Miller | KF817681 | Owner Manual | Miller MW250 User manual

Miller MW250 User manual
February
1995
Effective With Seria
Form:
OM-154501A
No. KF817681
MW250
TOLSfi
OWNERS
MANUAL
~ IMPORTANT:
Read and understand the entire contents of this manual, with special emphasis on the safety
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
material
understand these instructions.
coven
5/92*
ST-157 072-A
PRINTED IN LISA
ARC WELDING SAFETY PRECAUTIONS
WARNING
£~
ARC WELDING
be hazardous.
can
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.
ELECTRIC SHOCK
can
kill.
5.
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 touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1.
Do not touch live electrical
2.
Wear
3.
Insulate
mats
4.
or covers.
/,,~ ,
~9-~-~2-
stop engine before installing
I
I ~I
Do not
worn,
equipment according
to its
not in use.
equipment when
use
this
ground
damaged, undersized,
or
poorly spliced
cables.
8.
Do not wrap cables around your
9.
Ground the workpiece to
10.
a
body.
good electrical (earth) ground.
Do not touch electrode while in contact with the work
11.
Use only well-maintained equipment. Repair
damaged parts at once.
12.
Wear
(ground)
Wear
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
2.
Wear
3.
Use
and
covers
securely
in
place.
5.
5.
Work in
6.
Do not weld
to your health.
Welding produces fumes and gases. Breathing
be hazardous to your
can
prevent falling if working above floor
approved safety glasses. Side shields recommended.
protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Use approved ear plugs or ear muffs if noise level is high.
4.
these fumes and gases
health.
to
a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
1.
be hazardous
safety harness
Keep all panels
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
can
a
replace
or
level.
13.
FUMES AND GASES
~
Turn off all
7.
or
hearing.
~._
6.
parts.
or
install and
Manual and national, state, and local codes.
circuit.
dry, hole-free insulating gloves and body protection.
yourself from work and ground using dry insulating
Disconnect input power
servicing this equipment.
Properly
Owners
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
.
out of the fumes. Do not breathe the fumes.
1.
Keep your head
2.
If inside, ventilate the area and/or
remove welding fumes and gases.
3.
If ventilation is poor,
4.
operations.
form highly
use
exhaust at the
7.
on
coated metals, such
area
the
Do not weld
drums.
Connect work cable to the work
on
closed containers such
as
Do not weld where
strike flammable material.
9.
Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers,
10.
Remove stick electrode from holder
contact tip when not in use.
4.
Be alert that
11.
Wear oil-free
FLYING SPARKS AND HOT METAL
can
Chipping
and
can
grinding
cause
throw off
slag.
flying
metal. As welds
Do not
use
welder to thaw frozen
or
welding area as
traveling long,
and fire
pipes.
or
cut off
welding
wire at
protective garments such as leather gloves,
heavy shirt, cuffless trousers, high shoes, and a cap.
1.
Wear approved face shield
recommended.
or
2.
Wear proper
to
injury,
cool, they
tanks
partition
hazards.
3.
cause
as
close to the
practical to prevent welding current from
possibly unknown paths and causing electric shock
and hot metal.
welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
or
is removed from the
8.
2.
can
galvanized, lead,
is well ventilated, and if necessary, while
Protect
flying sparks
as
coating
1.
flying sparks
spraying
7.
fire.
and others from
or
with vapors to
or
5.
6.
yourself
can react
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead,
can cause fire on the hidden side.
explosion.
or
degreasing, cleaning,
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
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
near
plated steel, unless
weld area, the
and cleaners,
fire
Do not weld
cadmium
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals, consumables, coatings,
can cause
locations
arc to
use an
WELDING
in
The heat and rays of the arc
toxic and irritating gases.
body protection
safety goggles. Side
protect
skin.
shields
CYLINDERS
explode
can
if
Keep cylinders away
3.
damaged.
from any
welding
other electrical
or
circuits.
contain gas under
Shielding gas cylinders
high
pressure. If damaged, a cylinder can explode. Since
the
of
are
normally part
welding
gas cylinders
process, be sure to treat them carefully.
Never allow
4.
a welding electrode to touch any cylinder.
only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
5.
Use
6.
1,
Protect
compressed gas cylinders from excessive heat,
mechanical shocks, and
Install and
cylinders in
them to a stationary support
prevent falling or tipping.
2.
7.
arcs.
secure
in
an
or
upright position by chaining
equipment cylinder rack to
use or
connected for use.
Read and follow instructions
8.
associated
on compressed gas cylinders,
equipment, and CGA publication P-i listed in Safety
Standards.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting,
ANSI Standard Z49.i, from American
Welding Society,
550 NW. LeJeune Rd, Miami FL 33126
Safetyand Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government
D.C. 20402.
Printing Office, Washington,
Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Weld
ing Society Standard AWS F4.i, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Recommended Safe Practices for the
National Electrical
Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Handling of Compressed Gases
501, Arlington, VA 22202.
Safe
Code for
in
Cylinders,
Safety in Welding and Cutting, CSA
Rexdale, Ontario, Canada M9W
CGA
Pamphlet P-i,
from
Compressed
Gas Association, 1235 Jefferson Davis
Standard Wi 17.2, from Canadian Standards Association, Standards
Sales,
Highway, Suite
178 Rexdale
Boulevard,
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,
Batterymarch Park, Quincy,
NFPA Standard 51 B, from National Fire Protection Association,
MA 02269.
EMF INFORMATION
NOTE ~
Considerations About
Magnetic
Welding
And The Effects Of Low
Frequency Electric And
Fields
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Papei 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 scientifi
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.
The
To reduce
of the U.S.
procedures:
-.
magnetic fields
cables close
in
the
workplace,
together by twisting
1.
Keep
2.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
5.
Connect work clamp to workpiece
or
use
following
taping them.
cables to one side and away from the
or
the
operator.
drape cables around the body.
source
and cables
as
as
far away
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.
modlO.1 4/93
TABLE OF CONTENTS
SECTION 1
SAFETY INFORMATION
SECTION 2
SPECIFICATIONS
2-1.
2-2.
Volt-Ampere Curves
Duty Cycle
1
SECTION 4OPERATION
1
SECTION 5- MAINTENANCE & TROUBLESHOOTING 12
2
5-1. Routine Maintenance
12
2
5-2. Overload Protection
13
5-3. Wire Drive
SECTION 3INSTALLATION
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
Installing Work Clamp
Installing Gas Supply
Gun Polarity Connections
Installing Drive Rolls And Welding Gun
Connecting Input Power
Installing Wire Spool And Adjusting Hub
Threading And Feeding Welding Wire
10
3
3
Assembly Maintenance
5-4. Gun Maintenance
5-5.
Troubleshooting
14
15
16
4
5
5
6
Tension
.
.
.
.
8
8
SECTION 6
ELECTRICAL DIAGRAMS
SECTION 7- PARTS LIST
Figure
Figure
Figure
7-1. Main
Assembly
16
17
17
7-2. MWG-200M Gun
18
7-3. Baffle
19
w/Cmpts
SECTION 1
SAFETY INFORMATION
-
modl.1 2/93
Read all
0
Obey
U
all
safety messages throughout
safety messages
Learn the
meaning
to avoid
this manual.
injury.
of WARNING and CAUTION.
2
1
1
Safety
2
SignalWord
2
\
!\
~
WARNING means possible death
or serious injury can happen.
a CAUTION
:1~ll~~U
!ITLTIA
paila.~
_____________
ELECTRIC SHOCK
can
kill
Disconnect
installing
or
input power
servicing.
be~Jj~
MOVING PARTS
~
Do not touch live electrical parts.
4
Symbol
Alert
Keep away
Keep
when
from
panels
operating.
all
can
moving
and
Injure
covers
closed
CAUTION
means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And
Result
4
Safety Instructions
______
/
To Avoid
Hazard
5
4i~4~
6.i~I~
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
I
5
Hazard
6
Safety
Read safety blocks for each sym
bol shown.
NOTE
7
Turn Off switch when
Special instructions
using high frequency.
ation
1-1.
Figure
Safety
Symbol (If Available)
Banner
for best oper
not related to
safety.
Information
SECTION 2- SPECIFICATIONS
Table 1-1.
Welding
Power Source
Specifications
Description
Direct Current/Constant
Type Of Output
Rated Weld
Output
Type Of Input Power
Input Amperes
Maximum
Single-Phase; 60 Hz;
Al Rated
Idling
Open-Circuit Voltage
Control Circuit
Welding
Voltage
At Gun
Calculated
1.2 A At 200
Speed Range
At No Load
0.24 kVA/0.17 kW
42 Volts DC
24 Volts DC
128 To 1051
Overall Dimensions
Length:
Weight
Net: 225 lb
Rated
OM-154 501
Page
1
1pm (3.2
37 in
(0.8
And Flux Cored Arc
To 266.9
To 1.1
mm)
(940 mm); Width:
(102 kg); Ship:
Welding (FCAW)
mpm)
Flux Cored Wire, .023 To .045 in
(0.6 To
19 in
(768 mm)
271 lb
(483 mm); Height: 30-1/4
in
1.1
mm) Hard
(123 kg)
Gun
Output (Air Cooled)
Cable Length
(GMAW)
.030 To .045 in
Range
Welding
V, 1 A At 230 V, 0.5 A At 460 V, 0.4 A At 575 V
Gas Metal Arc
Processes
Wire Diameter
At 200, 230, 460, Or 575 Volts AC
9.5 kVAJ8.3 kW
Output
Maximum KVNKW Used While
DC, 60% Duty Cycle (See Section 2-2)
46AAt200V, 40AAt230 V, 20AAt460 V, 16AAt575V
Output
Input Amperes While Idling
KVA/KW Used At Rated
Max.
Volts
Amperes, 28
200
Voltage (DC/CV)
200
Amperes
15 ft
(4.5 m)
At 100%
Duty Cycle Using CO2 Shielding Gas (See Section 2-2)
Wire
Volt-Ampere Curves
2-1.
The
volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of the welding power source.
50
Curves of other
40
Cl)
settings
fall be
tween the curves shown.
30
OO20~~~
RANGE
I
I
I
125
150
175
I
0
0
25
50
75
100
200
225
DC AMPERES
ssbl.1 10/91 SB-049
Figure
2-2.
2-1.
Volt-Ampere Curves
Duty Cycle
a
CAUTION
I WELDING L ONGER THAN RATED DUTY CYCLE
~
424-0
Do not weld at rated load
can
damage
unit
or
gun and void
warranty.
longer than shown below.
wtwern8.2 8/93
UNIT
Definition
60%
Duty Cycle
is percentage of 10
.minutes..that unit or gun.can
weld at rated load without
At 200
Amperes
~~-C3~
over
heating.
Minutes
Duty Cycle
6 Minutes
4 Minutes
Welding
Chart
Resting
GUN
100%
Duty Cycle At
200
Amperes Using CO2
300
g.
250
(n
Lu
200
Continuous
~
Ui
a
~
GUN
.(
~
160
-I
30% Duty
Lu
~
Cycle
At 200
Amperes Using Mixed Gas
100
80
30
40
50
Z DUTY
50
7050
90
100
CYCLE
sbl.38/93SB-150215
Figure
2-2.
Duty Cycle
OM-154 501
Page
2
ic
SECTION 3- INSTALLATION
3-1.
Installing
Work
Clamp
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
er connection with boot.
4
4
Hardware
5
Work
Clamp
Route cable
and
cov~
through clamp
secure to
handle
top of clamp with
hardware.
Close door.
5
Tools Needed:
~==~ 1/2, 3/4 in
Ret. ST-154 630-A
Figure
OM-154 501
Page
3
3-1.
Installing
Work
Clamp
3-2.
Installing
Gas
a
Supply
WARNING
CYLINDERS
can
explode
Keep cylinders away
from
if
damaged.
welding
and
other
electrical circuits.
BUILDUP OF SHIELDING GAS
health or kill.
Shut off
shielding gas supply
can
when not in
harm
use.
Never touch cylinder with welding electrode.
Always secure cylinder
stationary support.
to
running gear, wall,
or
other
warn4.i 9/91
1
Cylinder
2
S-Hook
Bracket
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
9
so
face is vertical.
Gas Hose Connection
Fitting
5/8-18
Obtain and
has
threads.
hose.
10
Flow
right-hand
install
gas
Adjust
flow rate is 20 cfh (cubic
feet per hour). Check wire man
Typical
ufacturers
recommended
flow
rate.
Make
flow adjust is closed
opening cylinder to avoid
damage to the flowmeter.
sure
when
11
CO2 Adapter
12
0-Ring
Install
adapter with 0-ring between
and
regulator/flowmeter
CO2
cylinder.
Tools Needed:
5/8,1-1/8in
ssb3.2
Figure
3-2.
5/94
ST-i 54 623/ Ref. ST-i 49 627-6 / Ref. ST-i 58 697-A
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.
swarnl.1
Shown As Shipped
Set For Electrode
Positive (DCEP) For Solid Steel Or
Aluminum Wires (GMAW Process).
Wire Drive Assembly Lead
To Positive (+) Output Terminal
1
Polarity Changeover Label
2
Wire Drive Assembly
3
Positive
4
Negative () Output
(+) Output Terminal
Terminal
Always read and follow wire man
ufacturers recommended polarity.
5
Circuit Breaker CB1 (see
Section 5-2).
6
Pilot Light (see Section 5-2)
Close door.
Tools Needed:
Work Clamp Lead To
Negative () Output Terminal
.~ 314, llIl6in
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections
For Electrode
Negative (DCEN) For Flux Cored Wires
(FCAW Process). Drive Assembly
Becomes Negative
S-144 449-C
3
4
Ret. ST.801 102
Figure
3-4.
Installing Drivefiolls
And
3-3. Gun
Polarity Connections
Welding Gun
1
Pressure
Adjustment
2
Pressure
Assembly
3
Drive Roll
4
Securing Screw
Install correct drive roll forwire size
and type using supplied screws.
5
Wire Drive
6
Gun
7
Gun End
Assembly
Securing
Knob
Loosen securing knob. Insert gun
end through opening until it bot
toms
against
Tighten knob.
8
drive
assembly.
Gun Trigger Plug
Insert into receptacle, and
threaded collar.
Close pressure
door.
7
tighten
assembly. Close
Tools Needed:
6
ST- 154 621 / Ret. ST-aOl 101
Figure
OM-154 501
Pages
3-4. Gun Connections
3-5.
Connecting Input
Power
WARNING
a
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off
Have
welding
power source, and disconnect
only qualified persons install
input power before inspecting
or
installing.
unit.
Installation must meet National Electrical Code and all other codes.
A.
Positioning Jumper
swarn3.1 2193
Links
links allow
Jumper
operation on
input voltages and are
factory set for the highest input
voltage.
different
Check
site.
input voltage available
at
200 VOLTS
1
~OOo~
1
Input Voltage
Label
Only
One Is On Unit
Look at jumper links and compare
link position with applicable label.
230 VOLTS
460 VOLTS
o~J~oo
~O~Oo~
2
Screw
3
Access Door
To
change link position,
screw and pivot door up.
4
575 VOLTS
460 VOLTS
OoO~1
OoO~
S-156 140
S-153 981
remove
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.
Tools Needed:
==
c::::::1==in
3/8 in
ssb5.1
Figure
3-5.
2/92 / Ref. 5T-801 099 / Ref. ST-801 100
Input Voltage Jumper Links Location
OM-154 501 Page 6
B.
Connecting Input
Power
Have only qualified persons make
this installation.
1
Line Disconnect Device Of
2
230 Volts AC Wall
Proper Rating
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
ground.
to an earth
5
Overcurrent Protection
Select type
and
size
using
Table 3-1. Install into deenergized
line disconnect device
connect switch
(fused
dis
shown).
Input Power Plug
6
Turn off unit Power switch, and
connect plug to wall receptacle.
3
Tools Needed:
ssb2.2 12/94
3-6.
Figure
Input Power Connections
Table 3-1. Electrical Service
Input Voltage
Input Amperes
At Rated
Output
Max Recommended Standard Fuse Or Circuit
Breaker Rating In Amperes
Mm
Input Conductor
Size In AWGIKcmII
Max Recommended Input Conductor
Feet (Meters)
Mm
Grounding
Page
7
(NEC).
Requirements*
200
230
460
575
46
40
20
16
70
60
30
25
8
8
12
14
In
Conductor Size In AWG/Kcmil
Reference: 1993 National Electrical Code
OM-154 501
Length
Ref. ST-154 619-B / Ref. ST-149 405-B
89(27)
8
117
(36)
10
188
(57)
12
190(58)
14
S-oo92J
c~3:
.s
3-6.
Installing
Wire
Spool
And
Adjusting
Hub Tension
Turn Off unit.
Spool
1
Wire
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 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.
Hub Tension Nut
7
Grasp spool
using
while
a
in
one
hand and turn
adjust hub
wrench to
a slight force is
spool, tension is
tension nut. When
needed to turn
set.
(see Section
Thread
welding wire
Close door.
3-7).
Tools Needed:
~
15/16 in
Ref. ST-aOl 099 / Ref. ST-072 573-B
Figure
3-7.
Threading
a
And
3-7.
Installing
Wire
Feeding Welding
Spool
And
Adjusting
Hub Tension
Wire
WARNING
CYLINDERS
can
explode
Keep cylinders away
from
if
damaged.
welding and other
electrical circuits.
Never touch
cylinder
WELDING WIRE
wounds.
Do not press gun
with
welding
electrode.
Always secure cylinder to running gear, wall,
other stationary support.
ELECTRIC SHOCK
can
can
trigger
cause
puncture
until instructed to do
so.
Do not
or
kill.
Do not touch live electrical parts.
point gun toward any part of the body, other
people, or any metal when threading welding wire.
HOT SURFACES
can
Allow gun to cool before
burn skin.
touching.
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.
swarn5.1 10/91 /swarn2.1 9/91
OM-154 501 Page 8
1
Wire
2
Welding
Spool
Wire
3
Inlet Wire Guide
4
Pressure
Adjustment
5
Pressure
Assembly
6
Drive Roll
7
Outlet Wire Guide
8
Gun Conduit Cable
Lay gun cable
out
Knob
straight.
Hold wire tightly to keep it
from unraveling.
I.)
=~
Pull and hold wire; cut offend.
Open pressure assembly.
Push wire thru guides into gun;
continue to hold wire.
I0~~
POWER
~
~
I
Close and
Set switch.
Remove gun nozzle
and contact tip.
tighten pressure assembly,
and let go of wire.
-4
6
/
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Press gun trigger until wire
out of gun. Reinstall
contact tip and nozzle.
Cut off wire.
Close and latch door.
lighten
comes
OoFF~
ST-801 103/ 5T-154 251 / S-0627-A
Figure
OM-154 501
Page
9
3-8.
Threading
And
Feeding Welding
Wire
a
SECTION 4- OPERATION
WARNING
a
ELECTRIC SHOCK
Always
wear
Insulate
can
yourself from
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
t
dry insulating gloves.
work and
~
ground.
Wear
..
Do not touch live electrical parts.
Keep
all
panels and
covers
FUMES AND GASES
to your health.
Keep your head
can
in
place
MOVING PARTS
,~
be hazardous
~
Keep away
~
or use
Read Material
Safety
Keep
securely
and
can cause
fire
or
Pacemaker
~
near arc
keep extinguisher nearby.
Do not weld
on
Allow work and
can
injury.
pinch points such
panels,
place.
over
wearers
as
covers, and
drive rolls.
guards
closed
keep away.
welding, gouging,
or
going
spot welding opera
tions.
combustible surfaces.
WELDING CURRENT can
tronic parts in vehicles.
closed containers.
equipment
to cool before
handling
Disconnect both
ARCING
can cause
Wearers should consult their doctor before
~.
Do not locate unit
in
body protection.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can aftect pacemaker operation.
explosion.
Do not weld near flammable material.
Watch for fire;
with correct shade of filter.
breathing device.
Data Sheets (MSDS5) and
instructions for material used.
manufacturers
from
all doors,
out of the fumes.
Ventilate area,
WELDING
securely
welding helmet
Wear correct eye, ear, and
damage
switch.
damage elec
battery cables before welding on a
vehicle.
Do not change Voltage switch position while
welding.
Arcing inside switch can damage contacts, causing
Place work
as
close to the weld
as
possible.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
swarn6.2 8/92
switch to fail.
2
clamp
3
/
Wear the
following
while
welding:
1
Dry, Insulating Gloves
2
Safety Glasses
With Side
Shields
3
Helmet With Correct
Shade Of Filter (See ANSI
Welding
Z49.1)
sb3.1 1/94
Figure
4-1.
Safety Equipment
1
Wire Mode Switch
For better control of wire
speed use
speed is
between 90 and 670 ipm. Use Full
position when wire speed is be
tween 150 ipm and 1030 ipm.
Low
2
position
when wire
Voltage Range Selector
Place switch in desired
See inside rear cover for
position.
settings.
Ret. ST-801 102 / S-171 601
Figure
4-2. Center Baffle Controls
OM-154 501
Page
10
Wire
1
Speed Control
Use control to set wire teed
speed.
Voltage Control
2
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.
Power Switch
4
Use switch to turn unit On and Off.
pilot light comes on when unit
is turned on.
The
Use wire brush
or
clean metal at weld
Connect
work
paint-free
as
close
clamp
location
as
sandpaper
joint area.
on
possible
to
to
clean,
workpiece,
to weld area.
Tools Needed:
Ret. ST-154 622-9/ ST-171 639/ Ret. ST-154 251
Figure
OM-154 501
Page
11
4-3. Controls
K
~4*-~:-
SECTION 5- MAINTENANCE & TROUBLESHOOTING
a
WARNING
ELECTRIC SHOCK
can
kill.
M OVING PARTS
Do not touch live electrical parts.
Turn Off
input
can cause
injury.
Keep away from moving parts.
welding power source, and disconnect
power before inspecting, maintaining, or
$~
Keep
away from
pinch points such
as
drive rolls.
servicing.
HOT PARTS
can cause severe
Allow
cooling
servicing.
period
before
burns.
maintaining
or
*~
Maintenance and troubleshooting
only by qualified persons.
5-1.
to be
performed
swarn82
2/93
Routine Maintenance
Turn Off all power before
Each
maintaining.
Spool Of Wire
-~
3 Months
6 Months
WARNI
I
See
Section
~
~
Casing
Unreadable
Labels
Inside
7
Clean
And
Clean
Nozzle
And Check
Blow Out
Or
Vacuum
Replace
Blow Out
Gun
1
Tighten
Weld
Terminals
________
________
Contact Tip
Replace
~
During Heavy Service,
Clean Monthly
Clean
Drive
Rolls
3-4
Cracked
Parts
14-Pin Cord
Gas Hose
Figure
Gun Cable
5-1. Maintenance Schedule
OM-154 501
Page
12
~i
r&e
Overload Protection
5-2.
a
A.
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Circuit Breaker CB1
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.
Ret. ST-801 102
Figure
B.
5-2. Circuit Breaker CB1
Fuses Fl And F2
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
Figure
C.
5-3. Fuse Location
Overheating
Figure
OM-154 501
Page
13
5-4.
Overheating
5-3.
£~
Wire Drive
Assembly
Maintenance
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Turn Oft unit and disconnect input
power.
1
Wire
2
Gun Contact
Cut
welding
Spool
Tip
wire off at contact
Retract wire onto spool and
tip.
se
cure.
3
Drive Roll
Turn in
with wire
Alignment Bolt
out until groove lines up
or
guide.
4
Drive Roll
5
Wire Inlet Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole
from
rear
until it snaps in
6
Pressure Roll Arm
7
Cotter Pin
8
Pin
9
Screw
10
Bearing
Remove
new
bearing as
bearing and
screw.
secure
place.
shown. Install
secure
Reinstall arm onto
with cotter pin.
Thread welding wire
3-7). Close door.
(see
with
pin and
Section
Correct
Alignment
Tools Needed:
Ret. ST-801 099 / SA-145 763/ ST-154 633
Figure
5-5. Wire Drive
Assembly
Maintenance
OM-154 501
Page
14
-Tighten
5-4.
a
Gun Maintenance
READ SAFETY BLOCKS at start of
Section NO TAG before proceeding.
WARNING
FLYING METAL CHIPS AND DIRT
Point gun away from
people and
in
a
can cause
safe direction when
injury
blowing
and
damage equipment.
out with
compressed air.
swarnl0.1 10191
Turn Off unit and disconnect
input
power.
Spool
1
Wire
Cut
welding
wire off at contact
Retract wire onto spool and
tip.
se
cure.
2
Gun
Securing Knob
Loosen knob and
remove
gun and
trigger plug.
1
2
3
Nozzle
4
Contact
lip
5
Contact
lip Adapter
6
Head Tube
7
Setscrew
8
Wire Outlet Guide
Disassemble gun
9
as
shown.
Liner
Pull liner from this end. Blow gun
out with compressed air.
casing
Insert new liner into gun casing.
The liner end covered with clear
tubing goes to the head tube.
Reinstall guide so that 1/8 in (3
of liner sticks out. Hand tight
en guide, and then tighten two full
mm)
6
turns
more.
Cut liner oft so that 1/2 in (13 mm)
sticks out of head tube. Trim clear
tubing off 1/4 in (6.3 mm) from end
of liner.
7
head
screw
setscrew to secure liner in
tube. Overtightening set
crushes liner and causes
wire feed
9
problems.
Reassemble gun.
Reinstall gun (see Section 3-4).
Thread welding wire (see Section
3-7). Close door.
9
Tools Needed:
3/8in
Ret. 5T~801 101 / 5T~145 478~C / Ret. ST-150 436A
Figure
OM-154 501
Page
15
5-6. Gun Maintenance
ii
i
Troubleshooting
5-5.
a
Welding
No weld
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Remedy
Trouble
output; wire does
not feed.
-~
3.5
Reset circuit breaker CB1.
-~
5-2
-a
3-5
-~
3-4
line fuse
Replace building
Secure gun
trigger
No weld
output; wire does
not
motor continues to run and
feed; fan
pilot light
~
-~
is
Section
Secure power cord plug in receptacle.
trigger plug
in
Replace
or
fuse Fl and/or F2.
reset circuit breaker if open
receptacle
or
repair leads,
or
replace
switch.
Thermostat open (overheating). Allow fan to run; the thermostat
will close when the unit has cooled.
off.
I
No weld
-~
output; wire feeds.
Replace
I
Low weld
-~
Figure
I-..-
tip.
- Connect unit to proper input voltage
output.
1
Connect work clamp to get good metal to metal contact.
contact
--.~__5-2
or
-
check for low line volta
4-3
5-4
I
3-5
Wire Drive/Gun Trouble
Electrode wire
feeding stops during ~
-~
Straighten
gun cable and/or
replace damaged parts.
-~
5.4
I
welding.
Adjust
hub tension.
----~
3-6
Adjust
drive roll pressure.
--~
3-7
--~
5-4
---
5-3, 5-4
--~
5.3
---
3-4
Replace
Clean
or
Replace
if blocked.
contact
tip
replace
wire inlet
drive roll
or
guide
pressure
or
liner if
bearing
Secure gun trigger plug in receptacle
trigger switch.
if
or
dirty
or
worn or
plugged.
slipping
repair leads,
or
replace
Check and replace Fl and/or F2.
--~
5-2
Check and clear any restrictions at drive assembly and liner
--~
5-3, 5-4
Have nearest Factory Authorized Service Station check drive
---
motor.
SECTION 6- ELECTRICAL DIAGRAMS
CBI
091
PL~TI
Rd
nr~ _t~i
.0
C.
f~1 ~ ~I
A
A~~-A-A
0
0
0
~0
~
0
52
~
i
CU
I
2
RC3-13>
~G2
PLG2O
RC3-Il).>--~--<3
RC3- I >>~-<
RCO_3>>_____I!?_<
RC3-2)d.-~--<
914
PCI
CONTROL BOARD
RC3/PLG~
RC4/PLG4
RC5/PLG5
14r1
4
~
7
10
RC3-
I9>)–~~(
I
12
ONIVE
H~.J9IN0
WORK
CLA~
SB-i 74 099
Figure
6-1. Circuit
Diagram
For
Welding Power
Source
OM-154 501
Page
16
Cl) m C)
0z
-I Cl)
Cl) -I
610-A
13
ST-15
11
17
9
p
19
Asembly
20
6
Main
7-1.
Figure
21
N
7-3
4
Fig
I
3
7-2
23
I
0
(31 .0- (11 0
0,
cD
-.3
Fig
L.
.4
Parts For Main
NOTE: All items indented
Item
No.
Part
No.
by
a
dot(s)
Description
146168
Enclosure Panel
2
083 526
Housing Rcpt
Housing Plug
4
Fig
7-3
& Sockets
& Pins
Baffle
w/Cmpts
5
171 658
5
172 519
5
172 520
Transformer, 200/230
Transformer, 200/230/460
Transformer, 230/460/575
6
171 213
Stabilizer
Rear Panel
7
150783
Far,Blade
Speed
049 399
116996
Nylon Nut,
134 834
Hose
149 332
Hose
037 957
037 956
605 886
605 884
171 600
152 862
.750
.
.
j
Item
No.
Part
No.
153 197
Rectifier Bracket
RearPanel
Description
.
Selector Switch
148956
Switch Handle
057 478
Tank Bracket
152 626
Front Panel
044 426
155 418
Front Control Panel
171 639
Control Plate
153447
Nameplate
8
022 617
Cable Clamp
Cylinder Chain
9
146165
SidePanel,LH
10
151 187
Latch
144 127
11
146167
Side Panel
057 357
12
134 464
Warning
13
+170513
14
047 721
14
071 907
15
146161
Base
153 714
Regulator/Flowmeter
16
135390
Axle
154 829
Hose Kit
17
070799
Wheel
112 863
18
121 614
Retaining Ring
113129
Resistor
089 120
Adapter Fitting
PVCTubing
Hose Clamp, .375450
Label
Wrapper
Cord Set, (dual voltage)
Cord Set, (triple voltage)
19
091 685
20
605 741
Clip
Capacitor
21
008 999
Caster
Diode, RP
Diode, SP
Washer, .750
Half Nut, .750-16
Thermostat, NC
22
Clamp
Rectifier
152 742
048 420
above
Front Panel
Light
027 645
097 924
Stand-Off
Grommet
.
Receptacle w/Sockets
079 534
Terminal, female
Switch, DPST
.
Item
No.
5
4
3\\~
130 750
Ground
028 509
Regulator/Tank Adapter
Clamp
ordering
a
a component originally dis
precautionary label, the label should
provide Model and Serial Number
ordering replacement parts.
Part
No.
Description
Head Tube Kit
1
152 669
2
081 960
3
086281
Hose
4
154844
154 843
Nut, conduit
5
6
4154841
6
154842
7
4154837
7
154836
7
154835
7
4154834
Retaining Ring
Insulator
Adapter, .023
Adapter, .030.045
ContactTip, .023
ContactTip, .030
Contact lip, .035
Contact lip, .045
8
154 840
Nozzle, .625 orf
8
4154839
Nozzle, .5000rf
8
4154 838
9
144 344
Cable/Conduit
10
089902
Terminal
11
079 974
12
120 164
0-Ring, .500
Trigger Switch Assembly
13
154731
149927
14
2
21
.
Weld Cable
sure to
when
6
7-2)
also be ordered.
Be
.
MWG-200M Gun, (Fig
Consumables Label
600 318
playing
Knob
048 282
128755
Handle
Cap, handle
+When
Potentiometer
035 897
Bushing, 1.l25mtg
154 596
144 548
w/Cmpts
Cover, module opening
.
154007
154 833
23
Nut
GasValve
605 227
026 947
w/Cmpts
Fan Motor
148 808
Assembly
directly
Description
143810
Terminal, male
009 419
Part
No.
009 970
Terminal, female
009 418
072 802
included with the item listed
Item
No.
1
3
are
3
081 960
086 281
15
128 758
16
112 884
Nozzle, .437 orf
Set Screw
Handle
Retaining Ring
Hose
Locking Ring
17
091 602
Strain Relief, extension
Strain Relief, cable
18
049312
LockingRing
19
4154 874
20
128 769
19
154 875
20
120 995
19
4154 876
20
120 995
21
079 878
22
079 535
Liner
Kit, .023/.025
Wire Guide, .023
Liner Kit, .030/.035
Wire Guide, .030045
Liner Kit, .045
Wire Guide .030045
& Pins
Housing Plug
Terminal, male
22
048 834
Clamp
23
604 525
Cable
OPTIONAL
17
Figure
7-2. MWG-200M Gun
ST-155766
(Fig
7-1 Item
23)
OM-154 501
Page
18
13
40
7
6
9
50
45
46
ST-155 609-A
Figure
NOTE: All items indented
Item
No.
Part
No.
127 232
092 237
2
089477
3
085 244
4
089 562
5
010224
6
090416
8
a
dot(s)
Description
1
7
by
124778
9
151 828
10
112031
11
111 523
Item
No.
Part
No.
4)
directly above.
Item
No.
Description
Link
Motor
Motor Bracket
42
134201
PC Card Stand-Off
23
174023
Baffle
43
173002
Motor
24
148 956
Switch Handle
44
012 654
Fastener
25
027 645
Spring Pin
Hinge Pin
Drive Housing
26
011 609
Light
Toggle Switch, SPDT
Washer
.T-Knob
27
083 431
28
058 427
29
085 980
Speed Control Card
Fuse, mintr gI 2A 250V
165896
Connector & Sockets
135 558
Connector & Sockets
165 745
Connector & Sockets
Circuit Breaker
Retaining Ring
079 747
Nut
Cotter Hair Pin
30
605941
Flat Washer
45
.PressureLever
31
057 543
32
057971
Spring, .845 OD
Keyed Washer
46
Bearing
.
Description
114 786
152 632
.
.
Part
No.
122741
.Spring
Cupped
124 817
included with the item listed
7-1 Item
22
Assembly
Knob
.
w/Cmpts (Fig
21
Drive
.
are
7-3. Baftle
Connector,
rect skt
171 610
Selector Switch
153322
Terminal
038618
Assembly, pri 2V
Link
12
155 964
Drive Roll
33
010 191
Fiber Washer
47
010199
13
092865
Key
34
058628
Brake Washer
48
039047
14
124 820
Hub, drive roll
35
057 745
49
039046
15
079 625
36
058428
50
071 971
Cover
16
605 308
37
083 147
Grommet
17
021469
Spring Washer
Retaining Ring
DangerLabel
Spring, 2.430
Hub,spool
Tubing
Output Terminal,
Output Terminal,
38
082 902
18
144933
Access Door
39
092 186
19
058 549
Wire Guide, 1/16
40
156 517
Strip, mtg
Strip, mtg
Capacitor
20
130 365
Insulator
41
114 780
Contactor
OM-154 501
Page
19
OD
red
black
center
Recommended
LH & RH
Be
Parts
provide Model and Serial Number
ordering replacement parts.
sure to
when
Spare
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