P R O D U C T C A T A L O G U EW E L D I N G A N D P L A S M A C U T T I N G A U T O M A T I O N

07/2013

www.magmaweld.com

automation

Leading the way in many respects in this context in Turkey, our company continues to be the welders' most reliable assistant and manufacturers' trouble-free income source with its new products like the latest Cored Wires and high strength Magma Sepet. All our products are inspected according to international and national standards and many products are certified and periodically inspected by international and national certification bodies like CE, TV, DB, CWB, ABS, BV, RINA, DNV, GL, LR, RMR and TL in line with the market requirements. A welder is competent for his duty and welding is an art. Functionality of the electrode and of the welding machine is not to create problems for the welder. While the young Magmaweld works with innovative solutions as an apprentice for the welder in uninterrupted welding, it also fulfils its social responsibilities by means of the year-round welders' courses it opens and by material and training support it provides for many training establishments by making use of the knowledge accumulation and experience of more than half a century of Oerlikon.Magmaweld is a brand offering uninterrupted welding solutions by means of its past experience and by innovative, environment-friendly and energy efficient products. Main target of Magmaweld is to allow welders to have break only when they desire to do so. It is always easy to contact with Magmaweld, Magmaweld products are readily available everywhere, an authority to solve your problems is always available at Magmaweld, you receive affordable and fast after-sale services.

NON STOP WELDING & CUTTINGWelders desire their welding electrodes and machines not to let them down while they carry out their art while factories desire their production to be maintained uninterruptedly. Based on this awareness, we have redefined the Welder's Confidence Source in a much larger scope in order to meet requirements of welders.

We have brought a new energy to the world of welding by combining our Magmaweld brand, which we have created based on the inspiration of resemblance between the welding arc and the natural energy source of MAGMA at the core of our planet, with our strong arc technologies of many years. Even though Magmaweld is a young brand, the background of experience and knowledge behind it dates back to 1957. During those years, Oerlikon Kaynak Elektrodlar ve Sanayi A.. had started production of coated electrode by the license obtained from the Swiss based Oerlikon Schweisstechnik AG, and without being satisfied with this, it constantly developed new products by means of the R&D unit it had established and eventually put an end to the technological dependence on foreign sources years ago. Our factories today have a full knowledge of formulation and production technologies of all welding consumables like coated electrodes, cored wires and submerged arc welding powders and welding machines technologies, in addition to this they constantly develop and include in our production program ever new products in line with the developments in the welding industry.

Welding Consumables FactoryOrganize Sanayi Blgesi 2. Ksm - MANSA

Welding Machines and Automation FactoryOrganize Sanayi Blgesi 5. Ksm - MANSA

www.magmaweld.com

CONTENTS

automation

COLUMN - BOOM SYSTEMS

CBS-2 CBS-3 CBS-4 CBS-5 Column-Boom system Examples

TURNING BEARINGS

CRD / CRI 5 T CRD / CRI 10 T CRD / CRI 15 T CRD / CRI 30 T CRD / CRI 60 T CRD / CRI 100 T CRD / CRI 120 T

BIAXIAL AC POSITIONER

HR500 HR1000 HR3000 HR5000

LINEAR WELDING SYSTEMS

MLW-07 MLW-10 MLW-13 MLW-16 MLW-19 MLW-25 MLW-30

CIRCULAR WELDING SYSTEMS

LSP-60

LSP-130

CNC CUTTING STANDS

MAGMACUT DD MAGMACUT COMPACT HPR130XD (PLASMA POWER SOURCES) HPR260XD (PLASMA POWER SOURCES) HPR400XD (PLASMA POWER SOURCES) POWERMAX45 PLASMA CUTTING MACHINE POWERMAX65 PLASMA CUTTING MACHINE POWERMAX85 PLASMA CUTTING MACHINE POWERMAX105 PLASMA CUTTING MACHINE

1

1

112

1

3

3

333

3

4

4

44

4

33

5

5

555

5

6

6

7

8

9

910

101010101010

55

1COLUMN-BOOM SYSTEMS MODEL: CBS

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Magma (Light Series) Column & Boom Systems (CBS), offer an alternative solution to circular and linear welding operations. It enables the opportunity for high and long range welding applications. The column can rotate 360o around its own axis. Therefore, it provides a complete circular control over the process.

Movements along the axis are controlled by limit switches. All the cables are protected by cable tubes. Boom movement is balanced with a counter weight. Vertical axis boom movements are supported by highly secured chain and gear.

Column & Boom System Options: Movement on rail sliding system Welding line tracking system Powder collection and air drying units for subarc welding systems Boom end operator seat

Technical Features

Models

Effective Working Length

Boom Height (A) Rail Motion

Boom Height (A) With Fixed Platform

Boom Elongation (B)

Total Height (C) Rail Motion

Boom Linear Motion Speed (max.)

Application Areas Wind Turbine Fabrications Pressure Tank Manufacturing Pipe Production Lines

Boom Front End (max.)

Boom Rear End (max.)

Amount of Load

CBS 3x3 CBS 4x4 CBS 5x5

m

mm

mm

mm

mm

Total Height (C) With Fixed Platform mm

Lifting Speed m/min

Kg

m/min

Fixed Platform

Movable Platform on Rail

3 4 5

1120-4120 1120 -5120 1120-6120

970-3970 970-4970 970-5970

945-3945 945-4945 945-5945

5440 6440 7440

200 150 100

200 150 100

5300 6300 7300

2 2 2

2 2 2

COLUMN-BOOM SYSTEM EXAMPLES

2

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Welding on Roller and Support Circular and Axial Internal Welding

Circular and Vertical Welding on Turning Table Circular and Axial External Welding

Welding on Positioner Double Torch Welding

TURNING BEARINGS

Magma rotator bearings are designed such as to endure severe working conditions to turn work pieces weighing from 5 tons to 120 tons. Polyurethane coated rollers are used in all models. Thus, vibrations likely to occur during the process are avoided. Rail skid systems and manual or motorized roller inter-distance adjustment options are offered optionally along with the rotator bearings based on requirements. They are suitable for use especially in the manufacturing fields like pressure vessels, pipes and wind turbines.

3

MODEL: CRD / CRI and SRD / SRI

automation

CRD

CRI

SRD

SRI

Technical Features

Model

CRD / CRI 5T

CRD / CRI 10T

Supporting Capacity per Bearing

(tons)

2.5

5

Rotator Material

PU

PU

Min. Work Piece Dia.(mm)

165

165

Max. Work Piece Dia.(mm)

4250

4250

Tangential Speed(mm/min.)

62 - 618

102 - 1020

CRD / CRI 15T

CRD / CRI 30T

7.5

15

PU

PU

225

469

5000

7500

114 - 1137

130 - 1300

CRD / CRI 60T

CRD / CRI 100T

30

50

PU

PU

469

469

7500

7500

130 - 1300

130 - 1300

CRD / CRI 120T 60 PU469 7500 130 - 1300

SRD / SRI 5T 2.5 PU500 4500 130 - 1300

SRD / SRI 10T

SRD / SRI 15T

5

7.5

PU

PU

500

500

4500

4500

130 - 1300

130 - 1300

SRD / SRI 30T

SRD / SRI 60T

15

30

PU

PU

500

900

4500

6100

130 - 1300

130 - 1300

SRD / SRI 120T 60 PU1000 7800 130 - 1300

SRD / SRI 100T 50 PU1000 7800 130 - 1300

Magma HR positioner systems are designed to position work pieces weighing from 500 kg to 5000 kg on two axes. Pivoting and forward and backward motion of the table is easily achieved by means of a 6 m long cable remote control. T slots are provided on the table for ease of mounting.

BIAXIAL AC POSITIONER MODEL: HR

4

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Technical Features

Model

Maximum Loading Capacity

Turning Torque

kg

Nm

HR500

500

1500

HR1000

1000

3000

HR3000

3000

9000

HR5000

5000

15000

Tilting Torque

Eccentricity

Nm

mm

1500

300

3000

300

9000

300

15000

300

Centre of Gravity

Turning Speed

mm

mm/min

300

0.13-1.30

300

0.13-1.30

300

0.13-1.30

300

0.13-1.30

Tilting Angle degrees 0-135 0-135 0-135 0-135

Tilting Speed sec 41 70 60 113

Turning Motor

Tilting Motor

KW

KW

0.37

0.55

0.55

0.75

1.10

1.50

1.50

2.20

Power Supply

Voltage of Control

3 phase

V AC

380/400

24

380/400

24

380/400

24

380/400

24

Table Diameter ( D) mm 720 920 1220 1500

Weight kg 740 1000 1500 2750

External Dimensions (WxLxH) mm 860 x 1260 x 960 1100 x 1350 x 1000 1340 x 1620 x 1200 1540 x 1720 x 1250

L

H

LINEAR WELDING SYSTEMS MODEL: MLW

Magma Linear welding systems are designed for butt joining of bended or flat plate sheet metals by means of linear joining by MIG/MAG or TIG welding methods. Uniform high quality welding seams are obtained in a trouble-free and continuous manner by means of this excellent design combined with Oerlikon's experience in welding. The compact-structured system is very easy to use. Speed of the torch assembly moving on the precision-machined skid system can be adjusted and the assembly can pneumatically move upwards and downwards. Copper shoes are used in the system to remove the heat generated during welding and optional water cooling system is offered as well. The system has the advantage of receiving service from a single company as Magmaweld brand welding machines and equipment are used in the system. The entire system is covered by Oerlikon warranty.

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automation

Technical Features

Model

Length of Weld

Material Thickness

mm

mm

MLW-07

700

Minimum Piece Diameter ( D)

Maximum Piece Diameter ( C)

mm

mm

67

Torch Precision

Weld Speed

mm

mm/min

External Dimensions (WxLxH) mm

MLW-10

1000

86

MLW-13

1300

108

MLW-16

1600

1-6

133

770

0.1

Precisely adjustable between 100 to 1000.

MLW-19

1900

152

MLW-25

2500

184

MLW-30

3000

800x1500x1750 800x1800x1750 800x2100x2350 800x2350x1750 900x2750x1850 900x3250x1850 1100x4200x2000

241

WL

6automation

Technical Features

Turning Speed

Tilting Angle

0.15-1.50

Table Diameter

Distance Between Table and Centre

320

Max. Diameter of Work Piece Accepted

Max. Welding Curent

External Dimensions (WxLxH) 325 x 1100 x 675

* V/H: Vertical / Horizontal

300

300

420

0-90

Max. Loading Capacity (V/H)* 60/30

CIRCULAR WELDING SYSTEMS MODEL: LSP-60

rpm

degrees

mm

mm

mm

A

mm

kg

Magma circular welding systems are designed to join circular parts in various positions by means of MIG/MAG and TIG welding methods. Uniform high quality welding seams are obtained in a trouble-free and continuous manner by means of this excellent design combined with Oerlikon's experience in welding. The compact-structured system is very easy to use. The system, which offers possibility of welding the work piece in various positional angles through its flexible structure, is excellently user friendly with its torch that can be fixed in any desired position and with its turning speed that can be precisely adjusted. The work piece is tightened pneumatically and all necessary safety measures are taken. The system has the advantage of receiving service from a single company as Magmaweld brand welding machines and equipment can be used in the system. The entire system is covered by Oerlikon warranty.

L

W

* V/H: Vertical / Horizontal

7

automation

Technical Features

Turning Speed

Tilting Angle

d/dk

derece

0.15-1.50

Table Diameter

Distance Between Table and Centre

mm

mm

320

Max. Diameter of Work Piece Accepted

Max. Welding Curent

mm

A

External Dimensions (WxLxH) mm 900 x 1300 x 1350

350

300

660

0-90

Max. Loading Capacity (V/H)* kg 130

Magma circular welding systems are designed to join circular parts in various positions by means of MIG/MAG and TIG welding methods. Uniform high quality welding seams are obtained in a trouble-free and continuous manner by means of this excellent design combined with Oerlikon's experience in welding. The compact-structured system is also very easy to use. The system offers possibility of welding of the work piece in 7 different angles from horizontal position to vertical position. The system, which offers possibility of welding the work piece in various positional angles through its flexible structure, is excellently user friendly with its torch that can be fixed in any desired position and with its turning speed that can be precisely adjusted. The work piece is tightened pneumatically and all necessary safety measures are taken. The system has the advantage of receiving service from a single company as Magmaweld brand welding machines and equipment can be used in the system. The entire system is covered by Oerlikon warranty.

CIRCULAR WELDING SYSTEMS MODEL: LSP-130

8automation

Magma CNC cutting tables have a robust, easy to use structure with a long service life suitable for severe working conditions. Double-drive bridge system is used for a high precision. High precision is guaranteed by using low vacuolar planetary gear reducers along with Mitsubishi AC servo motors and drivers which operate by rack and pinion system. Linear skid is used for transversal motion and train rail system is used for longitudinal motion (only in DD series). Cutting quality and cutting precision is procured by using the best-of-class Hypertherm plasma power supplies and Hypertherm equipment in our systems. (Automatic torch height control and starting height detection with Hypertherm ArcGlide THC, magnetic torch impact prevention system with Hypertherm ArcGlide Breakaway Kit, Hypertherm CNC system ...etc.)

MAGMACUT DD Series

MAGMACUT COMPACT Series

CNC CUTTING TABLES

automation

CNC Unit: Microsoft Windows XP embedded 15 LCD touch-screen Intel 2.5 GHz or greater 1GB RAM 80 GB or greater RS232, RS485, RS422, Ethernet LAN, Hypernet or Usb Ports Feature of locating the point of stoppage in case of a power interruption More than fifty ready-to-cut shapes Automatic kerf adjustment possibility Possibility of simulation on screen prior to cutting Possibility to directly cut the drawings prepared by AutoCad With Hypertherm True Hole technology support

Hypertherm PRONEST Piece Layout Software: Effective automatic and manual shape layout feature Feature of cutting precise holes with Hypertherm True Hole technology Feature of automatic cutting direction, sorting and tool orientation Automatic assignment of material based input and output User defined material database and plate list composition Input/output position arrangement possibility in the layout Interactive and automatic plate breakdown feature Automatic piece and production cost calculation feature User defined material database and plate listcomposition

Technical Features

Type of Stand MAGMACUT DD MAGMACUT COMPACT

Model

Net Cutting Width (mm)

Net Cutting Length (mm)

Rail Span (mm)

Total Width Including the Board (mm)

Total Length (mm)

Heigth (mm)

Maximum Idle Speed (mm/min)

Total Width Excluding the Board (mm)

3000DD 4000DD 1500x3000 2000x40002500DD

3000 4000 1500 20002500

2 m and Multiples

Length of Stand + 2300 mm

3000 4000

4120 5120 2300 27043620

5035 6035 Mobile Board4535

4340 5340 2500 29043840

3865 4895

2520 1582

12000

9

CNC CUTTING TABLES

Technical Features

Models

Black Sheet Cutting Capacity

Without Burr (mm)

Production Drilling (mm)

Separation Edge Starts (mm)

HPR260XD(30-260 Amp)

HPR400XD(30-400 Amp)

HPR130XD(30-130 Amp)

32 3816

38 5032

Stainless Sheet Cutting Capacity

Production Drilling (mm)

Separation Edge Starts (mm)

32 4520

50 8025

Aluminium Sheet Cutting Capacity

Production Drilling (mm)

Separation Edge Starts (mm)

25 3820

50 8025

64 8038

Technical Features

Models

Suggested (mm)

Separation Edge Starts (mm)

Powermax65(20-65 Amp)

Powermax85(25-85 Amp)

Powermax105(30-105 Amp)

Powermax45(20-45 Amp)

19 25 3212

25 32 3819

Mechanised Drilling Capacity (mm) 12 16 2210

32 38 5025

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10

PLASMA POWER SUPPLIES FOR CNC CUTTING MACHINES

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NOTES

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NOTES

07/2013

www.magmaweld.com

Organize Sanayi Blgesi Manisa, Turkey

sales@magmaweld.com

+90 236 226 26 88

+90 236 226 26 89

@