MAGNAWELD MONOMAG 180 User manual

MONOMAG 180
USER MANUAL
MIG/MAG WELDING MACHINE
www.magmaweld.com

1Monomag 180
SAFETY RULES
1. TECHNICAL INFORMATIONS
1.1 GENERAL EXPLANATIONS
1.2 COMPONENTS OF MONOMAG 180
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 WELDING CONNECTIONS
2.3.1 Earth Clamp Connection
2.3.2 Connections
3. OPERATION
3.1 CONNECTING TO THE MAINS
3.2 CHOOSING AND CHANGING THE WIRE FEEDING ROLLS
3.3 LOADING THE WIRE SPOOL AND THREADING THE WIRE
3.4 ADJUSTING THE GAS FLOW
4. WELDING
4.1 ADJUSTING THE STICK OUT
4.2 WELDING PARAMETERS
5. MAINTENANCE AND TROUBLESHOOTING
5.1 PERIODIC MAINTENANCE
5.2 NONPERIODIC MAINTENANCE
5.3 BASIC TROUBLESHOOTING
5.4 FUSES
APPENDIX 1: SPARE PARTS LIST
APPENDIX 2: ELECTRICAL DIAGRAM
Gas
.................................................................................................................................................2
...............
..............................................................................................................7
........................................................................................................................................7
..............................................................................................................................................8
................................................................................................................8
............................................................................8
.....................................................................................................................9
.................................................................................................................9
.............................................................................................................................9
................................................................................................................................................10
10
...............................................................10
................................................................................................................11
......................................................12
............................................................................................12
........................................................................................................6
....................................................................................................................6
......................................................................................................6
............................................................................................................................................7
.............................................................................................................
..............................................................10
.....................................................................................................................................................12
.........................................................
.........................
..............................................................................................13
...................................................................................................................13
...........................................................................................................13
...............................................................................................................14
...................................................................................................................................................14
................................................................................................................15
.........................................................................................................16
CONTENTS

2 Monomag 180
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!

3Monomag 180
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.
.
.

4 Monomag 180
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
.
.

5Monomag 180
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 MONOMAG 180
Monomag 180 is a single phase, step controlled, constant voltage, compact MIG/MAG welding equipment to
be used especially for intensive thin metal repair applications. Any kind of metal can be welded with this
machine, if proper welding wire and gas is used. For mild steel welding, even under CO2 you can weld with low
spatter and stable arc.
The concept of this machine is based on our industrial 3 phase machines, only the wire feeder is 2 wheel drive.
The machine is fan cooled and thermally protected against overheating.
Figure 1: Front View Figure 2: Back View
ON/OFF and Voltage Step Switch
Wire Feeding Speed Adjustment Knob
Torch Cable
Earth Clamp Cable
Welding Parameters Chart
Gas Supply Inlet
CO Heater Socket (220 VAC)
2
1
2
3
4
5
6
7
8
9
Thermic Lamp
Mains Lamp
Lifting Eye
Handle
Swivel Wheel
Braked Swivel Wheel
Wheel
Drum Feeding
Gas Cylinder Safety Chain
10
11
12
13
14
15
16
17
18
6 Monomag 180
Fuses
Mains Cable
TECHNICAL INFORMATION
1. TECHNICAL INFORMATION
1.1 GENERAL EXPLANATIONS
DİKKAT
BU PRİZ CO ISITICISI
İÇİNDİR. KESİNLİKLE
BAŞKA MAKSATLA
KULLANMAYINIZ
2
FUSE
FUSE
FUSE
F2
F1
F3 30 A / 16 V - 140 A / 21 V
X20 % 60 % 100 %
80 A 60 A
18 V 17 V
CL.I. H
U V
220
50 Hz
1
S1
IP 21
I A
13
1I A
9,7
1I A
28
1
2,9 kVA 2,1 kVA
S
T 32 A
U V
14 - 29
0I2
U2
1R
MONOMAG 180
Seri No :
EN 60974-1
EN 60974-10
140 A
21 V
6,2 kVA
1R
1
23456
7
MONOMAG 180
V
A
12
0,5
mm
34
2
58
3
60 70
35
20 21
19
CO2Ar/CO2(80/20)
12
0,5 3
23
15
57
413,5
55 70
45 115
17 20
16 22
Ø : 0,6 mm
V
A
23
1
mm
45
3
5,5 7
4
90 105
75
20 21
19
23
15
45
36
68,5
4,5 11
100 125
80 145
19 21
18 22
Ø : 0,8 mm
V
A
35
2
mm
56
4
5,5 7
3,5
125 140 100
21 25
20
35
2
57
4
5,5 9,5
4,5
135 160
120
20 21
20
Ø : 1,0 mm
m/min
Th
18
20
1
2
3
4
5
6
7
8
9
10
11
12
16
17
14
15
18
13

30 A / 16 V - 140 A / 21 V
X20 % 60 % 100 %
80 A 60 A
18 V 17 V
CL.I. H
U V
220
50 Hz
1
S1
IP 21
I A
13
1I A
9,7
1I A
28
1
2,9 kVA 2,1 kVA
S
T 32 A
U V
14 - 29
0I2
U2
MONOMAG 180
Seri No :
Organize Sanayi Bölgesi 5.Kısım Manisa - TÜRKİYE
EN 60974-1
EN 60974-10
140 A
21 V
6,2 kVA
1R
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
S
1R
*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).
1.4 TECHNICAL SPECIFICATIONS
X
U
U
U
0
1
2
I
I
IP 21
S
CL.I.
1
2
1
Line Voltage
Input Power %
Input Current %
s
%
Drive Roll Size
Wire Feding Speed
(20 )
Recommended Line Fuse
(20 )
Welding Current Range
Voltage Adjustment Step
Rated Welding Current (20 )
Dimensions
Weight
Protection Class
(1 Phase)
(LxWxH)
(V socket)
kVA
A
A
ADC
2 0 V / 50 Hz
6.2
32
28
30 - 140
7
140
888x455x870
7
0.6 - .
1 - 17
IP2
3
9
1 0
1
A
mm
kg
mm
m/min
DC
1.5 ACCESORRIES
DEĞERBİRİMTECHNICAL SPECIFICATIONS
STANDARD ACCESORRIES
OPTIONAL ACCESORRIES
PRODUCT CODE
PRODUCT CODE
K301500002
S520001002
K120000001
Torch
Electrode Holder and Cable (Fişsiz) 16mm /3m
Gas Hose (2m)
2
CO /Ar Pressure Regulator
CO Heater
2
2
K301101203
S520009002
1R
1R
7Monomag 180
Single Phase Transformer Rectifier
Horizontal Characteristics
MIG / MAG Welding
Line Input 1 Phase Alternative Current
Appropriate To Operate In Dangerous Work Area
Direct Current
Fuse
:Duty Cycle*
:Open Circuit Voltage
:Line Voltage and Frequency
:Rated Welding Voltage
:Input Current
:Rated Welding Current
:Protection Class
:Input Power
:Insulation Class
TECHNICAL INFORMATION
1.3 DATA PLATE

8 Monomag 180
2. INSTALLATION
INSTALLATION
2.1 UPON RECEIPT AND CLAIMS

ú
ú
ú
ú
ú
Standard pallet contains:
Power Source
Torch
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.


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

2.3 WELDING CONNECTIONS
9Monomag 180
2.3.1 Connecting the Earth Cable to the Workpiece
Topraklama pensesini, kaynak yapılacak bölgeye
olabildiğince yakın yerden işparçasına sıkıca
bağlayın.



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.
(20)
(18)
(21)
(26)
(19) (20)
(7)
2 2
2 2
2.3.2 Gas Connections
Figure 3: Connections Gas Cylinder - Heater - Pressure Regulator
21
20
18
25
24
22
23
19
26
18
19
20
21
Gas Cylinder Safety Chain
Gas Pressure Regulator
Gas Cylinder
Gas Cylinder Valve
Gas FlowAdjustment Valve22
23
24
25
26
27
Gas Hose
Flow meter
Manometer
CO Heater
Power Cable of CO Heater
2
2
27
Figure 4: Gas Connections
6
7


Connect one end of gas hose to the gas
pressure regulator and connect the other end
to 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 11.
(23)
(19)
(6)
(21)
(22)
INSTALLATION

While inserting the plug into the socket,
pay attention that main switch is
positioned to “0”.
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.
3.2 CHOOSING AND CHANGING THE WIRE FEEDING ROLLS
Figure 7: Wire Feeding Roll
Unscrew the spool support nut . Place the
MIG/MAG wire spool through the spool
support and screw the spool support nut
tightly. (Figure 8).
(31)
(32)
(33) (31)
3.3 LOADING THE WIRE SPOOL AND THREADING THE WIRE
Figure 8: Loading the Wire Spool
29
30
28
Figure 6: Installing the Wire Feeding Roll
Figure 5: Removing the Wire Feeding Roll
3
2
1
4
5
6
1,0 0,8
0,8 1,0
0,8
1,0
32
31
33




Remove nozzle and contact tip of the torch.
Pull down the spring knob and release the
pressure roll .
Pull and hold the wire tightly to keep it from
unraveling, cut off end. Thread the wire through
the roll into the torch. (Figure 9).
Push down the pressure roll , push up and lock
the spring knob .
(29)
(28)
(28)
(29)
Screwing the spool support nut (31)
too tight may cause blockage of wire
feeding. Screwing the spool support
nut (31) loose may cause raveling of
the wire spool after stopping wire
feeding. Therefore, do not screw spool support
nut (31) neither too tight nor loose.
10 Monomag 180



For steel and 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 roll, pull down the spring knob and
Install the appropriate roll and screw the screw
. Lock the pressure assembly (Figure 6).
(29)
(30)
remove the screw of the feeding roll. Then
remove the feeding roll (Figure 5).
(30)


SWITCH ON the machine via ON/OFF switch .
Observe the fan noise and illumination of the
mains lamp .
(1)
(11)
3. OPERATION
OPERATION
3.1 CONNECTING TO THE MAINS
Both sides of the roll are labeled
according to appropriate wire
diameter. Roll must be inserted into
the flange in such a way that
appropriate diameter of the wire to be
fed is seen from outside (Figure 7).

3.4 ADJUSTING THE GAS FLOW
For accurate gas flow rate adjustments, use the
following table.
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 11: 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 11).
TAHTA
1
2
3
4
Figure 10: Threading Wire Through Torch and Adjusting Pressure
1
45
23



Push down the pressure roll , push up and lock
the spring knob .
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 roll via
spring knob . Cut off wire (Figure 10).
(28)
[1] (29)
[3]
[4]
[5]
(31) [6]
Hold the torch switch pressed until the wire
comes out of the torch.
[2]
6
Figure 9: Threading the Wire
1
2
3
11Monomag 180
OPERATION
Mild
Steel and
Metal Cored
Diameter
8 lt/min
9 lt/min
10 lt/min
Stainless
Steel Aluminium
8 lt/min
9 lt/min
10 lt/min
8 lt/min
9 lt/min
10 lt/min
Flux
Cored
7 lt/min
8 lt/min
9 lt/min
Practical adjustment of the gas flow rate (CO , Ar,
MIX) is 10 times of the diameter of the wire.
Diameter of the wire: 0,9 mm
Gas flow rate: 10 x 0,9 = 9 lt/min
2
EXAMPLE:
UNLOCK THE WIRE PRESSURE
ASSEMBLY DURING GAS FLOW
ADJUSTMENT.

4. WELDING
4.1 ADJUSTING THE STICK OUT
4.2 WELDING PARAMETERS
Ø : 0,6 mm
Ø : 0, mm8
Ø : mm1,0
mm
0.5
2
3
35
19
1
3
5
60
20
2
4
8
70
21
mm
A
V
1
3
4
75
19
2
4
5.5
90
20
3
5
7
105
21
mm
A
V
A
V
2
4
3.5
100
20
3
5
5.5
125
21
5
6
7
140
25
CO2
1
2
5
55
17
2
3
7
70
20
3
5
13.5
115
22
0.5
1
4
45
16
2
4
6
100
19
3
5
8.5
125
21
5
6
11
145
22
1
3
4.5
80
18
3
5
5.5
135
20
5
7
9.5
160
21
2
4
4.5
120
20
Ar/CO (80/20)
2
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.
12 Monomag 180
WELDING
Figure 12: 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
1.0mm
1.0mm
10d
12d
10mm 0-3mm
1 mm2 3-5mm
Wire
Diameter
(d) Coefficient Stick Out
Length
Distance Between
Nozzle and
Contact Tip
Arc Type
Short Arc
Globular
Transfer
Spray Arc 1.0mm 15d 15mm 5-8mm

13Monomag 180
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
machine . R e p a i r o r
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 .

5.4 FUSES
Fuse Amperage Feature Protected Circuit
F1
F2
F3
0.8A
1A
10A
T
F
F
Fan Motor
CO Heater
2
Wire Feeder
14 Monomag 180
MAINTENANCE AND TROUBLESHOOTING
5.3 TROUBLESHOOTING
TROUBLE REASON REMEDY
Contact your authorized technical service.
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 3.3.
Contact tip size is wrong or it is
worn out.
Pressure on rolls is not enough.
CO heater fuse is blown out “F2”.
2
Change the contact tip.
Adjust the pressure as explained in
the Section 3.3.
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 “F1”.
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.
Contactor is out of order.
Some diodes in the power pack
are out of order.
Fuse is blown out “F2”.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 “F3”.
Electronic card is out of order.

15Monomag 180
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 MATERIAL CODE DESIGNATION
SPARE PARTS LIST
APPENDIX 1
A253200001
A300101005
A300101015
A300102003
A300190001
A310310002
A310310004
A377100004
A410200003
A410801004
A229500002
A490300004
A314800102
K304400012
A229900004
A308010004
A250100003
A430902004
K405000032
K309002204
K304500028
K304000048
K302200032
A225220008
A225222010
A229102002
A229300006
A229200004
Gas Ventile (4W)T-GM1210-24VDC
Glass Fuse - Fast 1A
Glass Fuse - Fast 10A
Glass Fuse - Delayed 800mA
Glass Fuse Socket
Signal Lamp Neon 220VAC
Signal Lamp Neon 24VAC
Mono-phase Machine Socket - 16A / 240V
Stone Resistor - 11W 220 Ohm
Potentiometer 10K
Wire Feeding Speed Adjustmend Knob
Plastic Card Holder
Temperature Limiting Switch
Control Transformer - 220/28 50VA
Wire Spool Support SG602-116
Changeover Switch (1 Phase) (0-7) (20A) - CA10-TR2569
Axial Aspirator - AS250
Diode Bridge (1 Phase) - 65A (100%)
Electronic Board - ES212
Wire Feeding System-1 SF 15037
Choke Coil - Monomag180
Main Transformer - RE140M
Primary Secondary Coil - RE140M
Swivel Plastic Wheel 100x35
Plastic Wheel 250x50x20
Bakelite U Arm
Panel Cabinet Lock 1091-U114-01
Hinge - 1056 U6

ELECTRICAL DIAGRAM
APPENDIX 2
RE 414
1
2
3
4
5
6
7
8
9
10
JA
TEL HIZI
1k
TETIK
TH
TERMIK ATIK
5mm k›rm›z›led
1
2
JB
M2
24VDC/90W
1
2
3
4
JC
- +
C1
22000uF/63V
C2
22000uF/63V
R1
220R/11W
+
-
L1
860mH
RÖLE 1
2
TR1
0 1 2 3 4 5 6 7
7 6 5 4 3 2 1
1 1
4 4 4
6
10 14 12 16 18
8
4 4 4 4
4
3
2
1
R N
F1
T-0.8A
M1
BR1
E
Pk1
YEŞIL NEON
220VAC
V1
220VAC
TR2
BR2 KBL08
220VAC 24VAC - +
~ ~
VR1
275VAC
R2
220R/11W
F3
F-10A
F2
F-1A
+-
16 Monomag 180

OWM 09.06.2011
[phone]
[phone]
FACTORY
Made in TÜRKİYE
Organize Sanayi Bölgesi 5.Kısım 5503. Sokak No:1 MANİSA
www.magmaweld.com