Magmaweld ID 400 M PULSE EXPERT Le manuel du propriétaire

EXPERT SERIES

(+90) 444 93 53

magmaweld.com

info@magmaweld.com (+90) 538 927 12 62

USER MANUAL



Magma Mekatronik may modify the information and the images without any prior notice.







3

MIG / MAG WELDING MACHINE EN

POSTE À SOUDER MIG / MAG FR

MÁQUINA DE SOLDAR MIG/MAG PT

MÁQUINA DE SOLDADURA MIG / MAG ES

MIG/MAG-LASAPPARAAT NL

 /    AR

 TR

MIG / MAG-SCHWEISSMASCHINE DE

 RU

4

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www.magmaweld.comUSER MANUAL

EXPERT SERIES

CONTENTS

1

1.1

1.2

1.3

1.4

1.5

2

2.1

2.2

2.3

2.3.1

2.3.2

2.3.3

2.3.4

2.3.5

3

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

4

4.1

4.2

4.3

4.4

5

5.1

5.2

5.3

5.4

SAFETY PRECAUTIONS

TECHNICAL INFORMATION

General Information

Machine Components

Product Label

Technical Data

Accessories

INSTALLATION

Delivery Control

Installation and Operation Recommendations

Connections

Mains Plug Connection

Connecting the Grounding Clamp to the Workpiece

Connecting the Gas Cylinder

Water Cooling Unit (for MW Models)

Connection of Interconnection Hose Package

OPERATION

User Interface

Menu Structure

Remote Control

Arc Length Adjustment (ArC)

MIG Curve

Connection to Mains

Selection and Replacement of Wire Feed Rollers

Placing The Wire Spool And Wire Feeding Process

Adjustment of Gas Flow

Machine Features

MAINTENANCE AND SERVICE

Maintenance

Non-Periodic Maintenance

Troubleshooting

Error Codes

ANNEX

Fine Settings in the Wire Feed Unit

Spare Parts Lists

Block Diagram

Water Unit Circuit Diagram

5

11

13

14

16

17

18

19

20

21

31

32

33

34

35

36

37

38

39

40

41

44

45

Contents

5

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www.magmaweld.com USER MANUAL

EXPERT SERIES Safety Precautions

Be Sure To Follow All Safety Rules In This Manual!

• Safety symbols found in the manual are used to identify potential hazards.

• When any one of the safety symbols are seen in this manual, it must be understood that there is

a risk of injury and the following instructions should be read carefully to avoid potential hazards.

• The possessor of the machine is responsible for preventing unauthorized persons from

accessing the equipment.

• Persons using the machine must be experienced or fully trained in welding / cutting they have to

read the user manual before operation and follow the safety instructions.

Explanation Of Safety

Information

• Read the user manual, the label on the machine and the safety instructions carefully.

• Make sure that the warning labels on the machine are in good condition. Replace missing and

damaged labels.

• Learn how to operate the machine, how to make the checks in a correct manner.

• Use your machine in suitable working environments.

• Improper changes made in your machine will negatively affect the safe operation and its

longevity.

• The manufacturer is not responsible for the consequences resulting from the operation of the

 

Comprehending Safety

Precautions

Explanation Of Safety

Symbols

ATTENTION

Indicates a potentially hazardous situation that could cause injury or damage.

In case if no precaution is taken, it may cause injuries or material losses / damages.

IMPORTANT



DANGER

Indicates a serious danger. In case if not avoided, severe or fatal injuries may occur.

Make certain that the installation procedures comply with national electrical standards



persons.

• Wear dry and sturdy insulated gloves and working apron. Never use wet or damaged gloves and

working aprons.

 

operator must be protective against sparks, splashing and arc radiation.

• Do not work alone. In case of a danger make sure you have someone for help in your working

environment.

• Do not touch the electrode with the bare hand. Do not allow the electrode holder or electrode to

come in contact with any other person or any grounded object.

• Never touch parts that carry electricity.

• Never touch the electrode if you are in contact with the electrode attached to the work surface,

 



 

material that is large enough to cut off the operator’s contact with the work surface.

• Do not connect more than one electrode to the electrode holder.

• Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld

as practical.

• Check the torch before operating the machine. Make sure the torch and its cables are in good

condition. Always replace a damaged, worn torch.

• Do not touch electrode holders connected to two machines at the same time since double

open-circuit voltage will be present.

• Keep the machine turned off and disconnect cables when not in use.

• Before repairing the machine, remove all power connections and / or connector plugs or turn

off the machine.

• Be careful when using a long mains cable.

Electric Shocks

May Kill

SAFETY PRECAUTIONS

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www.magmaweld.comUSER MANUAL

EXPERT SERIESSafety Precautions

• Turn off the electric power.

• Use non-conducting material, such as dry wood, to free the victim from contact with live parts

or wires.

• Call for emergency services.



• If the victim is not breathing, Administer cardiopulmonary resuscitation (CPR) immediately

after breaking contact with the electrical source. Continue CPR (cardiac massage) until

breathing starts or until help arrives.



• Treat an electrical burn as a thermal burn by applying sterile, cold (iced) compresses. Prevent

contamination, and cover with a clean, dry dressing.

Procedures for

Electric Shock

Long-term inhalation of fumes and gases released from welding / cutting is very dangerous.

• Keep away from the moving parts.



closed and in locked position.

• Wear metal toe shoes against the possibility of heavy objects falling on to your feet.

• Burning sensations and irritations in the eyes, nose and throat are signs of inadequate

ventilation. In such a case, immediately boost the ventilation of the work area, and if the

problem persists, stop the welding / cutting process completely.



• Use a suitable fume extraction system where welding / cutting works are being carried out. If

necessary, install a system that can expel fumes and gases accumulated in the entire workshop.

 



cadmium, zinc, coated or painted materials, use masks that provide fresh air in addition to the

above precautions.

• If the gas tanks are grouped in a separate zone, ensure that they are well ventilated, keep the

main valves closed when gas cylinders are not in use, pay attention to possible gas leaks.

• Shielding gases such as argon are denser than air and can be inhaled instead of air if used in

 

• Do not perform welding / cutting operations in the presence of chlorinated hydrocarbon vapors

released during lubrication or painting operations.

• Some welded / cut parts require special ventilation. The safety rules of products that require

special ventilation should be read carefully. A suitable gas mask should be worn when

necessary.

Fumes and Gases

May Be Harmful To

Your Health

Moving Parts May

Cause Injuries

Make sure all connections are tight, clean, and dry.

• Keep cables dry, free of oil and grease, and protected from hot metal and sparks.

• Bare wiring can kill. Check all cables frequently for possible damage. If a damaged or an

uninsulated cable is detected, repair or replace it immediately.

• Insulate work clamp when not connected to workpiece to prevent contact with any metal

object.

• Make sure that the grounding of the power line is properly connected.

 

• Use AC output ONLY if required for the welding process.

• If AC output is required, use remote output control if present on unit.

Additional safety precautions are required when any of the following electrically hazardous

conditions are present :

• in damp locations or while wearing wet clothing,

 

• when in cramped positions such as sitting, kneeling, or lying,

• when there is a high risk of unavoidable or accidental contact with the workpiece or ground.

For these conditions, use the following equipment in order presented:

• Semiautomatic DC constant voltage (CV) MIG welding machine,

• DC manual MMA welding machine,

• DC or AC welding machine with reduced open-circuit voltage (VRD), if available.

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www.magmaweld.com USER MANUAL

EXPERT SERIES Safety Precautions

• Performing works such as welding / cutting, surface grinding, and brushing cause sparks and

metal particles to splatter. Wear approved protective work goggles which have edge guards

under the welding masks to prevent sustaining possible injuries.

Sparks and Spattering

Particles May Get

Into Eyes and Cause

Damage

• Do not touch the hot parts with bare hands.

• Wait until the time required for the machine to cool down before working on its parts.

• If you need to hold hot parts, use suitable tools, welding / cutting gloves with high-level thermal

 

Hot Parts May Cause

Severe Burns

 

• Protect other naked parts of your body (arms, neck, ears, etc.) with suitable protective clothing

from these rays.



so that people around you will not sustain injuries from arc rays and hot metals.

• This machine is not used for heating of icebound pipes. This operation performed with the

 

Arc Light May Damage

Your Eyes and Skin

• The noise generated by some equipment and operations may damage your hearing ability.

• Wear approved personal ear protective equipment if the noise level is high.

Noise May Cause

Damage To Your

Hearing Ability

• Do not apply welding / cutting operations into completely closed tanks or pipes.

• Before welding to tanks and closed containers, open them, completely empty them, and clean

them. Pay the greatest attention possible to the welding / cutting operations you will perform in

such places.

• Do not weld in tanks and pipes which might have previously contained substances that may

 

• Welding / cutting equipment heats up. For this reason, do not place it on surfaces that could

easily burn or be damaged !

• Do not point the torch towards any part of the body, other persons, or any metal while

unwrapping the welding / cutting wire.

• When welding wire is run manually from the roller especially in thin diameters the wire can slip

out of your hand, like a spring or can cause damage to you or other people around, therefore you

must protect your eyes and face while working on this.

Welding Wires Can

Cause Injuries



explosions.

• Before starting the welding / cutting work, remove these materials form the environment or cover

 

• National and international special rules apply in these areas.

Welding Operations

May Cause Fire and

Explosion

 

extinguishers tubes, water, and sand in easily accessible places.



circuits. Make sure that they are periodically inspected and pay attention that they run reliably.

• Electrical equipment should not be repaired by unauthorized persons.

Errors occurred if failed to do so may result in serious injury or death when using the

equipment.

• The gas circuit elements operate under pressure; explosions may occur as a result of services

provided by unauthorized persons, users may sustain serious injuries.

• It is recommended to perform technical maintenance of the machine and its auxiliary units at

least once a year.

Maintenance Work



Persons To Machines

and Apparatus May

Cause Injuries

8

EN

www.magmaweld.comUSER MANUAL

EXPERT SERIESSafety Precautions



operations, accompanied by another person.

• Avoid performing welding / cutting operations in such enclosed areas as much as possible.

• Take all necessary precautions when moving the machine. The areas where the machine to be

transported, parts to be used in transportation and the physical conditions and health of the

person carrying out the transportation works should be suitable for the transportation process.

• Some machines are extremely heavy; therefore, make sure that the necessary environmental

safety measures are taken when changing their places.

• If the machine is to be used on a platform, it must be checked that this platform has suitable load

bearing limits.

• If it is to be transported by means of a haulage vehicle (transport trolley, forklift etc.), make sure

of the durableness of the vehicle, and the connection points (carrying suspenders, straps, bolts,

nuts, wheels, etc.) that connect the machine to this vehicle.

• If the machine will be carried manually, make sure the durableness of the machine apparatuses

(carrying suspenders, straps, etc.) and connections.

• Observe the International Labor Organization’s rules on carriage weights and the transport

regulations in force in your country in order to ensure the necessary transport conditions.

• Always use handles or carrying rings when relocating the power-supply sources. Never pull

from torches, cables or hoses. Be absolutely sure to carry gas cylinders separately.

• Remove all interconnections before transporting the welding / cutting equipment, each being

separately, lift and transport small ones using its handles, and the big ones from its handling

rings or by using appropriate haulage equipment, such as forklifts.

Welding / Cutting in





Failure To Take

Precautions During

Transport May Cause

Accidents



 

of tripping over on cables and hoses; yet, large, easily ventilatable, dust-free areas. To prevent

 

 

way that they would not tip over for sure.

• Allow operators to easily access settings and connections on the machine.

Falling Parts May

Cause Injuries Improper positioning of the power-supply sources or other equipment can cause serious injury

to persons and physical damage to other objects.

• Allow the machine to cool down according to operation cycle rates.

• Reduce the current or operation cycle rate before starting the welding / cutting again.

• Do not block the fronts of air vents of the machines.



Excessive Use Of The

Machine Causes

Overheating

Excessive Use Of The

Machine Causes

Overheating

• This device is in group 2, class A in EMC tests according to TS EN 55011 standard.

• This class A device is not intended for use in residential areas where electrical power is supplied

 

compatibility due to radio frequency interference transmitted and emitted in such places.

• Make sure that the work area complies with electromagnetic compatibility (EMC).

Electromagnetic interferences during welding / cutting operations may cause undesired effects

on your electronic devices and network; and the effects of these interferences that may occur

during these operations are under the responsibility of the user.

• If there is any interference, to ensure compliance; extra measures may be taken, such as the

use of short cables, use of shielded (armored) cables, transportation of the welding machine to

 

the work area under protection in terms of EMC.

• To avoid possible EMC damage, make sure to perform your welding / cutting operations as far

away from your sensitive electronic devices as possible (100 m).

This device is not compliant with IEC 61000 -3-12. In case if it is desired to be

connected to the low voltage network used in the home, the installer to make the

electrical connection or the person who will use the machine must be aware that

the machine has been connected in such a manner; in this case the responsibility

belongs to the user.

9

EN

www.magmaweld.com USER MANUAL

EXPERT SERIES Safety Precautions

• Ensure that your welding and/or cutting machine has been installed and situated in its place

according to the user manual.



Before installing the welding / cutting equipment, the person in charge of the operation and / or

the user must conduct an inspection of possible electromagnetic interference in the environment.

Aspects indicated below has to be taken into consideration;

a) Other supply cables, control cables, signal and telephone cables, above and below the welding

/ cutting machine and its equipment,

b) Radio and television transmitters and receivers,

c) Computer and other control hardware,

d) Critical safety equipment, e.g. protection of industrial equipment,

e) Medical apparatus for people in the vicinity, e.g. pacemakers and hearing aids,

f) Equipment used for measuring or calibration,

g) Immunity of other equipment in the environment. The user must ensure that the other

equipment in use in the environment is compatible. This may require additional protection

measures.

h) Considering the time during which the welding / cutting operations or other activities take

place during the day, the boundaries of the investigation area can be expanded according to the

size of the building, the structure of the building and other activities that are being performed

in the building.



for solving the interfering effect. In case if deemed necessary, on-site measurements can also be



(Source: IEC 60974-9).

• The appliance must be connected to the electricity supply in the recommended manner by a

 

 

tube or with an equivalent shielded cable. The housing of the power supply must be connected

and a good electrical contact between these two structures has to be provided.

• The recommended routine maintenance of the appliance must be carried out. All covers on the

body of the machine must be closed and / or locked when the device is in use. Any changes,

other than the standard settings without the written approval of the manufacturer, cannot be

 

possibly occur.



the work area, in a side by side manner. Welding / cutting cables should not be wound in any

way.



machine to pull metal parts on to itself. To avoid this attraction, make sure that the metal

 

interconnected metal materials.

• In cases where the workpiece cannot be connected to the ground due to electrical safety, or

because of its size and position (for example, in building marine vessel bodies or in steel

construction manufacturing), a connection between the workpiece and the grounding may

reduce emissions in some cases, it should be kept in mind that grounding of the workpiece may

cause users to sustain injuries or other electrical equipment in the environment to break down.

In cases where necessary, the workpiece and the grounding connection can be made as a direct

connection, but in some countries where direct connection is not permissible, the connection

can be established using appropriate capacity elements in accordance with local regulations

and ordinances.

• Screening and shielding of other devices and cables in the work area can prevent aliasing

 

applications.

Evaluation Of

Electromagnetic

Suitability Of The

Work Area

Electromagnetic

Interferance

Reduction Methods



(EMF).

All operators must follow the following procedures to minimize the risk of exposure to EMF;



secured as far as possible with the joining materials (tape, cable ties etc.).

• The operator’s body and head should be kept as far away from the welding / cutting machine

and cables as possible,

Electromagnetic Field

(EMF)

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EXPERT SERIESSafety Precautions

• Choose the welding / cutting method and welding machine for the welding work you are to

perform.

• Select the welding / cutting current and/or voltage to match the material and thickness you are

going to weld.

• If you have to wait for a long time before you start your welding / cutting work, turn off the machine

after the fan has cooled it down. Our machines with smart fan control will turn off on their own.

• This device is not domestic waste. It must be directed to recycling within the framework of the

European Union directive and national laws.

• Obtain information from your dealer and authorized persons about the waste management of

your used machines.

Waste Procedure



(EMF).

All operators must follow the following procedures to minimize the risk of exposure to EMF;



secured as far as possible with the joining materials (tape, cable ties etc.).

• The operator’s body and head should be kept as far away from the welding / cutting machine

and cables as possible,

• Welding / cutting and electric cables should not be wrapped around the body of the machine in

any way,

• The body of the machine should not get caught between the welding / cutting cables. The source

cables must be kept away from the body of the machine, both being placed side by side,

• The return cable must be connected to the workpiece as close as possible to the work area,

• The welding / cutting machine should not rest against the power unit, ensconce on it and not

work too close to it,

• Welding / cutting work should not be performed when carrying the wire supply unit or power

unit.

EMF may also disrupt the operation of medical implants (materials placed inside the body), such

as pacemakers. Protective measures should be taken for people who carry medical implants. For

example, access limitation may be imposed for passers-by, or individual risk assessments may be

conducted for welders. Risk assessment should be conducted and recommendations should be

made by a medical professional for users who carry medical implants.

• Do not expose the machine to rain, prevent the machine from splashing water or

pressurized steam.

Protection



WARRANTY FORM

Please visit our website www.magmaweld.com/warranty-form/wr for warranty form.

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EXPERT SERIES

14

17

15

16

1

8

9

10

11

12

13

2

3

4

5

6

7

TECHNICAL INFORMATION

1.1 General Information

1.2 Machine Components

Technical Information

The ID 300-400-500 M/MW PULSE EXPERT is a three-phase industrial inverter MIG/MAG welding machine

with pulse and double pulse technologies, designed for heavy duty applications. It offers excelent welding

characteristics with all type solid and cored wires. CC / CV power supply allows you to perform MIG, TIG, MMA

welding methods and carbon cutting with a single machine. With its synergistic feature, welding current and

voltage are adjusted automatically after determining the wire type, thickness and gas composition on the LCD

screen. Its classic and intelligent modes make it easy for the user to adapt to synergistic mode and accelerate their

acclimatization.

Figure 1 : ID 300-400-500 M PULSE EXPERT Front and Rear View

10- Remote Control Torch Socket

11- Power Led

12- Gas Output

13- Data Socket

14- Gas Inlet

15- Heater Socket

16- Energy Socket

17- Mains Cable

1- Digital Display

2- Digital Display

3- Torch Connection

4- On / Off Switch

5- Torch Connection

6- Pole Connection

7- Electrode (+) Pole Connection

8- Adjustment Pot

9- Adjustment Pot

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EXPERT SERIES

Figure 2 : ID 300-400-500 MW PULSE EXPERT Front and Rear View

1

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

2

3

4

5

1- Digital Display

2- Digital Display

3- Torch Connection

4- On / Off Switch

5- Torch Connection

6- Pole Connection

7- Electrode (+) Pole Connection

8- Adjustment Pot

9- Adjustment Pot

10- Hot Water Inlet

11- Cold Water Outlet

12- Remote Control Torch Socket

13- Power Led

14- Gas Output

15- Data Socket

16- Water Unit Led

17- Water Unit Hot Water Inlet

18- Water Unit Cold Water Outlet

19- Water Unit

20- Gas Inlet

21- Heater Socket

22- Cooling System Connection

23- Mains Cable

Technical Information

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EXPERT SERIES

1.3 Product Label

Technical Information

CC / CV



Constant Current / Constant Voltage

Direct Current

MIG/MAG Welding

Mains Input 3-Phase Alternating

Current

Suitable for Operation at Hazardous

Environments

X

U

I

U

IP21S

U

S

I

Duty Cycle

Open Circuit Voltage

Rated Welding Current

Mains Voltage and Frequency

Protection Class

Rated Welding Voltage

Rated Power

Rated Mains Current

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EXPERT SERIES







4 minutes should be kept idle for the machine cool down (zone 2).

Duty Cycle



6 min. 6 min.6 min.4 min. 4 min. 4 min. Time (min.)

1.4 Technical Data

400

UNIT

VMains Voltage (3-Phase 50-60 Hz)

300

82

50 - 300

VDC

ADC

Welding Current Range

Rated Welding Current

1075 x 531 x 1334

M : 103.5

MW : 113.5

IP 21

kg

mm

Protection Class

Dimensions (l x w x h)

Weight

Open Circuit Voltage

TECHNICAL DATA ID 300 M/MW PULSE EXPERT

Technical Information

400

UNIT

VMains Voltage (3-Phase 50-60 Hz)

400

82

50 - 400

VDC

ADC

Welding Current Range

Rated Welding Current

1075 x 531 x 1334

M : 103.5

MW : 113.5

IP 21

kg

mm

Protection Class

Dimensions (l x w x h)

Weight

Open Circuit Voltage

TECHNICAL DATA ID 400 M/MW PULSE EXPERT

kVARated Power

kVARated Power 



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EXPERT SERIES

400

500

82

50 - 500

UNIT

V

VDC

kVA

ADC

Mains Voltage (3-Phase 50-60 Hz)

Welding Current Range

Rated Power

Rated Welding Current

1075 x 531 x 1334

M : 103.5

MW : 113.5

IP 21

kg

mm

Protection Class

Dimensions (l x w x h)

Weight

Open Circuit Voltage

TECHNICAL DATA ID 500 M/MW PULSE EXPERT

Technical Information



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EXPERT SERIES

1.5 Accessories

STANDARD ACCESSORIES

Workpiece Clamp and Cable



Gas Hose



QTY

1

7905305005 (50 mm² - 5 m)

-

7907000002

-

ID 300 M/MW PULSE EXPERT

STANDARD ACCESSORIES

Workpiece Clamp and Cable



Gas Hose



QTY

1

7905305005 (50 mm² - 5 m)

-

7907000002

-

ID 400 M/MW PULSE EXPERT

STANDARD ACCESSORIES

Workpiece Clamp and Cable



Gas Hose



QTY

1

7905509505 (95 mm² - 5 m)

-

7907000002

-

ID 500 M/MW PULSE EXPERT



OPTIONAL ACCESSORIES

CO Heater

Gas Regulator (Mix)

Gas Regulator (CO)

Lava MIG 50W Water Cooled MIG Torch (3 m)

QTY

1

7020009003

7120050003

7020001005 / 7020001007

7020001004 / 7020001006

ID 400 M/MW PULSE EXPERT

OPTIONAL ACCESSORIES

CO Heater

Gas Regulator (Mix)

Gas Regulator (CO)

Lava MIG 50W Water Cooled MIG Torch (3 m)

QTY

1

7020009003

7120050003

7020001005 / 7020001007

7020001004 / 7020001006

ID 300 M/MW PULSE EXPERT

OPTIONAL ACCESSORIES

CO Heater

Gas Regulator (Mix)

Gas Regulator (CO)

Lava MIG 50W Water Cooled MIG Torch (3 m)

Lava MIG 65W Water Cooled MIG Torch (3 m)

QTY

1

7020009003

7120050003

7120160003

7020001005 / 7020001007

7020001004 / 7020001006

ID 500 M/MW PULSE EXPERT

Technical Information

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EXPERT SERIES

INSTALLATION

2.1 Delivery Control

Make sure that all the materials you have ordered have been received. If any material is missing or damaged,

contact your place of purchase immediately.

The standard box includes the following;

 

• Workpiece clamp and cable • User manual

• Gas hose • Welding Wire

In case of a damaged delivery, record a report, take a picture of the damage and report to the transport

company together with a photocopy of the delivery note. If the problem persists, contact the customer service.

2.2 Installation and Operation Recommendations

• Lifting rings or forklifts should be used to move the machine. Do not lift the machine with the gas cylinder.

Place the power supply on a hard, level, smooth surface where it will not fall or tip over.

• For a better performance, place the machine at least 30 cm away from the surrounding objects. Pay attention

to overheating, dust and moisture near the machine. Do not operate the machine under direct sunlight. If the

 

• Avoid welding outdoors in windy and rainy weather circumstances. If welding is necessary in such cases,

protect the welding area and the welding machine with a curtain and canopy.

• When positioning the machine, make sure that materials such as walls, curtains, boards do not prevent easy

access to the machine’s controls and connections.

• If you weld indoors, use a suitable fume extraction system. Use breathing apparatus if there is a risk of

 



damage the machine and this may invalidate the warranty.



• Tighten the ground wire as close as possible to the workpiece. Do not allow the welding current to pass

through equipment other than the welding cables such as the machine itself, gas cylinder, chain and roller

bearing.

• When the gas cylinder is placed on the machine, secure the gas cylinder by connecting the chain immediately.

If you will not place the gas cylinder on the machine, secure the gas cylinder to the wall with a chain.

• The electrical outlet on the back of the machine is for the C0 heater. Never connect a device to the C0 outlet

other than the C0 heater !

Symbols and their meanings on the device

Welding may be dangerous. Proper working conditions should be ensured and necessary precautions

should be taken. Specialists are responsible for the machine and have to be equipped with the necessary

equipment and those who are not relevant should be kept away from the welding area.

This device is not compatible with IEC 61000-3-12. If it is desired to connect to the low voltage mains used

in homes, it is essential that the installer or the person who will operate the machine to make the electrical

connection has information on the machine’s connectivity. In this case the responsibility will be assumed

by the person who will perform the installation or by the operator.

The safety symbols and warning notes on the device and in the operating instructions must be observed

and the labels must not be removed.

Grids are intended for ventilation. The openings should not be covered in order to provide good cooling and

no foreign objects should be inserted.

Installation

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EXPERT SERIES

2.3 Connections

For your safety, never use the mains cord of the machine without a plug.

2.3.1 Mains Plug Connection

Installation

• No plug has been connected to the mains cable since there may different types of outlets available in plants,

 

the grounding cable marked with and a yellow / green color is present.

• After connecting the plug to the cable, do not attach it to the outlet at this stage.

2.3.2 Connecting the Grounding Clamp to the Workpiece

• Firmly connect the grounding clamp to the workpiece as close as possible to the welding area.

Figure 3 : Gas Cylinder - Heater - Regulator Connections

2.3.3 Connecting the Gas Cylinder

• Use regulators and heaters that comply with international standards to work safely and achieve the best

results. Make sure the size of the hose connection of the gas regulator you are using is 3/8 .

• Open the gas cylinder valve, keeping your head and face away from the outlet of the valve and keep it open for

5 seconds. By this means, possible sediment and impurities will be discharged.

• If the CO heater to the gas cylinder. After connecting the gas

regulator to the CO heater, insert the plug of the CO heater into the CO heater outlet on the back of the

machine.

• If the CO heater will not be used, connect the gas regulator directly to the gas cylinder.

• Connect one end of the tube hose to the gas regulator and tighten the clamp. Connect the other end to the gas

inlet at the back of the machine and tighten the nut.

 

If you hear a noise and/or detect a smell of gas as a leak indicator, examine your connections and eliminate

leakage.

1- Gas Cylinder Valve 6- Gas Regulator

2- Gas Cylinder 7- Manometer

3- CO Heater 8- Flowmeter

4- Chain 9- Flow Adjustment Valve

5- CO Heater Energy Cable 10- Gas Hose

1

2

5

4

3

6

7 8

9

10

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Dirty and lime (hard) waters reduce the operating life of the torch and the pump.

If the coolant is below the minimum value, there is a possibility of damage and malfunction

for the pump and torch.

• For easy transport of machines with hose package of 10 meters or longer, the wire feed unit and the interim

package have been designed to be detachable. Both ends of the long hose packages are the same and the

connections on the machine front must be made with the connectors and sockets on the back of the wire

feeder.

• If interconnection hose package is 10 meters or longer, connect the wire feed unit with the hose package as

follows.

2.3.5 Connection of Interconnection Hose Package

Figure 4 : Long Harness Connections

c

b

a

c

b

a

d

e

2.3.4 Water Cooling Unit (for MW Models)

• Unit the water cooling unit is used to cool the torch It is a closed circuit system consisting of radiator, fan,

pump coolant reservoir.

• Connect the cold (blue) water hose to the cold water outlet on the water cooling system, and the hot (red)

water hose to the hot water inlet on the water cooling system.

• Magmaweld welding machines come with Magmaweld coolant, which is produced to give the best

performance. In case of lack of coolant, open the coolant reservoir cap and add Magmaweld coolant suitable

for the temperature of the working environment. The coolant must be within the minimum and maximum

values shown on the front panel of the unit.

• Different coolant or water should not be added. Different liquid additives can cause chemical reactions or

different problems.

• Magmaweld is not responsible for the risks that may arise in case of adding different liquids. All warranty

provisions will be void if different coolant or water is added to the Magmaweld coolant.

• If it is desired to use a different brand of coolant, the inside of the coolant tank should be completely empty

and there should be no residue or liquid in it.

• It is not suitable to use the water-cooling units with welding machines other than manufactured by Magma

 

• There are 2 leds in front of the machine: The power led will light as soon as the machine is activated and the

water-cooling unit led will light when the water unit is activated.

• As soon as the machine starts welding, the water circulation will start and after the welding is completed, the

water-cooling unit led will remain on during the time set in the menu. In case of any air inlet or problem, the

water will not be recirculated.

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EXPERT SERIES

3.1 User Interface

OPERATION

Operation

Digital Display

Shows the menu contents. All menu parameters are available on digital display.

Depending on the selected Mode, shows wire speed and welding current in the idle or

loaded position. Displays the error code.

Depending on the selected Mode, shows the idle value or welding voltage at the time

of welding.

Depending on the selected Mode, welding set current adjustment will be done with the

help of the adjustment knob. The current will be adjusted by turning the adjustment

knob to the right and left.

Depending on the selected Mode, welding set voltage adjustment will be done with the

help of the adjustment knob. The voltage will be adjusted by turning the adjustment

knob to the right and left.

Idle

Synergic Mode Welding Set Current Welding Current

Smart Mode Welding Set Current Welding Current

Classic Mode Wire Speed Welding Current

Load

Idle

Synergic Mode Welding Set Voltage Welding Voltage

Smart Mode Welding Set Voltage Welding Voltage

Classic Mode Welding Set Voltage Welding Voltage

Load

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