Magmaweld Monostick 160i Bedienungsanleitung

CONTENTS

MONOSTICK 160i

SAFETY RULES

1. TECHNICAL INFORMATION

1.1 GENERAL EXPLANATIONS

1.2 COMPONENTS OF MONOSTICK 160i

1.3 DATA PLATE

1.4 TECHNICAL SPECIFICATIONS

1.5 ACCESSORRIES

2. INSTALLATION AND OPERATION

2.1 UPON RECEIPT AND CLAIMS

2.2 INSTALLING AND WORKING RECOMMENDATIONS

2.3 CONNECTIONS FOR MMA WELDING

2.4 CONNECTIONS FOR TIG WELDING

3. MAINTENANCE AND TROUBLESHOOTING

3.1 PERIODIC MAINTENANCE

3.2 NONPERIODIC MAINTENANCE

3.3 TROUBLESHOOTING

APPENDIX:

APPENDIX 1: SPARE PARTS

APPENDIX 2: ELECTRICAL DIAGRAM

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2MONOSTICK 160i

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!

3MONOSTICK 160i

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.

4MONOSTICK 160i

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

5MONOSTICK 160i

SAFETY RULES

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

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.

1.2 COMPONENTS OF MONOSTICK 160i

TECHNICAL INFORMATION

1. TECHNICAL INFORMATION

1.1 GENERAL EXPLANATIONS

Monostick 160i is an inverter type portable, mono-phase DC MMA welding machine designed to weld stick

electrodes up to 4 mm. This unit can also be used as a DC TIG power source for touch-start applications.

Even though the machine is mono-phase, due to the inverter technology it provides stable arc and good re-

striking performance, also the electric consumption is approximately 10% less than the silicon controlled

rectifier equipments and 25% less than the magnetically controlled equipments.

Monostick 160i proved well that it can work between 160 to 240 V 50/60 Hz line voltages. Therefore this

machine is quite immune to mains voltage fluctuations and perfectly welds with generator-sets.

Monostick 160i can also be used with long welding cables up to 25 mt.

The machine is fan cooled and thermally protected against over heating.

(*) For more information about TIG welding, check page 10.

Figure 1: Components of Monostick 160i

Power Switch

Power LED

Current Adjustment Knob

Thermic / Error LED

Earth Cable and Welding Cable Socket (-)

Earth Cable and Welding Cable Socket (+)

Handle

Line Cable Inlet

6MONOSTICK 160i

TECHNICAL INFORMATION

1.3 DATA PLATE

Manual Metal Arc Welding

Direct Current

Descending Characteristics

Line Input-1 Phase Alternating Current

Appropriate To Operate In Dangerous Work Area

X :Duty Cycle*

U :Open Circuit Voltage

U :Line Voltage and Frequency

U :Rated Welding Voltage

I :Input Current

I :Rated Welding Current

IP23S :Protection Class

S :Input Power

Single Phase Static Frequency Converter

Transformer Rectifier

1.4 TECHNICAL SPECIFICATIONS

1.5 ACCESORRIES

STANDARD ACCESORRIES PIECE PRODUCT CODE

A390000200

K301100203

Electrode Holder and Cable (200A)

Earth Clamp and Cable (16mm² - 3mt)

VALUE

UNIT

TECHNICAL SPECIFICATIONS

Line Voltage (Single Phase)

Input Power

Input Current

Open Circuit Voltage

Welding Current Range

Rated Welding Current

Protection Class

(% )

Rated (% )

(% )

( x x )

Power Factor

Fuse

Cooling Method

Dimensions L W H

Weight

Standarts and Approvals

kVA

2 03

7,2

31,5

0,97

10 - 160

150

32 - Delayed

IP23S

Air

160x312x405

7,8

CE, EN60974-1, EN60974-10

*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).

7MONOSTICK 160i

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

• DO NOT USE THE MACHINE WITH LONG

ELECTRIC CABLES AT CONSTRUCTION

SITES! Do not forget that electric cable carries

220V/50 Hz and these cables are not suitable to

work in harsh environments, they can easily wear

and tear which may lead to electric leakage to the

metals where welders may be working on.

ELECTRIK SHOCK CAN KILL or cause people to

FALL DOWN from dangerously high places

(iskele). Instead, ALWAYS use long

WELDING CABLES for safety reasons

•For a better performance, keep the machine at

least 20 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 when ambient

air temperature exceeds .

scaffolding

lower capacities

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.

•se suitable welding fume extraction systems.

Use breathing apparatus if there is a risk of inhaling

in confined places.

•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.

INSTALLATION AND OPERATION

2.3 CONNECTIONS FOR MMA WELDING

SWITCH ON the machine via power switch and

check if power LED lights up and cooler fan

works.

(1)

(2)



According to the polarity of the electrode to be used,

i s into the appropriate socket

them clock-wise

Below table is given as a reference for current

adjustment of mild steel electrodes, please refer to

the electrode manufacturer's recommendations.

nsert welding cable

and tighten by turning .

( )5-6

Connect the earth clamp tightly to the workpiece

as close as possible to the welding area.

Adjust the desired current and the machine is ready

to weld.

While inserting the plug into the

socket, pay attention that main

switch is positioned to “OFF” “0”.

Before plugging your machine to the

electrical line, check if the correct

voltage exists.

Diameter Rutile Basic Cellulosic

2.0

2.5

3.25

4.0

40-60 A

60-90 A 60-90 A 60-100 A

100-140 A 100-130 A 70-130 A

140-180 A 140-180 A 120-170 A

-- --

8MONOSTICK 160i

INSTALLATION AND OPERATION

Figure 2: TIG Welding Connections

Diameter of

Electrode

(mm)

Diameter of

Nozzle

(mm)

Welding

Current

(A )

Gas Debit

(lt/min)

1.0

1.6

6.3

9.5

15 - 70

30 - 150

6 - 8



Install the Argon gas regulator onto the Argon gas

cylinder.

C gas hose of the torch the

regulator

onnect the to gas

TIG torch with a valve should be

used.

Connect TIG orch

to the negative

the machine.

the t power

cable welding

socket and the earth cable to

the positive welding socket

(5)

6( )

Figure 3: Connecting Gas Cylinder

2.4 CONNECTIONS FOR TIG WELDING

9MONOSTICK 160i



Install the Argon gas regulator onto the Argon gas

cylinder.

C gas hose of the torch the

regulator

onnect the to gas

Adjust the desired current and the machine is

ready to weld.

SWITCH ON the machine via power switch and

check if power LED lights up and cooler fan

works.

(1)

(2)

While inserting the plug into the

socket, pay attention that main

switch is positioned to “OFF” “0”.

Before plugging your machine to the

electrical line, check if the correct

voltage exists.

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