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Summary of Contents for MAC TOOLS MW50
- Page 1 OM-154 501L August 1998 Processes Gas Metal Arc (MIG) Welding ® Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source And Wire Feeder MW250...
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. -
Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message. - Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. -
Page 9: Section 2 − Specifications
SECTION 2 − SPECIFICATIONS 2-1. SPECIFICATIONS 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 Or 230 Volts AC Input Amperes At Rated Output 46 A At 200 V, 40 A At 230 V Maximum Input Amperes While Idling... -
Page 10: Duty Cycle And Overheating
2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. UNIT If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for 60% Duty Cycle At 200 Amperes unit to cool. -
Page 11: Installing Gas Supply
3-2. Installing Gas Supply Cylinder Bracket S-Hook Crimp between small hole in brack- et and chain. Chain Snap Crimp onto open end of chain. Obtain gas cylinder and chain to running gear. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. -
Page 12: Gun Polarity Connections
3-3. Gun Polarity Connections Polarity Changeover Label Wire Drive Assembly Positive (+) Output Terminal Negative (−) Output Terminal Always read and follow wire man- Shown As Shipped − Set For Electrode ufacturer’s recommended polarity. Positive (DCEP) For Solid Steel Or Aluminum Wires (GMAW Process). -
Page 13: Positioning Jumper Links
3-6. Positioning Jumper Links Check input voltage available at site. 200 VOLTS Jumper Links Access Door Open door. Jumper Link Label Input Voltage Jumper Link 230 VOLTS Move jumper link to match input voltage. Close and secure access door. Close side door. S-153 980 Tools Needed: 3/8 in... -
Page 14: Connecting Input Power
3-7. Connecting Input Power Have only qualified persons make this installation. Line Disconnect Device Of Proper Rating 230 Volts AC Wall Receptacle Input Conductors Grounding Conductor Select size and length using 3-5. Conductor rating must comply with national, state, and local electrical codes. -
Page 15: Installing Wire Spool And Adjusting Hub Tension
3-8. Installing Wire Spool And Adjusting Hub Tension Wire Spool Gun Contact Tip If necessary, cut welding wire off at contact tip, and retract wire onto spool and secure. Retaining Ring Compression Spring Remove ring and pull off spool. Compression spring is used with 8 in (200 mm) spools. -
Page 16: Threading Welding Wire
3-9. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Tools Needed: Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. 4 in 6 in (102 mm) (150 mm) Open pressure assembly. Pull and hold wire;... -
Page 17: Section 4 − Operation
SECTION 4 − OPERATION 4-1. Front Panel Controls Wire Speed Control Use control to set wire feed speed. Voltage Control Use control and Voltage Range Se- lector (see 4-2) to set arc voltage. Step 6 of Low range and Step 1 of High range overlap. -
Page 18: Center Baffle Controls
4-2. Center Baffle Controls Wire Mode Switch For better control of wire speed use Low position when wire speed is between 90 and 670 ipm. Use Full DO NOT SWITCH position when wire speed is be- tween 150 ipm and 1030 ipm. UNDER LOAD Voltage Range Selector WIRE MODE... -
Page 19: Section 5 − Maintenance & Troubleshooting
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 3 Months Clean And Repair Or Replace Tighten Replace Damaged Or Weld Cracked Unreadable Terminals Cables And Labels Cords 6 Months Remove drive roll and Blow Out Or carrier. -
Page 20: Fuses F1 And F2
5-3. Fuses F1 And F2 Turn Off unit and disconnect input power. Fuse F1 (See Parts List For Rating) F1 protects the 115 volts ac winding of transformer T1. If F1 opens, all weld output stops and pilot light PL1 goes out. -
Page 21: Replacing Gun Contact Tip
5-6. Replacing Gun Contact Tip Y Turn power before replacing contact tip. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: Ref. ST-801 978 5-7. Gun Maintenance Y Disconnect gun first. -
Page 22: Troubleshooting
5-8. Troubleshooting Welding Trouble Remedy No weld output; wire does not feed. Check input power connections (see Section 3-7). Reset circuit breaker CB1 (see Section 5-2). Replace fuse F1 and/or F2 (see Section 5-3). Replace building line fuse or reset circuit breaker if open (see Section 3-7). Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 3-4). -
Page 23: Section 6 − Electrical Diagram
SECTION 6 − ELECTRICAL DIAGRAM SB-173 544-E Figure 6-1. Circuit Diagram For Welding Power Source OM-154 501 Page 19... -
Page 24: Section 7 − Parts List
SECTION 7 − PARTS LIST FIG 7−2 FIG 7−4 ST-155 610-D Figure 7-1. Main Assembly NOTE: All items indented by a dot(s) are included with the item listed directly above. Item Part Item Part Item Part Description Description Description 146 168 Enclosure Panel 009 970 ·... - Page 25 Fig.7−3 − 27 ST-155 609-E Figure 7-2. Baffle w/Components (Fig 7-1 Item 2) NOTE: All items indented by a dot(s) are included with the item listed directly above. Item Part Item Part Item Part Description Description Description 058 427 Retaining Ring 186 355 Contactor 038 618...
- Page 26 See Table 7-1 for Drive Roll & Wire Drive Kits Hardware is common and not available unless listed. ST-148 529-D Figure 7-3. Wire Drive And Gears (Fig 7-2 Item 27) Item Part Item Part Item Part Description Description Description 602 009 Screw, .250-20 x 1.25 151 828 Cotter Hair Pin...
- Page 27 Item Part Description 110 793 Handle Assembly 110 780 Nut, M 10 x 1 175 180 Head Tube 175 177 Diffusor 175 175 Holder, tip recessed ♦ 175 176 Holder, tip flush ♦ 175 230 Contact Tip, .025 (10pk) ♦ 175 231 Contact Tip, .030 (10pk) 175 232...
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Page 29: Warranty
Warranty Effective January 1, 1998 (Equipment with a serial number preface of “KJ” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or Items furnished by manufacturer, but manufactured by warranties expressed or implied. - Page 30 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment...
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