Magmaweld Monostick 200i User Manual

Explanation Of Safety Information

⚠️ Safety symbols found in the manual are used to identify potential hazards. When any one of the safety symbols are seen in this manual, it must be understood that there is a risk of injury and the following instructions should be read carefully to avoid potential hazards.

• The possessor of the machine is responsible for preventing unauthorized persons from accessing the equipment.
• Persons using the machine must be experienced or fully trained in welding; they have to read the user manual before operation and follow the safety instructions.

Explanation Of Safety Symbols

⚠️ ATTENTION: Indicates a potentially hazardous situation that could cause injury or damage. In case if no precaution is taken, it may cause injuries or material losses / damages.

ℹ️ IMPORTANT: Specifies notifications and alerts on how to operate the machine.

❌ DANGER: Indicates a serious danger. In case if not avoided, severe or fatal injuries may occur.

Comprehending Safety Precautions

• Read the user manual, the label on the machine and the safety instructions carefully.
• Make sure that the warning labels on the machine are in good condition. Replace missing and damaged labels.
• Learn how to operate the machine, how to make the checks in a correct manner.
• Use your machine in suitable working environments.
• Improper changes made in your machine will negatively affect the safe operation and its longevity.
• The manufacturer is not responsible for the consequences resulting from the operation of the device beyond the specified conditions.

Electric Shocks May Kill

Make certain that the installation procedures comply with national electrical standards and other relevant regulations, and ensure that the machine is installed by authorized persons.

• Wear dry and sturdy insulated gloves and working apron. Never use wet or damaged gloves and working aprons.
• Do not work alone. In case of a danger make sure you have someone for help in your working environment.
• Do not touch the electrode with the bare hand. Do not allow the electrode holder or electrode to come in contact with any other person or any grounded object.
• Never touch parts that carry electricity.
• Never touch the electrode if you are in contact with the electrode attached to the work surface, floor or another machine.
• By isolating yourself from the work surface and the floor, you can protect yourself from possible electric shocks. Use a non-flammable, electrically insulating, dry and undamaged insulation material that is large enough to cut off the operator's contact with the work surface.
• Do not connect more than one electrode to the electrode holder.
• Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
• Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.

Procedures for Electric Shock

• Turn off the electric power.
• Use non-conducting material, such as dry wood, to free the victim from contact with live parts or wires.
• Call for emergency services.

If you have first aid training:

• If the victim is not breathing, Administer cardiopulmonary resuscitation (CPR) immediately after breaking contact with the electrical source. Continue CPR (cardiac massage) until breathing starts or until help arrives.
• Where an automatic electronic defibrillator (AED) is available, use according to instructions.
• Treat an electrical burn as a thermal burn by applying sterile, cold (iced) compresses. Prevent contamination, and cover with a clean, dry dressing.

Moving Parts May Cause Injuries

• Keep away from the moving parts.
• Keep all protective devices such as covers, panels, flaps, etc., of machinery and equipment closed and in locked position.
• Wear metal toe shoes against the possibility of heavy objects falling on to your feet.

Fumes and Gases May Be Harmful To Your Health

Long-term inhalation of fumes and gases released from welding and cutting is very dangerous.

• Burning sensations and irritations in the eyes, nose and throat are signs of inadequate ventilation. In such a case, immediately boost the ventilation of the work area, and if the problem persists, stop the welding process completely.
• Create a natural or artificial ventilation system in the work area.
• Use a suitable fume extraction system where welding and cutting works are being carried out. If necessary, install a system that can expel fumes and gases accumulated in the entire workshop. Use a suitable filtration system to avoid polluting the environment during discharge.
• If you are working in narrow and confined spaces or if you are welding lead, beryllium, cadmium, zinc, coated or painted materials, use masks that provide fresh air in addition to the above precautions.
• If the gas tanks are grouped in a separate zone, ensure that they are well ventilated, keep the main valves closed when gas cylinders are not in use, pay attention to possible gas leaks.
• Shielding gases such as argon are denser than air and can be inhaled instead of air if used in confined spaces. This is dangerous for your health as well.
• Do not perform welding operations in the presence of chlorinated hydrocarbon vapors released during lubrication or painting operations.

Arc Light May Damage Your Eyes and Skin

• Use a suitable protective mask and glass filter (4 to 13 according to EN 379) suitable for that to protect your eyes and face.
• Protect other naked parts of your body (arms, neck, ears, etc.) with suitable protective clothing from these rays.
• Enclose your work area with flame-resistant folding screens and hang warning signs at eye level so that people around you will not sustain injuries from arc rays and hot metals.
• This machine is not used for heating of icebound pipes. This operation performed with the welding machine causes explosion, fire or damage to your installation.

Sparks and Spattering Particles May Get Into Eyes and Cause Damage

• Performing works such as welding, surface grinding, and brushing cause sparks and metal particles to splatter. Wear approved protective work goggles which have edge guards under the welding masks to prevent sustaining possible injuries.

Hot Parts May Cause Severe Burns

• Do not touch the hot parts with bare hands.
• Wait until the time required for the machine to cool down before working on its parts.
• If you need to hold hot parts, use suitable tools, welding gloves with high-level thermal insulation and fire-resistant clothes.

Noise May Cause Damage To Your Hearing Ability

• The noise generated by some equipment and operations may damage your hearing ability.
• Wear approved personal ear protective equipment if the noise level is high.

Welding Wires Can Cause Injuries

• Do not point the torch towards any part of the body, other persons, or any metal while unwrapping the welding wire.
• When welding wire is run manually from the roller especially in thin diameters the wire can slip out of your hand, like a spring or can cause damage to you or other people around, therefore you must protect your eyes and face while working on this.

Welding Operations May Cause Fire and Explosion

• Never perform welding work in places near flammable materials. There may be fire or explosions.
• Before starting the welding work, remove these materials form the environment or cover them with protective covers to prevent combustions and flaring.
• National and international special rules apply in these areas.
• Do not apply welding or cutting operations into completely closed tanks or pipes.
• Before welding to tanks and closed containers, open them, completely empty them, and clean them. Pay the greatest attention possible to the welding operations you will perform in such places.
• Do not weld in tanks and pipes which might have previously contained substances that may cause explosions, fires or other reactions.
• Welding equipment heats up. For this reason, do not place it on surfaces that could easily burn or be damaged!
• Welding sparks can cause fire. For this reason, keep materials such as fire extinguishers tubes, water, and sand in easily accessible places.
• Use holding valves, gas regulators and valves on flammable, explosive and compressed gas circuits. Make sure that they are periodically inspected and pay attention that they run reliably.

Maintenance Work Performed by Unauthorized Persons To Machines and Apparatus May Cause Injuries

• Electrical equipment should not be repaired by unauthorized persons. Errors occurred if failed to do so may result in serious injury or death when using the equipment.
• The gas circuit elements operate under pressure; explosions may occur as a result of services provided by unauthorized persons, users may sustain serious injuries.
• It is recommended to perform technical maintenance of the machine and its auxiliary units at least once a year.

Welding In Small Sized and Confined Spaces

• In small-sized and confined spaces, absolutely make sure to perform welding and cutting operations, accompanied by another person.
• Avoid performing welding and cutting operations in such enclosed areas as much as possible.

Failure To Take Precautions During Transport May Cause Accidents

• Take all necessary precautions when moving the machine. The areas where the machine to be transported, parts to be used in transportation and the physical conditions and health of the person carrying out the transportation works should be suitable for the transportation process.
• Some machines are extremely heavy; therefore, make sure that the necessary environmental safety measures are taken when changing their places.
• If the welding machine is to be used on a platform, it must be checked that this platform has suitable load bearing limits.
• If it is to be transported by means of a haulage vehicle (transport trolley, forklift etc.), make sure of the durableness of the vehicle, and the connection points (carrying suspenders, straps, bolts, nuts, wheels, etc.) that connect the machine to this vehicle.
• If the machine will be carried manually, make sure the durableness of the machine apparatuses (carrying suspenders, straps, etc.) and connections.
• Observe the International Labor Organization's rules on carriage weights and the transport regulations in force in your country in order to ensure the necessary transport conditions.

Falling Parts May Cause Injuries

• Always use handles or carrying rings when relocating the power-supply sources.
• Never pull from torches, cables or hoses. Be absolutely sure to carry gas cylinders separately.
• Remove all interconnections before transporting the welding and cutting equipment, each being separately, lift and transport small ones using its handles, and the big ones from its handling rings or by using appropriate haulage equipment, such as forklifts.

Improper positioning of the power-supply sources or other equipment can cause serious injury to persons and physical damage to other objects.

• Place your machine on the floor and platforms with a maximum tilt of 10° so that it does not fall or tip over. Choose places that do not interfere with the flow of materials, where there is no risk of tripping over on cables and hoses; yet, large, easily ventilatable, dust-free areas. To prevent gas cylinders from tipping over, on machines with a gas platform suitable for the tanks, fix the tanks on to the platform; in stationary usage applications, fix them to the wall with a chain in a way that they would not tip over for sure.
• Allow operators to easily access settings and connections on the machine.

Excessive Use Of The Machine Causes Overheating

• Allow the machine to cool down according to operation cycle rates.
• Reduce the current or operation cycle rate before starting the welding again.
• Do not block the fronts of air vents of the machines.
• Do not put filters that do not have manufacturer approvals into the machine's ventilation ports.

Excessive Use Of The Machine Causes Overheating

This device is in group 2, class A in EMC tests according to TS EN 55011 standard. This class A device is not intended for use in residential areas where electrical power is supplied from a low-voltage power supply. There may be potential difficulties in providing electromagnetic compatibility due to radio frequency interference transmitted and emitted in such places. This device is not compliant with IEC 61000 -3-12. In case if it is desired to be connected to the low voltage network used in the home, the installer to make the electrical connection or the person who will use the machine must be aware that the machine has been connected in such a manner; in this case the responsibility belongs to the user.

Make sure that the work area complies with electromagnetic compatibility (EMC). Electromagnetic interferences during welding or cutting operations may cause undesired effects on your electronic devices and network; and the effects of these interferences that may occur during these operations are under the responsibility of the user.

If there is any interference, to ensure compliance; extra measures may be taken, such as the use of short cables, use of shielded (armored) cables, transportation of the welding machine to another location, removal of cables from the affected device and/or area, use of filters or taking the work area under protection in terms of EMC.

To avoid possible EMC damage, make sure to perform your welding operations as far away from your sensitive electronic devices as possible (100m).

Ensure that your welding and/or cutting machine has been installed and situated in its place according to the user manual.

Evaluation Of Electromagnetic Suitability Of The Work Area

According to article 5.2 of IEC 60974-9;

Before installing the welding and cutting equipment, the person in charge of the operation and/or the user must conduct an inspection of possible electromagnetic interference in the environment. Aspects indicated below has to be taken into consideration;

• a)Other supply cables, control cables, signal and telephone cables, above and below the welding machine and its equipment,
• b)Radio and television transmitters and receivers,
• c) Computer and other control hardware,
• d)Critical safety equipment, e.g. protection of industrial equipment,
• e)Medical apparatus for people in the vicinity, e.g. pacemakers and hearing aids,
• f) Equipment used for measuring or calibration,
• g)Immunity of other equipment in the environment. The user must ensure that the other equipment in use in the environment is compatible. This may require additional protection measures.
• h)Considering the time during which the welding operations or other activities take place during the day, the boundaries of the investigation area can be expanded according to the size of the building, the structure of the building and other activities that are being performed in the building.

In addition to the evaluation of the field, evaluation of device installations may also be necessary for solving the interfering effect.

In case if deemed necessary, on-site measurements can also be used to confirm the efficiency of mitigation measures. (Source: IEC 60974-9).

Electromagnetic Interference Reduction Methods

• The appliance must be connected to the electricity supply in the recommended manner by a competent person. If interference occurs, additional measures may be applied, such as filtering the network.
• The supply of the fixed-mounted arc welding equipment must be made in a metal tube or with an equivalent shielded cable. The housing of the power supply must be connected and a good electrical contact between these two structures has to be provided.
• The recommended routine maintenance of the appliance must be carried out. All covers on the body of the machine must be closed and/or locked when the device is in use. Any changes, other than the standard settings without the written approval of the manufacturer, cannot be modified on the appliance. Otherwise, the user is responsible for any consequences that may possibly occur.
• Welding cables should be kept as short as possible. They must move along the floor of the work area, in a side by side manner. Welding cables should not be wound in any way.
• A magnetic field is generated on the machine during welding. This may cause the machine to pull metal parts on to itself. To avoid this attraction, make sure that the metal materials are at a safe distance or fixed. The operator must be insulated from all these interconnected metal materials.
• In cases where the workpiece cannot be connected to the ground due to electrical safety, or because of its size and position (for example, in building marine vessel bodies or in steel construction manufacturing), a connection between the workpiece and the grounding may reduce emissions in some cases, it should be kept in mind that grounding of the workpiece may cause users to sustain injuries or other electrical equipment in the environment to break down. In cases where necessary, the workpiece and the grounding connection can be made as a direct connection, but in some countries where direct connection is not permissible, the connection can be established using appropriate capacity elements in accordance with local regulations and ordinances.
• Screening and shielding of other devices and cables in the work area can prevent aliasing effects. Screening of the entire welding area can be evaluated for some specific applications.

Arc Welding May Cause Electromagnetic Field (EMF)

The electrical current passing through any conductor generates zonal electric and magnetic fields (EMF). All welders must follow the following procedures to minimize the risk of exposure to EMF from the welding circuit;

• In the name of reducing the magnetic field, the welding cables must be assembled and secured as far as possible with the joining materials (tape, cable ties etc.).
• The welder's/worker's body and head should be kept as far away from the welding machine and cables as possible,
• Welding and electric cables should not be wrapped around the body of the machine in any way,
• The body of the machine should not get caught between the welding cables. The source cables must be kept away from the body of the machine, both being placed side by side,
• The return cable must be connected to the workpiece as close as possible to the welded area,
• The welding machine should not rest against the power unit, ensconce on it and not work too close to it,
• Welding work should not be performed when carrying the welding wire supply unit or welding power unit.

EMF may also disrupt the operation of medical implants (materials placed inside the body), such as pacemakers. Protective measures should be taken for people who carry medical implants. For example, access limitation may be imposed for passers-by, or individual risk assessments may be conducted for welders. Risk assessment should be conducted and recommendations should be made by a medical professional for users who carry medical implants.

Protection

ℹ️ ✔️ Do not expose the machine to rain, prevent the machine from splashing water or pressurized steam.

Energy Efficiency

ℹ️ Choose the welding method and welding machine for the welding work you are to perform.

⚡ Select the welding current and/or voltage to match the material and thickness you are going to weld.

ℹ️ If you have to wait for a long time before you start your welding work, turn off the machine after the fan has cooled it down. Our machines (our products) with smart fan control will turn off on their own.

Waste Procedure

ℹ️ This device is not domestic waste. It must be directed to recycling within the framework of the European Union directive and national laws.

ℹ️ Obtain information from your dealer and authorized persons about the waste management of your used machines.

1.1 General Information

Monostick 200i is an inverter type portable, mono-phase DC MMA welding machine designed to weld stick electrodes up to 4 mm. Even though the machine is mono-phase, due to the inverter technology it provides stable arc and good re-striking performance, also the electric consumption is approximately 10% less than the silicon controlled rectifier equipments and 25% less than the magnetically controlled equipments. Monostick 200i proved well that it can work between 185 to 250 V 50/60 Hz line voltages. Therefore this machine is quite immune to mains voltage fluctuations and perfectly welds with generator-sets. Monostick 200i can also be used with long welding cables up to 25 mt. The machine is fan cooled and thermally protected against over heating.

1.2 Machine Components

Figure 1: Monostick 200i

A textual description of Figure 1 showing the front and rear views of the Monostick 200i machine with numbered components.

• 1- Power Switch
• 2- Power LED
• 3- Thermic / Error LED
• 4- Current Adjustment Knob
• 5- Earth Cable and Welding Cable Socket (-)
• 6- Earth Cable and Welding Cable Socket (+)
• 7- Line Cable Inlet
• 8- Handle
• 9- Fan

1.3 Product Label

The product label displays manufacturer information, product name (MONOSTICK 200i), serial number, compliance standards (EN 60974-1 / EN 60974-10 / Class A), and technical ratings including current, voltage, and power at different duty cycle percentages (14%, 60%, 100%). It also indicates protection class (IP23S) and CE marking.

A graph illustrates the Working Cycle, showing a 10-minute period divided into a welding phase (Zone 1) and a cooling phase (Zone 2). For example, a machine rated at 250A at 60% duty cycle can weld for 6 minutes continuously within a 10-minute cycle, followed by 4 minutes of cooling.

1.4 Technical Data

1.5 Accessories

2.1 Delivery Control

To unpack your purchased welding machine to comply with truck transport regulations, carefully tear the packaging, cut the securing ring, and lift the machine off the pallet. Ensure you receive your order in full. If any material is missing or damaged, contact your place of purchase immediately.

The standard pallet includes:

• Power Source
• Electrode Holder Cable
• Earth Clamp Cable
• User Manual
• Carrying Strap
• Warranty Certificate
• User Manual

In the case of a damaged delivery, draw up a record, take a picture of the damage, and report to the transport company along with a photocopy of the delivery note. If the problem persists, contact customer service.

Symbols and their meanings on the device;

Welding process is dangerous. Proper working conditions should be ensured and necessary precautions should be taken. Specialists are responsible for the machine and have to be equipped with the necessary equipment. Irrelevant persons should be kept away from the welding area.

This device is not compatible with IEC 61000-3-12. If it is desired to connect to the low voltage mains used in homes, it is essential that the installer or the person who will operate the machine to make the electrical connection has information on the machine's connectivity. In this case, the responsibility will be assumed by the person who will perform the installation or by the operator.

The safety symbols and warning notes on the device and in the operating instructions must be observed and the labels must not be removed.

Grids are intended for ventilation. The openings should not be covered in order to provide good cooling and no foreign objects should be inserted.

2.2 Installation And Operation Recommendations

• Necessary precautions should be taken during transportation of the machine. Do not lift the machine with the gas cylinder. Place the power supply on a hard, level surface where it will not fall or tip over.
• For better performance, place the machine at least 30 cm away from surrounding objects. Pay attention to overheating, dust, and moisture around the machine. Do not operate the machine in direct sunlight. When the ambient temperature exceeds 40°C, operate the machine at a lower current or at a lower cycle rate.
• Avoid welding with wind and rain outdoors. If welding is required in such cases, protect the welding area and the welding machine with curtains and awnings.
• When positioning the machine, make sure that materials such as walls, curtains, panels, etc., do not impede easy access to the controls and connections of the machine.
• If welding inside, use a suitable smoke extraction system. Use breathing apparatus if there is a risk of inhaling welding fumes and gas indoors.
• Observe the duty cycle rates specified on the product label. Frequent exceeding of duty cycle rates can damage the machine and void the warranty.
• Use the appropriate fuse for your system.
• Connect the ground wire as close to the welding area as possible. Do not allow welding current to pass through elements other than welding cables, e.g., the machine itself, the gas cylinder, the chain, the bearing.
• When the gas cylinder is placed on the machine, immediately fasten the chain to secure the gas cylinder. If you do not place the gas cylinder on the machine, fasten it to the wall with a chain.
• The electrical outlet on the back of the machine is for the CO₂ heater. NEVER connect a device other than a CO₂ heater to the CO₂ socket!

2.3 Connections For MMA Welding

Check the mains voltage before connecting the machine to the mains. When plugging the power plug into the outlet, make sure that the power switch is set to "0" in the turned-off position.

• Switch ON the machine via power switch (1) and check if power LED (2) lights up and cooler fan works.
• According to the polarity of the electrode to be used, insert welding cables into the appropriate socket (5-6) and tighten them by turning clock-wise.
• Connect the earth clamp tightly to the workpiece as close as possible to the welding area.
• Adjust the desired current and the machine is ready to weld.

Below table is given as a reference for current adjustment of mild steel electrodes; please refer to the electrode manufacturer's recommendations.

2.4 Connections For TIG Welding

Check the mains voltage before connecting the machine to the mains. When plugging the power plug into the outlet, make sure that the power switch is set to "0" in the turned-off position.

• Start the machine with the on/off switch and check whether the LEDs are on and the cooling fan is working.
• TIG torch with a valve should be used.
• Connect the TIG torch power cable to the negative welding socket (5) and the earth cable to the positive welding socket (6) of the machine.

A textual description of Figure 2 showing TIG Welding Connections.

• Install the Argon gas regulator onto the Argon gas cylinder.
• Connect the gas hose of the torch to the gas regulator.
• Adjust the desired current and the machine is ready to weld.

A textual description of Figure 3 showing Gas Cylinder Connection.

3.1 Maintenance

Every 3 Months

• Do not remove the warning labels on the device. Replace the worn/torn labels with the new ones. Labels can be obtained from the authorized service.
• Check your clamps and cables. Pay attention to the connections and the durability of the parts. Replace the damaged/defective parts with the new ones. Do not ever make additions to/repair the cables.

Every 6 Months

• Clean and tighten fasteners such as bolts and nuts.
• Check the electrode clamp and grounding clamp cables.
• Open the side covers of the machine and clean with low pressure dry air. Do not apply compressed air to electronic components at close distance.

NOTE: The above mentioned periods are the maximum ones that should be applied if no problems are encountered in your device. Depending on the work load and contamination of your work environment, you can repeat the above processes more frequently.

3.2 Troubleshooting

• If the Thermal Protection LED (3) lights up while cooling fan is working and the machine doesn't weld; the machine may be overheated and stopped for auto protection due to overheat. Hot weather or working in high current values for long time may cause this. Let the machine run for a while in order to cool down itself with the cooling fan. After it cools enough, Thermal Protection LED (3) fades away and the machine can weld.
• When the Power LED (2) green is lighting, cooling fan is working, but the machine does not weld; turn off the machine for 1 minute, then turn it on again and try to weld. If it still doesn't weld, contact your authorized technical service.
• If the cooling fan is working but the power LED (2) color is yellow. Then the mains input is at low voltage. In this case, close the machine. Wait 30 sec. after the yellow LED is turned off. Then start the machine again. If you see the yellow LED is lighting, then check your mains input. If there is not a problem with your mains voltage, then contact your authorized technical service. If the mains voltage is low, the output current of the machine can be set to 130A maximum.

ANNEX 1 - SPARE PARTS LIST

A textual description of the diagram showing the internal components of the Monostick 200i machine.

ANNEX 2 - ELECTRICAL DIAGRAM

A textual description of the electrical schematic diagram for the Monostick 200i. The diagram shows the main power input (F, N, Ground) connected via a switch (S2, 16A) to the E201B FLT module. This module connects to the E203A PFC PWR V43 and E203A PWR V43 modules. The E203A CNT V43 module receives inputs for Voltage Sense, Relay, Power, Termic, and Fan, and outputs control signals. The front panel connections include Current, Pot, Termic, and Power. The diagram illustrates the flow of power and control signals through various electronic cards (E203A PWR, E205A-RL, E203A CNT, etc.) and components like a transformer, rectifier, and fan (M1).