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

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USE AND MAINTENANCE MANUAL
MAGIC WELD 200 YD
MAGIC WELD 200 YDE
• Motosaldatrice
• Engine Driven Welder
• Motosoudeuse
• Motosoldadoras
• Schweißaggregat
• Motosoldadora
M A D E
I N
I T A L Y
Codice
Code
222709003
Codigo
Kodezahl
Edizione
Edition
02.2014
Edición
Ausgabe

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  • Page 1 USE AND MAINTENANCE MANUAL MAGIC WELD 200 YD Codice MAGIC WELD 200 YDE Code 222709003 Codigo Kodezahl • Motosaldatrice Edizione • Engine Driven Welder Edition 02.2014 • Motosoudeuse Edición • Motosoldadoras Ausgabe • Schweißaggregat • Motosoldadora M A D E I T A L Y...
  • Page 3 DESCRIPTION OF THE MACHINE MAGIC WELD 200 YD - YDE 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 va- rious parts such as: engine, alternator, electric and electronic controls, the fairing at a protective structure.
  • Page 4 · 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 5 Index MAGIC WELD 200 YD - YDE REV.0-02/14 DESCRIPTION OF THE MACHINE M 01 QUALITY SYSTEM M 1.01 COPYRIGHT M 1.1 NOTES M 1.4 CE MARK M1.4.1 DECLARATION OF CONFORMITY M 1.5 TECHNICAL DATA M 1.6 TECHNICAL DATA ADVICE M 2.1 SYMBOLS M 2.2...
  • Page 6 (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 documen- tation are registered by the respective owners.

  • Page 7: Notes About The Manual

    Notes REV.1-03/14 INFORMATION INFORMATION OF GENERAL TYPE In the envelope given together with the machine and/or Dear Customer, set you will find: the manual for Use Maintenance and We wish to thank you for having bought a high quality set. Spare Parts, the manual for use of the engine and the tools (if included in the equipment), the guarantee (in the Our sections for Technical Service and Spare Parts will...
  • Page 8 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.

  • Page 9: Dichiarazione Di Conformita

    Konformitätserklärung Dichiarazione conformità Declaration of conformity Declaración de conformidad 1.4.1 Déclaration de conformité Declaração de conformidade REV.2-10/13 BCS S.p.A. Stabilimento di Cusago, 20090 (Mi) - Italia V.le Europa 59 Sede legale: Tel.: +39 02 903521 Via Marradi 1 Fax: +39 02 90390466 20123 Milano - Italia DICHIARAZIONE DI CONFORMITA' Déclaration de Conformité...
  • Page 10 Technical data MAGIC WELD 200 YD - YDE REV.0-02/14 Technical data MAGIC WELD 200 YD MAGIC WELD 200 YDE A.C. GENERATION 50/60 Hz Single-phase output 230V (max) 3.3 kVA / 230 V / 14.3 A Single-phase output 230V (continuous) 3 kVA / 230 V / 13 A Single-phase output 115V (max) 2.1 kVA / 110 V / 18.3A...

  • Page 11: Welding Current

    Technical data MAGIC WELD 200 YD - YDE REV.0-02/14 D.C. WELDING Current range, continuous 20 - 200A Open circuit voltage Duty cycle 200 A - 60% OUTPUT CARACTERISTIC SIMULTANEOUS UTILIZATION FACTORS In case Welding and Generation can be used simultaneously, however, the engine cannot be overloaded. The...
  • Page 12 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.
  • Page 13 SYMBOLS AND SAFETY PRECAUTIONS REV.2-06/10 SYMBOLS PROHIBITIONS No harm for persons Use only with safety clothing - STOP - Read absolutely and be duly attentive It is compulsory to use the personal protection means given in equip- ment. Use only with safety clothing - Read and pay due attention It is compulsory to use the personal protection means given in equipment.

  • Page 14: Arc Welding Hazards

    SYMBOL TS_, DSP_ © MOSA 1.0-05/04 ARC WELDING HAZARDS Do not weld on drums, thanks, or any Electric shock from welding electrode or closed containers unless a qualified person wiring can kill. has tested it and declared it or prepared it to be safe.

  • Page 15: Engine Hazards

    SIMBOLI E AVVERTENZE RELATIVE ALLA SICUREZZA TS_, DSP_ 2.2.1 © MOSA 1.0-05/04 ENGINE HAZARDS Fuel can cause fire or explosion. Exhaust sparks can cause fire. Use approved engine exhaust spark arrestor in required areas. Keep exhaust and exhaust pipes away from Engine fuel plus flames or sparks can cau- flammables.

  • Page 16: Gasoline Engines

    INSTALLATION AND ADVICE REV.1-06/07 Check that the air gets changed completely and the hot INSTALLATION AND ADVICE BEFORE USE air sent out does not come back inside the set so as to cause a dangerous increase of the temperature. GASOLINE ENGINES Use in open space, air swept or vent exhaust gases, which contain the deathly carbone oxyde, far from the work area.
  • Page 17 Installazione Luftzirkulation Installation Instalación MAGIC WELD 200 YD - YDE Installation REV.0-02/14...
  • Page 18 Installazione Luftzirkulation Installation Instalación MAGIC WELD 200 YD - YDE 2.7.1 Installation REV.0-02/14...
  • Page 19 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 pack- aging, 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.
  • Page 20 TRANSPORT AND DISPLACEMENTS COVERED UNITS 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.
  • Page 21 ASSEMBLY CTM-MW200-D 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 mo- vements.
  • Page 22 ASSEMBLY TRM-MW200-D 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 mo- vements.

  • Page 23: Recommended Oil

    Set-up for operation MAGIC WELD 200 YD - YDE REV.0-02/14 BATTERY WITHOUT MAINTENANCE FUEL (where it is assembled) The included battery must be activated. ATTENTION To activate it (fi ll the included acid) please follow the instructions shown on the manual attached to Stop engine when fueling.

  • Page 24: Electric Starting

    STARTING MAGIC WELD 200 YD - YDE REV.0-02/14 Check daily ELECTRIC STARTING 1) Carry out operations 1) and 5) as with pull start 2) Turn the starter key to the “ON” position, the accelerator NOTE control solenoid will automatically move the accelerator lever into the "START"...
  • Page 25 STOPPING MAGIC WELD 200 YD - YDE REV.0-02/14 B efore 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”...
  • Page 26 Comandi Controls Mandos MAGIC WELD 200 YD - YDE Commandes REV.0-02/14 (*) YDE VERS. Pos. Descrizione Description Description Descripción Prese di saldatura (+) Welding sockets (+) Prises de soudage (+) Tomas de soldadura (+) Prese di saldatura (-) Welding sockets (-) Prises de soudage (-) Tomas de soldadura (-) Presa di messa a terra Earth terminal Prise de mise à terre Toma de puesta a tierra Presa di corrente in c.a. a.c. socket Prises de courant en c.a. Toma de corriente en c.a Comando acceleratore Accelerator control Commande accélérateur Mando de aceleración Filtro aria motore...

  • Page 27: Remote Control

    USE AS WELDER MAGIC WELD 200 YD - YDE REV.0-02/14 This symbol (Norm EN 60974-1 security REMOTE CONTROL standards for arc welders) signifes that the The welding machine is predisposed for connection welders can be used in areas with increa- to a remote control (optional) by means of the circu- sed risk of electrical shock.
  • Page 28 Parallel engine driven welder MAGIC WELD 200 34.3 MAGIC WELD 200 YD - YDE 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 29 Use as a generator MAGIC WELD 200 YD - YDE REV.0-02/14 wiring it to the ground of the electrical plant with ATTENTION which the machine is going to work. It is absolutely forbidden to connect the unit WARNING: bound the neutral to frame BEFORE to the public mains and/or another electrical the GFI.
  • Page 30 REMOTE CONTROL ACCESSORY USE (TS SERIES) 38.10 RC2/90° 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. To regulate the current from the RC2, move the switch (7), located above the multipole connector (8), to "ON"...
  • Page 31 ACCESSORY USE REMOTE CONTROL 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. When the remote control is connected to the remote control connector (8), it is functional and automati- cally excludes the front panel regulation.
  • Page 32 ENGINE PROTECTIONS MAGIC WELD 200 YDE 39.6 REV.0-02/14 The engine is equipped with system protection (stop) in the event the oil pressure is too low. In the event of a malfunction in the battery charging system, the warning light will come on without stop- ping the engine.

  • Page 33: Troubleshooting

    Trouble-shooting MAGIC WELD 200 YD - YDE REV.0-02/14 Problem Possible cause Solution MOTORE The motor does not start up, 1) Lack of fuel in tank 1) Rifornire il serbatoio or starts up and then stops 2) Air in the fuel circuit...

  • Page 34: Welding Circuit

    Trouble-shooting MAGIC WELD 200 YD - YDE 40.1 REV.0-02/14 Problem Possible cause Solution WELDING CIRCUIT No current under no-load 1) Faulty welding control board 1) With a voltmeter check that between pins conditions in weld mode A (-) and B (+) of the circular connector on the front panel there is 5 Vdc.
  • Page 35 MAINTENANCE REV.1-01/13 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 at- tention moving parts, hot parts (exhaust manifold and muffler, etc.) electrical parts which may be unprotected when the machine is open.

  • Page 36: Gasoline Engine

    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.
  • Page 37 CUST OFF REV.0-06/07 Have qualified personnel disassemble the In case of necessity for first aid and fire prevention, machine and dispose of the parts, including the see page M2.5. oil, fuel, etc., in a correct manner when it is to be taken out of service.
  • Page 38 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.
  • Page 39 ELECTRICAL SYSTEM LEGENDE REV.10-05/13 A : Alternator E3 : Open circuit voltage switch I6 : Start Local/Remote selector N9 : UP/DOWN button mast B : Wire connection unit F3 : Stop push-button L6 : Choke button O9 : Hydraulic unit solenoid valve C : Capacitor G3 : Ignition coil M6 : Switch CC/CV P9 : Hydraulic unit engine D : G.F.I. H3 : Spark plug N6 : Connector – wire feeder Q9 : Ignitor E : Welding PCB transformer I3 : Range switch O6 : 420V/110V 3-phase transformer...
  • Page 40 Schema elettrico Electric diagram MAGIC WELD 200 YDE Esquema eléctrico REV.0-02/14...
  • Page 41 Schema elettrico Electric diagram MAGIC WELD 200 YD - YDE 61.2 Esquema eléctrico REV.0-02/14...
  • Page 44 MOSA div. della BCS S.p.A. Viale Europa, 59 20090 Cusago (Milano) Italy Tel.+39 - 0290352.1 Fax +39 - 0290390466 www.mosa.it...

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