Mosa Magic Weld 200 User manual

Use and Maintenance Manual
C1VN70009003_EN
09-2022
D5260800
Engine driven welder
MAGIC WELD 200
MAGIC WELD 250
Original instructions

i-1
Contents
Contents
1. Introduction.......................................................................................................................................1
1.1 Foreword ............................................................................................................................................1
1.2 Supplied documentation.....................................................................................................................1
1.3 Customer service................................................................................................................................2
1.4 Spare parts.........................................................................................................................................2
1.5 Declaration of conformity....................................................................................................................2
1.6 Unauthorized changes........................................................................................................................2
1.7 Allowed and non-allowed use.............................................................................................................2
1.8 Identicationdata ...............................................................................................................................3
2. Safety.................................................................................................................................................5
2.1 Safety information...............................................................................................................................5
2.2 Positioning of safety decal and information........................................................................................6
2.2.1 Decal explanation..................................................................................................................7
2.3 General precautions...........................................................................................................................9
2.3.1 Personal protective equipment..............................................................................................9
2.3.2 Check the work area..............................................................................................................9
2.4 Fire prevention..................................................................................................................................10
2.4.1 Fire due to fuel, oil...............................................................................................................10
2.4.2 Firescausedbyammablematerialbuild-up ......................................................................10
2.4.3 Fire caused by electrical wiring ...........................................................................................10
2.4.4 Fire caused by piping ..........................................................................................................10
2.5 Lifting and transport precautions......................................................................................................11
2.5.1 Lifting by chains or ropes.....................................................................................................11
2.5.2 Lifting and manual transport................................................................................................11
2.5.3 Transport with towing carriage.............................................................................................12
2.6 Precautions for positioning the machine...........................................................................................13
2.6.1 Positioning site precautions.................................................................................................13
2.6.2 Precautions for electric connections....................................................................................13
2.7 Precautions during operation............................................................................................................14
2.8 Precautionsduringfuelandengineoillling ....................................................................................14
2.9 Precautions against noise ................................................................................................................14
2.10 Electromagnetic Compatibility (EMC)...............................................................................................15
2.10.1 Installation and use..............................................................................................................15
2.10.2 Assessment of the area.......................................................................................................15
2.10.3 Emission-reducing methods................................................................................................16
2.11 Precautions during welding ..............................................................................................................17
2.11.1 Precautions in the workplace...............................................................................................17
2.11.2 Welding precautions............................................................................................................17
2.12 Maintenance precautions .................................................................................................................19
2.13 Precautions for disposal of waste material.......................................................................................20
2.14 Disposal of the machine...................................................................................................................20
3. Technical data.................................................................................................................................21
3.1 Dimensions.......................................................................................................................................21
3.2 MAGIC WELD 200 technical data....................................................................................................22
3.3 MAGIC WELD 250 technical data....................................................................................................23

Contents
i-2
4. Description......................................................................................................................................25
4.1 Main components.............................................................................................................................25
4.2 Control panel components................................................................................................................26
5. Delivery and unpacking.................................................................................................................27
5.1 Delivery.............................................................................................................................................27
5.2 Unpacking.........................................................................................................................................27
6. Operation.........................................................................................................................................29
6.1 Grounding.........................................................................................................................................29
6.2 Checks before start-up.....................................................................................................................30
6.3 Starting and stopping the engine......................................................................................................30
6.3.1 Starting the engine ..............................................................................................................30
6.3.2 Stopping the engine.............................................................................................................31
6.4 Engine driven welder operation........................................................................................................32
6.4.1 Welding cables connection..................................................................................................32
6.4.2 Adjusting the welding current ..............................................................................................32
6.4.3 Duty cycle............................................................................................................................33
6.4.4 Welding arc striking ............................................................................................................33
6.4.5 Simultaneous use of welding and auxiliary generation functions........................................33
6.5 Setting the engine speed..................................................................................................................34
6.5.1 Checking and calibrating the minimum speed.....................................................................34
6.5.2 Checking and setting the maximum speed..........................................................................34
6.6 Generating set operation..................................................................................................................36
6.6.1 Auxiliary generation in AC 230V/50Hz (60Hz) or 115V/50Hz (60Hz)..................................36
6.6.2 Overload protection (overcurrent)........................................................................................36
7. Maintenance....................................................................................................................................37
7.1 Refuelling..........................................................................................................................................37
7.1.1 Fuel......................................................................................................................................37
7.1.2 Engine oil.............................................................................................................................37
7.2 Cleanairlter ...................................................................................................................................38
7.2.1 Inspection............................................................................................................................38
7.2.2 Cleaning ..............................................................................................................................38
7.3 Storage.............................................................................................................................................39
7.4 Disposal............................................................................................................................................39
8. Troubleshooting .............................................................................................................................41
8.1 Engine ..............................................................................................................................................41
8.2 Welding circuit..................................................................................................................................41

1
1. Introduction
1. Introduction
1.1 Foreword
ThismanualsuppliestheOperatorandqualiedandauthorisedTechnicianswithtechnicalinformationonthe
"MAGIC WELD" 200 and “MAGIC WELD” 250 engine driven welders set (hereinafter also referred to as the
"machine") produced by MOSA Div. of BCS S.p.A. (hereinafter also referred to as the "manufacturer").
Inthismanual,theOperatorinchargeandthequaliedTechnicianswillndtheindicationsfor:
• Getting familiar with the safety measures and basic standards to be adopted, to prevent hazards and
damage to people, to the engine driven welder and to the environment.
• Getting to know the main components of the engine driven welder and its operation.
• Performing the programmed routine maintenance.
• Getting to know any extraordinary maintenance operation.
This manual is an integral part of the engine driven welder and must follow it in any changes of ownership,
untilthenaldismantling.
The manual and all the publications attached to it must be kept with care, in an easily accessible place,
knowntotheoperatorandtothequaliedtechniciansauthorizedformaintenance.Readthedescriptions
carefully before starting to work or carrying out the required adjustments or maintenance.
If the manual is lost, damaged or becomes illegible, request a copy to MOSA, indicating the model of the
engine driven welder, the serial number and the year of construction.
If the engine driven welder is transferred, the transferor must deliver this manual to the new owner.
The engine driven welder is subject to updates to improve its performance; this manual summarises the
information regarding the current state of technology at the moment of the supply.
MOSAreservestherighttomakeimprovementsandmodicationstopartsandaccessories,withoutprompt-
ly updating this manual, except in exceptional cases of fundamental integrations concerning safe operation.
CAUTION
• Improper use or maintenance can cause serious damage to people and shorten the "useful
life" of the engine driven welder.
• The Operator and the qualied Technicians must be familiar with all the indications given in
this manual before using the engine driven welder or carrying out maintenance operations on
it.
• The procedures contained in this manual are intended to be applicable to engine driven weld-
ers only for permitted uses, and with all safety devices in function.
If the engine driven welder is used for purposes other than those indicated or in safety condi-
tions other than those indicated, the Customer becomes directly responsible for any person
possibly involved in accidents or injuries and for abnormal wear and tear of the machine.
1.2 Supplied documentation
The documentation supplied with the engine driven welder includes this Use and Maintenance Manual and
the main component manuals (e.g. engine).

1. Introduction
2
1.3 Customer service
The Technical Assistance and Spare Parts Service are available to the Customers.
MOSA recommends that you contact the nearest authorised service centre for specialised intervention for all
control and overhaul operations.
Inordertoobtainquickande󰀨ectiveresponses,indicatetheModelandSerialNumbershownontheidenti-
cation plate (see “1.8Identicationdata”).
1.4 Spare parts
Only original spare parts that guarantee functionality and durability must be used.
The use of non-original spare parts will void all warranty and Technical Support obligations.
1.5 Declaration of conformity
Themanufacturer:
MOSA Div. of BCS S.p.A.
Viale Europa, 59 20047 Cusago (Milano) Italy
Declaresthatthemachines:
MAGIC WELD 200
MAGIC WELD 250
ComplywiththerequirementsofthefollowingEC/EUDirectives:
• Machine Directive 2006/42/EC
• Low Voltage Directive 2014/35/EU
• Electromagnetic Compatibility Directive 2014/30/EU
andwiththerequirementsofthefollowingUKregulations:
• The Supply of Machinery (Safety) Regulations 2008/1597
• The Electrical Equipment (Safety) - Regulations 2016/1101
• Electromagnetic Compatibility - Regulations 2016/1091
1.6 Unauthorized changes
NochangescanbemadetothemachinewithoutMOSA'Sauthorization.
Unauthorized changes void any form of warranty on the machine and any civil and/or criminal liability in case
of accidents or injuries
1.7 Allowed and non-allowed use
Theseenginedrivenweldersperformthefollowingfunctions:
• Direct current generator for arc welding with manual electrode (stick).
• 50/60 Hz alternating current generator to supply power tools (grinding wheels, drills, etc.) used during
welding operations.
WARNING
• The engine driven welder is designed for industrial and professional use, and must only be
used by qualied and/or trained personnel.

3
1. Introduction
1.8 Identication data
ThedataidentifyingthemachinearegivenontheECplateappliedintheareaindicatedinthegure.
They are necessary for spare parts requests and communications with the Customer Service Department.
B
A
C
D
E
A
D5260810
B
C
D
E
1
1
236
45
4
1
34
25
123
123
4
4
5
6
6
7
7
8
89
2
3
4
6
A- Manufacturer'sdata
B - Machine data
(1) Year of manufacture
(2) Model
(3) Serial number
(4) Technical standard reference
C - Welding data
(1) Welding process
(2) Symbol for engine driven welders that can be used in environments with a higher risk of electric
shock
(3) Welding current symbol
(4) Minimum and maximum welding current value and corresponding voltage value

1. Introduction
4
(5) Duty cycle values
(6) Rated welding current values
(7) Welding voltage values
(8) Rated no-load welding voltage or adjustment range between minimum and maximum value
(9) Reduced rated no-load welding voltage with a voltage reduction device (VRD)
D - Auxiliary generation data
(1) Rated frequency
(2) Ratedcosϕ(powerfactor)
(3) Insulation class
(4) Rated power (kVA/kW)
(5) Rated voltage (V)
(6) Rated current (A)
E - Engine and machine data
(1) Motor symbol
(2) Rated speed
(3) Rated minimum speed
(4) Rated no-load speed
(5) Rated engine power
(6) IP protection degree
(7) Dry weight

5
2. Safety
2. Safety
2.1 Safety information
Always respect the warnings contained in this manual and present on the decal applied to the machine.
This allows the machine to be used safely, avoiding damage to property and injury or death to people.
The following words and symbols were used to identify important safety messages.
Symbol identiesimportantsafetymessagesonthemachine,inthemanualandelsewhere.Whenyou
see this symbol, follow the instructions in the safety messages.
DANGER
• This word indicates a situation of imminent risk that, if not avoided, could cause serious injury
or even death to people and serious damage to property.
WARNING
• This word indicates a potential risk situation which, if not avoided, could result in serious inju-
ry or even death to people and serious damage to property.
CAUTION
• This word indicates a potential risk situation that, if not avoided, could cause minor or moder-
ate injuries.
It can also be used to prevent dangerous operations that can cause damage to the machine.
The following terms are used to transmit the information to be followed to the user, to avoid damage to the
machine.
* Important
• If the precautions described are not observed, the machine could be damaged and its useful life re-
duced.
Note:
• This word is used to indicate further useful information.

2. Safety
6
2.2 Positioning of safety decal and information
4
5
6
3
7
3
1
2
D5260920

7
2. Safety
2.2.1 Decal explanation
D5260930
• Pos. 1 Consult the manual
Read the contents of the manual carefully before using
the machine or carrying out maintenance operations
on it.
D5260940
• Pos. 2 - Stop the engine before servicing
To avoid burns due to contact with hot parts, before
carrying out checks or servicing of the machine, stop
theengineandwaituntiltheyhavecooledsu󰀩ciently.
To avoid serious injury, do not insert limbs near the
rotating parts without stopping the engine.
M734500250
• Pos. 3 - Electrical voltage hazard
Stop the machine before carrying out checks or main-
tenance.
D5260950
• Pos. 4 - Fire and exhaust gas inhalation hazard
Fuelishighlyammable.Turntheengineo󰀨andallow
it to cool before fuelling.
Engine carbon monoxide emissions are highly toxic
and poisonous.
Use the machine in outdoor and ventilated places.
D5260820
• Pos. 5- Sound power level
Unit of measurement dB(A); represents the amount of
acoustic energy emitted in the unit of time, regardless
of the distance of the measuring point.
D5260960
• Pos. 6 - Safety marking
Indicates that the engine driven welder may used in
environments with a higher risk of electric shock.

2. Safety
8
D5260970
• Pos. 7 - Power Optimizer
Function patented by MOSA that prevents engine
overload during welding operations.

9
2. Safety
2.3 General precautions
Any errors during use, checks or maintenance could cause
the risk of injury, even serious
• Before performing the operations, read this manual and
the decals applied to the machine and follow the warn-
ings.
Ifyoudon'tunderstandanypartofthemanual,askyour
SafetyO󰀩cerforexplanations.
• The machine can only be used and repaired by trained
and authorized personnel.
• Do not work if you feel unwell, have drunk alcohol or
take medicines that impair your ability to work safely or
repair the machine.
• Before starting the operations, check the machine. If
anomalies are detected, do not operate on the machine
before having completed the necessary repairs.
• Comply with the provisions and laws in force in the coun-
try in which you work.
2.3.1 Personal protective equipment
• Do not wear clothes that are too loose or accessories, to
prevent them from becoming entangled, causing person-
al injury.
• Always wear the personal protective equipment pre-
scribed for the place where you work, such as a protec-
tive helmet, safety footwear, safety glasses, gloves and
noise protection headphones.
• Before using personal protective equipment, check that it
is in perfect condition.
2.3.2 Check the work area
• Ask the site safety manager for information on the regu-
lations to be observed.
• Understand the signs and indications on site.
• Makesurethatreextinguishersandrstaidkitare
available on site and inquire about where they are locat-
ed.
• Check that the area is clear of materials that may be
hazardous during the operation of the machine (such as
ammablematerialsorliquids).
• Make sure that there are no unauthorized persons in the
area.
D5260050
D5260060
D5260070
D5260080

2. Safety
10
2.4 Fire prevention
2.4.1 Fire due to fuel, oil
• Avoidapproachinganyametoammablesubstances
such as fuel and oil.
• Donotsmokeoruseopenamesnearammablesub-
stances.
• Stop the machine before refuelling.
• Makesurenottospillammablesubstancesonover-
heated surfaces or on parts of the electrical system.
• Afterrefuelling,removeanyspillsandtightenalllling
caps tightly.
• For safety in the workplace, store the cloths soaked in
ammablematerialsinacontainer.
• Store oil and fuel in pre-established and well-ventilated
locations and prohibit the entry of unauthorised person-
nel.
• Whencleaningthemachine,donotuseammablesub-
stances such as diesel or gasoline.
2.4.2 Fires caused by ammable material build-up
• Removedryleaves,chips,piecesofpaper,carbondust,orotherammablematerialsaccumulatedfrom
the machine.
2.4.3 Fire caused by electrical wiring
• Always keep the electrical wiring clean and tightened.
• Periodically check that there are no loose or damaged parts. Tighten loose wiring connectors or termi-
nals.
• Repair or replace any damaged cables.
2.4.4 Fire caused by piping
• Periodicallycheckthatthehoseclampsarermlyxed.
• Ifloosened,theymayvibrateduringmachineoperationandcauseleakageofliquids,provokingresand
serious injuries, including fatalities.
D5260090

11
2. Safety
2.5 Lifting and transport precautions
2.5.1 Lifting by chains or ropes
• Make sure that the handling area is clear of obstacles
and people.
• Handlethemachinewiththeengineo󰀨,theelectrical
cables disconnected and the fuel tank empty.
• Lift the machine only by the frame.
A central hook can be mounted on request (optional).
• Check the condition of the frame. If it is damaged, re-
place it before lifting the machine.
• Always use lifting equipment adequately sized and con-
trolled by authorized bodies.
• Do not harness the machine with a single rope.
Use two ropes placed symmetrically to keep the machine
in a horizontal position.
• Do not subject the machine and the lifting equipment
used to undulating or abrupt movements that transmit
dynamic stresses to the structure.
• Do not lift the machine at a height higher than that nec-
essary for handling.
• Do not leave the machine suspended for longer than
necessary for handling.
2.5.2 Lifting and manual transport
• The machine should be lifted and transported by at least
2 people.
• Handlethemachinewiththeengineo󰀨,theelectrical
cables disconnected and the fuel tank empty.
• On request, the machine can be equipped with an op-
tional kit consisting of 4 handles for easier handling.
D5260830
D5260980
D5261000

2. Safety
12
2.5.3 Transport with towing carriage
• Handlethemachinewiththeengineo󰀨,theelectrical
cables disconnected and the fuel tank empty.
• On request, the machine can be equipped with an op-
tional trolley that facilitates handling.
D5260990

13
2. Safety
2.6 Precautions for positioning the machine
2.6.1 Positioning site precautions
• This machine has been designed for outdoor use and can therefore be positioned outdoors.
In case of meteorological precipitation (rain, snow, etc.), place the machine in an adequately sheltered
place. If this is not possible, do not use the machine.
• Donotplacemachinesorequipmentnearheatsources,inareasatriskwithexplosionhazardorre
hazard.
Placethemachineatasafedistancefromfueltanks,fromammablematerial(rags,paper,etc.),from
chemicals.
Follow the instructions of the competent authorities.
• To limit potentially dangerous situations, isolate the area around the machine, thus preventing any unau-
thorized personnel from getting close to it.
• Although the machines produced comply with the regulations on electromagnetic compatibility, do not
placethemachinenearequipmentinuencedbythepresenceofmagneticelds.
• Make sure that the area immediately surrounding the machine is clean and free of debris.
• Alwaysplacethemachineonaat,solidsurfacethatisnotsubjecttofailureinordertoavoidtipping,
slipping or falling during operation.
Avoid using the machine on land with a slope greater than 10°.
• The machine must always be positioned so that exhaust
gases disperse into the air without being inhaled by
people or animals.
The exhaust gases of an engine contain carbon mon-
oxide:thissubstanceisharmfultohealthand,inhigh
concentration, can cause poisoning and death.
• If the machine is used indoors, make sure that the area
is well ventilated.
2.6.2 Precautions for electric connections
• Use appropriate electrical plugs at the machine output
sockets and make sure that the electrical cables are in
good condition.
• Do not use the machine with wet or damp hands and/or
clothing.
D5260150
D5260160

2. Safety
14
2.7 Precautions during operation
• Keep all panels closed during normal operation.
• Access to the internal parts of the machine must only be carried out for maintenance purposes.
• Keeptheareanearthemu󰀪erfreefromobjectssuchasrags,paper,cartons.
Thehightemperatureofthemu󰀪ercouldcausetheobjectstoburnandcauseare.
• Immediately stop the machine in case of malfunctions.
Donotrestartthemachinewithoutrstidentifyingandsolvingtheproblem.
• Do not wrap or cover the machine with cloths while it is running.
Before covering the machine, make sure that the engine parts are cold
Iftheenginepartsarestillwarm,thereisariskofdamagetothemachineandre.
• Do not place objects or obstacles near the air suction and expulsion windows; a possible overheating of
themachinecouldcauseare.
2.8 Precautions during fuel and engine oil lling
• Fuelandengineoilareammable.
Rellwiththeengineo󰀨.
• Refuel only outdoors or in well-ventilated environments.
• Donotsmokeorusenakedamesduringrefuelling.
• Do not fuel with the engine running or hot.
• Clean and dry any leaks of engine oil and fuel before
restarting the machine.
• After refuelling, fully tighten the tank caps.
• Donotllthefueltankcompletelytoallowexpansionof
the fuel inside it.
• Do not exceed the MAX level line of the engine oil level
dipstick.
2.9 Precautions against noise
• Excessive noise can cause temporary or permanent hearing problems.
The actual risk arising from the use of the machine depends on its use conditions.
• There is a decal on the machine that declares the sound power level dB(A) emitted by it. The value pro-
vides an indication of the noise level emitted by the machine when used, in order to assess the noise in
the workplace.
• Theadoptionofspecicmeasures(suchasheadphonesorearplugs)mustbeassessedbytheoperator.
D5260090

15
2. Safety
2.10 Electromagnetic Compatibility (EMC)1
The machine is compliant with European Directive 2014/30/EU on electromagnetic compatibility, and with
harmonizedstandard:EN60974-10ElectromagneticCompatibility(EMC)ProductStandardforArcWelding
Equipment.
All electrical equipment generates small amounts of electromagnetic emission.
Electrical emission may be transmitted through power lines or radiated through space, similar to a radio
transmitter.
When emissions are received by other equipment, electrical interference may result.
Electricalemissionsmaya󰀨ectmanykindsofelectricalequipment;othernearbyweldingequipment,radio
and TV reception, numerical controlled machines, telephone systems, computers, etc.
WARNING
• This Class A equipment is not intended for use in residential locations where the electrical
power is provided by the public low-voltage supply system. There may be potential di󰀩culties
in ensuring electro-magnetic compatibility in those locations, due to conducted as well as radi-
ated disturbances.
2.10.1 Installation and use
• The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions.
• If electromagnetic disturbances are detected, the user of the welding equipment is responsible for solving
the situation with the technical assistance of the manufacturer.
In some cases, this remedial action may be as simple as grounding the welding circuit.
In other cases, it could involve constructing an electromagnetic screen enclosing the generating set and
theentireweldingarea,withrelatedinputlters.
In all cases electromagnetic disturbances must be reduced to the point where they are no longer trouble-
some.
Note:
The welding circuit could be earthed for safety reasons.
Follow your local and national standards for installation and use.
Changes to grounding connections should only be authorized by someone competent to assess whether
the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may
damage the earth circuits of other equipment.
2.10.2 Assessment of the area
• Before installing the welding equipment, assess any potential electromagnetic problems in the surround-
ing area.
Checkforthepresenceof:
◦Supply cables, control cables, signalling and telephone cables, above, below and adjacent to the
welding equipment.
◦Radio and television transmitters and receivers.
◦Computer and other control equipment.
◦Safety critical equipment, e.g., industrial equipment guards.
◦ Presenceofpeoplewithpacemakers,implantabledebrillators,neurostimulatorsandotheractive
devices.
1 PortionsofthistextarecontainedinEN60974-10:“ElectromagneticCompatibility(EMC)productstandardforarc
welding equipment.”

2. Safety
16
◦Equipment used for calibration or measurement.
• Check that the other equipment in the environment is immune against electromagnetic disturbances.
Ensure that the other equipment being used in the environment is compatible.
This may require additional protection measures.
• Check the time of day that welding or other activities are to be carried out.
• The size of the surrounding area to be considered will depend on the structure of the building and other
activities taking place there. The surrounding area may extend beyond the boundaries of the work site.
2.10.3 Emission-reducing methods
Welding equipment maintenance
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is running.
Theweldingequipmentshouldnotbemodiedinanywayexceptforthosechangesandadjustmentscov-
ered in the manufacturer’s instructions.
Welding cables
The welding cables should be kept as short as possible and should be positioned close together, running at
orclosetooorlevel.
Equipotential bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. How-
ever, metallic components bonded to the work piece will increase the risk that the operator could receive a
shock by touching these metallic components and the electrode at the same time.
The operator should be insulated from all such bonded metallic components.
Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the grounding of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, grounding
of the workpiece to should be achieved by a direct connection to the workpiece; however, in some countries
where direct connection is not permitted, grounding should be achieved by suitable capacitors, selected
according to national regulations.
Screening and shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special applications