MAGIC WELD 200 0310 222509003 - GB ENGLISH 18/11/08 22262M00 preparato da UPT approvato da DITE
DESCRIPTION OF THE MACHINE © MOSA MAGIC WELD 200 M 0 REV.1 - 03/10 The engine driven welder is arranged as a single block composed of the engine and stainless steel box structure where the front is the cover.
M 01 Quality system © MOSA REV.3-02/09 UNI EN ISO 9001 : 2000 MOSA has certified its quality system according to UNI EN ISO 9001:2000 to ensure a constant, high quality of its products. This certification covers the design, production and servicing of engine driven welders and generating sets.
INDEX M 1 REV.1 - 03/10 M 01 M 1.01 M 1.1 M 1.4 M 1.5 M2 M 2.1 M 2.2 M 2.6 M 2.7 M3 M 6.15 M 25 M 26 M 27 M 31 M 34... M 34.2 M 34.3 M 37 M 40.2... M 43 M 45 M 53 M 55 M 60 M 61-…..
Copyright © MOSA GE_, MS_, TS_, EAS M 1.01 1.0-10/02 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.
Notes © MOSA GE_, MS_, TS_, EAS_ M 1-1 1.0-10/02 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.
M 1.4 CE MARK © MOSA REV.4-10/07 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.
Technical data © MOSA MAGIC WELD 200 M 1.5 REV.1-03/10 Technical data MAGIC WELD 200 Current range, continuous Open circuit voltage Duty cycle A.C. GENERATION 20 - 200A 70V 200 A - 60% 230 V Single-phase output (max) Single-phase output (continuous) Cos ϕ ALTERNATOR 3 kVA / 230 V / 13 A 2.5 kVA/ 230 V /10.9 A 0.
ADVICE © MOSA REV.0 - 11/08 NEW MAGIC WELD MAGIC WELD 200 M 2 The installation and the general advice concerning the operations, are finalized 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.
SYMBOLS REV.0 - 11/08 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. STOP - Read absolutely and be duly attentive HIGH VOLTAGE - Attention High Voltage.
ADVICE ENGINE DRIVEN WELDER © MOSA REV.0 - 11/08 NEW MAGIC WELD MAGIC WELD 200 M 2.2 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. DANGEROUS Arc welders can be dangerous.
INSTALLATION AND ADVICE © MOSA REV.0 - 11/08 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. M 2.6 NEW MAGIC WELD MAGIC WELD 200 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.
REV.0-11/08 Luftzirkulation Instalación MAGIC WELD 200 M 2.
UNPACKING AND TRANSPORT MAGIC WELD 200 M 3 © MOS 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.
ASSEMBLY © MOSA CTM-MW200 M 6.15 REV.0-11/08 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.
Set-up for operation © MOSA NEW MAGIC WELD MAGIC WELD 200 REV.0 - 11/08 M 25 LUBRICANT FUEL 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. ATTENTION Gasoline is highly flammable. Refuel with motor shut off in a flat surfaced well-ventilated area. Do not refuel in the presence of flames. Avoid spilling fuel.
Engine starting © MOSA NEW MAGIC WELD MAGIC WELD 200 REV.0 - 11/08 check daily M 26 Lightly pull the start-up knob (73) until meeting resistance, then pull decisively. ATTENTION: NOTE Do not alter the primary conditions of regulation and do not touch the sealed parts. Allow the start-up knob to re-enter slowly, avoiding having it knock against the motor and thereby damaging the start-up system. 1. Turn the fuel cock (87) to ON. FUEL COCK STARTER GRIP 2. Switch the choke control (66) to CLOSE N.
Stopping the engine © MOSA REV.0 - 11/08 NEW MAGIC WELD MAGIC WELD 200 M 27 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.
© MOSA REV.1-03/10 X1 Comandi Controls Mandos F Commandes M 31 MAGIC WELD 200 9 T 10 22 27 26 15 Pos. Descrizione 9 10 12 15 22 23 24 26 27 28 31 73 T X1 Prese di saldatura (+) Prese di saldatura (-) Presa di messa a terra Presa di corrente in c.c.
Use as a welder © MOSA MAGIC WELD 200 M 34 REV.0 - 11/08 WARNING Areas for which access by non-authorized personnel is forbidden are: - the control panel (at the front) - the endothermic motor discharge. RECOMMENDED ELECTRODES All the electrodes on the market can be used. CONNECT WELDING CABLES Insert the welding cable plugs completely in the sockets, turning clockwise to lock them in place. PUSH AND TWIST Connect the earth clamp to the negative pole and the electrode holder to the positive.
Use as a welder © MOSA MAGIC WELD 200 REV.0 - 11/08 M 34.1 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.
Verifica e taratura della massima corrente di saldatura Checking and adjusting the maximum welding current 11 1 12 2 Ti 14 8 2 Sol. 2 dal solenoide from solenoid Sol. 1 2 1 13 7 1 dal sensore di corrente from current sensor dal frontale from frontal dal ponte chopper from chopper welding bridge M 34.2 REV.0-11/08 Tu © MOSA MAGIC WELD 200 T T ON OFF Dip switch taratura corrente max. di sald. (*) welding max.
Parallel engine driven welder © MOSA MAGIC WELD 200 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.
Use as a generator © MOSA MAGIC WELD 200 M 37 REV.0 - 11/08 WARNING 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. AUXILIARY GENERATION IN AC 230V/50Hz The auxiliary output is drawn by means of a 3 pole socket, the two poles are live, phase and neutral, plus the earth for the machine.
MAGIC WELD 200 Trouble-shooting REV.
Trouble-shooting © MOSA MAGIC WELD 200 M 40.2.1 REV.0 - 11/08 Problem Possible cause Solution Incorrect maximum voltage under no-load conditions 1) Incorrect maximum engine speed 1) Adjust the maximum engine speed as shown on page M34. Engine always at idle speed 1) Faulty circuit 1) Replace Engine always at maximum speed 1) faulty circuit 2) Faulty solenoid 1) Engine 1) Dirty petrol filter, dirty air filter, dirty carburetor. See engine instruction booklet.
NEW MAGIC WELD MAGIC WELD 200 MAINTENANCE © MOSA REV.0 - 11/08 M 43 ATTENTION ● ● ● MOVING PARTS can injure ● ● Maintenance and repair work should only be done by qualified 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.
STORAGE - CUST OFF © MOSA NEW MAGIC WELD MAGIC WELD 200 REV.0 - 11/08 Have qualified personnel prepare the machine 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.
REV.
MAGIC WELD 200 REV.1-03/10 Legenda schema elettrico Electrical system legende Legende des schemas electriques A H I R T Y Z W F1 S2 F3 G3 H3 W6 R8 S8 Z8 A : H : I : R : T : Y : Z : W : F1 : S2 : F3 : G3 : H3 : W6 : R8 : S8 : Z8 : A : Alternateur H : Prise 230V monophasé I : Prise 110V monophasé R : Unite contrôle soudage T : Régulateur courant soudage Y : Pont diodes soudage Z : Prises de soudage W : Rèactance c.c.
3~ GS Y F3 OFF ON (Y) W W6 F1 - Z + P1 R Sol. 1 (BR) Alla Pag. To Page Da Pag. From Page Si T1 Data: Date: H 230V/16A Dis. n°: Dwg. n°: 15.06.2009 R8 T Macchina: Machine: 22250.prg + - + - (B) (R) (B) (Y) (BL) Wiring Diagram Disegnatore: Designer: + - + - S8 1 2 3 4 5 6 Data Date Progetto: Project: R2 S2 T2 R1 S1 C B A Modifica Modification Denominazione: Denomination: Ru Ri Su Z8 D J F A I E H B G C 2 Approvato: Approved: 2 Dis. Appr.
3~ GS S1 R1 T2 S2 R2 T1 G3 Y S2 F3 OFF ON (Y) W W6 F1 - Z + P1 R Sol. 1 (BR) Alla Pag. To Page Da Pag. From Page Si T1 Data: Date: 5 3 1 I (B) (B) (R) R8 (BL) (Y) T 15.06.2009 Dis. n°: Dwg. n°: 110V/16A S8 6 4 2 Macchina: Machine: 22251.
R 1 SPARE PARTS LIST © MOSA 1.0-03/00 MOSA guarantees that any request for spare parts will be satisfied. To keep the machine in full working order, when replacement of MOSA spare parts is required, always ask for genuine parts only. The requested data are to be found on the data plate located on the machine structure, quite visible and easy to consult. ✹ When ordering the spare parts, it is recommended to indicate: V.le Europa,59 - 20090 CUSAGO (MI) ITALY Tel. +39-02 90352.
© MOSA Ricambi Spare parts Piéces de rechange REV.
Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19a 19b 19c 20 21 22 23 24 25 26 Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19a 19b 19c 20 21 22 23 24 25 26 REV.0-11/08 Rev. Cod. M222503045 M306412200 M222503061 M222418263 M222503025 M222503047 M222406020 M222402244 M222508169 M222507169 M222509800 M256011035 M222505400 M208029104 M222409050 M372955107 M222509757 M222509756 M222509755 M222519755 M222539755 M1270080 M306418310 M222504126 M222501050 M222504100 M222501372 M256011035 Rev. Cod.
REV.
Pos. 1 2 2a 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Pos. REV.1-03/10 Rev. Cod. M222507205 M22250c001 M22251c001 M307047250 M307017240 M259107241 M222502230 M222502199 M222508460 M6060050 M107011870 M6060070 M207409751 M107799349 M1018090 M222507020 M270009701 M765009911 M765009910 M222509632 M222440543 Rev. Cod. Ersatzteile Tabla de recambios Descr. MAGIC WELD 200 AG 7.
CTM-MW200 222500130 © MOSA KA 20 REV.0-06/09 1 3 2 4 11 5 10 6 9 8 1 2 3 4 5 6 7 8 9 10 11 219861159 222421226 102011270 222500183 222421160 6075020 222422038 222421051 222421170 222500184 222429359 Descr. Descr. MANOPOLA MANIGLIA DI SOLLEVAMENTO TAPPO PER MANIGLIA PIASTR.(SX) FISS.MANIGLIA ASSALE COPIGLIA RONDELLA PIEDE DI STAZIONAMENTO RUOTA PIASTR.(DX) FISS.
