MAC TOOLS MW250 User manual

December
1995
Form:
OM-154
501D
Effective
With
Serial
No.
KG034070
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.
TOOLSfi
coven
5/92

ST-157
072-A
PRINTED
IN
LiSA

ARC WELDING SAFETY
PRECAUTIONS
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or severe
burns. 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
touchin9
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
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.
ARC
WELDING
can
be
hazardous.
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
falling
if
working
above
floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
1.
Wear
approved
face
shield
or
safety goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
a
WARNING
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.
1.
2.
3.
/~
,,
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.
hearing.
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.
r
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
(MSDS5)
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.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece.
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
1.
Protect
yourself
and others from
flying
sparks
and
hot metal.
2. Do
not
weld
where
flying
sparks
can
strike
flammable material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is not
possible,
tightly
cover
them
with
approved
covers,
4.
Be
alert that
welding sparks
and hot
materials
from
welding
can
easily
go
through
small
cracks and
openings
to
adjacent
areas.
5.
6.
7.
8.
9.
10.
11.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
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 tire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove stick electrode
from holder
or cut
off
welding
wire
at
contact
tip
when
not
in
use.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
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.

ERRATA
SHEET
June
1,
1995
FORM:
OM-154
501B
Use
above
FORM
number
when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment design
occurred.
This
sheet
lists
exceptions
to data
appearing
later
in
this
manual.
18-
18-8..
18-10
18-
20-22
20-23
20-44
20-44
057
478
022
617
151
187
152
626
152
632
174
023
012
654
012
654
169
654
602
387
089 899
175
060
175
775
174
815
012
658
073
426
*aFirst
digit
represents
page
no

digits
following
dash
represent
item
no.
BE SURE TO
PROVIDE
MODEL
AND
SERIAL
NUMBER WHEN
ORDERING
REPLACEMENT
PARTS.
CHANGES
TO SECTION
7
PARTS LIST
Change
Parts List
as
follows:
Dia.
Part
Mkgs.
No.
Replaced
With
Fl
F2
Description
BRACKET,
support
tank
(Eff
w/KF903919)
CYLINDER
CHAIN
LATCH
FRONT
PANEL,
(Eff w/KF903919)
MOTOR
BRACKET,
(Eff w/KF903919)
BAFFLE,
(Eff
w/KF903919)
FUSE,
mintr
gI
slo-blo
2A
125V
FUSE,
mintr
gl
slo-blo 5A
125V

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
over
valve
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
Ad,
Miami FL
33126
Safetyand
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
Ad,
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,
Arlington.
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
For
Occupation
And
Educational
Eye
And
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
Welding
Gun
5
3-5.
Connecting
Input
Power
6
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension....
8
3-7.
Threading
And
Feeding
Welding
Wire
8
SECTION
4-OPERATION
10
SECTiON
5-
MAINTENANCE
&
TROUBLESHOOTING
12
5-1.
Routine
Maintenance
12
5-2.
Overload Protection
13
5-3. Wire
Drive
Assembly
Maintenance
14
5-4.
Gun
Maintenance
15
5-5.
Troubleshooting
16
SECTION
6-
ELECTRICAL
DIAGRAMS
16
SECTION
7
PARTS
LIST
17
Figure
7-1.
Main
Assembly
17
Figure
7-2.
MWG-200M
Gun
18
Figure
7-3.
Baffle
w/Cmpts
19
NOTE
~
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,
Office
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
clearly
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
fields
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.
5;
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
among
those also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.

SECTION
1
-
SAFETY
INFORMATION

Read
all
safety
messages
throughout
this
manual.

Obey
all
safety
messages
to
avoid
injury.

Learn the
meaning
of
WARNING
and
CAUTION.
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
modl.1
2/93
SpecificatIons DescriptIon
Type
Of
Output
Direct
Current/Constant
Voltage
(DC/CV)
Rated
Weld
Output
200
Amperes,
28
Volts
DC,
60%
Duty
Cycle
(See
Section
2-2)
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
200, 230,
460,
Or 575
Volts
AC
Input Amperes
At
Rated
Output
46
A
At
200
V,
40 A At
230
V
Maximum
Input
Amperes
While
Idling
1.2
A
At
200
V,
1
A At 230
V
KVAIKW
Used
At
Rated
Output
9.5
kVAI8.3
kW
Maximum
KVA/KW
Used While
Idling
0.24
kVA/0.17 kW
Max.
Open-Circuit
Voltage
42
Volts
DC
Control Circuit
Voltage
At
Gun
24
Volts
DC
Welding
Processes Gas
Metal
Arc
(GMAW)
And
Flux Cored
Arc
Welding
(FCAW)
Calculated
Speed
Range
At No
Load 128
To
1051
ipm (3.2
To 266.9
mpm)
Wire Diameter
Range
.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
Overall Dimensions
Length:
37
in
(940 mm):
Width: 19
in
(483
mm);
Height:
30-1/4
in
(768
mm)
Weight
Net: 225
lb
(102
kg): Ship:
271
lb
(123
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
200
Amperes
At
60%
Duty
Cycle
Using
CO2
Shielding
Gas
(See
Section
2-2)
Cable
Length
15
ft
(4.5
m)
1
2
2
~
\~
__
t~!A~f~ :
I
___________________I
~
ELECTRIC
SHOCK
can
kiII.~
~
MOVING PARTS
can
injure.

Do
not
touch live electflcal
parts.
~
IIj~P~~
S
Keep
away
from
moving
parts.
i

Disconnect
input
power
beforeJj_
4

Keep
all
panels
and covers
closed
I
installing
or
selvicing.
when
operating.
I
/
a
CAUTION
5
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
6
a
WARNING
7-H
NOTE
~
4
Safety
Instructions To
Avoid
Hazard
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding.
Turn
Off switch
when
using
high
frequency.
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.
OM-154
501
Page
1

2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty Cycle
-
a
CAUTION.
~0
Ui
~
Ui
a
~
~c
~
-J
Ui
~
~60
~0
Figure
2-2.
Duty Cycle
40
30
Cl)
0
>
0
20
10
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
tween
the
curves
shown.
ssbl.1
10/91
SB-049424-D
0
DC
AMPERES
WELDING
LONGER
THAN
RATED
DUTY
CYCLE
can
damage
unit
or
gun
and
void
warranty.

Do
n ot
weld
at
rated load
longer
than
shown
below.
wtwam8.2
8/93
Definition
Duty
Cycle
is
percentage
of
10
I~
10
minutes
that
unit
or
gun
can
weld
at
rated load
without
over
Minutes
heating.
UNIT
60%
Duty Cycle
At
200
Amperes
g
6
Minutes
Welding
4
Minutes
Resting
Chart
GUN
~r~o
ouwtir1
60%
Duty
Cycle
At
200
Amperes Using
CO2
~
6
minutes
Welding
4 minutes
Resting
GUN

 
I
      
60%
Duty
Cycle
At
180
Amperes
Using
Mixed Gas
g~-g~
6
minutes
Welding
4
minutes
Resting
sbl
.38/93

SB.150
215
-
-
I
-------~------
30 40 60
80
70
60
90~0
Z
DUTY CYCLE
OM-154
501
Page
2

3-1.
Installing
Work
Clamp
Figure
3-1.
Installing
Work
Clamp
SECTION
3-
INSTALLATION
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
cov
er
connection with
boot.
4
Hardware
4
5
Work
Clamp
Route
cable
through
clamp
handle
and
secure
to
top
of
clamp
with
hardware.
Close
door.
Tools Needed:
~
1/2,3/4
in
Ret. ST-154
630-A
2
3
OM-154
501
Page
3

3-2.
Installing
Gas
Supply
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.

Shut off
shielding
gas
supply
when
not
In
use.
Cylinder
Bracket
S-Rook
2
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
Cf
h
(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.
Figure
3-2.
Typical
Regulator/Flowmeter
Installation
A~ WARNING
U.


CYLINDERS
can
explode
if
damaged.
S
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.
1
wam4.1
9/91
Tools
Needed:
~
518,1-1/8in
ssb3.2 5/94

ST-154 623
/ Ref.
ST-149 827-B
/
Ref.
ST-158
697-A
OM-154
501
Page
4

3-3.
Gun
Polarity
Connections
A~
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Turn
Off
welding
power
source,
and disconnect
input
power
before
inspecting
or
installing.
3-4.
Installing
Drive
Rolls And
Welding
Gun
swaml.1
2/93
Shown
As
Shipped

Set
For Electrode
Positive
(DCEP)
For Solid
Steel Or
Aluminum
Wires
(GMAW
Process).
Wire
Drive
Assembly
Lead
To
Positive
(+) Output
Terminal
6 5
Work
Clamp
Lead
To
Negative
()
Output
Terminal
GUN
POLARITY
CHANGEOVER
CONNECTIONS
Reverse
Lead
Connections

For
Electrode
Negative
(DCEN)
For Flux
Cored
Wires
(FCAW
Process).
Drive
Assembly
Becomes
Negative
I
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,
11/16
in
Ref.
ST-801
102
3
Figure
3-3.
Gun
Polarity
Connections
4
1
Pressure
Adjustment
2
Pressure
Assembly
3
Drive Roll
4
Securing
Screw
Install
correct
drive
roll
for
wire size
and
type
using
supplied
screws.
5
Wire Drive
Assembly
6
Gun
Securing
Knob
7
Gun End
Loosen
securing
knob. Insert
gun
end
through
opening
until it bot
toms
against
drive
assembly.
Tighten
knob.
8
Gun
Trigger
Plug
Insert into
receptacle,
and
tighten
threaded
collar.
Close
pressure
assembly.
Close
door.
ST.
154 621
/ Ref. ST-801
101
7
6
Tools Needed:
Figure
3-4.
Gun
Connections
OM-154
501
Page
5

3-5.
Connecting Input
Power
c::::::z:J=iJ
3/8
in
Figure
3-5.
Input Voltage
Jumper
Links Location
Jumper
links allow
operation
on
different
input
voltages
and
are
factory
set
for
the
highest input
voltage.
Check
input
voltage
available
at
site.
1
Input
Voltage
Label
Look
at
jumper
links
and
compare
link
position
with
applicable
label.
2
Screw
3 Access
Door
To
change
link
position,
remove
screw
and
pivot
door
up.
4
Input
Voltage
Jumper
Links
Location
Move
links
to
match
input
voltage.
For
example,
use
200
volts
posi.
tion
when
200 volts
input
power
is
available.
Close
door
and
secure
with
screw.
Close
side
door.
ssb5.V
2/92/
Ref. ST-801
099/ Ref.
ST-801
100
____
a
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
swam3.1 2/93
200
VOLTS
1
230
VOLTS
S-153
980
Tools
Needed:
OM.154
501
Page
6

B.
Connecting
Input
Power
Table
3-1.
Electrical
Service
Requirements*
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
electrical
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
ott
unit
Power
switch,
and
connect
plug
to
wall
receptacle.
ssb2.2 12/94

Ref.
ST-154 619-B
/
Ref.
ST-149
405-B
Input
Voltage
200 230
460
575
Input Amperes
At
Rated
Output
46 40 20
16
Max
Recommended Standard Fuse Or Circuit
Breaker
Rating
In
Amperes
70 60
30
25
Mm
Input
Conductor Size
In
AWG/Kcmll
8 8
12
14
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
89(27)
117
(36)
188(57)
190(58)
Mm
Grounding
Conductor Size
In
AWG/KcmlI
8 10
12
14
Reference:
1993
National
Electrical
Code
(NEC).
9-0092J
5
3
Tools Needed:
Figure
3-6.
Input
Power
Connections
OM-154
501
Page
7

3-6.
Installing
Wire
Spool
And
Adjusting
Hub Tension
Figure
3-7.
Installing
Wire
Spool
And
Adjusting
Hub Tension
3-7.
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
teeding
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.
swam5.1
10/91 /
swam2.1 9/91
1
Turn
Off
unit.
1
Wire
Spool
2
Gun Contact
Tip
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
spnng
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
3-7).
Close
door.
Tools
Needed:
~
15/16
in
Ret. ST-801
099
/
Ref. ST.072
573-B
ci
OM-154
501
Page
8

I
Wire
Spool
2
Welding
Wire
3
Inlet Wire
Guide
4
Pressure
Adjustment
Knob
5
Pressure
Assembly
6 Drive
Roll
7
Outlet
Wire
Guide
8
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Close and
tighten
pressure
assembly,
and let
go
of
wire.
/
Press
gun
trigger
until
wire
comes
out of
gun.
Reinstall
contact
tip
and
nozzle.
Remove
gun
nozzle
and
contact
tip.
Feed
wire
to
check drive roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut off
wire.
Close
and
latch
door.
Figure
3-8.
Threading
And
Feeding
Welding
Wire
ST-801
103/
ST-154
251
/
S-0627.A
2
3
6
7
Hold wire
tightly
to
keep
it
from
unraveling.
1)
(
Open
pressure
assembly.
Pull
and
hold
wire;
cut offend.
Push wire
thru
guides
into
gun;
continue
to
hold
wire.
-,
=~
101
POWER
QocF
Set
switch.
~1
~I II
OM-154
501
Page
9

SECTION
4-
OPERATION
4A
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
(MSDSs)
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~
~
-~-
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.
swam62
8/92
:
1
~
2
3
/
SD
Wear
the
following
while
welding:
I
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.
Ref.
ST.801
102
IS.171
601
Figure
4-2. Center
Baffle Controls
OM-154501
Page
10

Tools Needed:
1
Wire
Speed
Control
Use
control
to set
wire
feed
speed.
2
Voltage
Control
Use
control
and
Voltage Range
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-free
location
on
workpiece,
as
close
as
possible
to
weld
area.
3
.4
Figure
4-3.
Controls
Ref. ST-154
622-B
/ST-ill 639/
Ref.
ST-154
251
2
OM154
501
Page
11

SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
__
£~
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.
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swam8.2
2/93
~
4~
M


OVING
PARTS
can cause
Injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch points
such
as
drive
rolls.
*~
5-1.
Routine Maintenance
Turn Off
all
power
before
maintaInIng.
-
3 Months
WARN
I
Replace
Unreadable
Labels
Clean
And
________
Tighten
Weld
Terminals
Replace

Cracked
Parts


14-Pin
Cord
Gas
Hose
Gun Cable
Figure
5-1.
Maintenance
Schedule
OM-154501
Page
12

5-2.
Overload
Protection
a
WARNING
A.
Circuit
Breaker CB1
C.
Overheating
Figure
5-4.
Overheating
READ
Sectio
SAFETY
n
5
befor
BLOCKS
at start
of
e
proceeding.
1
Circuit
Breaker CB1
2 Pilot
Light
If
CB1
opens,
pilot
light
goes
out,
and wire feed
stops.
Check
gun
lin
er
for
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
102
B.
Fuses
Fl
And F2
Figure
5-2.
Circuit
Breaker
CB1
Tum
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
Figure
5-3.
Fuse
Location
When
overheated,
thermostat
Let
fan
run
for
Start
welding.
opens,
output stops,
and
cooling
15
minutes.
fan
keeps
running.
ssblo.1 1)94
-
Ret.
ST-157
072-A
OM-154
501
Page
13