Magmaweld Monostick 160i User manual

1
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
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

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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
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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
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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
1
2
4
3
5
6
8
7
2
3
4
56
8
1
7
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
0
1
2
1
2
S :Input Power
1
Single Phase Static Frequency Converter
Transformer Rectifier
1.4 TECHNICAL SPECIFICATIONS
1.5 ACCESORRIES
STANDARD ACCESORRIES PIECE PRODUCT CODE
A390000200
K301100203
1
1
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 )
25
25
Power Factor
25
Fuse
Cooling Method
Dimensions L W H
Weight
Standarts and Approvals
V
kVA
A
V
A
A
A
mm
kg
DC
DC
DC
2 03
7,2
31,5
0,97
75
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: [phone]
draw
up a record, take a photo of the damage and
report

ú
ú
ú
ú
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 .
like
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.
U
.
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 )
DC
Gas Debit
(lt/min)
1.0
1.6
6.3
9.5
15 - 70
30 - 150
6 - 8
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
of
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.
AR

3.2 NONPERIODIC MAINTENANCE
Contact tip and nozzle on the torch have to be cleaned regularly and
changed if required. Contact tips must be in good condition, longer tips
generally give better results.
NOTE: The above recommended maintenence periods are indicative, these may vary according to the
work shop conditions.
3.3 TROUBLESHOOTING


If the Thermal Protection LED lights up while cooling fan is working and the machine doesn't weld; machine
maybe overheated and stopped for auto protection due to overheat. Hot weather or working in high current
values for long time may cause this. Let the machine on for a while in order to cool down itself with the cooling
fan.After it cools enough, Thermal Protection LED fades away and the machine can weld.
When the Power LED is lighting, cooling fan is working but the machine does not weld; turn off the machine
for 1 minute then turn it on again and try to weld. If it still doesn't weld,
(3)
(3)
(2)
contact to your authorized technical
service.
3. MAINTENANCE AND TROUBLESHOOTING
MAINTENANCE AND TROUBLESHOOTING
3.1 PERIODIC MAINTENANCE
Clean the labels on the
machine, replace the worn
out labels.
Repair or replace the worn
out welding cables.
ONCE IN EVERY 3 MONTHS
ONCE IN EVERY 6 MONTHS
Open the covers of the
machine and clean with
dry air.
Clean and tighten the weld
terminals.
Check isolation of the
electrode holder,
and their cables.
earth
clamp
OR
10 MONOSTICK 160i
Strictly follow the instructions contained in safety rules while servicing the
machine.
Before removing any screw on the machine for maintenance, power
supply must be disconnected from the electric lines and enough time
should be allowed for capacitor discharging.

SPARE PARTS LIST
APPENDIX 1
Upper Electronic Card
Middle
Underside
Current Adjustment Potentiometer
Fan
Filter Card
Power LED - Green
Thermic / Error LED - Red
Electronic Card
Electronic Card
Power Switch
DESIGNATION
E201B-03
E201B-02
E201B-01
Current 1K
M1
E201B-FLT
LED-Green Power
LED-Red TH-Err
IN ELECTRICAL DIAGRAM
4
8
7
1
6
2
5
3
1
2
3
4
5
6
7
8
NO
K405000104
A410801001
A430801002
A310100008
K405000103
K405000102
A250200006
K405000101
A430801001
MATERIAL CODE
11MONOSTICK 160i

ELECTRICAL DIAGRAM
APPENDIX 2
F
N
Earth
F
N
J4
J1
J2
J3
Earth
J7
J8
J2
J1 6P5 J5 P8
2
2
P4
TH1 - N.O.
+75°C
1K
Current
Led-Green
Power
Led-Redı
TH-Err
T1
Power Transformer
1
2
Earth
+ -
1 2
P3
S1
16A E201B-FLT
E201B-01
E201B-03
E201B-02
M1
24VDC
1 2 3
P1
1 2 3 4
P2
1 2
J1
12 MONOSTICK 160i

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OWM 06.21.2011