Magmaweld RA 300 E User manual

USER MANUAL

WELDING RECTIFIER

www.magmaweld.com

RA 300 E

RA 400 E

RA 650 E

CONTENTS

SAFETY RULES

1. TECHNICAL INFORMATION

1.1 GENERAL EXPLANATIONS

1.2 COMPONENTS OF RA 300 E / RA 400 E / RA 650 E

1.3 DATA PLATE

1.4 TECHNICAL SPECIFICATIONS

1.5 ACCESORRIES

2. INSTALLATION

2.1 UPON RECEIPT AND CLAIMS

2.2 WORKING CONDITIONS

2.3 ELECTRIC PLUG CONNECTION

2.4 CONNECTIONS FOR MMA WELDING

2.5 CONNECTIONS FOR TIG WELDING

3. OPERATION

3.1 CONNECTING TO THE MAINS

3.2 WELDING ADJUSTMENTS

3.2.1 Welding Adjustments

3.2.2 Remote Control (Optional)

4. MAINTENANCE AND TROUBLESHOOTING

4.1 MAINTENANCE

4.2 TROUBLESHOOTING

APPENDIX 1: SPARE PARTS LIST FOR RA 300 E / RA 400 E / RA 650 E

APPENDIX 2: ELECTRICAL DIAGRAM FOR RA 300 E / RA 400 / RA 650 E

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1RA 300 E / RA 400 E / RA 650 E

RA 300 E / RA 400 E / RA 650 E2

IDENTIFYING SAFETY INFORMATION



These symbols are being used to identify potential risks.

When seen a safety symbol in the manual, it must be understood that there is an injury risk and following

instructions must be read carefully to avoid potential risks.

While welding, keep the third persons and especially the children away from the work area.

UNDERSTANDING THE SAFETY WARNINGS

Read carefully the manual and the labels and the safety warnings on the machine.

Make sure that the warning labels positioned on your machine are in good order. Renew the damaged and

the missing labels.

Learn to operate the machine and how to make the controls properly.

Operate your machine in convenient work areas. Improper modifications affect the safety of your machine

negatively and shorten its lifetime.



SAFETY RULES

ELECTRICAL SHOCK C FATALAN BE

Installation procedure must comply with national electricity standards and other relevant

regulations and ensure that installation is performed by qualified persons.



Wear dry insulating gloves and body protection.

Do not touch electrode with bare hand. Do not wear wet or damaged gloves and

body protection.

Do not touch live electrical parts

Never touch electrode while in contact with working surface, ground or another

electrode which is connected to a different machine

free of damage



Protect yourself from electric shock by insulating yourself from work and ground.

Use non-flammable, dry insulating material if possible, or use dry rubber mats, dry

wood or plywood, or other dry insulating material big enough to cover your full area

of contact with the work or ground, and watch for fire.

Never connect more than electrode to the .one electrode holder



Turn off the machine, when not in use

Disconnect input plug or power before working on machine.

Frequently inspect input power cord for damage or bare wiring - repair or replace

cord immediately if damaged.

Be sure ground

swtich off the the

that the machine is properly ed.

HOT PARTS CAN CAUSE SEVERE BURNS



Do not touch hot parts

Allow cooling time before servicing

hot parts, use appropriate tool, insulating gloves and fireproof clothes.

If needed to hold

OBEY ALL THE SAFETY RULES

STATED IN THE MANUAL!

RA 300 E / RA 400 E / RA 650 E

SAFETY RULES

BREATHING WELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH

Inhaling fumes and gases over a long period of time, generated during welding is dangerous and

forbidden .



Irritation of the eyes, nose and throat are symptoms of inadequate ventilation. Take

immediate steps to improve ventilation. Do not continue welding if symptoms persist

Install a natural or forced air ventilation system in the work area

Install an adequate ventilation system in the welding and cutting area, if needed

install a system that can remove the fume and vapor accumulated in the entire work

area, to prevent pollution use adequate filtration in discharge

In the event of welding in small, confined places, or welding lead, beryllium,

cadmium, zinc, zinc coated or painted materials; also wear a fresh air supplied

respirator in addition to the above mentioned rules

Always have a trained watchperson nearby, while working in small confined places.

Avoid working in such confined places if possible

If gas cylinders are grouped in a different area, make sure that it is a well-ventilated

area. When not being used, turn off the main cylinder valve and watch out for gas

leakage

Shielding gasses such as argon is denser than air and when being used in confined

places, can be inhaled is dangerous for health

Do not perform welding operations near chlorinated hydrocarbon vapors produced

by degreasing or painting

it which .

ARC RAYS CAN BURN EYES AND SKIN



Use adequate welding helmet with correct shade of filter (4 or 13 considering EN 379)

to protect your eyes and face

Protect open parts of your body (arms, neck and ears) from arc rays by adequate

protective clothing

To protect others by arc rays and hot metals, surround the working area with flame

proof curtains which are higher than eye level and put up warning boards.

SPARKS & FLYING METALS CAN INJURE EYES



Welding, wire brushing and grinding cause sparks and flying metal.

To prevent injuries wear appropriate safety glasses with side shields even under your welding helmet .

MOVING PARTS CAN CAUSE INJURY



Keep away from moving parts

Keep all doors, panels, and guards closed and secured

Wear shoes with metal protection over the fingers.

RA 300 E / RA 400 E / RA 650 E4

SAFETY RULES

NOISE CAN DAMAGE HEARING



Noise from certain industrial processes or equipments can damage hearing.

Wear approved ear protection if noise level is high.

WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS



While welding and cutting in small, confined places, always have a trained watchperson nearby

Avoid working in such confined places

WELDING CAN CAUSE FIRE OR EXPLOSION



Never weld near flammable material. It may cause fire or explosions.

Before starting to weld, move flammables away or protect them with flame-proof

covers.



Do not weld on and cut closed tubes or pipes

Before welding on closed containers, open and clear them entirely. Welding

operations on these parts must be performed with the utmost caution

Never weld containers or pipes containing or which have contained substances

that could give rise to explosions

Welding equipments warms up so never position them on flammable surfaces.



Welding sparks can cause fire. For that reason, keep extinguishing means, such as

fire extinguishers, water and sand easy reach

security valves, regulators and other valves on flammable, explosive

and compressed gas circuits in good condition

which are to .

Keep , used

, .

WELDING WIRE MAY CAUSE INJURY



Do not point the torch toward any part of a human body, other persons or any type of metal when unwinding

welding wire

While extracting the wire from the spool by hand, it may spring suddenly and injure you or a nearby person,

protect especially your eyes and face.

MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES



Electrical devices should not be repaired by unqualified persons. Improper repairs can cause serious

injuries or even death during applications

The components of the gas circuit works under pressure. The service given by unqualified persons may

cause explosions and operators can be injured seriously

RA 300 E / RA 400 E / RA 650 E

FALLING UNIT CAN CAUSE INJURY

Wrong positioned power source or other equipment may cause serious injury to persons or damage

to objects.



While repositioning the power source always carry by using the lifting eye. Never pull cable, hose or torch.

Always carry the gas cylinders separately

Before carrying the welding and cutting equipment, disassemble all the connections between and

separately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriate

vehicles like forklifts

Install your machine on flat platforms having maximum 10 that it does not fall over. Install it on well

ventilated, non-confined places away from the dust, also avoiding the risk of falling caused by cables and

hoses. For gas cylinders not to fall over, attach it to the mobile machine or to the wall with a chain

Ensure that operators easily reach the controls and connections on the machine.

° slope

SAFETY RULES

OVERUSE CAN CAUSE OVERHEATING



Allow cooling period; follow rated duty cycle

Reduce current or reduce duty cycle before starting to weld again

Do not block airflow t unit.

Do not filter airflow to unit without the approval of manufacturer

hrough the

ARC WELDING CAN CAUSE INTERFERENCE



Electromagnetic energy arising during welding and cutting operations can interfere with sensitive electronic

equipment such as microprocessors, computers, and computer-driven equipment such as robots

Be sure all equipment in the welding area is electromagnetically compatible

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such

as on the floor

To avoid possible EMC damages, locate welding operation as far as possible (100 meters) from any

sensitive electronic equipment

Be sure this welding machine is installed and grounded according to this manual

If interference still occurs, the user must take extra measures such as moving the welding machine, using

shielded cables, using line filters, or shielding the work area

Do not expose the welding machine to rain, protect from water drops and vapour.

PROTECTION

ENERGY EFFICIENCY



Choose appropriate welding method and welding machine for your work.

Choose appropriate welding current and welding voltage for the material and its thickness.

If you will have a long break after welding, turn off the machine after cooler fan cooled the machine.

TECHNICAL INFORMATION

1. TECHNICAL INFORMATION

1.1 GENERAL EXPLANATIONS

1.2 COMPONENTS OF RA 300 E / RA 400 E / RA 650 E

Power Switch (Changeover Switch)

Mains LED

HOT START Current Knob

Handles

V/A Digital Meter

Rutile/Basic/Cellulosic Selection Switch

Welding And Earth Cable Outlets

Current Adjustment Knob

12 Lifting Eyes

Thermal LProtection ED

ARC FORCE Adjustment Knob

Welding Carbon Gouging Selection Switch/

Figure 1: ineComponents of the Mach

RA 650 E

RA300E, RA400E and RA650E are t yristor (SCR) controlled welding machines, designed to weld all type of

coated electrodes from 2mm, 300 model up to 5 mm, 400 & 650 models up to 6mm, while 400 model can

carbon gauge up to 6mm, 650 model can carbon gauge up to 10mm. For RA650E, cellulosic welding at low

currents is not recommended. Since 300 & 400 models can go as low as 20 Amps, their cellulosic welding

behavior is excellent and if a proper TIG starting unit is connected, they can perform as a DC TIG welder as

well. These units can be grouped as 4, 6, 8 or 9 machines in a rack, for large construction sites like shipbuilding

etc.

Due to th ristor (SCR) and electronic close loop control technology, current is adjusted precisely by a

potentiometer, initial striking ability of the electrodes can be improved via Hot Start potentiometer and certain

electrodes like basic electrodes which have tendency to short circuit and stick to the weld pool could be

avoided by adjusting the Arc Force potentiometer. Also due to this technology, pre-adjusted current stays

stable even during mains fluctuations or if additional welding cables are used. Electrical efficiency of these

machines are 70%.

Even though there is a certain level of electronics is involved in this machine, the PCB is protected in a

separate cabinet inside of the machine against dust and corrosion. With its telescopic arms and big wheels it

can be pulled easily across the working area especially at outdoor welding sites. Also stepless remote current

controlling is possible as an option.

These machines are fan cooled and thermally protected against overheating and phase failures.

RA 300 E / RA 400 E / RA 650 E6

10 A / 20,4 V - 300 A / 32 V

X25 % 60 % 100 %

190 A 150 A

28 V 22 V

CL.I. H

U V

380

50 Hz

IP 22

I A

1I A

13 kVA 10 kVA

T 32 A

U V

0I2

300 A

32 V

20 kVA

RA 00E3

Seri No :

EN 60974-1

EN 60974-10

Organize Sanayi Bölgesi 5.K s m Manisa-TÜRK YEı ı İ

MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.

20 A / 21 V - 650 A / 46 V

X35 % 60 % 100 %

500 A 385 A

40 V 35 V

CL.I. H

U V

380

50 Hz

IP 22

I A

1I A

19 kVA 14 kVA

T 80 A

U V

0I2

650 A

46 V

25 kVA

RA 0E65

Seri No :

EN 60974-1

EN 60974-10

Organize Sanayi Bölgesi 5.K s m Manisa-TÜRK YEı ı İ

MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.

20 A / 20,4 V - 400 A / 36 V

X35 % 60 % 100 %

305 A 235 A

32 V 29 V

CL.I. H

U V

380

50 Hz

IP 22

I A

1I A

19 kVA 14 kVA

T 40 A

U V

0I2

400 A

36 V

25 kVA

RA 00E4

Seri No :

EN 60974-1

EN 60974-10

Organize Sanayi Bölgesi 5.K s m Manisa-TÜRK YEı ı İ

MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş. X :Duty Cycle*

U :Open Circuit Voltage

U :Line Voltage and Frequency

U :Rated Welding Voltage

I :Input Current

I :Rated Welding Current

IP 21 :Protection Class

S :Input Power

CL.I. :Insulation Class

3 Phase Transformer Rectifier

Descending Characteristics

Line Input 3 Phase Alternative Current

Direct Current

Appropriate For Dangerous Work Area

ick Electrode Welding

*Duty Cycle

1 2

Temperature ( C)°

Time (min.)

6 min. 6 min. 6 min.4 min. 4 min. 4 min.

Duty cycle defines the percentage of welding time out of a period of 10 minutes at a given current and ambient

temperature (standard is 40°C). For example, a welder with 60% duty cycle must be rested (2) for 4 minutes,

after 6 minutes of continuous welding (1).

1.3 DATA PLATE

TECHNICAL INFORMATION

7RA 300 E / RA 400 E / RA 650 E

1.4 TECHNICAL SPECIFICATIONS

TECHNICAL INFORMATION

1.5 ACCESSORIES

UNIT

TECHNICAL SPECIFICATIONS RA 400 E RA 650 E

380

3x40

20 - 400

400

950x660x640

173.5

IP22

2 - 5

kVA

380V

3x80

20 - 650

650

950x660x640

208

IP22

2 - 6

RA 300 E

380

3x32

10 - 300

300

950x660x640

155

IP22

2 - 4

Line Voltage (3 Phases 50 Hz)

Input Power (35%)

Input Current (35%)

Recommended Line Fuses

Welding Current Range

Open Circuit Voltage

Rated Welding Current (35%)

Carbon Gouging

Dimensions (LxWxH)

Weight

Protection Class

Electrode Diameter

RA 400 E RA 650 E

Electrode Holder and Cable

(35mm - 5m)

(70mm - 5m)

(35mm - 5m)

(70mm - 5m)

Earth Clamp and Cable

Remote Control Box With 10m Cable

Remote Control Box With 20m Cable

Remote Control Box With 50m Cable

RA 300 E

STANDARD ACCESSORIES

OPTIONAL ACCESSORIES

K301000405

K301100403

K301400210

K301400220

K301400250

K301000605

K301100603

K301400310

K301400320

K301400350

K301000405

K301100403

K301400210

K301400220

K301400250

RA 300 E / RA 400 E / RA 650 E8

INSTALLATION

2.1 UPON RECEIPT AND CLAIMS



Be sure that you have received all the items that

you have ordered. In case of any item is missing or

damaged, contact your supplier immediately.

In the event of damaged or missing delivery,

it to the shipping agency and MAGMA

MEKATRONIK with the photocopy of shipping bill.

E-mail: [email protected]

Fax: +90 236 226 27 28

draw

up a record, take a photo of the damage and

report



Standard pallet contains:

Power Source

H Cable

Earth Clamp Cable

User Manual

Electrode older

2. INSTALLATION

2.2 INSTALLATION AND WORKING RECOMMENDATIONS

• Use lifting eyes or fork-lift to carry the machine.

Transport and place the device on a firm and level

ground so that it may not fall over. The maximum

permissible angle of inclination for transport and

assembly is 10°.

• For a better performance, keep the machine at

least 30 cm away from the surrounding objects.

Beware of excessive heat, dust and humidity

around the machine. Try not to operate the

machine under direct sunlight. Machines should

be operated on lower capacities when ambient air

temperature exceeds 40ºC.

• Avoid welding at outdoors where it is windy and

rainy, if this is a must, protect the welding area with

curtains, mobile screens or tents.

• Ensure that operators can easily reach the

machine controls and connections.

• Respect the duty cycles given at the data plate.

Exceeding the duty cycles frequently can damage

the machine and this would void the warranty.

• Do not use stronger fuses than those stated on the

data plate.

• Ensure that the earth clamp is tightly connected as

close as possible to the welding location. Do not let

welding current flow through any media other than

welding cables; e.g. over the machine itself, gas

tubes, chains, ball bearings, etc.

• Use suitable welding fume extraction systems.

Use breathing apparatus if there is a risk of inhaling

in confined places.

RA 300 E / RA 400 E / RA 650 E

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