Mosa Magic Weld 200 User manual
Use and Maintenance Manual
C1VN70009003_EN
09-2022
D5260800
Engine driven welder
MAGIC WELD 200
MAGIC WELD 250
Original instructions
i-1
Contents
Contents
1. Introduction.......................................................................................................................................1
1.1 Foreword ............................................................................................................................................1
1.2 Supplied documentation.....................................................................................................................1
1.3 Customer service................................................................................................................................2
1.4 Spare parts.........................................................................................................................................2
1.5 Declaration of conformity....................................................................................................................2
1.6 Unauthorized changes........................................................................................................................2
1.7 Allowed and non-allowed use.............................................................................................................2
1.8 Identicationdata ...............................................................................................................................3
2. Safety.................................................................................................................................................5
2.1 Safety information...............................................................................................................................5
2.2 Positioning of safety decal and information........................................................................................6
2.2.1 Decal explanation..................................................................................................................7
2.3 General precautions...........................................................................................................................9
2.3.1 Personal protective equipment..............................................................................................9
2.3.2 Check the work area..............................................................................................................9
2.4 Fire prevention..................................................................................................................................10
2.4.1 Fire due to fuel, oil...............................................................................................................10
2.4.2 Firescausedbyammablematerialbuild-up ......................................................................10
2.4.3 Fire caused by electrical wiring ...........................................................................................10
2.4.4 Fire caused by piping ..........................................................................................................10
2.5 Lifting and transport precautions......................................................................................................11
2.5.1 Lifting by chains or ropes.....................................................................................................11
2.5.2 Lifting and manual transport................................................................................................11
2.5.3 Transport with towing carriage.............................................................................................12
2.6 Precautions for positioning the machine...........................................................................................13
2.6.1 Positioning site precautions.................................................................................................13
2.6.2 Precautions for electric connections....................................................................................13
2.7 Precautions during operation............................................................................................................14
2.8 Precautionsduringfuelandengineoillling ....................................................................................14
2.9 Precautions against noise ................................................................................................................14
2.10 Electromagnetic Compatibility (EMC)...............................................................................................15
2.10.1 Installation and use..............................................................................................................15
2.10.2 Assessment of the area.......................................................................................................15
2.10.3 Emission-reducing methods................................................................................................16
2.11 Precautions during welding ..............................................................................................................17
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
3. Technical data.................................................................................................................................21
3.1 Dimensions.......................................................................................................................................21
3.2 MAGIC WELD 200 technical data....................................................................................................22
3.3 MAGIC WELD 250 technical data....................................................................................................23
Contents
i-2
4. Description......................................................................................................................................25
4.1 Main components.............................................................................................................................25
4.2 Control panel components................................................................................................................26
5. Delivery and unpacking.................................................................................................................27
5.1 Delivery.............................................................................................................................................27
5.2 Unpacking.........................................................................................................................................27
6. Operation.........................................................................................................................................29
6.1 Grounding.........................................................................................................................................29
6.2 Checks before start-up.....................................................................................................................30
6.3 Starting and stopping the engine......................................................................................................30
6.3.1 Starting the engine ..............................................................................................................30
6.3.2 Stopping the engine.............................................................................................................31
6.4 Engine driven welder operation........................................................................................................32
6.4.1 Welding cables connection..................................................................................................32
6.4.2 Adjusting the welding current ..............................................................................................32
6.4.3 Duty cycle............................................................................................................................33
6.4.4 Welding arc striking ............................................................................................................33
6.4.5 Simultaneous use of welding and auxiliary generation functions........................................33
6.5 Setting the engine speed..................................................................................................................34
6.5.1 Checking and calibrating the minimum speed.....................................................................34
6.5.2 Checking and setting the maximum speed..........................................................................34
6.6 Generating set operation..................................................................................................................36
6.6.1 Auxiliary generation in AC 230V/50Hz (60Hz) or 115V/50Hz (60Hz)..................................36
6.6.2 Overload protection (overcurrent)........................................................................................36
7. Maintenance....................................................................................................................................37
7.1 Refuelling..........................................................................................................................................37
7.1.1 Fuel......................................................................................................................................37
7.1.2 Engine oil.............................................................................................................................37
7.2 Cleanairlter ...................................................................................................................................38
7.2.1 Inspection............................................................................................................................38
7.2.2 Cleaning ..............................................................................................................................38
7.3 Storage.............................................................................................................................................39
7.4 Disposal............................................................................................................................................39
8. Troubleshooting .............................................................................................................................41
8.1 Engine ..............................................................................................................................................41
8.2 Welding circuit..................................................................................................................................41
1
1. Introduction
1. Introduction
1.1 Foreword
ThismanualsuppliestheOperatorandqualiedandauthorisedTechnicianswithtechnicalinformationonthe
"MAGIC WELD" 200 and “MAGIC WELD” 250 engine driven welders set (hereinafter also referred to as the
"machine") produced by MOSA Div. of BCS S.p.A. (hereinafter also referred to as the "manufacturer").
Inthismanual,theOperatorinchargeandthequaliedTechnicianswillndtheindicationsfor:
• Getting familiar with the safety measures and basic standards to be adopted, to prevent hazards and
damage to people, to the engine driven welder and to the environment.
• Getting to know the main components of the engine driven welder and its operation.
• Performing the programmed routine maintenance.
• Getting to know any extraordinary maintenance operation.
This manual is an integral part of the engine driven welder and must follow it in any changes of ownership,
untilthenaldismantling.
The manual and all the publications attached to it must be kept with care, in an easily accessible place,
knowntotheoperatorandtothequaliedtechniciansauthorizedformaintenance.Readthedescriptions
carefully before starting to work or carrying out the required adjustments or maintenance.
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.
If the engine driven welder is transferred, the transferor must deliver this manual to the new owner.
The engine driven welder is subject to updates to improve its performance; this manual summarises the
information regarding the current state of technology at the moment of the supply.
MOSAreservestherighttomakeimprovementsandmodicationstopartsandaccessories,withoutprompt-
ly updating this manual, except in exceptional cases of fundamental integrations concerning safe operation.
CAUTION
• Improper use or maintenance can cause serious damage to people and shorten the "useful
life" of the engine driven welder.
• The Operator and the qualied Technicians must be familiar with all the indications given in
this manual before using the engine driven welder or carrying out maintenance operations on
it.
• The procedures contained in this manual are intended to be applicable to engine driven weld-
ers only for permitted uses, and with all safety devices in function.
If the engine driven welder is used for purposes other than those indicated or in safety condi-
tions other than those indicated, the Customer becomes directly responsible for any person
possibly involved in accidents or injuries and for abnormal wear and tear of the machine.
1.2 Supplied documentation
The documentation supplied with the engine driven welder includes this Use and Maintenance Manual and
the main component manuals (e.g. engine).
1. Introduction
2
1.3 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.
Inordertoobtainquickandeectiveresponses,indicatetheModelandSerialNumbershownontheidenti-
cation plate (see “1.8Identicationdata”).
1.4 Spare parts
Only original spare parts that guarantee functionality and durability must be used.
The use of non-original spare parts will void all warranty and Technical Support obligations.
1.5 Declaration of conformity
Themanufacturer:
MOSA Div. of BCS S.p.A.
Viale Europa, 59 20047 Cusago (Milano) Italy
Declaresthatthemachines:
MAGIC WELD 200
MAGIC WELD 250
ComplywiththerequirementsofthefollowingEC/EUDirectives:
• Machine Directive 2006/42/EC
• Low Voltage Directive 2014/35/EU
• Electromagnetic Compatibility Directive 2014/30/EU
andwiththerequirementsofthefollowingUKregulations:
• The Supply of Machinery (Safety) Regulations 2008/1597
• The Electrical Equipment (Safety) - Regulations 2016/1101
• Electromagnetic Compatibility - Regulations 2016/1091
1.6 Unauthorized changes
NochangescanbemadetothemachinewithoutMOSA'Sauthorization.
Unauthorized changes void any form of warranty on the machine and any civil and/or criminal liability in case
of accidents or injuries
1.7 Allowed and non-allowed use
Theseenginedrivenweldersperformthefollowingfunctions:
• Direct current generator for arc welding with manual electrode (stick).
• 50/60 Hz alternating current generator to supply power tools (grinding wheels, drills, etc.) used during
welding operations.
WARNING
• The engine driven welder is designed for industrial and professional use, and must only be
used by qualied and/or trained personnel.
3
1. Introduction
1.8 Identication data
ThedataidentifyingthemachinearegivenontheECplateappliedintheareaindicatedinthegure.
They are necessary for spare parts requests and communications with the Customer Service Department.
B
A
C
D
E
A
D5260810
B
C
D
E
1
1
236
45
4
1
34
25
123
123
4
4
5
6
6
7
7
8
89
2
3
4
6
A- Manufacturer'sdata
B - Machine data
(1) Year of manufacture
(2) Model
(3) Serial number
(4) Technical standard reference
C - 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
(4) Minimum and maximum welding current value and corresponding voltage value
1. Introduction
4
(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)
D - Auxiliary generation data
(1) Rated frequency
(2) Ratedcosϕ(powerfactor)
(3) Insulation class
(4) Rated power (kVA/kW)
(5) Rated voltage (V)
(6) Rated current (A)
E - Engine and machine data
(1) Motor symbol
(2) Rated speed
(3) Rated minimum speed
(4) Rated no-load speed
(5) Rated engine power
(6) IP protection degree
(7) Dry weight
5
2. Safety
2. Safety
2.1 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.
Symbol identiesimportantsafetymessagesonthemachine,inthemanualandelsewhere.Whenyou
see this symbol, follow the instructions in the safety messages.
DANGER
• This word indicates a situation of imminent risk that, if not avoided, could cause serious injury
or even death to people and serious damage to property.
WARNING
• This word indicates a potential risk situation which, if not avoided, could result in serious inju-
ry or even death to people and serious damage to property.
CAUTION
• This word indicates a potential risk situation that, if not avoided, could cause minor or moder-
ate injuries.
It can also be used to prevent dangerous operations that can cause damage to the machine.
The following terms are used to transmit the information to be followed to the user, to avoid damage to the
machine.
* Important
• If the precautions described are not observed, the machine could be damaged and its useful life re-
duced.
Note:
• This word is used to indicate further useful information.
2. Safety
6
2.2 Positioning of safety decal and information
4
5
6
3
7
3
1
2
D5260920
Other manuals for Magic Weld 200
2
This manual suits for next models
1
Table of contents
Other Mosa Welding System manuals
Mosa
Mosa CT 350 LSX User manual
Mosa
Mosa DSP 2x400 PS-PL User manual
Mosa
Mosa GE 10000 HZDM User manual
Mosa
Mosa Magic Weld User manual
Mosa
Mosa TS 400 PS-BC User manual
Mosa
Mosa TS 300 SC-SXC Guide
Mosa
Mosa TS 415 VS/VSX Guide
Mosa
Mosa TS 350 YSX BC User manual
Mosa
Mosa MS 200 S User manual
Mosa
Mosa Magic Weld 200 User manual
Popular Welding System manuals by other brands
TAFA
TAFA 30*8B35 owner's manual
Lincoln Electric
Lincoln Electric INVERTEC V350-PRO CE Technical specifications
ESAB
ESAB Buddy Arc 145 instruction manual
CIGWELD
CIGWELD 636804 use instructions
Red-D-Arc
Red-D-Arc DC-400 Operator's manual
Hobart Welding Products
Hobart Welding Products Spool Gun DP 3035-10 owner's manual
