Magmaweld RS 200 MK User manual

USER MANUAL
MIG/MAG WELDING MACHINE
www.magmaweld.com
RS 200 MK
RS 300 MK
RS 400 MK

RS 200 MK / RS 300 MK / RS 400 MK 1
CONTENTS
SAFETY RULES
1. TECHNICAL INFORMATIONS
1.1 GENERAL EXPLANATIONS
1.2 COMPONENTS OF RS 200 MK / RS 300 MK / RS 400 MK
1.3 DATA PLATE
1.4 TECHNICAL SPECIFICATIONS
1.5 ACCESSORIES
2. INSTALLATION
2.1 UPON RECEIPT AND CLAIMS
2.2 INSTALLING AND WORKING RECCOMENDATIONS
2.3 ELECTRIC PLUG CONNECTION
2.4 WELDING CONNECTIONS
2.4.1 Earth Clamp Connections
2.4.2 Connections
3. OPERATION
3.1 CONNECTING TO THE MAINS
3.2 CHOOSING AND CHANGING THE LINER
3.3 CONNECTING THE TORCH
3.4 CHOOSING AND CHANGING THE WIRE FEEDING ROLLS
3.5 LOADING THE WIRE SPOOL AND THREADING THE WIRE
3.6 ADJUSTING THE GAS FLOW
3.7 USING THE TRIGGERING MODES
4. WELDING
4.1 ADJUSTING THE STICK OUT
4.2 WELDING PARAMETERS FOR RS 200 MK
4.3 WELDING PARAMETERS FOR RS 300 MK
4.4 WELDING PARAMETERS FOR RS 400 MK
5. MAINTENANCE AND TROUBLESHOOTING
5.1 PERIODIC MAINTENANCE
5.2 NONPERIODIC MAINTENANCE
5.3 BASIC TROUBLESHOOTING
5.4 FUSES
APPENDIX 1: SPARE PARTS LIST FOR RS 200 MK / RS 300 MK / RS 400 MK
APPENDIX 2: LIST OF THE COMPONENTS IN THE ELECTRICAL DIAGRAM
APPENDIX 3: ELECTRICAL DIAGRAM FOR RS 200 MK
APPENDIX 4: ELECTRICAL DIAGRAM FOR RS 300 MK
APPENDIX 5: ELECTRICAL DIAGRAM FOR RS 400 MK
Gas
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...................................................................................................................10
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11
...........................................................................................11
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............................................................................................14
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....................................................................................................................6
...................................................................6
............................................................................................................................................7
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.........................................................................................11
..............................................................12
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RS 200 MK / RS 300 MK / RS 400 MK
2
IDENTIFYING SAFETY INFORMATION
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

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!

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 .
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






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.
.
.
RS 200 MK / RS 300 MK / RS 400 MK 3

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
.
.
RS 200 MK / RS 300 MK / RS 400 MK
4

SAFETY RULES
FALLING UNIT CAN CAUSE INJURY
Wrong positioned power source or other equipment may cause serious injury to persons or damage
to objects.
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


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
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
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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



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.
RS 200 MK / RS 300 MK / RS 400 MK 5

1.2 COMPONENTS OF RS 200 MK / RS 300 MK / RS 400 MK
TECHNICAL INFORMATION
1. TECHNICAL INFORMATION
1.1 GENERAL EXPLANATIONS
RS 200 MK, RS 300 MK, RS 400MK are 3 phase step controlled, Constant Voltage industrial compact
MIG/MAG machines to weld all types of solid and flux cored wires in any kind of fabrication and repair work
shops.
Wire feeding unit is a robust 4 wheel drive system which is placed inside of the machine. This way of
construction, harness and excessive cabling has been avoided.
Even though you can manufacture 24/7 with these machines in a big range of current scale, model 200 is
optimized for 0.8 mm, model 300 for 1.0 mm, model 400 for 1.2mm.
These machines are fan cooled and thermally protected against overheating.
Figure 1: Front View Figure 2: Back View
1
2
3
4
5
8
9
Line Voltage & Coarse Step Switch
Fine Step Switch
Wire Feeding Speed Adjustment Knob
Switch For 2/4 Function Selection
Digital Voltmeter
Digital Ampermeter
Earth Clamp Socket
Torch Connector
Welding Parameters Chart
Mains Cable
6
7
10
11
16
17
18
Electrical Socket for CO Heater
Gas Supply Inlet
Fuses
Drum Feeding
Handle
Lifting Eye
Swivel Wheel
Wheel
Gas Cylinder Safety Chain
Braked Wheel
12
13
14
15
19
20
2
RS 200 MK / RS 300 MK / RS 400 MK
6
7
8
9
3
4
2
1
5
6
15
10
11
12
13
14
20
16
1917 18

45 A / 16 V - 400 A / 34 V
X45 % 60 % 100 %
350 A 270 A
31,5 V 27,5 V
CL.I. H
U V
380
50 Hz
1
S1
IP 21
I A
22
1I A
15
1
14,5kVA 9,9 kVA
S
T 32 A
U V
18,5 - 45
0I2
U2
3R
RS 400 MK
400 A
34 V
I A
28
1
18,5kVA
3RSeri No :
EN 60974-1
EN 60974-10
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
Organize Sanayi Bölgesi 5.Kısım Manisa-TÜRKİYE
40 A / 16 V - 300 A / 29 V
X40 % 60 % 100 %
250 A 200 A
27 V 24 V
CL.I. H
U V
380
50 Hz
1
S1
IP 21
I A
15
1I A
12
1
9,9kVA 7,9 kVA
S
T 25 A
U V
19 - 44
0I2
U2
3R
RS 300 MK
300 A
29 V
I A
20
1
13,2kVA
3RSeri No :
EN 60974-1
EN 60974-10
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
Organize Sanayi Bölgesi 5.Kısım Manisa-TÜRKİYE
40 A / 16 V - 240 A / 26 V
X23 % 60 % 100 %
160 A 125 A
23 V 21 V
CL.I. H
U V
380
50 Hz
1
S1
IP 21
I A
7
1I A
5
1I A
12
1
4,6 kVA 3,3 kVA
S
T 16 A
U V
17 - 36
0I2
U2
3R
RS 200 MK
240 A
26 V
7,9 kVA
3RSeri No :
EN 60974-1
EN 60974-10
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
Organize Sanayi Bölgesi 5.Kısım Manisa-TÜRKİYE 3 Phase Transformer Rectifier
Horizontal Characteristics
MIG / MAG Welding
Line Input 3 Phase Alternative Current
Appropriate To Operate In Dangerous Work Area
Direct Current
Fuse
S
3R
3R
TECHNICAL INFORMATION
1.3 DATA PLATE
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
0
1
2
1
2
1
*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).
RS 200 MK / RS 300 MK / RS 400 MK 7

RS 300 MKRS 200 MK RS 400 MK
1.5 ACCESSORIES
V
kVA
A
A
V
A
A
DC
DC
DC
mm
kg
mm
m/min
380
9.9
15
3x16
19 - 44
40 - 300
250
3x7
890x510x950
95
IP21
0.8/1.0
380
14.5
22
3x32
18,5 - 45
45 - 400
350
4x7
890x510x950
116
IP21
1.0/1.2
2 - 20
2/4
1 - 20
2/4
1.4 TECHNICAL SPECIFICATIONS
TECHNICAL INFORMATIONS
UNIT
POWER SOURCE
Line Voltage
Input Power
Input Current
Open Circuit Voltage
Drive Roll Size
Wire Feding Speed
Trigger Control
Recommended Line Fuse
Welding Current Range
Rated Welding Current
Voltage Adjustment Steps
Dimensions
Weight
Protection Class
(3 Phases 50 Hz)
(Coarse x Fine)
(LxWxH)
(60%)
(60%)
(V socket)
380
4.6
7
3x16
17 - 36
40 - 240
160
1x10
890x460x950
90
IP21
0.6 / 0.8
2 - 20
2/4
WIRE FEEDING UNIT
RS 200 MK / RS 300 MK / RS 400 MK
8
RS 300 MKRS 200 MK RS 400 MK
STANDARD ACCESSORIES
Earth Clamp and Cable
Earth Clamp and Cable
Earth Clamp and Cable
Gas Hose
(16mm -3m)
(25mm -3m)
(35mm -3m)
2
2
2
K301100303
K301100203 -
-
-K301100403
K120000001 K120000001K120000001
OPTIONAL ACCESSORIES
Torch MBG 25 AK-3
Torch MBG 25 AK-4
Torch MTB 25-3
Torch MTB 25-4
Torch MBG 36 KD-3
Torch MBG 36 KD-4
Torch MTB 35-3
CO Heater
2
S520022205
-
-
-
S520022206
S520022305
S520022304
-
-
S520022205
-
-
-
S520022206
-
-
-
CO /Ar Pressure Regulator
2
S520009002 S520009002 S520009002
S520022303
S520001002 S520001002 S520001002
-
-
S520022203
S520022204
S520022203
S520022204

2. INSTALLATION
INSTALLATION
2.1 UPON RECEIPT AND CLAIMS

ú
ú
ú
ú
Standard pallet contains:
Power Source
Earth Cable
Gas Hose
User Manual
2.2 INSTALLATION AND WORKING RECOMMENDATIONS
•Use lifting eyes or fork-lift to carry the machine. DO
NOT lift the machine together with the gas cylinder.
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.
•Use 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.
When the gas cylinder is placed on the machine,
immediately lock the chain to secure the cylinder,
otherwise, the stand alone cylinders should also be
secured to a wall by chains.
•The electrical socket behind the machine is for CO
heater, it is not recommended to connect other
devices.
2
2.3 ELECTRIC PLUG CONNECTION
Since mains connection sockets may vary from
factory to factory, an appropriate plug must be
installed to the built-in mains cable of the machine
by qualified electricians. Please observe that the
earth cable is in yellow/green colour and labeled
as . After installing the electric plug, DO NOT
INSERT IT INTO THE SOCKETAT THIS STAGE.
Figure 3: Electric Plug Connection


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
RS 200 MK / RS 300 MK / RS 400 MK 9

2.4 WELDING CONNECTIONS
2.4.1 Earth Clamp Connections
Figure 4: Earth Clamp Connections



Connect the earth cable to one of the earth clamp
sockets on the power source very tight.
Sockets with different inductance values help the
machine to weld with less spatter at a wider current
range. For the smaller currents or wire diameters
the socket should be chosen, for the bigger
currents and wire diameters use the socket .
on the workpiece,
as possible area
(7)
To increase the quality of the welding, earth clamp
should be clamped tightly as
close to the welding .
*Only RS 400 MK model has more than one inductance
sockets.
Figure 5: Connections Gas Cylinder - Heater - Pressure Regulator
23
22
20
27
26
24
25
21
28
20
21
22
23
24
Gas Cylinder Safety Chain
Gas Pressure Regulator
Gas Cylinder
Gas Cylinder Valve
Gas FlowAdjustment Valve
25
26
27
28
29
Gas Hose
Flow meter
Manometer
CO Heater
Power Cable of CO Heater
2
2
29


Connect one end of gas hose to the gas
pressure regulator and connect the other end
to the the gas supply inlet at the back of the
machine. Open the gas cylinder valve .
Set the gas quantity with the pressure adjustment
valve . For more information about gas
adjustment check the page 13.
(25)
(21)
(12)
(23)
(24)
RS 200 MK / RS 300 MK / RS 400 MK10
2.4.2 Gas Connections



After placing the gas cylinder on its platform,
fasten it with the gas cylinder safety chain . To
operate safely and get best results use approved
gas regulators and heaters.
Open and close the gas cylinder valve few
times in order to blow out any possible dirt or
particles.
If CO is going to be used, firstly connect the CO
heater and then connect the gas pressure
regulator to the gas cylinder . Connect the
power cable of the CO heater to the CO heater
socket at the back of the machine.
(22)
(20)
(23)
(28)
(21) (22)
(11)
2 2
2 2 Figure 6: Gas Connections
INSTALLATION
12
11

RS 200 MK / RS 300 MK / RS 400 MK 11



Before plugging your machine to the
electrical line check with a voltmeter the correct
voltages indicated at the plate of the machine and
then insert the plug into the socket.
SWITCH ON the machine via power switch .
Observe the fan noise and illumination of the V/A
digital meters .
(1)
(5-6)
While inserting the plug
into the socket, pay
attention that main
switch is positioned to
“0”.
Figure 7: Mains Connection
3.2 CHOOSING AND CHANGING THE LINER
3.3 CONNECTING THE TORCH
Nozzle Contact Tip
Adapter
Figure 8: Removing the Nozzle, the Contact Tip and the Adapter
Nut of Liner
Liner
Figure 9: Removing the Liner and Installing the New Liner
Figure 10: Cutting off the Liner Stick Out and Reassembling the Torch


Check if the liner and the contact tip is matching
with the diameter of the welding wire. If it is
needed, change the liner and the contact tip.
To change the liner; remove the nozzle, the
contact tip and the adaptor respectively
(Figure 8).
Unscrew the liner's nut which is on torch connector
side and remove the liner existing in torch. After
inserting the new liner into the torch, screw its nut
tightly (Figure 9).


Cut off the stick out of the liner with a side cutter. Be
sure that head of the liner is smooth.
Reassemble the adaptor, the contact tip and the
nozzle respectively with help of an appropriate
hand tool (Figure 10).
Liner
Stickout
3. OPERATION
OPERATION
3.1 CONNECTING TO THE MAINS
0
1
234
Insert the torch into the torch connector and
screw its nut tightly.
(8)
Figure 11: Connecting the Torch
Nut of Torch

3.5 LOADING THE WIRE SPOOL AND THREADING THE WIRE
Figure 15: Loading the Wire Spool
Unscrew the spool support nut . Place the
MIG/MAG wire spool through the spool
support and screw the spool support nut
tightly. (Figure 15).
(33)
(34)
(35) (33)
34
33
35
Figure 16: Threading the Wire
3.4 CHOOSING AND CHANGING THE WIRE FEEDING ROLLS



F o r s t e e l a n d
stainless steel wires
use V-shape rolls, for
flux cored wires use
knurled V-shape rolls,
for aluminium wires
choose U-shape rolls.
For changing the wire
feeding rolls, pull
down the spring knob and
Install the appropriate rolls and screw the screws
. Lock the pressure assembly (Figure 13).
(31)
(30)
remove the screws
of the feeding rolls. Then remove the feeding
rolls (Figure 12).
(30)
31
30
32
Figure 12: Removing the Wire Feeding Rolls
Figure 13: Installing the Wire Feeding Rolls
3
3
2
2
1
4
4
5
5
6
Figure 14: Wire Feeding Roll
1,0 0,8
0,8 1,0
0,8
1,0



Remove nozzle and contact tip of the torch.
Pull down the spring knob and release the
pressure rolls.
Pull and hold the wire tightly to keep it from
unraveling, cut off end. Thread the wire through
the rolls into the torch. (Figure 17).
(31)
Push down the pressure rolls , push up and
lock the spring knob .
(32)
(31)
Screwing the spool support nut (33)
too tight may cause blockage of wire
feeding. Screwing the spool support
nut (33) loose may cause raveling of
the wire spool after stopping wire
feeding. Therefore, do not screw spool support
nut (33) neither too tight nor loose.
OPERATION
1
2
2
3
Both sides of the rolls are labeled
according to appropriate wire
diameter. Rolls must be inserted into
the flange in such a way that
appropriate diameter of the wire to be
fed is seen from outside (Figure 14).
RS 200 MK / RS 300 MK / RS 400 MK12

3.6 ADJUSTING THE GAS FLOW
Practical adjustment of the gas flow rate (CO , Ar,
MIX) is 10 times of the diameter of the wire.
Diameter of the wire: 1,2 mm
Gas flow rate: 10 x 1,2 = 12 lt/min
2
EXAMPLE:
UNLOCK THE WIRE PRESSURE
ASSEMBLY DURING GAS FLOW
ADJUSTMENT.
For accurate gas flow rate adjustments, use the
following table.
1.6
Mild
Steel and
Metal Cored
Diameter (mm)
8 lt/min
12 lt/min
9 lt/min
10 lt/min
16 lt/min
Stainless
Steel Aluminium
8 lt/min
12 lt/min
9 lt/min
10 lt/min
8 lt/min
12 lt/min
9 lt/min
10 lt/min
16 lt/min 16 lt/min
Flux
Cored
7 lt/min
11 lt/min
8 lt/min
9 lt/min
15 lt/min
1.6
Mode 2 : Once the torch switch is triggered ,
wire feeding and current starts and when it is
released the operation ends.
[2]
[2]
Mode 4 Mode 4 gives more comfort to the welder
for long welding operations and automatic
applications. When the switch is triggered
hen the switch is pressed again the current
stops and when it is released the gas stops.
:
gas
flow starts and when it is released current starts.
W
[1]
[2]
[3]
[4]
Figure 19: Using the Triggering Modes
3.7 USING TRIG ERING MODESG
Mode 2 and Mode 4 are selected via the 2/4 function
selection switch and these modes function as told
below.
(4)
OPERATION
A B
CD E
A:
B:
C:
D:
E:
Appropriate pressure on wire and appropriate roll size
(canal depth) selection.
Over pressure on wire may result in deformation of
the shape of the wire.
Over pressure on wire may result in deformation of
the shape of the feed roll.
Roll size is small. The result is deformation of the
shape of the wire.
Roll size is too big. Wire may not be driven to the
welding point.
Figure 18: Mistakes at Pressure Adjustment and Choice of Rolls
The effects which are seen in side
table occur in case adjusting the
pressure assembly too tight or loose
or choosing wrong feeding rolls
(Figure 18).
Figure 17: Threading Wire Through Torch and Adjusting Pressure


Hold the torch switch pressed until the wire comes
out of the torch, In the meantime by triggering the
torch switch on and off, check if the tension of the
wire is correct, that is, neither too tight, nor loose.
Then reinstall the contact tip and the nozzle.
Feed the wire on a piece of wood in order to check
and adjust the pressure of the rolls via spring knob
. Cut off wire (Figure 17).(31)
WOOD
1
2
3
4
1
45
23
6
RS 200 MK / RS 300 MK / RS 400 MK 13

4. WELDING
WELDING
In order to obtain good welding characteristics, free
wire length has to be adjusted by the following
instructions. The diameter of the wire and the
distance between the nozzle and the contact tip is
important.
Figure 20: Arc Lengths
Short Arc Globular
Transfer
Spray Arc
ddd
0-3 mm
2-5 mm
5-8 mm
10d
8-12d
15d
Contact
Tip
Nozzle
4.1 ADJUSTING THE STICK OUT
Arc Type Wire
Diameter (d) Coefficient Free Wire Length
Short Arc
Globular
Transfer
Spray Arc
1,0
1,0
1,0
10d
12d
15d
10
12
15
4.2 WELDING PARAMETERS FOR RS 200 MK
1
1
2
7.1
80
18
1
1
2
7.1
80
18
1
1
2
7.1
80
18
1
1
2
7.1
80
18
2
1
4
8.3
90
19
2
1
4
8.3
90
19
2
1
4
8.3
90
19
2
1
4
8.3
90
19
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
Ø : 0,6 mm
Ø : 0, mm8
Ø : mm1,0
Ø : mm1,2
mm
mm
mm
mm
A
A
A
A
V
V
V
V
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
1
1
3
4.8
60
19
1
1
3
4.8
60
19
1
1
3
4.8
60
19
1
1
3
4.8
60
19
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
CO2Ar/CO2(80/20)
RS 200 MK / RS 300 MK / RS 400 MK14

WELDING
1
1
2
7.1
80
18
1
1
2
7.1
80
18
1
1
2
7.1
80
18
1
1
2
7.1
80
18
1
1
2
7.1
80
18
1
1
2
7.1
80
18
1
1
2
7.1
80
18
2
1
4
8.3
90
19
2
1
4
8.3
90
19
2
1
4
8.3
90
19
2
1
4
8.3
90
19
2
1
4
8.3
90
19
2
1
4
8.3
90
19
2
1
4
8.3
90
19
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
3
1
7
13
120
20
Ø : 0,6 mm
Ø : 0, mm8 Ø : 0, mm8
Ø : mm1,0 Ø : mm1,0
Ø : mm1,2 Ø : mm1,2
mm
A
V
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
0.5
1
1
5.2
70
17
1
1
3
4.8
60
19
1
1
3
4.8
60
19
1
1
3
4.8
60
19
1
1
3
4.8
60
19
1
1
3
4.8
60
19
1
1
3
4.8
60
19
1
1
3
4.8
60
19
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
2
1
5
6.5
70
20
CO2Ar/CO (80/20)
2
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
3
35
18
0.5
1
1
3
35
18
4.3 WELDING PARAMETERS OF RS 300 MK
4.4 WELDING PARAMETERS OF RS 400 MK
mm
mm
mm
A
A
A
V
V
V
mm
mm
mm
A
A
A
V
V
V
CO2Ar/CO (80/20)
2
RS 200 MK / RS 300 MK / RS 400 MK 15

Open the covers of the
machine and clean with
dry air.
OR
5. MAINTENANCE AND TROUBLESHOOTING
5.1 EPERIODIC MAINTENANC
Clean the labels on the
machi n e . Repair or
replace the worn out
labels.
Repair or replace the worn
out welding cables.
Clean and tighten the weld
terminals.
Check the isolation of the
torch, electrode holder,
earth clamp and their
cables.
Once every three months
Once every six months
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 10 seconds
should be allowed for capacitor discharging.
MAINTENANCE AND TROUBLESHOOTING
5.2 ENONPERIODIC MAINTENANC
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 maintenance periods are indicative, these may vary according to the
work shop conditions.
DO NOT PLUG THE MAINS ELECTRIC CABLE BEFORE CLOSING ALL THE
CABINET PANELS.
Wire feeding rolls and the surrounding parts should be kept clean and
the surface of the drive rolls should definitely not be lubricated. Each
time the wire is replaced, the dirt accumulated on the mechanism must
be cleaned with dry air .
RS 200 MK / RS 300 MK / RS 400 MK16

5.3 TROUBLESHOOTING
TROUBLE REASON REMEDY
MAINTENANCE AND TROUBLESHOOTING
Machine does not work.
Contact your authorized technical service.
Wire feeder doesn’t work. Torch
doesn’t perform the triggering.
Wire feeder works but wire is
not fed.
The drive roll is not appropriate
for the wire diameter.
Pressure on rolls is not enough.
Select the appropriate drive roll.
Adjust the pressure as explained in
the Section 3.5.
Contact tip size is wrong or it is
worn out.
Pressure on rolls is not enough.
CO heater fuse is blown out “F3”.
2
Change the contact tip.
Adjust the pressure as explained in
the Section 3.5.
Change the fuse.
Check the gas and its adjustment.
Contact the authorized service if the gas
adjustment can not be made.
Trouble in welding operation.
Shielding gas flow is not appropriate.
Ventilator does not function. Fuse is blown out “F3”.
Ventilator motor is out of order. Contact your authorized technical service.
Machine works noisily.
Welding current isn’t stabilized
and/or cannot be adjusted.
Heater socket is not working.
Voltmeter or ampermeter
is not working.
Contactor is out of order.
Some diodes in the power pack
are out of order.
Fuse is blown out “F3”.
Fuse is blown out “F4”.
Electronic card is out of order.
Change the fuse.
Change the fuse.
Change the fuse.
Contact your authorized technical service.
Contact your authorized technical service.
Change the fuse.
Change the fuse.
Electronic card is out of order.
Fuse is blown out “F1”.
Contactor is out of order. Contact your authorized technical service.
Electronic card is out of order.
5.4 FUSES
Fuse Feature Protected Circuit
F1
F3
F4
Amperage
10A
1A
0.8A
1A
0.25A
Fast
Fast
Fast
Motor and Card of the Wire Feeder
CO Heater
2
Card of Voltmeter/Ampermeter
F2 Fan Motor
Delayed
(RS 200 MK)
(RS 300 MK, RS 400 MK)
RS 200 MK / RS 300 MK / RS 400 MK 17

SPARE PARTS LIST FOR RS 200 MK / RS 300 MK / RS 400 MK
APPENDIX 1
1
2
4
3
6
78 9
11 12
10
5
}
13
14
15
16
17
26 27
18
19
20
21
22
23
24
25
28
RS 200 MK / RS 300 MK / RS 400 MK18

SPARE PARTS LIST FOR RS 200 MK / RS 300 MK / RS 400 MK
APPENDIX 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
NO
Changeover Switch (1-7)
Wire Feeding Speed Adjustmend Knob
Potentiometer - 10K
Welding Socket 35-70
Switch For 2/4 Function Selection
Electronic Board - ES212
EMC Filter
Control Transformer - 500VA
Wire Feeding System
Wire Coil Support
Cooling Ventilator
Glass Fuse Socket - 20x5mm
Mono-phase Machine Socket - 16A/240V
Gas Ventile - 24 VDC
Hinge
Panel Cabinet Lock
Bakalite U Arm
Eye Bolt - M10
Swivel Plastic Wheel 100x35
Swivel Plastic Wheel - Braked 100x35
Plastic Wheel 250x50x20
Ampermeter-Voltmeter Card E901A
DESIGNATION
Changeover Switch (0-3)
Changeover Switch (0-4)
Contactor 24VAC/16A
Contactor 24VAC/16A Contactor 24VAC/25A
Impedance Coil RS 300
Impedance Coil RS 200 Impedance Coil RS 400
Diode Bridge - 240A
Diode Bridge - 160A Diode Bridge - 350A
Main Transformer RS 300
Main Transformer RS 200 Main Transformer RS 400
Prim. Secondary RS 300
Prim. Secondary RS 200 Prim. Secondary RS 400
A308033114
A308033108
A229500002
A410801004
A377900106
A310030002
K405000032
A490400001
A311000025
K304400024
K309002210
A229900004
K304500044
A430901011
K304000064
K302200056
A250200003
A300190001
A377100004
A253200001
A229200004
A229300006
A229102002
A281000010
A225220008
A225220106
A225222010
K405000016
MATERIAL CODE
RS 400 MK
RS 300 MK
RS 200 MK
A308033112
A308033108
A229500002
A410801004
A377900106
A310030002
K405000032
A490400001
A311000016
K304400024
K309002210
A229900004
K304500040
A430901010
K304000060
K302200048
A250200003
A300190001
A377100004
A253200001
A229200004
A229300006
A229102002
A281000010
A225220008
A225220106
A225222010
K405000016
A308033106
A308033108
A229500002
A410801004
A377900106
A310030002
K405000032
A490400001
A311000016
K304400024
K309002210
A229900004
K304500032
A430901009
K304000052
K302200040
A250100003
A300190001
A377100004
A253200001
A229200004
A229300006
A229102002
A281000010
A225220008
A225220106
A225222010
K405000016
Changeover Switch (1-0-2)
Cooling Ventilator
Axial Aspirator
RS 200 MK / RS 300 MK / RS 400 MK 19