Magmaweld GL 451 Инструкция по применению

GL 451

GL 600

(+90) 444 93 53

magmaweld.com

info@magmaweld.com (+90) 538 927 12 62

USER MANUAL



Magma Mekatronik may modify the information and the images without any prior notice.







3GL 451 / GL 600

WELDING INVERTER



POSTE ONDULEUR



FR

RU

TR

EN

4GL 451 / GL 600

EN

www.magmaweld.comUSER MANUAL

CONTENTS

Contents

1

1.1

1.2

1.3

1.4

1.5

2

2.1

2.2

2.3

2.4

2.5

2.6

3

3.1

3.2

4

4.1

4.2

SAFETY PRECAUTIONS

TECHNICAL INFORMATION

General Information

Machine Components

Product Label

Technical Data

Accessories

INSTALLATION

Delivery Control

Installation and Operation Recommendations

Mains Plug Connection

Connection to Mains

Welding Connections

Welding Adjustments

MAINTENANCE AND SERVICE

Maintenance

Troubleshooting

ANNEX

Spare Parts List

Connection Diagrams

5

11

12

13

14

15

16

17

18

19

5GL 451 / GL 600

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Safety Precautions

Be Sure To Follow All Safety Rules In This Manual!

• 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 / cutting they have to

read the user manual before operation and follow the safety instructions.

Explanation Of Safety

Information

• 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

 

Comprehending Safety

Precautions

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.

IMPORTANT



DANGER

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

Make certain that the installation procedures comply with national electrical standards



persons.

• Wear dry and sturdy insulated gloves and working apron. Never use wet or damaged gloves and

working aprons.

 

operator must be protective against sparks, splashing and arc radiation.

• 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,

 



 

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.



as practical.

• Check the torch before operating the machine. Make sure the torch and its cables are in good

condition. Always replace a damaged, worn torch.

• Do not touch electrode holders connected to two machines at the same time since double

 

• Keep the machine turned off and disconnect cables when not in use.

• Before repairing the machine, remove all power connections and / or connector plugs or turn

off the machine.

• Be careful when using a long mains cable.

Electric Shocks

May Kill

SAFETY PRECAUTIONS

6GL 451 / GL 600

EN

www.magmaweld.comUSER MANUAL

Safety Precautions

• Turn off the electric power.



or wires.

• Call for emergency services.



• 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.



• Treat an electrical burn as a thermal burn by applying sterile, cold (iced) compresses. Prevent

contamination, and cover with a clean, dry dressing.

Procedures for

Electric Shock

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

• Keep away from the moving parts.



closed and in locked position.

• Wear metal toe shoes against the possibility of heavy objects falling on to your feet.

• 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 / cutting process completely.



• Use a suitable fume extraction system where welding / cutting works are being carried out. If

necessary, install a system that can expel fumes and gases accumulated in the entire workshop.

 



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

 

• Do not perform welding / cutting operations in the presence of chlorinated hydrocarbon vapors

released during lubrication or painting operations.

• Some welded / cut parts require special ventilation. The safety rules of products that require

special ventilation should be read carefully. A suitable gas mask should be worn when

necessary.

Fumes and Gases

May Be Harmful To

Your Health

Moving Parts May

Cause Injuries

Make sure all connections are tight, clean, and dry.

• Keep cables dry, free of oil and grease, and protected from hot metal and sparks.

• Bare wiring can kill. Check all cables frequently for possible damage. If a damaged or an

uninsulated cable is detected, repair or replace it immediately.

• Insulate work clamp when not connected to workpiece to prevent contact with any metal

object.

• Make sure that the grounding of the power line is properly connected.

 

• Use AC output ONLY if required for the welding process.

• If AC output is required, use remote output control if present on unit.

Additional safety precautions are required when any of the following electrically hazardous

conditions are present :

• in damp locations or while wearing wet clothing,

 

• when in cramped positions such as sitting, kneeling, or lying,

• when there is a high risk of unavoidable or accidental contact with the workpiece or ground.

For these conditions, use the following equipment in order presented:

• Semiautomatic DC constant voltage (CV) MIG welding machine,

• DC manual MMA welding machine,



7GL 451 / GL 600

EN

www.magmaweld.com USER MANUAL

Safety Precautions

• Performing works such as welding / cutting, 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.

Sparks and Spattering

Particles May Get

Into Eyes and Cause

Damage

• 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.

 

 

Hot Parts May Cause

Severe Burns

 

• Protect other naked parts of your body (arms, neck, ears, etc.) with suitable protective clothing

from these rays.



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

 

Arc Light May Damage

Your Eyes and Skin

• 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.

Noise May Cause

Damage To Your

Hearing Ability

• Do not apply welding / 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 / cutting operations you will perform in

such places.

• Do not weld in tanks and pipes which might have previously contained substances that may

 

• Welding / cutting equipment heats up. For this reason, do not place it on surfaces that could

easily burn or be damaged !

• Do not point the torch towards any part of the body, other persons, or any metal while

unwrapping the welding / cutting 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 Wires Can

Cause Injuries



explosions.

• Before starting the welding / cutting work, remove these materials form the environment or cover

 

• National and international special rules apply in these areas.

Welding Operations

May Cause Fire and

Explosion

 

extinguishers tubes, water, and sand in easily accessible places.



circuits. Make sure that they are periodically inspected and pay attention that they run reliably.

• 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.

Maintenance Work



Persons To Machines

and Apparatus May

Cause Injuries

8GL 451 / GL 600

EN

www.magmaweld.comUSER MANUAL

Safety Precautions



operations, accompanied by another person.

• Avoid performing welding / cutting operations in such enclosed areas as much as possible.

• 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 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.



from torches, cables or hoses. Be absolutely sure to carry gas cylinders separately.

• Remove all interconnections before transporting the welding / 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.

Welding / Cutting in





Failure To Take

Precautions During

Transport May Cause

Accidents



 

 

 

 

way that they would not tip over for sure.

• Allow operators to easily access settings and connections on the machine.

Falling Parts May

Cause Injuries Improper positioning of the power-supply sources or other equipment can cause serious injury

to persons and physical damage to other objects.

• Allow the machine to cool down according to operation cycle rates.

• Reduce the current or operation cycle rate before starting the welding / cutting again.

• Do not block the fronts of air vents of the machines.



Excessive Use Of The

Machine Causes

Overheating

Excessive Use Of The

Machine Causes

Overheating



• This class A device is not intended for use in residential areas where electrical power is supplied

 

compatibility due to radio frequency interference transmitted and emitted in such places.

• Make sure that the work area complies with electromagnetic compatibility (EMC).

Electromagnetic interferences during welding / 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

 

the work area under protection in terms of EMC.

• To avoid possible EMC damage, make sure to perform your welding / cutting operations as far

 



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.

9GL 451 / GL 600

EN

www.magmaweld.com USER MANUAL

Safety Precautions

• Ensure that your welding and/or cutting machine has been installed and situated in its place

according to the user manual.



Before installing the welding / 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

/ cutting 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 / cutting 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.









• The appliance must be connected to the electricity supply in the recommended manner by a

 

 

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

 

possibly occur.



the work area, in a side by side manner. Welding / cutting cables should not be wound in any

way.



machine to pull metal parts on to itself. To avoid this attraction, make sure that the metal

 

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

 

applications.

Evaluation Of

Electromagnetic

Suitability Of The

Work Area

Electromagnetic

Interferance

Reduction Methods



(EMF).

All operators must follow the following procedures to minimize the risk of exposure to EMF;



secured as far as possible with the joining materials (tape, cable ties etc.).

• The operator’s body and head should be kept as far away from the welding / cutting machine

and cables as possible,

Electromagnetic Field

(EMF)

10 GL 451 / GL 600

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Safety Precautions

• Choose the welding / cutting method and welding machine for the welding work you are to

perform.

• Select the welding / cutting current and/or voltage to match the material and thickness you are

going to weld.

• If you have to wait for a long time before you start your welding / cutting work, turn off the machine

after the fan has cooled it down. Our machines with smart fan control will turn off on their own.

• This device is not domestic waste. It must be directed to recycling within the framework of the

European Union directive and national laws.

• Obtain information from your dealer and authorized persons about the waste management of

your used machines.

Waste Procedure



(EMF).

All operators must follow the following procedures to minimize the risk of exposure to EMF;



secured as far as possible with the joining materials (tape, cable ties etc.).

• The operator’s body and head should be kept as far away from the welding / cutting machine

and cables as possible,

• Welding / cutting 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 / cutting 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 work area,

• The welding / cutting machine should not rest against the power unit, ensconce on it and not

work too close to it,

• Welding / cutting work should not be performed when carrying the wire supply unit or 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



conducted for welders. Risk assessment should be conducted and recommendations should be

made by a medical professional for users who carry medical implants.

• Do not expose the machine to rain, prevent the machine from splashing water or

pressurized steam.

Protection



WARRANTY FORM

Please visit our website www.magmaweld.com/warranty-form/wr for warranty form.

11GL 451 / GL 600

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123

4

5

6

4

6

7

1- Power Switch 5- Current Adjustment Indicator

2- Lifting Eye 6- Wheel

3- Current Adjustment Lever 7-

4- Handle

TECHNICAL INFORMATION

1.1 General Information







current adjustment is made by just turning the lever on top of the machine clockwise or counter clockwise

and adjusted value of the current is observed by the scale in front of the machine. Although it is not an

    

low. Since there is no electronics involved, the machine can perform great at dusty, humid, corrosive, very

hot and very cold environments. With its telescopic arms and big wheels it can be pulled easily across the

working area especially at outdoor welding sites. The machine is fan cooled and thermally protected against

overheating and phase failures.

Figure 1 : GL 451

1.2 Machine Components

Technical Information

12 GL 451 / GL 600

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1.3 Product Label







4 minutes should be kept idle for the machine cool down (zone 2).

Duty Cycle



6 min. 6 min.6 min.4 min. 4 min. 4 min. Time (min.)

Duty Cycle

Open Circuit Voltage

Rated Welding Current

Mains Voltage and Frequency

Protection Class

Rated Welding Voltage

Rated Power

Rated Mains Current

X

U

I

U

IP22S

U

S

I



Direct Current

MMA Welding

Vertical Characteristic



Suitable for Operation at Hazardous

Environments

Technical Information

13GL 451 / GL 600

EN

www.magmaweld.com USER MANUAL

Technical Information

1.4 Technical Data

UNIT

1.5 Accessories

V

VDC

kVA

mm

ADC

kg

mm

STANDARD ACCESSORIES

Workpiece Clamp and Cable

Electrode Clamp and Cable

QTY

1









GL 600

GL 451

OPTIONAL ACCESSORIES

Carbon Gouging Clamp

QTY

1

GL 600GL 451





73



27







228

IP 22S





72



35







244

IP 22S

TECHNICAL DATA



Stick Electrode Diameter Range

Largest Carbon Electrode Diameter

Welding Current Range

Protection Class

Rated Power

Dimensions (l x w x h)



Weight

Open Circuit Voltage

14 GL 451 / GL 600

EN

www.magmaweld.comUSER MANUAL

INSTALLATION

2.1 Delivery Control

Make sure that all the materials you have ordered have been received. If any material is missing or damaged,

contact your place of purchase immediately.

The standard box includes the following;

 

• Workpiece clamp and cable • User manual

• Electrode clamps and cable

In case of a damaged delivery, record a report, take a picture of the damage and report to the transport

company together with a photocopy of the delivery note. If the problem persists, contact the customer service.

2.2 Installation and Operation Recommendations



to overheating, dust and moisture near the machine.



machine at a lower current or a lower duty cycle.

• Avoid welding outdoors in windy and rainy weather circumstances. If welding is necessary in such cases,

protect the welding area and the welding machine with a curtain and canopy. If you weld indoors, use a

suitable fume extraction system. Use breathing apparatus if there is a risk of inhaling welding fumes and gas

 



machine and this may invalidate the warranty.

• Use the fuse that is compliant with your system.

• Secure the ground cable as close as possible to the welding area.

• Do not allow the welding current to pass through equipment other than the welding cables.

• Secure the gas cylinder to the wall with a chain.

• The welding cables and the mains cable must not be wrapped in the machine housing during operation.

Symbols and their meanings on the device

Welding may be 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 and those who are not relevant should be kept away from the welding area.



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.

Installation

15GL 451 / GL 600

EN

www.magmaweld.com USER MANUAL

2.3 Mains Plug Connection

For your safety, never use the mains cord of the machine without a plug.

• No plug has been connected to the mains cable since there may different types of outlets available in plants,

 

the grounding cable marked with and a yellow / green color is present.

• After connecting the plug to the cable, do not attach it to the outlet at this stage.

Installation



 

plug into the wall outlet.

• Start the machine with the on / off switch.



after hearing the fan sound and seeing the ammeter and voltmeter

lights are on.

Figure 2 : Mains Connection

2.4 Connection to Mains

When plugging the power plug into the outlet, make sure that the power switch is set to “0”.

• According to the electrode to be used, insert the welding cables, with

correct polarity into the welding and earth cable sockets and tighten

 

• Connect the earth clamp tightly to the workpiece as close as possible

to the welding area.

• By turning the current adjustment lever clockwise, current is

increased. Approximate value of the adjusted current can be read on

the corrent adjustment indicator.

• 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.

Figure 3 : Welding Cable Sockets

Figure 4 : Current Adjustment Lever

2.5 Welding Connections

2.6 Welding Adjustments

Rutile Basic Cellulosic



2.5

3.25









































Diameter (mm)

16 GL 451 / GL 600

EN

www.magmaweld.comUSER MANUAL

Never operate the machine when covers are open.

MAINTENANCE AND SERVICE



be responsible for any accidents that may occur by unauthorized interventions.

• Parts that will be used during repair can be obtained from our authorized services. The use of original spare

parts will extend the life of your machine and prevent performance losses.

• Always contact the manufacturer or an authorized service designated by the manufacturer.

• Never make interventions yourself. In this case the macufacturer warranty is no langer valid.

• Always comply with the applicable safety regulations during maintenance and repair.

• Before performing any work on the machine for repair, disconnect the machine’s power plug from the power

 

3.1 Maintenance

Daily Maintenance

• 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 torch, clamps and cables. Pay attention to the connections and the

durableness of the parts. Replace the damaged/defective parts with the new ones.

Do not ever make additions to/repair the cables.

• Ensure adequate space for ventilation.



 

process.

• 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.

• Check the socket to which the power supply plug of the machine is connected. If

there is any looseness in the power cable connection points of the socket, remove

such looseness. If there is an arc or expansion in the socket slots, replace them with

new ones.

• Check the power supply plug of the machine. If there is any looseness in the power

cable connection points in the electricity plug, remove such looseness. If there is an

arc or deformation at the ends of the plug, replace it with a new one.

or

Every 6 Months

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.

Maintenance and Service

17GL 451 / GL 600

EN

www.magmaweld.com USER MANUAL

3.2 Troubleshooting

The following tables contain possible errors to be encountered and their solutions.

• Phase failure

• No neutral line

• Fuse blown out

Machine does not work

• Phase failure

• Diode unit breakdown

• Primary or secondary coil born down

Welding current is low

• Fan supply voltage phase failure

• Fan motor break down

Fan is out of order

Error Solution

Maintenance and Service

18 GL 451 / GL 600

EN

www.magmaweld.comUSER MANUAL

DEFINITIONNO

Cooling Ventilator

Gray Cast Iron

Secondary Coil

Chain Wheel

Primary Coil

On / Off Switch

EMC Filter

Contactor

Current Adjustment Shaft (Long)

Welding Socket

Chain

Diode Group

Current Adjustment Shaft (Short)

Plastic Wheel

Ampere Scale

1

8

4

11

7

14

15

2

9

5

12

3



6

13

GL 600GL 451

























































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ANNEX

4.1 Spare Parts List

Annex

19GL 451 / GL 600

EN

www.magmaweld.com USER MANUAL

Electrode Clamp

R

S

T

Line Filter Contactor Main Transformer Secondary Recti�ier Output Shock

Workpiece

Annex

4.2 Connection Diagrams

Block Diagram

20 GL 451 / GL 600

EN

www.magmaweld.comUSER MANUAL

Annex

Circuit Diagram

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Magmaweld GL 451 Инструкция по применению

Magmaweld GL 451 Инструкция по применению

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