Mosa NEW MAGIC WELD Manual
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Mosa NEW MAGIC WELD Manual

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NEW MAGIC WELD
1 1 0 8
222629003 - GB
ENGLISH
18/11/08 22262M00
preparato da UPT
approvato da DITE

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Summary of Contents for Mosa NEW MAGIC WELD

  • Page 1 NEW MAGIC WELD 1 1 0 8 222629003 - GB ENGLISH 18/11/08 22262M00 preparato da UPT approvato da DITE...

  • Page 3: Description Of The Machine

    DESCRIPTION OF THE MACHINE NEW MAGIC WELD © MOSA REV.0 - 11/08 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.
  • Page 5 · Competent support in the solution of problems; ofthe International Certification Network IQNet, · Information and training in the correct applicatio- awarded the official approval to MOSA after an- nand use of the products to assure the security examination of its operations at the head office ofthe operator and protect the environment;...
  • Page 6 INDEX NEW MAGIC WELD © MOSA REV.0 - 11/08 M 01 QUALITY SYSTEM M 1.01 COPYRIGHT M 1.1 NOTES M 1.4 CE MARK 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...
  • Page 7 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.A. All other possible logos contained in the documentation are registered by the respective owners.

  • Page 8: Notes About The Manual

    (fastenings, holes, electric or mechanical devices, incorrect maintenance. The manual is for qualified others..) if not duly authorized in writing by MOSA: personnel, who knows the rules: about safety and the responsibility coming from any potential...
  • Page 9 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.
  • Page 10 Technical data NEW MAGIC WELD © 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...
  • Page 11 ADVICE NEW MAGIC WELD MAGIC WELD 200 © MOSA REV.0 - 11/08 The installation and the general advice concerning the operations, are finalized to the correct use of the ma- chine, in the place where it is used as generator group and/or welder.

  • Page 12: Symbols In This Manual

    SYMBOLS NEW MAGIC WELD MAGIC WELD 200 © MOSA REV.0 - 11/08 Use only with safety clothing - SYMBOLS IN THIS MANUAL It is compulsory to use the personal pro- tection means given in equipment. - The symbols used in this manual are designed to call...
  • Page 13 ADVICE ENGINE DRIVEN WELDER NEW MAGIC WELD MAGIC WELD 200 © MOSA REV.0 - 11/08 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.
  • Page 14 SYMBOLS - ABBREVIATIONS LEGEND NEW MAGIC WELD © MOSA REV.0 - 11/08 2000 / 14 / CE Conformity EN 60974-1 Single-phase Users' Information Various Sound power conformity manual news conformity Equipment and optional Engine Gasoline Manual Engine shut engine cooling...
  • Page 15 INSTALLATION AND ADVICE NEW MAGIC WELD MAGIC WELD 200 © MOSA REV.0 - 11/08 INSTALLATION AND ADVICE BEFORE USE Check that the air gets changed completely and the hot air sent out does not come back inside the set so as to Use in open space, air swept or vent exhaust gases, cause a dangerous increase of the temperature.
  • Page 16 Installazione Luftzirkulation Installation Instalación NEW MAGIC WELD Installation © MOSA REV.O-11/08...

  • Page 17: Unpacking And Transport

    UNPACKING AND TRANSPORT NEW MAGIC WELD © MOSA REV.0 - 11/08 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.
  • Page 18 CTM-MW 6.11 ASSEMBLY © MOSA REV.0-06/07 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 move- ments.

  • Page 19: Recommended Oil

    Gasoline is highly flammable. Refuel with RECOMMENDED OIL motor shut off in a flat surfaced well-venti- MOSA recommends selecting AGIP engine oil. lated area. Do not refuel in the presence Refer to the label on the motor for the recommended of flames.
  • Page 20 Engine starting NEW MAGIC WELD MAGIC WELD 200 © MOSA REV.0 - 11/08 check daily Lightly pull the start-up knob (73) until meeting resistance, then pull decisively.  ATTENTION: NOTE Allow the start-up knob to re-enter slowly, avoiding having it knock against the motor and Do not alter the primary conditions of regula- thereby damaging the start-up system.
  • Page 21 Stopping the engine NEW MAGIC WELD MAGIC WELD 200 © MOSA REV.0 - 11/08  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.
  • Page 22 Comandi Commandes NEW MAGIC WELD Controls Mandos © MOSA REV.O-11/08 27 26 9 10 31 23-24 Pos. Descrizione Description Description Descripción Prese di saldatura (+) Welding sockets (+) Prises de soudage (+) Tomas de soldadura (+) Prese di saldatura (-)

  • Page 23: Recommended Electrodes

    Use as a welder NEW MAGIC WELD © MOSA REV.0 - 11/08 RECOMMENDED ELECTRODES WARNING All the electrodes on the market can be used, Areas for which access by non-authorized however for cellulose electrodes we recom- personnel is forbidden are: mend Magic Weld with added reactor.
  • Page 24 Use as a welder NEW MAGIC WELD 34.1 © MOSA REV.0 - 11/08 AUTO IDLE Adjusting the maximum engine speed Operation When the engine is switched on it immediately reaches a maximum speed of 4000 rpm for ap- FIG. 1...
  • Page 25 34.2 Checking and adjusting the maximum welding current NEW MAGIC WELD © MOSA REV.0 - 11/08 dal frontale dal solenoide from frontal from solenoid Dip switch dall'alternatore dai ponti ausiliari taratura corrente max. di sald. (*) from alternator from aux. bridges welding max.
  • Page 26 Parallel engine driven welder NEW MAGIC WELD 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.
  • Page 27 Use as a generator NEW MAGIC WELD © MOSA 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 endo- thermic motor discharge.

  • Page 28: Troubleshooting

    Trouble-shooting NEW MAGIC WELD 40.2 © MOSA REV.0 - 11/08 Problem Possible cause Solution The motor does not start up, 1) Engine switch (28) at position 1) Position switch to ON or starts up and then stops immediately 2) Lack of or insufficient oil in the...
  • Page 29 Trouble-shooting NEW MAGIC WELD 40.2. © MOSA REV.0 - 11/08 Problem Possible cause Solution Incorrect maximum voltage 1) Incorrect maximum engine 1) Adjust the maximum engine spe- under no-load conditions speed ed as shown on page M34. 1) Faulty circuit...
  • Page 30 NEW MAGIC WELD MAINTENANCE MAGIC WELD 200 © MOSA REV.0 - 11/08 ATTENTION • Maintenance and repair work should only be done by qua- lified 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.
  • Page 31 M2. - tank fuel - engine lubricating oil IMPORTANT NOTE: MOSA is involved with custing off the In the storage or cust-off operations avoid machine only for the second hand ones, when that polluting substances, liquids, exhausted not reparable.
  • Page 32 MS_, TS_ RECOMMENDED ELECTRODES (In accordance with A.W.S Standard) © 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.
  • Page 33 Dimensioni Abmessungen Dimensions Dimensiones NEW MAGIC WELD Dimensions © MOSA REV.O-11/08...
  • Page 34 NEW MAGIC WELD © MOSA REV.O-11/08 Legenda schema elettrico Electrical system legende Legende des schemas electriques : Alternatore Alternator A : Alternateur : Fusibile Fuse F : Fusible : Presa 230V monofase 230V 1phase socket H : Prise 230V monophasé...
  • Page 35 Schema elettrico Electric diagram NEW MAGIC WELD Esquema eléctrico (110V version) © MOSA REV.O-11/08 10µH...
  • Page 36 Schema elettrico Electric diagram NEW MAGIC WELD 61.1 Esquema eléctrico (EU Version) © MOSA REV.O-11/08 10µH...

  • Page 37: 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.
  • Page 38 Ricambi Ersatzteile Spare parts Tabla de recambios NEW MAGIC WELD Piéces de rechange © MOSA REV.O-11/08 (110V version) (230V Version) (230V version) (110V Version)
  • Page 39 Ricambi Ersatzteile Spare parts Tabla de recambios NEW MAGIC WELD Piéces de rechange © MOSA REV.O-11/08 Pos. Rev. Cod. Descr. Note 222406020 VENTOLA CENTRIFUGA / FAN 222403047 ASSIEME MOZZO/ROTORE / HUB / SHAFT ASSY 222413025 STATORE AVVOLTO 230 VAC / STATOR 230V...
  • Page 40 Ricambi Ersatzteile Spare parts Tabla de recambios NEW MAGIC WELD Piéces de rechange © MOSA REV.O-11/08 230I Version (*) 14 110I Version 230I Schuko Version...
  • Page 41 Ricambi Ersatzteile Spare parts Tabla de recambios NEW MAGIC WELD Piéces de rechange © MOSA REV.O-11/08 Pos. Rev. Cod. Descr. Note 1291180 FUSIBILE Versione 230V 1291090 FUSIBILE Versione 110V fino a REV.2-11/05 Del. 78/06 del 18/05/06 103011320 PORTA FUSIBILE da REV.3-06/07 Del.78/06 del 18/05/06...
  • Page 42 CTM-MW 222420130 © MOSA REV.0-06/07 Pos. Rev. Cod. Descr. Descr. Note 222421050 BARELLA PROTECTIVE FRAME LIFTING HANDLE 222421226 MANIGLIA DI SOLLEVAMENTO 219861159 MANOPOLA KNOB 222422038 RONDELLA WASHER 222421170 RUOTA WHEEL 222421051 PIEDE DI STAZIONAMENTO PARKING STAND 222421160 ASSALE AXLE 6075020...
  • Page 44 MOSA div. della BCS S.p.A. Stabilimento di Viale Europa, 59 20090 Cusago (MI) Italia Tel. + 39 - 0290352.1 Fax + 39 - 0290390466...

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