MAC TOOLS MW250 User manual

July
1997 Form:
OM-154501F
FIIL~
C'~y
1fl~
F~ll~
Effective
With
Serial
No.
KH450070
MW250
OWNERS
MANUAL
~
IMPORTANT:
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equipment.
This unit
and
these
instructions
are
for
use
only
by
persons
trained and
experienced
in
the safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor if
you
do
not
fully
understand
these
instructions.
L._
___
TOOLSfi
coven
5/92
-
ST-157 072-A
PRINTED
IN
USA

ARC
WELDING SAFETY
PRECAUTIONS
ELECTRIC
SHOCK
can
kill.
Touching
live electrical
parts
can cause
fatal
shocks
or
severe
bums. The electrode
and
work circuit
is
electrically
live whenever the
output
is
on.
The
input
power
circuit
and
machine
internal circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive roll
housing,
and all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work and
ground
using dry insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
A~
WARNING
ARC
WELDING
can
be hazardous.
PROTECT YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP CHILDREN
AWAY.
PACEMAKER WEARERS
KEEP AWAY UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that will
be
found
in
the
Safety
Standards listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION, OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY BY
QUALIFIED PEOPLE.
I,
5.
Properly
install and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Turn
off all
equipment
when
not
in
use.
7.
Do
not
use
worn,
damaged,
undersized,
or
poorly spliced
cables.
8.
Do
not
wrap
cables
around
your
body.
9.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
10. Do
not
touch electrode while
in
contact
with
the
work
(ground)
circuit.
11. Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12. Wear
a
safety
harness
to
prevent
tailing
if
working
above floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
,~,
/~
.9~/~
~.
ARC RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet fitted with
a
proper
shade
of filter
(see
NOISE
can
damage
hearing.
ANSI
Z49.1
listed
in
Safety Standards)
to
protect
your
face and
eyes
when
welding
or
watching.
Arc
rays
from the
welding
process
produce
intense
2. Wear
approved
safety
glasses.
Side
shields recommended.
heat and
strong
ultraviolet
rays
that
can
bum
eyes
3. Use
protective
screens or
barriers
to
protect
others from flash
and skin.
Noise from
some
processes
can
damage
and
glare;
warn
others
not
to
watch the
arc.
earing.
4.
Wear
protective
clothing
made from
durable,
flame-resistant
material
(wool
and
leather)
and foot
protection.
5.
Use
approved
ear
plugs
or ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be hazardous
5.
Work
in
a
confined
space
only
if
it is
well
ventilated,
or
while
~
to
your
health. wearing
an
air-supplied
respirator.
Shielding
gases
used
for
~
Welding
produces
fumes and
gases.
Breathing
welding
can
displace
air
causing injury
or
death.
Be
sure
the
these fumes and
gases
can
be
hazardous
to
your
breathing
air is
safe.
-.
health.
6. Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat and
rays
of
the
arc can
react
with
vapors
to
1.
Keep
your
head
out
of
the fumes. Do
not
breathe
the
fumes.
form
highly
toxic and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation is
poor,
use an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed from
the
4.
Read
the Material
Safety
Data Sheets
(MSDSs)
and the
weld
area,
the
area
is
well
ventilated,
and if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and cleaners,
containing
these elements
can
give
off toxic
fumes
if
welded.
WELDING
can
cause
fire
or
explosion.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Sparks
and
spatter
fly
oft from
the
welding
arc.
The
flying
sparks
and hot
metal,
weld
spatter,
hot
workpiece,
and hot
equipment
can cause
fires and
bums.
Accidental
contact
of
electrode
or
welding
wire
to
metal
objects
can cause
sparks, overheating,
or
fire.
6.
7.
8.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
Connect
work cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
hazards.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
10.
Remove stick electrode
from
holder
or
cut
off
welding
wire
at
If
this is
not
possible,
tightly
cover
them
with
approved
covers,
contact
tip
when
not
in
use.
4.
Bealertthatweldingsparksandhotmaterialsfromweldingcan
11.
Wear
oil-free
protective garments
such
as
leather
gloves,
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
heavy
shirt,
cuftless
trousers,
high
shoes,
and
a
cap.
>~
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury,
Chipping
and
grinding
cause
flying
metal.
As welds
cool,
they
can
throw off
slag.
1.
2.
Wear
approved
face shield
or
safety
goggles.
Side
shields
recommended.
Wear
proper
body protection
to
protect
skin.

CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping
-
____________________________
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve outlet
when
opening
cylinder
valve.
7.
Keep protective
cap
in
place
overvalve
except
when
cylinder
is
in
use
or
connected for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
PRINCIPAL
SAFETY STANDARDS
Safety
in
Welding
and
Cutting,
ANSI Standard
Z49.
1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safelyand
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S. Government
Printing
Office,
Washington,
D.C.
20402.
Recommended Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That Have Held
Hazardous
Substances,
American Weld
ing
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,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,from
Compressed
Gas
Association,
1235
Jefferson Davis
Highway,
Suite
501,
Ariington,
VA
22202.
Code for
Safety
in
Welding
and
Cutting,
CSA Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
ForoccupationAnd
Educational
EyeAnd
Face
Protection,
ANSI
Standard
Z87.1
,from
American National
Standards
Institute,
1430
Broadway,
New
York,
NY 10018.
Cutting
And
Welding
Processes,
NFPA Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA 02269.
EMF
INFORMATION
TABLE
OF CONTENTS
SECTION
1

SAFETY
INFORMATION
1
SECTION
2

SPECIFICATIONS
1
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3
INSTALLATION
3
3-1.
Installing
Work
Clamp
3
3-2.
Installing
Gas
Supply
4
3-3:
Gun
Polarity
Connections
5
3-4.
Installing
Drive Rolls
And
Wire
Inlet
Guide
5
3-5.
Installing
Welding
Gun
6
3-6.
Connecting
Input
Power
7
3-7.
Installing
Wire
Spool
And
Adjusting
Hub Tension....
9
3-8.
Threading
And
Feeding
Welding
Wire
9
3-1.
Threading
Welding
Wire
10
SECTION 4OPERATION
11
SECTION
5MAINTENANCE
&
TROUBLESHOOTING
13
5-1.
Routine
Maintenance
13
5-2.
Overload
Protection
14
5-3.
Aligning
Drive Rolls And Wire
Guide
15
5-4.
Gun
Maintenance
16
5-5.
Troubleshooting
17
SECTION
6
ELECTRICAL DIAGRAM
17
SECTION
7PARTS
LIST
18
Figure
7-1.
Main
Assembly
18
Figure
7-2.
Baffle
w/Components
19
Figure
7-3.
Wire Drive And
Gears
20
Figure
7-4.
MWG-23B
21
NOTE
~
F
Magnetic
Fields
Considerations
About
Welding
And
The
Effects
Of Low
Frequency
Electric
And
The
following
is
a
quotation
from
the
General
Conclusions
Section
of the
U.S.
Congress,
Oftice
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields

Background Paper,
OTA-BP-E-53
(Washington,
DC: U.S.
Government
Printing
Office,
May
1989):
.
.
.
there
is
now
a
very
large
volume of scientific
findings
based
on
experiments
at
the
cellular
level
and
from studies
with
animals
and
people
which
cleariy
establish that
low
frequency magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of this
work is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent framework.
Even
more
frustrating,
it does
not
yet
allow
us
to
draw
definite conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based advice
on
strategies
to
minimize
or
avoid
potential
risks.
To
reduce
magnetic
ifelds in
the
workplace,
use
the
following
procedures:
1.
Keep
cables close
together by twisting
or
taping
them.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables
around
the
body.
4.
Keep
welding
power
source
and cables
as
far
away
as
practical.
About
Pacemakers:
5.
Connect
work
clamp
to
workpiece
as
close
to
the weld
as
possible.
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
modlO.1
4/93

SECTION
1
-
SAFETY INFORMATION
N
Read
all
safety
messages
throughout
this manual.

Obey
all
safety
messages
to
avoid
injury.

Learn the
meaning
of
WARNING
and
CAUTION.
modl.1
2/93
Figure
1-1.
Safety
Information
SECTION 2-SPECIFICATIONS
Table
2-1.
Welding
Power Source
1 2 2
a
CAUTION
/
5
MOVING
PARTS
can
injure.
L~
ELECTRIC
SHOCK
can
kiII.~~
~%

Do
not
touch
live
electrical
parts
~

Keep
away
from
moving
parts.

Keep
all
panels
and covers
closed
I
S
Disconnect
input
power
before
instaJling
or
servicing.
when
operating.
I
1
Safety
Alert
Symbol
2
SignalWord
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement Of
Hazard
And
Result
; II
~e
:~p~N~~
READ SAFETY BLOCKS
at
start
of
Section
3-1 before
proceeding.
7H
NOTE
~
Turn Off
switch
when
using
high frequency.
4
Safety
Instructions To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks for each
sym
bol shown.
7
NOTE
Special
instructions
for
best
oper
ation

not
related
to
safety.
Type
Of
Output
Specifications Description
Direct
Current/Constant
Voltage
(DC/CV)
Rated
Weld
Output
Type
Of
Input
Power
Input
Amperes
At
Rated
Output
Maximum
Input Amperes
While
Idling
KVA/KW
Used At
Rated
Output
Maximum KVAJKW
Used While
Idling
Max.
Open-Circuit
Voltage
Control Circuit
Voltage
At
Gun
Welding
Processes
Calculated Speed
Range
At No Load
Wire
Diameter
Range
Overall
Dimensions
Weight
200
Amperes,
28 Volts
DC,
60%
Duty Cycle
(See
Section
2-2)
Single-Phase;
60
Hz;
At
200
Or
230
Volts AC
46
A
At
200
V,
40
A
At
230 V
1.2AAt200V,
1
AAt23OV
9.5
kVN8.3 kW
0.24 kVNO.17
kW
42 Volts DC
24 Volts DC
Gas
Metal
Arc
(GMAW)
And
Flux Cored
Arc
Welding (FCAW)
128
To 1051
ipm
(3.2
To
266.9
mpm)
.030
To
.045 in
(0.8
To
1.1
mm)
Flux
Cored
Wire,
.023
To .045
in
(0.6
To 1.1
mm)
Hard
Wire
Length:
37
in
(940
mm);
Width:
19 in
(483
mm);
Height:
30-1/4
in
(768
mm)
Net:
225
lb
(102 kg); Ship:
271
lb
(123
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
Cable
Length
200
Amperes
At 60%
Duty Cycle Using CO2
Shielding
Gas
(See
Section
2-2)
15
ft(4.5
m)
OM-154
501
Page
1

2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
a
CAUTION
~o.
R~W ~flR~
Figure
2-2.
Duty Cycle
The
volt-ampere
curves
show
the
50
minimum
and maximum
voltage
and
amperage
output
capabilities
of the
welding
power
source.
Curves
of
other
settings
fall
be-
40
tween
the
curves
shown.
0
0
25 60 75 100 126
150
176
200
225
DC
AMPERES
ssbl.1 10/91
SB-049424-D
I
~
w

ELDING LONGER THAN RATED DUTY CYCLE
can
damage
unit
or
gun
and
void
warranty.
Do
not
weld
at
rated
load
longer
than
shown
below.
wfwam8.2 8/93
0
Definition
~
Duty
Cycle
is
percentage
of
10
10
weld
at
rated load
without
over-
minutes
that
unit
or
gun
can
Minutes
heating.
UNIT
60%
Duty Cycle
At
200
Amperes
g
6
Minutes
Welding
4
Minutes
Resting
Chart
GUN
3C0
~.
Ui
~
~
~
I
Ui
~

~

-

-
-
-
--
I
 

- --
-t---

-
-
40
~
x
ou~v
cyct.~
.
6
minutes
Welding
4
minutes
Resting
sbl.38193SB-150215
~7
OM-154
501
Page
2

3-1.
Installing
Work
Clamp
SECTION
3-INSTALLATION
Figure
3-1.
Installing
Work
Clamp
5
1
2
1
Work Cable
2
Boot
Slide
boot
onto
work
cable.
Route
cable
out
front
panel
opening
from
inside.
3
Negative () Output
Terminal
Connect
cable
to
terminal
and
cover
connection
with
boot.
4
Hardware
5
Work
Clamp
Route
cable
through
clamp
handle
and
secure
as
shown.
Close
door.
Tools Needed:
-,~1/2,3I4in
Ref.
ST-800
918-B
3
OM-154501
Page3

3-2.
Installing
Gas
Supply
4A
WARNING
CYLINDERS
can
explode
if
damaged.
~
BUILDUP
OF
SHIELDING GAS
can
harm

Keep
cylinders
away
from
welding
and
other
r
health
or
kill.
electrical circuits.

Shut
off
shielding
gas
supply
when
not
in
use.

Never
touch
cylinder
with
welding
electrode.
I

Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
wam4.1 9/91
1
Cylinder
Bracket
2
S-Hook
Crimp
between
small hole in
brack
et
and
chain.
3
Chain
4
Snap
Crimp
onto
open
end
of chain.
Obtain
gas
cylinder
and
chain
to
running
gear.
5
Cap
6
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow blows
dust
and
dirt
from
valve.
Close valve.
7
Cylinder
8
Regulator/Flowmeter
install
so
face
is
vertical.
9
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads. Obtain and
install
gas
hose.
10
Flow
AdjUst
Typical
flow rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers recommended flow
rate.
Make
sure
flow
adjust
is
closed
when
opening
cylinder
to
avoid
damage
to
the
flowmeter.
11
CO2
Adapter
12
0-Ring
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
Toots Needed:
518,1-1/8in
ssb3.2 5/94
-
ST-154
623
I Ref.
ST-149
827-B
I
Ref. ST-15B
697~A
Figure
3-2.
Typical Regulator/Flowmeter
Installation
OM-154
501
Page
4

3-3.
Gun
Polarity
Connections
a
WARNING
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Turn
Oft
welding
power
source,
and disconnect
input
power
before
inspecting
or
installing.
3-4.
Installing
Drive
Rolls And
Wire
Inlet
Guide
Figure
3-4.
Installing
Drive
Rolls
And
Wire
Inlet
Guide
Shown
As
Shipped

Set
For Electrode
Positive
(DCEP)
For Solid Steel
Or
Aluminum Wires
(GMAW
Process).
Wire Drive
Assembly
Lead
To
Positive
(+)
Output
Terminal
swami
.1
2/93
5
Work
Clamp
Lead
To
Negative
() Output
Terminal
1
Polarity Changeover
Label
2
Wire
Drive
Assembly
3
Positive
(+)
Output
Terminal
4
Negative
() Output
Terminal
Always
read and
follow
wire
man
ufacturers
recommended
polarity.
5
Circuit Breaker CB1
(see
Section
5-2).
6
Pilot
Light (see
Section
5-2)
Close
door.
Tools
Needed:
~
3/4,11/l6in
Ref.
ST-8Oi
~O3-B
GUN
POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections

For
Electrode
Negative
(DCEN)
For
Flux Cored Wires
(FCAW
Process).
Drive
Assembly
Becomes
Negative
~
3
4
Figure
3-3.
Gun
Polarity
Connections
3
5
1
Securing
Screw
2
Inlet
Wire
Guide
Loosen
screw.
Slide
tip
as
close
to
drive rolls
as
possible
without
touching.
Tighten
screw.
3
Anti-Wear
Guide
Install
guide
as
shown.
4
Drive
Roll
Install
correct
drive roll for wire size
and
type.
5 Drive
Roll
Securing
Nut
Tum
nut
one
click
to
secure
drive
Tools
Needed:
roll.
5/64
in
~
7/16
in
ST-i 50
227-C
OM-154
501
Page
5

3-5.
Installing
Welding
Gun
Figure
3-5.
Gun
Connections
Table 3-1.
Electrical Service
Requirements
Input
Voltage
200
230
Input
Amperes
At
Rated
Output
46
40
Max
Recommended Standard
Fuse
Or Circuit
Breaker
Rating
In
Amperes
70 60
Mm
Input
Conductor
Size
In
AWGIKcmiI
8
8
Max
Recommended
Input
Conductor
Length
In Feet
(Meters)
89
(27)
117(36)
Mm
Grounding
Conductor Size
In
AWGIKcmiI 8
10
Reference: 1996
National Electrical
Code
(NEC).
S-oo92J
-4
3
2
1
Wire
Drive
Assembly
2
Gun
Securing
Knob
3
Gun
End
Loosen
securing
knob.
Insert
gun
end
through
opening
until
it bot
toms
against
drive
assembly.
Tighten
knob.
4
Gun
Trigger
Plug
Insert
into
receptacle,
and
tighten
threaded
collar.
Close
pressure
assembly.
Close
door.
Ref. ST-801
101-B
OM-154
501
Page
6

3-6.
Connecting
Input
Power
I~
WARNING
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.

Have
only
qualified
persons
install unit.

Installation
must meet
National
Electrical
Code and
all
other
codes.
A.
Positioning
Jumper
Links
Figure
3-6.
Input
Voltage Jumper
Links
Location
swam3.1
2/93
200
VOLTS
I
Check
input
voltage
available
at
site.
1
Jumper
Links
Access Door
Open
door.
_________________
2
Jumper
Link
Label
23
Input
Voltage Jumper
Link
Move
jumper
link
to
match
input
voltage.
~
~~~~3oVOLTS
~:::
:
secure
access
door.
S-153
980
Tools
Needed:
EIJ~J
3/8
in
Ref.
ST-801 100-B
OM-154
501
Page
7

B.
Connecting
Input
Power
Have
only
qualified
persons
make
this
installation.
1 Line
Disconnect
Device
Of
Proper
Rating
2
230
Volts
AC
Wall
Receptacle
3
Input
Conductors
4
Grounding
Conductor
Select
size and
length
using
Table
3-1.
Conductor
rating
must
comply
with
national,
state,
and
local electncal
codes.
Install
and
connect
grounding
conductor
and
input
conductors
in
conduit
or
equivalent
between wall
receptacle
and
deenergized
line
disconnect
device.
Connect
grounding
conductor
first,
then
line
input
conductors.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
5
Overcurrent Protection
Select
type
and
size
using
Table
3-1.
Install
into
deenergized
line
disconnect device
(fused
dis
connect
switch
shown).
6
Input
Power
Plug
Turn oft unit Power
switch,
and
connect
plug
to
wall
receptacle.
ssb2.2
12/94

Ret.
ST-i
54619-B / Ref.
ST-149
405-B
Tools
Needed:
Figure
3-7.
Input
Power Connections
OM-154
501
Page
8

3-7.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
Figure
3-8.
Installing
Wire
Spool
And
Adjusting
Hub Tension
3-8.
Threading
And
Feeding Welding
Wire
a
WARNING
CYLINDERS
can
explode
if
damaged.

Keep
cylinders
away
from
welding
and
other
electrical circuits.

Never
touch
cylinder
with
welding
electrode.

Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC SHOCK
can
kill.

Do
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
or
feeding
wire
using
gun
trigger.
WELDING
WIRE
can
cause
puncture
wounds.

Do
not
press
gun
trigger
until
instructed
to
do
so.

Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.

Allow
gun
to
cool
before
touching.
Turn
Off
unit.
1
Wire
Spool
2 Gun
Contact
lip
If
necessary,
cut
welding
wire off
at
contact
tip,
and
retract
wire
onto
spool
and
secure.
3
Retaining
Ring
4
Compression
Spring
Remove
ring
and
pull
off
spool.
Compression
spring
is used
with
8
in
(200
mm)
spools.
5
Hub
6
Hub Pin
Slide
spool
onto
hub
so
wire
feeds
off
bottom.
Turn
spool
until
hub
pin
fits hole
in
back of
spool.
Reinstall
retaining
ring.
7
Hub
Tension
Nut
Grasp
spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
hub
tension
nut.
When
a
slight
force
is
needed
to turn
spool,
tension
is
set.
Thread
welding
wire
(see
Section
3-8).
Close
door.
Tools
Needed:
~
15/l6in
Ref. ST-801
103-B /
Ref. ST-072
573-B
swam5.1
10/91 /swam2.1 9/91
OM-154
501
Page
9

3-1.
Threading
Welding
Wire
1
Wire
Spool
2
Welding
Wire
3
InletWire
Guide
4
Pressure
Adjustment
Knob
5
Drive
Roll
6
Outlet
Wire
Guide
7
Gun Conduit Cable
Lay
gun
cable
out
straight.
~=Th~
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and nozzle.
Remove
gun
nozzle
and
contact
tip.
1111
II
Feed wire
to
check drive roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
10
-4-e~~
I_____
Cut off
wire.
Close
and latch
door.
Ret. ST-801 103-B
/ ST-154
251
/
S-0627-A
Figure
3-9.
Threading
And
Feeding
Welding
Wire
Tools
Needed:
Open
pressure
assembly.
Pull
and
hold
wire;
cutoff
end. Push wire thru
guides
into
gun;
continue
to
hold wire.
Close
and
tighten
pressure
assembly,
and let
go
of wire.
Turn On.
OM-154501
Page
10

SECTION
4-
OPERATION
AA
WARNING
ELECTRIC
SHOCK
can
kill.

Always
wear
dry
insulating
gloves.

Insulate
yourself
from
work
and
ground.

Do
not
touch live
electrical
parts.

Keep
all
panels
and
covers
securely
in
place
FUMES
AND
GASES
can
be
hazardous
to
your
health.

Keep
your
head
out
of the
fumes.

Ventilate
area,
or
use
breathing
device.

Read Material
Safety
Data Sheets
(MSDS5)
and
manufacturers
instructions for
material
used.
WELDING
can
cause
fire
or
explosion.

Do
not
weld
near
flammable material.

Watch
for
fire;
keep
extinguisher
nearby.

Do
not
locate
unit
over
combustible
surfaces.

Do
not
weld
on
closed containers.

Allow work
and
equipment
to cool
before
handling
ARCING
can
damage
switch.

Do
not
change
Voltage
switch
position
while
welding.
Arcing
inside switch
can
damage
contacts,
causing
switch
to
fail.
j
9t~
~~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.

Wear
welding
helmet with
correct
shade
of
filter.

Wear
correct
eye,
ear,
and
body
protection.
,~
~
MOVING PARTS
can cause
injury.

Keep
away
from
pinch points
such
as
drive
rolls.

Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.

-
~
MAGNETIC
FIELDS FROM HIGH CUR
RENTS
can
affect
pacemaker
operation.

Pacemaker
wearers
keep
away.

Wearers should consult
their
doctor before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
WELDING CURRENT
can
damage
elec
tronic
parts
in
vehicles.

Disconnect
both
battery
cables
before
welding
on a
vehicle.

Place
work
clamp
as
close
to
the weld
as
possible.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
swam6.2
8/92
1
~(
2 3
/
~8
Wear the
following
while
welding:
1
Dry, Insulating
Gloves
2
Safety
Glasses With
Side
Shields
3
Welding
Helmet With
Correct
Shade
Of
Filter
(See
ANSI
Z49.1)
sb3.1
1/94
Figure
4-1.
Safety
Equipment
1
Wire
Mode
Switch
For
better
control
of
wire
speed
use
Low
position
when wire
speed
is
between 90
and
670
ipm.
Use
Full
position
when
wire
speed
is
be
tween
150
ipm
and 1030
1pm.
2
Voltage
Range
Selector
Place
switch
in
desired
position.
See
inside
rear
cover
for
settings.
Ret.
ST-801 103-B/S-171
601
Figure
4-2.
Center
Baffle
Controls
OM-154
501
Page
11

Tools Needed:
1
Wire
Speed
Control
Use control
to set
wire
feed
speed.
2
Voltage
Control
Use
control
and
Voltage
Range
2
Selector
(see
Figure
4-2)
to
set
arc
voltage.
Step
6
of
Low
range
and
Step
1
of
High
range
overlap.
3
Pilot
Light
4
Power
Switch
Use switch
to turn
unit
On
and Off.
The
pilot
light
comes
on
when unit
is
turned
on.
5
Work
Clamp
Use wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Connect
work
clamp
to
clean,
paint-f
ree
location
on
workpiece,
as
close
as
possible
to
weld
area.
Ref.
ST-i
54
622-B
/
ST-i84
596
/ Ref.
ST-i
54251
Figure
4-3. Controls
OM-154
501
Page
12

SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can cause
severe
burns.

Allow
cooling
period
before
maintaining
or
servicing.
~
M
OVING
PARTS
can
cause
injury.

Keep
away
from
moving
parts.
r

Keep
away
from
pinch
points
such
as
drive rolls.
*~
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
~
2J93
5-1.
Routine Maintenance
Turn
Off
all
power
before
maintaining.
Each
Spool
Of
Wire
Blow
Out
See
I
Gun
Section
I
Casing
~
Clean
Nozzle
________
And Check
 
Contact
Tip
3
Months
WAR
Ni
I
Replace
Unreadable
Labels
7
Clean
3~1 Tern~nals
Replace
~
Cracked

Parts
Gas
Hose
14-Pin Cord
Gun Cable
Figure
5-1.
Maintenance
Schedule
OM-154
501
Page
13

5-2.
Overload
Protection
B.
Fuses
Fl And
F2
READ
SAFETY
BLOCKS at
start
of
Section
5
before
proceeding.
A.
Circuit
Breaker CB1
1
Circuit Breaker
CB1
2
Pilot
Light
If CB1
opens,
pilot
light
goes
out,
and
wire
feed
stops.
Check
gun
un
erfor
blockage
or
kinks,
and
check
for
jammed
wire,
binding
drive
gear,
or
misaligned
drive
rolls.
Al
low
a
cooling
period
before
reset
ting
CB1.
Ref.
ST-801 103-B
Figure
5-2. Circuit Breaker CB1
Turn
Off
unit and disconnect
input
power.
1
Fuse
Fl
(See
Parts List
For
Rating)
Fl
protects
the
115
volts
ac
wind
ing
of
transformer
Ti.
If Fl
opens,
all weld
output stops
and
pilot light
PL1
goes
out.
2 Fuse F2
(See
Parts
List For
Rating)
F2
protects
the
24
volts
ac
winding
of
transformer
Ti. If
F2
opens,
all
weld
output
stops.
Ref.
ST-800 928-B
C.
Overheating
Figure
5-3.
Fuse Location
Figure
5-4.
Overheating
OM-154501
Page
14

5-3.
Aligning
Drive
Rolls
And
Wire
Guide
READ
SAFETY
BLOCKS
at start
of
Section
5
before
proceeding.
Figure
5-5.
Aligning
Drive
Rolls And
Wire Guide
A
Turn
Off
unit.
Horizontal
Alignment
View
is
from
top
of
drive
rolls
look
ing
down with
pressure
assembly
open.
1
Allen Wrench
2
Drive
Roll
Securing
Nut
3
Drive Roll
4
Wire
Guide
5
Welding
Wire
6 Drive
Gear
Insert
wrench,
and
turn
screw
in
or
out
until drive
roll
groove
lines
up
with wire
guide.
Vertical
Alignment
7
Housing
Bolts
8
Weld
Cable
Terminal
Loosen
bolts
and
terminal
nut(s).
9
Wire
Guide
10
Drive
Roll
11
Pressure
Roll
Slide
housing
up
or
down
until
groove
in
drive
roll and
pressure
roll
line
up
with
wire
guide.
Tighten
hardware. Close
pressure
roll
assembly.
Horizontal
Alignment
Correct
45
Incorrect
6
+
Vertical
Alignment
Tools Needed:
5/16i~
3/16
in
Ref.
ST-800
412-A
OM-154
501
Page
15

5-4.
Gun
Maintenance
READ
SAFETY BLOCKS
at
start
of
Section
5
before
proceeding.
FLYING METAL CHIPS
AND DIRT
can
cause
injury
and
damage
equipment.

Point
gun
away
from
people
and
in
a
safe
direction
when
blowing
out
with
compressed
air.
swamlo.1
1W91
Turn
Off
unit and disconnect
input
power.
1
Wire
Spool
Cut
welding
wire off
at contact
tip.
Retract
wire
onto
spooi
and
se
cure.
2
Gun
Securing
Knob
Loosen
knob and
remove
gun
and
trigger plug.
Reassemble
gun.
To
Reassembe Gun:
Install
contact
tip.
Insert
new
liner.
Install
collet
onto
liner and
tighten
into
gun/feeder
connector
using
wrench.
Cut
liner
off
near
collet
so
that liner
end
is
as
close
to
drive rolls
as
pos
sible
without
touching.
Install nozzle.
Reinstall
gun
(see
Section
3-5).
Thread
welding
wire
(see
Section
3-8).
Close door.
4,
Remove liner.
Tools
Needed:
~
3/8in
Figure
5-6.
Gun
Maintenance
Ref.
ST-801
1O1-B/ST-801
149
1
2
I
Remove
nozzle,
contact
tip,
and
liner
collet.
Blow
out
gun
casing.
Gun/Feeder
Connector
C
/
OM-154
501
Page
16

No weld
output;
wire does
not
feed;
fan -s
motor
continues
to
run
and
pilot light
is
off.
No weld
output;
wire feeds.

-~
Connect
work
clamp
to
get
good
metal
to
metal
contact.
Replace
contact
tip.
Section
-s
3-6
-s
5-2
-s
3-6
-s 3-5
-s
5-2
Figure
4-3
1-~
5-4
SECTION
6-
ELECTRICAL
DIAGRAM
5-5.
Troubleshooting
I
Welding
Trouble
INO
weld
output;
wire does
not
feed
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Remedy
Secure
power
cord
plug
in
receptacle.
Reset
circuit
breaker
CB1.
Replace
fuse
Fl
and/or
F2.
Replace
building
line fuse
or
reset
circuit
breaker
if
open
Secure
gun
trigger plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
Thermostat
open (overheating).
Allow
fan
to
run;
the
thermostat
will close when the unit
has cooled.
Electrode
wire
feeding
stops
during
-s
welding.
I
Low
weld
output

-
Connect
unit
to
proper
input
voltage
or
check
for
low
line
voltage.
~

-
3-6
]
Wire Drive/Gun Trouble
_________
-s 5-4
Straighten
gun
cable
and/or
replace
damaged
parts.
Adjust
hub tension.
Adjust
drive roll
pressure.
Replace
contact
tip
if
blocked.
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged.
Replace
drive roll
or
pressure
bearing
if
wom
or
slipping
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
Check and
replace
Fl
and/or F2.
Check and clear
any
restrictions
at
drive
assembly
and
liner
Have
nearest
Factory
Authorized
Service
Station
check drive
motor.
--a
--s
--s
--s
--s
--a
--a
--a
--a
3-7
3-8
5-4
5-3,
5-4
5-3
3-5
5-2
5-3,
5-4
WI
5Z
r~
~u~i
AAA-A-A
~
;~~
ci
c
ci~
~3~<1FU~
R3-1I~>---~-<3
14.
~
4
~3-2
>>~<
I
~3-9
~3-~
>~~~~<n
Figure
6-1.
Circuit
Diagram
For
Welding
Power Source
I~4TNE
SB-174 099-A
OM-154
501
Page
17