MAC TOOLS MW15O Bedienungsanleitung

June

1992

Form:

OM-154

500

Effective

With

Serial

No.

KC256471

MW15O

''\~7

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

this

manual,

with

special

emphasis

the

safety

material

throughout

the

manual,

before

installing,

operating,

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

operation

welding

equipment.

not

allow

untrained

persons

install,

operate,

maintain

this

unit.

Contact

your

distributor

you do

not

fully

understand

these

instructions.

1~oLsﬁ

coven

5/92*

ST-155

63

PRINTED

USA

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

call

attention

and

identify

different

levels

hazard

and

special

instructions.

WARNING

statements

identify

procedures

practices

which

must

followed

avoid

serious

personal

injury

loss

life.

CAUTION

statements

identify

procedures

practices

which

must

followed

avoid

minor

personal

injury

damage

this

equipment.

~

IMPORTANT:

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

this

equipment.

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

severe

burns.

The

electrode

and

work

circuit

electrically

live

whenever

the

output

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

on.

semiautomatic

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live,

Incorrectly

installed

improperly

grounded

equipment

hazard.

not

touch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

covers.

Disconnect

input

power

stop

engine

before

installing

servicing

this

equipment.

Properly

install

and

ground

this

equipment

according

its

Owners

Manual

and

national,

state,

and

local

codes.

Turn

off

all

equipment

when

not

use.

not

use

worn,

damaged,

undersized,

poorly

spliced

cables.

not

wrap

cables

around

your

body.

Ground

the

workpiece

good

electrical

(earth)

ground.

not

touch

electrode

while

contact

with

the

work

(ground)

circuit.

11.

Use

only

well-maintained

equipment.

Repair

replace

damaged

parts

once.

12.

Wear

safety

harness

prevent

falling

working

above

floor

level.

13.

Keep

all

panels

and

covers

securely

place.

WARNING

ARC

WELDING

can

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

welding,

most

jobs,

exposure

certain

hazards

occurs.

Welding

safe

when

precautions

are

taken.

The

safety

information

given

below

only

summary

the

complete

safety

information

that

will

found

the

Safety

Standards

listed

the

page.

Read

and

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

QUALIFIED

PEOPLE.

to.

/~,.

ARC

RAYS

can

burn

eyes

and

skin;

Wear

welding

helmet

fitted

with

proper

shade

filter

(see

NOISE

can

damage

hearing.

ANSI

Z49.1

listed

Safety

Standards)

protect

yourface

and

eyes

when

welding

watching.

Arc

rays

from

the

welding

process

produce

intense

Wear

approved

safety

glasses.

Side

shields

recommended.

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

Use

protective

screens

barriers

protect

others

from

flash

and

skin.

Noise

from

some

processes

can

damage

and

glare;

warn

others

not

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

Use

approved

ear

plugs

ear

muffs

noise

level

high.

FUMES

AND

GASES

can

hazardous

Work

confined

space

only

well

ventilated,

while

your

health.

wearing

air-supplied

respirator.

Shielding

gases

used

for

Welding

produces

fumes

and

gases.

Breathing

these

welding

can

displace

air

causing

injury

death.

sure

the

fumes

and

gases

can

hazardous

your

health,

breathing

air

safe.

a_a.

not

weld

locations

near

degreasing,

cleaning,

spraying

Keep

your

head

out

the

fumes.

not

breath

the

fumes.

operations.

The

heat

and

rays

the

arc

can

react

with

vapors

form

highly

toxic

and

irritating

gases.

inside,

ventilate

the

area

and/or

use

exhaust

the

arc

remove

welding

fumes

and

gases.

not

weld

coated

metals,

such

galvanized,

lead,

ventilation

poor,

use

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

removed

from

the

Read

the

Material

Safety

Data Sheets

(MSDSs)

and

the

weld

area,

the

area

well

ventilated,

and

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

air-supplied

respirator.

The

coatings

and

any

metals

and

cleaners,

containing

these

elements

can

give

off

toxic

fumes

welded.

ERRATA

SHEET

.ApriI22,

1993

FORM:

OM-154

500

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

NOTE

This

unit

now

equipped

with

running

gear

and

has

been

renamed

the

MW1

50K.

CHANGES

SECTION

2INSTALLATION

Add

Figure

2-2A.

Installing

Safety

Chain,

Section

2-2.

Installing

Gas

Supply

Cylinder

Bracket

Shipped

S-Nook

Crimp

between

small

hole

bracket

and

chain.

Chain

Snap

Crimp

onto

open

end

chain.

Cylinder

Bracket

For

Large

Gas

Cylinder

Gas

Fitting

Tools

Needed:

ST-160

791

CHANGES

SECTION

PARTS

LIST

Change

Parts

List

follows:

Part

No.

Replaced

With

Description

12-37

137

800

157

044

Circuit

Card,

(Eft

w/KD352528)

12-

154

005

Deleted

Eff

w/KD407671

12-53

147

578

152

872

Base,

(Eff

w/KD407671)

12-

Added

156

339

Bottle

Retainer,

(Effw/KD407671)

12-

Added

602 389

Hook,

(Effw/KD407671)

12-

Added

156

340

Chain,

(Eff

w/KD407671)

12-

Added

602

384

Snap,

Chain

(Eff

w/KD407671)

12-

Added

147893

Axle,

(Effw/KD407671)

12-

Added

090 693

Wheel,

(Eff

w/KD407671)

12-

Added

602250

Washer,

.750

(Effw/KD407671)

12-

Added

121

614

Retaining

Ring,

(Effw/KD407671)

12-

Added

109

318

Caster,

2.500

(Eff

w/KD407671)

**First

digit

represents

page



digits

following

dash

represent

item

no.

SURE TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Figure

2-2A.

Installing

Safety

Chain

WELDING

can

cause

fire

explosion.

Sparks

and

spatter

fly

off

from

the

weldin9

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

electrode

orwelding

wire

metal

objects

can

cause

sparks,

overheating,

fire.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

all

flammables

within

(10.7

the

welding

arc.

this

not

possible,

tightly

cover

them

with

approved

covers.

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

through

small

cracks

and

openings

adjacent

areas.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

welds

cool,

they

can

throw

off

slag.

CYLINDERS

can

explode

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

damaged,

cylinder

can

explode.

Since

gas

cylinders

are

normally

part of

the

welding

process,

sure

treat

them

carefully.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

Install

and

secure

cylinders

upright

position

chaining

them

stationary

support

equipment

cylinder

rack

prevent

falling

tipping.

Watch

for

fire,

and

keep

fire

extinguisher

nearby.

aware

that

welding

ceiling,

floor,

bulkhead,

partition

can

cause

fire

the

hidden

side.

not

weld

closed

containers

such

tanks

drums.

Connect

work

cable

the

work

the

welding

area

practical

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

not

use

welder

thaw

frozen

pipes.

Remove

stick

electrode

from

holder

cut

off

welding

wire

contact

tip

when

not

use.

11.

Wear

oil-free

protective

garments

such

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

cap.

Wear

approved

face

shield

safety

goggles.

Side

shields

recommended.

Wear

proper

body

protection

protect

skin.

Keep

cylinders

away

from

any

welding

other

electrical

circuits.

Never

allow

welding

electrode

touch

any

cylinder.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

good

condition.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

Keep

protective

cap

place

over

valve

except

when

cylinder

use

connected

for

use.

Read

and

instructions

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

Safety

Standards.

PRINCIPAL

SAFETY

STANDARDS

Safety

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd.

Miami

33126

Safetyand

Health

Standards,

OSHA

CFR

1910,

from

Superintendent

Documents,

U.S.

Govemmerit

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

Containers

That

Have

Held

Hazardous

Substances,

American

Welding

Society

Standard

AWS

F4.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd, Miami,

FL 33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

Safe

Handling

Compressed

Gases

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501.

Arlington,

22202.

Code

for

Safety

Welding

and

Cutting,

CSA

Standard

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

P3.

Safe

Practices

For

Occupation

And

Educat

lanai

EyeAnd

Face

Protection,

ANSI

Standard

Z87.

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

TABLE

CONTENTS

SECTION



SPECIFICATIONS

1.1.

Volt-Ampere

Curve

And

Duty

Cycle

Chart

SECTION

INSTALLATION

2-1.

Installing

Work

Clamp

2-2.

Installing

Gas

Supply

2-3.

Gun

Polarity

For

Wire

Type

Installing

Welding

Gun

Connecting

Input

Power

Threading

And

Feeding

Welding

Wire

SECTION

MAINTENANCE

TROUBLESHOOTING

4-1.

Thermal

Overload

Protection

4-2.

Overload

Protection

4-3.

Drive

Assembly

Maintenance

4-4.

Gun

Maintenance

4-5.

Troubleshooting

SECTION

5

ELECTRICAL

DIAGRAMS

SECTION

6

PARTS

LIST

Figure

6-i.

Main

Assembly

Figure

6-2.

GA-i

Gun

10.

2-4.

2-5.

2-6.

SECTION

3OPERATION

SECTION



SPECIFICATIONS

Table

1-1.

Welding

Power

Source

Specification

Description

Type

Output

Direct

Current/Constant

Voltage

(DCICV)

Rated

Weld

Output

120

Amperes,

Volts

DC,

30%

Duty

Cycle

Type

Input

Power

Single-Phase;

Hz;

230

Volts

Input

Amperes

Rated

Output

20A

KVAIKW

Used

Rated

Output

4.7

kVN3.9

Max.

Open-Circuit

Voltage

Volts

Control

Circuit

Voltage

Gun

Volts

Welding

Processes

Gas

Metal

Arc

(GMAW)

And

Flux

Cored

Arc

Welding

(FCAW)

Speed

Range

690

(1.2

17.5

mpm)

Wire

Diameter

Range

.023

.035

in.

(0.58

0.89

mm)

Overall

Dimensions

Length:

in.

(686

mm);

Width:

in.

(305

mm);

Height:

22-1/2

in.

(571

mm)

Weight

Net:

117

lbs.

(53

kg);

Ship;

120

lbs.

(54

kg)

Welding

Gun

Rated

Output

(Air

Cooled)

160

Amperes

60%

Duty

Cycle

Using

CO2

Shielding

Gas

Cable

Length

ft.

rn)

1-1.

Volt-Ampere

Curve

And

Duty

Cycle

Chart

SING

GUN

BEYOND

DUTY

CYCLE

RATING

can

damage

gun.



not

use

gun

beyond

rated

amperage

when

using

CO2

shielding

gas.



Use

gun

30%

duty

cycle

when

using

mixed

shielding

gas.

~am8

10/91

~

The

volt-ampere

curves

show

the

minimum

and

maximum

voltage

and

amperage

output

capabilities

the

welding

power

source.

Curves

other

settings

fall

tween

the

curves

shown.

Duty

cycle

how

long

the

unit

can

operate

within

ten

minute

period

without

causing

overheating

damage.

This

unit

rated

30%

duty

cycle

~..

~2L

s.....

allowing

welding

minutes

out

every

minutes.

200

This

gun

rated

60%

duty

cycle

D.C.

AIERES

when

using

CO2

shielding

gas

and



30%

when

using

mixed

shielding

gas.

50

~



..

100



.5

60 10

00 00 00

~JT~

C~V..5

sObl.1

10/91



58-124

625/

Sbl.3

10/91



SB-124

624

CAUTION

Figure

1-1.

Volt-Ampere

Curve

And

Duty

Cycle

Chart

OM-154

500

Page

SECTION

2INSTALLATION

Insulator

Bolt

Smaller

Hole

Work

Clamp

Tabs

2-1.

Installing

Work

Clamp

Tools

Needed:

tabs

around

work

cable.

7/16

in.

3/8

In.,

Work

Cable

From

Unit

Nut

Ref

ST.025

I9O~C

Figure

2-1.

Installing

Work

Clamp

2-2.

Installing

Gas

Supply

WARNiNG

Obtain

gas

running

gea

cylinder

and

chain

wall,

other

station.

ary

support.

Cap

Cylinder

Valve

Remove

cap,

stand

side

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Cylinder

(CO2

shown)

CO2

0-Ring

Tools

1-1/8

in.,

5/8

in.

WARNING



YLINDERS

can

explode

damaged.



Keep

cylinders

away

from

welding

and

other

BUILDUP

SHIELDING

GAS

can

harm

health

kill.

electrical

circuits.



Shut

off

shielding

gas

supply

when

not

use.

Never

touch

cylinder

with

welding

electrode.

Always

secure

cylinder

running

gear,

wall,

other

stationary

support.

warn4.I

9/91

Regulator

Install

onto

gas

cylinder

that

face

vertical.

Flowmeter

Flow

rate

set

cfh

(cubic

feet

2per

hour).

Gas

Hose

Connection

Install

gas

hose

between

flowmeter

and

welding

power

source.

ssb3P

2/92



ST-154

583

ST.l

623

Figure

-2.

TypIcal

CO2

Regulator/Flowmeter

Installation

2-3.

Gun

Polarity

For

Wire

Type

ELECTRiC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Turn

OFF

welding

power

source,

and

disconnect

inputpower

before

inspecting

installing.

swaml.1

9/SI

There

are

two

Jumper

links

set)

across

each

set

terminals.

sure

move

each

set

links

when

changing

polarity.

Tools

Needed:

Pilot

Light

(See

Section

4.1)

3/8

in.

door.

Ref.

sT.149631.c

Polarity

Changeover

Label

Polarity

Jumper

Links

Always

read

and

wire

man

ufacturers

recommended

polarity.

Figure

2-3.

Gun

Polarity

Connections

OM-154

500

Page

2-4.

lnstallin.g

Welding

Gun

2-5.

Connecting

Input

Power

WARNING

ELECTRIC

SHOCK

can

kill.

not

touch

live

electrical

parts.



Turn

OFF

welding

power

source,

and

disconnect

input

power

before

inspecting

installing.



Have

Only

qualified

electrician

install

unit.



Installation

must

meet

National

Electrical

Code

and

all

other

codes.

swam3.1~

~0/~1

Have

Only

qualified

persons

make

this

installation.

in.

(457

mm)

Open

Space

Front

And

Rear

For

Good

Airflow

Rating

Label

Supply

correct

input

power.

230

Volts

Wall

Receptacle

Input

Conductors

Grounding

Conductor

Select

size

and

length

using

Table

2-1.

Conductor

insulation

must

comply

with

national,

state,

and

local

codes.

Install

and

connect

input

conduc

tors

and

grounding

conductor

conduit

equivalent

between

wall

receptacle

and

deenergized

line

disconnect

switch.

sure

ground

ing

conductor

goes

earth

ground.

Line

Disconnect

Switch

Proper

Rating

Obtain

and

install

switch

and

wall

receptacle.

Line

Fuses

Select

fuses

circuit

breakers

using

Table

2-1.

Install

into

deenergized

line

disconnect

switch.

Input

Power

Plug

Turn

OFF

unit

POWER

switch,

and

connect

plug

wall

receptacle.

____________

ub~~_3/92A

ST.149

630

Gun

Securing

Knob

Drive

Assembly

Gun

End

Loosen

securing

knob.

Insert

end

through

front

panel

opening

until

bottoms

against

drive

assembly.

Tighten

knob.

Gun

Trigger

Plug

Insert

into

receptacle

and

tighten

threaded

collar.

door.

Ref.

ST.t46

629~B

Figure

2-4.

Gun

Connections

Figure

2-5.

Location

And

Input

Power

Connections

OM-154

500

PageS

Table

2-1.

Electrical

Service

Requirements*

Input

Amperes

Rated

Output

Circuit

Breaker

Size

Range

Amperes

Fuse

Size

Amperes2



Input

Conductor

Size

AWG/KcmiI3

Maximum

input

Conductor

Length

Feet

(Meters)4

Grounding

Conductor

Size.

AWG/KcmiI5

thru

These

values

are

calculated

from

the

1990

edition

the

National

Electrical

Code

(NEC).

Circuit

breaker

range

50%

not

thuan

200%

rated

input

amperage

the

welding

pow

source

(Article

630.t2(a)

NEC).

Standard

fuse

size

that

closest

50%

rated

input

amperage

the

welding

power

source

rticle

630-126

NEC).



Input

conductor

size

for

insulated

CoPoer

wire

with

75C

ratuflq

with

not

than

three

single

rrent.carrying

conductors

cable

raceway

(Article

630-16

NEC1.



Maximum

length

prevent

than

voltage

drop

between

service

entrance

and

input

Icr

murals

the

welding

power

source

(Articles

210.19(a)

and

215-2(b)

NEC).

The

grounding

conductor

shall

colored

identified

specified

the

NEC.

Grounding

con.

ductor

size

for

copper

wire

not

required

larger

than

input

conductor

(Article

250-95

NEC)

-0092-C

Input

Voltage

230

(20)

2.6.

Threading

And

Feeding

Welding

Wire

WARNING

YLINDERS

can

explode

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

cirCuitS.

Never

touch

cylinder

with

welding

electrode.

Always

secure

cylinder

running

gear,

wall,

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

feeding

wire

using

gun

trigger.

WELDING

WIRE

can

cause

puncture

wounds.



not

press

gun

trigger

until

instructed

so.



not

point

gun

toward

any

part

the

body,

other

people,

any

metal

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

gun

cool

before

touching.

swern5.t

10/91

awarn2.1

9/91

Wire

Spool

Hub

Tension Nut

Grasp

spool

one

hand

and

turn

while

using

wrench

adjust

nut.

When

slight

force

needed

turn

spool,

tension

set.

Loosen

wire

from

spool

and

Cut

off

bent

wire

and

pull

in.

(150mm)

wire

from

spool.

3Pressure

Adjustment

Open

pressure

assembly

Wire

Inlet

Guide

Drive

Roll

Wire

Outlet

Guide

Thread

wire

through

inlet

guide,

along

drive

roll

groove,

and

into

outlet

guide.

pressure

as~

sembly.

Lay

gun

cable

Out

straight.

Nozzle

Contact

Tube

Remove

nozzle

and

contact

tube.

Gun

Trigger

Turn

unit,

press

gun

trigger,

and

feed

In.

(55

mm)

wire

out

gun.

Turn

OFF

unit

and

reinstall

contact

tube

and

nozzle.

Adjusting

Pressure

Tools

Needed:

9/16

in.

Turn

unit

and

check

drive

roll

pressure

feeding

wire

against

wood

board

concrete

surface;

wire

should

feed

steadily

without

Tighten

pressure

adjustment

nec~

essary.

door.

Ref.

ST.

149

632.C

S-0627-A

Figure

2-6.

FeedIng

Welding

Wire

OM154

500

Page

SECTION

3

OPERATION

MOVING

PARTS

can

cause

injury.

=~~

READ

SAF

manual

ETY

BLOCKS

beginning

before

proceeding.

ARCING

can

damage

switch.



Keep

away

from

pinch

points

such

drive

rolls.



not

change

VOLTAGE

switch

position

while



Keep

all

doors,

panels,

covers,

and

guards

closed

welding.

and

securely

place.

Arcing

inside

switch

can

damage

contacts,

causing

switch_to_fail.

Insulating

Gloves

Safety

Glasses

With

Side

Shields

Welding

Helmet

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

welding

helmet

with

correct

shade

filter

(see

ANSI

Z49.1).

sb3.t

0/SI

FIgure

-1.

Safety

Equipment

Wire

Speed

Adjustment

Con

trol

Use

control

select

wire

feed

speed.

VOLTAGE

ADJUST

MENT

switch

setting

increases,

wire

speed

range

also

increases.

The

numbers

around

the

control

are

not

wire

feed

speed

(see

rear

cover).

Voltage

Adjustment

Switch

Use

switch

select

arc

voltage.

The

higher

the

selected

number,

the

thicker

the

material

that

can

welded

(see

rear

cover).

Power

Switch

Use

switch

turn

unit

and

OFF.

Work

Clamp

Use

wire

brush

sandpaper

clean

metal

weld

joint

area.

Connect

work

clamp

clean,

paint-free

location

workpiece,

possible

weld

area.

Ref.

ST.150

192A

fRet

ST.153

448

Figure

3-2.

Controls

Tools

Needed:

OM.154 500

Page

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