Mosa MAGIC WELD 200 Use And Maintenance Manual
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Mosa MAGIC WELD 200 Use And Maintenance Manual

Engine driven welder
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C1VN70009003_EN
09-2022
Use and Maintenance Manual
D5260800
Engine driven welder
MAGIC WELD 200
MAGIC WELD 250
Original instructions

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Summary of Contents for Mosa MAGIC WELD 200

  • Page 1 C1VN70009003_EN 09-2022 Use and Maintenance Manual D5260800 Engine driven welder MAGIC WELD 200 MAGIC WELD 250 Original instructions...

  • Page 3: Table Of Contents

    2.11.1 Precautions in the workplace ....................17 2.11.2 Welding precautions ......................17 2.12 Maintenance precautions .........................19 2.13 Precautions for disposal of waste material ..................20 2.14 Disposal of the machine ........................20 Technical data ..........................21 Dimensions ............................21 MAGIC WELD 200 technical data ....................22 MAGIC WELD 250 technical data ....................23...
  • Page 4 Contents Description ............................25 Main components ..........................25 Control panel components ........................26 Delivery and unpacking .........................27 Delivery .............................27 Unpacking ............................27 Operation ............................29 Grounding ............................29 Checks before start-up ........................30 Starting and stopping the engine ......................30 6.3.1 Starting the engine ......................30 6.3.2 Stopping the engine ......................31 Engine driven welder operation ......................32 6.4.1 Welding cables connection ....................32...

  • Page 5: Introduction

    If the manual is lost, damaged or becomes illegible, request a copy to MOSA, indicating the model of the engine driven welder, the serial number and the year of construction.

  • Page 6: Customer Service

    1. Introduction Customer service The Technical Assistance and Spare Parts Service are available to the Customers. MOSA recommends that you contact the nearest authorised service centre for specialised intervention for all control and overhaul operations. In order to obtain quick and effective responses, indicate the Model and Serial Number shown on the identifi- cation plate (see “1.8 Identification data”).

  • Page 7: Identification Data

    1. Introduction Identification data The data identifying the machine are given on the EC plate applied in the area indicated in the figure. They are necessary for spare parts requests and communications with the Customer Service Department. D5260810 A - Manufacturer 's data Machine data (1) Year of manufacture (2) Model (3) Serial number (4) Technical standard reference Welding data (1) Welding process (2) Symbol for engine driven welders that can be used in environments with a higher risk of electric shock (3) Welding current symbol...
  • Page 8 1. Introduction (5) Duty cycle values (6) Rated welding current values (7) Welding voltage values (8) Rated no-load welding voltage or adjustment range between minimum and maximum value (9) Reduced rated no-load welding voltage with a voltage reduction device (VRD) Auxiliary generation data (1) Rated frequency (2) Rated cosϕ (power factor)

  • Page 9: Safety

    2. Safety Safety Safety information Always respect the warnings contained in this manual and present on the decal applied to the machine. This allows the machine to be used safely, avoiding damage to property and injury or death to people. The following words and symbols were used to identify important safety messages.

  • Page 10: Positioning Of Safety Decal And Information

    2. Safety Positioning of safety decal and information D5260920...

  • Page 11: Decal Explanation

    2. Safety 2.2.1 Decal explanation • Pos. 1 Consult the manual Read the contents of the manual carefully before using the machine or carrying out maintenance operations on it. D5260930 • Pos. 2 - Stop the engine before servicing To avoid burns due to contact with hot parts, before carrying out checks or servicing of the machine, stop the engine and wait until they have cooled sufficiently.
  • Page 12 2. Safety • Pos. 7 - Power Optimizer Function patented by MOSA that prevents engine overload during welding operations. D5260970...

  • Page 13: General Precautions

    2. Safety General precautions Any errors during use, checks or maintenance could cause the risk of injury, even serious • Before performing the operations, read this manual and the decals applied to the machine and follow the warn- ings. If you don't understand any part of the manual, ask your Safety Officer for explanations.

  • Page 14: Fire Prevention

    2. Safety Fire prevention 2.4.1 Fire due to fuel, oil Avoid approaching any flame to flammable substances • such as fuel and oil. Do not smoke or use open flames near flammable sub- • stances. • Stop the machine before refuelling. Make sure not to spill flammable substances on over- • heated surfaces or on parts of the electrical system. After refuelling, remove any spills and tighten all filling • caps tightly. D5260090 •...

  • Page 15: Lifting And Transport Precautions

    2. Safety Lifting and transport precautions 2.5.1 Lifting by chains or ropes • Make sure that the handling area is clear of obstacles and people. Handle the machine with the engine off, the electrical • cables disconnected and the fuel tank empty. • Lift the machine only by the frame. A central hook can be mounted on request (optional).

  • Page 16: Transport With Towing Carriage

    2. Safety 2.5.3 Transport with towing carriage Handle the machine with the engine off, the electrical • cables disconnected and the fuel tank empty. • On request, the machine can be equipped with an op- tional trolley that facilitates handling. D5260990...

  • Page 17: Precautions For Positioning The Machine

    2. Safety Precautions for positioning the machine 2.6.1 Positioning site precautions • This machine has been designed for outdoor use and can therefore be positioned outdoors. In case of meteorological precipitation (rain, snow, etc.), place the machine in an adequately sheltered place.

  • Page 18: Precautions During Operation

    2. Safety Precautions during operation • Keep all panels closed during normal operation. • Access to the internal parts of the machine must only be carried out for maintenance purposes. Keep the area near the muffler free from objects such as rags, paper, cartons. • The high temperature of the muffler could cause the objects to burn and cause a fire. • Immediately stop the machine in case of malfunctions. Do not restart the machine without first identifying and solving the problem.

  • Page 19: Electromagnetic Compatibility (Emc)

    2. Safety 2.10 Electromagnetic Compatibility (EMC) The machine is compliant with European Directive 2014/30/EU on electromagnetic compatibility, and with harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter.

  • Page 20: Emission-Reducing Methods

    2. Safety ◦ Equipment used for calibration or measurement. • Check that the other equipment in the environment is immune against electromagnetic disturbances. Ensure that the other equipment being used in the environment is compatible. This may require additional protection measures. •...

  • Page 21: Precautions During Welding

    2. Safety 2.11 Precautions during welding • Access to the internal parts of the machine must only be carried out for maintenance purposes. • Immediately stop the machine in case of malfunctions. Do not restart the machine without first identifying and solving the problem. 2.11.1 Precautions in the workplace Do not use the welding equipment near heat sources, in areas at risk with explosion hazard or fire haz- • ard.
  • Page 22 2. Safety • Welding generates large amounts of heat. Welded surfaces and materials can cause serious burns. Use gloves and pliers when touching or moving materials in the work area. D5260210 • Welding generates fumes and gases that are hazardous to health. Use sufficient ventilation or a fume extractor to keep fumes and gases away from the breathing area.

  • Page 23: Maintenance Precautions

    2. Safety 2.12 Maintenance precautions • Stop the machine and turn the engine switch and fuel valve to OFF. • To avoid injury, do not perform maintenance with the engine running. ◦ Rotating parts, such as the fan, are dangerous and can get entangled on body parts or a worn object.

  • Page 24: Precautions For Disposal Of Waste Material

    2. Safety 2.13 Precautions for disposal of waste material • Be sure to store the waste liquid in containers or tanks. • Do not discharge the oil directly into the soil or sewage system, rivers, seas or lakes. • When disposing of harmful waste such as oil, fuel, cool- ant, solvents, filters and batteries, follow current laws and regulations.

  • Page 25: Technical Data

    3. Technical data Technical data Dimensions 626 mm 490 mm D5260900...

  • Page 26: Magic Weld 200 Technical Data

    3. Technical data MAGIC WELD 200 technical data Welding Welding Process SMAW (Stick - Coated Electrode) - DC Direct Cur- rent Welding current range 20A / 20.8V - 200A / 24V IEC - Rating 20A / 20.8V - 175A / 27V...

  • Page 27: Magic Weld 250 Technical Data

    3. Technical data MAGIC WELD 250 technical data Welding Welding Process SMAW (Stick - Coated Electrode) - DC Direct Cur- rent Welding current range 20A / 20.8V - 250A / 25V IEC - Rating 20A / 20.8V - 220A / 28.8V 220A / 28.8V @35% Duty Cycle 200A / 28V @60%...
  • Page 28 3. Technical data NOTES:...

  • Page 29: Description

    4. Description Description The engine driven welder is a machine that transforms the mechanical energy generated by a engine into a source of electrical energy suitable for arc welding processes. It is also able to supply AC to power tools (grinding wheels, drills, etc.) used during welding operations. Main components D5261010...

  • Page 30: Control Panel Components

    4. Description Frame Control panel Fuel tank cap Engine Oil drain plug 6 - Oil filler cap / Oil level dipstick 7 - Muffler 8 - Engine air filter Engine switch 10 - Starter handle 11 - Vibration dampers 12 - Welding level reactor 13 - Choke control 14 - Fuel valve 15 - Alternator 16 -...

  • Page 31: Delivery And Unpacking

    If this occurs, immediately inform the transport company and write down the "Conditional Acceptance” clause in the delivery note. In the event that, at the time of delivery, significant damage is found, caused during transport, together • with any missing parts that may be found, promptly notify MOSA Div. of BCS S.p.A. Unpacking • Unloading of the packaging must be carried out with the utmost care, using lifting equipment of a suitable capaci- ty (e.g.
  • Page 32 5. Delivery and unpacking 2 - Check the machine identification plate, the integrity of the decal and data, and read the use and maintenance manual before proceeding with use. D5261230...

  • Page 33: Operation

    6. Operation Operation WARNING • Before positioning and starting the machine, read section “2. Sicurezze” carefully. • After stating the machine, the power outlets are live, even without cables connected. Grounding WARNING • The machine is not equipped with a residual current circuit breaker, and must not be connect- ed to a grounding system.

  • Page 34: Checks Before Start-Up

    6. Operation Checks before start-up 1 - Check the oil and fuel levels. For the details, see “7. Maintenance”. 2 - Check that there are no oil and fuel leaks. 3 - Check that there is no flammable or dirty material around the muffler. 4 - Check that there are no unauthorized persons in the area adjacent to the machine. Starting and stopping the engine WARNING •...

  • Page 35: Stopping The Engine

    6. Operation 4 - Pull the start handle (4) until you feel resistance, then pull vigorously in the arrow’s direction. 5 - Gently return the starter handle to its position, without hitting the engine. Important • When the engine starts, the machine immediately reaches maximum speed for about 7 seconds, and then automatically decreases to the lowest speed.

  • Page 36: Engine Driven Welder Operation

    6. Operation Engine driven welder operation This symbol (standard EN 60974-1 – safety requirements for arc welding equipment) indicates that the engine driv- en welder is designed to be used in environments with an increased risk of electric shock. • To reduce the risk of electromagnetic interference, use the minimum length of welding cables and keep them close and low (e.g. on the floor).

  • Page 37: Duty Cycle

    If welding and auxiliary generation are used simultaneously, refer to the operating limits for the engine driven welder, shown in the following table. MAGIC WELD 200 ≥ 175A Welding current range...

  • Page 38: Setting The Engine Speed

    6. Operation Setting the engine speed • When the engine starts, the machine immediately reaches maximum speed for about 6/7 seconds, and then automatically decreases to the lowest speed. • During operation, the engine speed increases to a maximum when power is drawn during welding or auxiliary power supply of power tools.
  • Page 39 43-44 k Ω R76 Power Optimizer Resistance should be measured between terminals (1) and (3) of the two trimmers R13 and R76. Terminal (2) should not be considered. Example of R13 set-up for the Magic Weld 200 model 5,5 k (1)(+) (–) (–)

  • Page 40: Generating Set Operation

    6. Operation Generating set operation WARNING It is forbidden to connect the set to the public grid and/or other source of electricity. • • The machine must not be grounded. 6.6.1 Auxiliary generation in AC 230V/50Hz (60Hz) or 115V/50Hz (60Hz) Auxiliary power generation is available via the 3-pole socket (1).

  • Page 41: Maintenance

    7. Maintenance Maintenance WARNING • Before proceeding with maintenance, carefully read section “2. Safety”. • For engine maintenance, refer to the engine maintenance manual. Refuelling • Use fuel and lubricants according to the ambient temperature. 7.1.1 Fuel Only use gasoline and fill the tank with clean fuel. • Keep the engine off during refuelling. •...

  • Page 42: Clean Air Filter

    7. Maintenance 2 - Insert the cap into the filler neck without screwing it in, and remove it again to check the oil level on the dipstick (2). D5261140 3 - If the oil level is near or below the lower limit mark (Min.), Min. fill the oil to the upper limit mark (Max.) (lower edge of the filler hole). D5261150 Clean air filter 7.2.1 Inspection 1 - Remove the air filter cover and inspect the filter elements.

  • Page 43: Storage

    7. Maintenance Storage • Carefully clean the fairings and all other machine parts. • If the machine is not used for more than 30 days, make sure that the machine is protected from heat sources and from weather phenomena that can cause rust, corrosion of the components and damage to the machine.
  • Page 44 7. Maintenance NOTES:...

  • Page 45: Troubleshooting

    8. Troubleshooting Troubleshooting Engine Issue Possible cause Solution 1) Set the switch to ON. The engine will not start, or starts 1) Engine switch (28) in the OFF posi- and stops immediately. tion. 2) No or insufficient oil in the engine. 2) Refill or top up. 3) Faulty engine stop device (oil-alert). 3) Replace. 4) No fuel in tank or fuel tap closed. 4) Fill the tank. Open the fuel tap. 5) Faulty or dirty spark plug.
  • Page 46 2) Check the resistance of the failure solenoid winding, it must be about 10 Ohms. Replace. Request the intervention of the Support Service. Table (1) Magic Weld 200 and Magic Weld 250 Winding resistors at 20 °C mΩ Outputs Welding 20.5 Yellow Cables R1 – S1 – T1 Auxiliary Black Cables R2 – S2 – T2 Auxiliary...
  • Page 48 MOSA div. della BCS S.p.A. Viale Europa, 59 20047 Cusago (Milano) Italy Tel.+39 - 0290352.1 Fax +39 - 0290390466 www.mosa.it...

This manual is also suitable for:

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