02/04 NOTE ! + Be sure that the lifting devices are: correctly mounted, adequate 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 find damages, rough handling or absence of parts (envelopes, manuals, etc.
TRANSPORT AND DISPLACEMENTS COVERED UNITS M 4-1 REV.2-09/11 ! NOTE Transportation must always take place with the engine off, electrical cables and starting battery disconnected and fuel tank empty. 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.
ASSEMBLY CTM-MW200-D M 6.21 REV.0-02/14 Note: Lift the machine and assemble the parts as shown in the drawing ATTENTION 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.
ASSEMBLY TRM-MW200-D M 6.22 REV.0-02/14 Note: Lift the machine and assemble the parts as shown in the drawing ATTENTION The TRM 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.
Set-up for operation MAGIC WELD 200 YD - YDE M 20 REV.0-02/14 BATTERY WITHOUT MAINTENANCE FUEL (where it is assembled) The included battery must be activated. To activate it (fill the included acid) please follow the instructions shown on the manual attached to the battery. When battery is activated, DON’T add any other liquid. LUBRICANT ! ATTENTION Do not smoke or use open flames during refuelling operations, in order to avoid explosions or fire hazards.
STARTING M 21 MAGIC WELD 200 YD - YDE REV.0-02/14 Check daily NOTE Do not alter the primary conditions of regulation and do not touch the sealed parts.
STOPPING MAGIC WELD 200 YD - YDE M 22 REV.0-02/14 + Before stopping the engine it is compulsory to stop the load: - stop welding; - shut off any loads which are connected to the unit auxiliary outputs. RECOIL VERSION Let the motor run at no load for several minutes to allow for cooling and then move the accelerator control into the “STOP” position.
I GB F Comandi Controls Commandes Mandos M 31 MAGIC WELD 200 YD - YDE REV.0-02/14 (*) YDE VERS. 9 10 12 15 16 22 23 24 26 27 28 31 73 N1 O1 Q1 S1 S8 T X1 Descrizione Prese di saldatura (+) Prese di saldatura (-) Presa di messa a terra Presa di corrente in c.a.
USE AS WELDER M 34 MAGIC WELD 200 YD - YDE REV.0-02/14 This symbol (Norm EN 60974-1 security standards for arc welders) signifes that the welders can be used in areas with increased risk of electrical shock. ! ATTENTION It is prohibited for any unauthorized persons to access areas adjacent to the engine driven welder or the welding process. ! The welding machine is predisposed for connection to a remote control (optional) by means of the circular connector located on the front panel.
Parallel engine driven welder MAGIC WELD 200 MAGIC WELD 200 YD - YDE M 34.3 REV.0 - 11/08 How to put two machines in parallel: from the front panels of the machines connect the two positives welding sockets(+) between themselves and the two negative welding sockets bethween themselves. To effect the connection ask for the accessory K2X150. ATTENTION: use fit cables and tight at the connection point.
I GB F Use as a generator MAGIC WELD 200 YD - YDE M 37 REV.0-02/14 ATTENTION wiring it to the ground of the electrical plant with which the machine is going to work. It is absolutely forbidden to connect the unit to the public mains and/or another electrical power source. WARNING: bound the neutral to frame BEFORE the GFI. ! ! ATTENTION It is prohibited for any unauthorized persons to access areas adjacent to engine driven welder.
ACCESSORY USE (TS SERIES) REMOTE CONTROL RC2 RC2/90° M 38.10 REV.0-12/11 PUSH AND SCREW TIGHT PUSH AND SCREW TIGHT The remote control device for regulating the welding current is connected to the front panel by means of a multipole connector. Position welding current adjusting (T) knob at the necessary current value for the diameter and type of electrode. 09/04/02 M38GB To regulate the current from the RC2, move the switch (7), located above the multipole connector (8), to "ON" position.
ACCESSORY USE REMOTE CONTROL TC7 M 38.12 REV.0-06/10 PUSH AND SCREW TIGHT The remote control device for regulating the welding current is connected to the front panel by means of a multipole connector. Position welding current adjusting (T) knob at the necessary current value for the diameter and type of electrode. 09/11/99 M38GB When the remote control is connected to the remote control connector (8), it is functional and automatically excludes the front panel regulation.
I GB F ENGINE PROTECTIONS MAGIC WELD 200 YDE M 39.6 REV.0-02/14 The engine is equipped with system protection (stop) in the event the oil pressure is too low. 20/02/14 22270-GB In the event of a malfunction in the battery charging system, the warning light will come on without stopping the engine.
Trouble-shooting MAGIC WELD 200 YD - YDE M 40 REV.0-02/14 Problem Possible cause MOTORE The motor does not start up, 1) or starts up and then stops 2) immediately 3) 4) Solution Lack of fuel in tank 1) 2) Air in the fuel circuit Incorrect position of accelerator control 3) knob Battery low 4) Rifornire il serbatoio Check power supply circuit Check position Recharge or replace. Check the battery charge circuit. Tighten and clean. Replace if corroded. Repair or replace.
I GB F Trouble-shooting MAGIC WELD 200 YD - YDE M 40.1 REV.0-02/14 Problem Possible cause WELDING CIRCUIT No current under no-load 1) Faulty welding control board conditions in weld mode 2) Faulty Hall sensor Solution With a voltmeter check that between pins A (-) and B (+) of the circular connector on the front panel there is 5 Vdc. Ask for intervention of Service Department to replace the board. 2) Ask for intervention of Service Department to replace the Hall sensor.
M 43 MAINTENANCE REV.1-01/13 ! MOVING PARTS can injure WARNING ●● Have qualified personnel do maintenance and troubleshooting work. ●● Stop the engine before doing any work inside the machine. If for any reason the machine must be operated while working inside, pay attention moving parts, hot parts (exhaust manifold and muffler, etc.) electrical parts which may be unprotected when the machine is open.
I GB F M 45 STORAGE REV.0-06/07 In case the machine should not be used for more than 30 days, make sure that the room in which it is stored presents a suitable shelter from heat sources, weather changes or anything which can cause rust, corrosion or damages to the machine. + Have qualified personnel prepare the machine for storage. GASOLINE ENGINE Start the engine: lt will run until it stops due to the lack of fuel. Drain the oil from the engine sump and fill it with new oil (see page M25).
I GB F + M 46 CUST OFF REV.0-06/07 Have qualified personnel disassemble the machine and dispose of the parts, including the oil, fuel, etc., in a correct manner when it is to be taken out of service. As cust off we intend all operations to be made, at utilizer’s care, at the end of the use of the machine.
M 55 RECOMMENDED ELECTRODES (In accordance with A.W.S Standard) REV.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..
A B C D E F G H I L M N P Q R S T U V Z X W Y A1 B1 C1 D1 E1 F1 G1 H1 I1 L1 M1 N1 O1 P1 Q1 R1 S1 T1 U1 V1 Z1 W1 X1 Y1 A2 B2 C2 D2 E2 F2 G2 H2 I2 L2 M2 N2 O2 P2 Q2 R2 S2 T2 U2 V2 Z2 W2 X2 Y2 A3 B3 C3 D3 M 60 ELECTRICAL SYSTEM LEGENDE : Alternator : Wire connection unit : Capacitor : G.F.I.
Schema elettrico Electric diagram Esquema eléctrico MAGIC WELD 200 YDE M 61 REV.
Schema elettrico Electric diagram Esquema eléctrico MAGIC WELD 200 YD - YDE M 61.2 REV.
WWW.MOSA.IT MOSA div. della BCS S.p.A. Stabilimento di Viale Europa, 59 20090 Cusago (MI) Italia Tel. + 39 - 0290352.
