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  5. Owner's Manual

MAC TOOLS MW250 Owner's Manual

Summary of MW250

  • Page 1

    Mw250 processes description gas metal arc (mig) welding flux cored arc (fcaw) welding arc welding power source and wire feeder om-154 501l august 1998 ®.

  • Page 3: Table of Contents

    Table of contents section 1 − safety precautions - read before using 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc welding hazards ...

  • Page 5

    Om-154 501 page 1 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. Y marks a special safety message. . Means “note”; not safety related....

  • Page 6

    Om-154 501 page 2 arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Arc rays can burn eyes and skin. D wear a welding helmet fitted with a proper shade of filter to protect your face and ...

  • Page 7

    Om-154 501 page 3 1-3. Additional symbols for installation, operation, and maintenance fire or explosion hazard. D do not install or place unit on, over, or near combustible surfaces. D do not install unit near flammables. D do not overload building wiring − be sure power supply system is properly s...

  • Page 8

    Om-154 501 page 4 1-5. Emf information considerations about welding and the effects of low frequency electric and magnetic fields welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after exami...

  • Page 9

    Om-154 501 page 5 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 ampere...

  • Page 10: Section 3 − Installation

    Om-154 501 page 6 2-2. Duty cycle and overheating rduty1 5/95 − sb-150 215 duty cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage...

  • Page 11

    Om-154 501 page 7 3-2. Installing gas supply 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. Ga...

  • Page 12

    Om-154 501 page 8 3-3. Gun polarity connections 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). Close door. Ref. St-801 103-b 1 ...

  • Page 13

    Om-154 501 page 9 3-6. Positioning jumper links check input voltage available at site. 1 jumper links access door open door. 2 jumper link label 3 input voltage jumper link move jumper link to match input voltage. Close and secure access door. Close side door. 1 2 200 volts 230 volts s-153 980 3 ref...

  • Page 14

    Om-154 501 page 10 3-7. 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 3-5. Conductor rating must comply with national, state, an...

  • Page 15

    Om-154 501 page 11 3-8. Installing wire spool and adjusting hub tension 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 spring is used with 8 in...

  • Page 16

    Om-154 501 page 12 3-9. Threading welding wire 1 wire spool 2 welding wire 3 inlet wire guide 4 pressure adjustment knob 5 drive roll 6 outlet wire guide 7 gun conduit cable lay gun cable out straight. 4 7 3 5 6 2 1 tools needed: ref. St-801 103-b / st-154 251 / s-0627-a 6 in (150 mm) 4 in (102 mm) ...

  • Page 17: Section 4 − Operation

    Om-154 501 page 13 section 4 − operation 4-1. Front panel controls 1 wire speed control use control to set wire feed speed. 2 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. 3 pilot light 4 power switch use ...

  • Page 18: Wire Mode

    Om-154 501 page 14 4-2. Center baffle controls 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 ipm. 2 voltage range selector place switch in desired position. See inside re...

  • Page 19

    Om-154 501 page 15 section 5 − maintenance & troubleshooting 5-1. Routine maintenance y disconnect power before maintaining. . Maintain more often during severe conditions. 3 months replace damaged or unreadable labels clean and tighten weld terminals repair or replace cracked cables and cords 6 mon...

  • Page 20

    Om-154 501 page 16 5-3. Fuses f1 and f2 turn off unit and disconnect input power. 1 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. 2 fuse f2 (see parts list for rating) f2 protects the 24 vo...

  • Page 21

    Om-154 501 page 17 5-6. Replacing gun contact tip ref. St-801 978 y turn off power before replacing contact tip. 1 nozzle 2 contact tip cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. 1 2 tools needed: 5-7. Gun maintenance y disco...

  • Page 22

    Om-154 501 page 18 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 (s...

  • Page 23

    Om-154 501 page 19 section 6 − electrical diagram sb-173 544-e figure 6-1. Circuit diagram for welding power source.

  • Page 24: Section 7 − Parts List

    Om-154 501 page 20 section 7 − parts list 1 2 fig 7−2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 fig 7−4 st-155 610-d 17 figure 7-1. Main assembly note: all items indented by a dot(s) are included with the item listed directly above. Description part no. Item no. Part no. Item no. Description...

  • Page 25

    Om-154 501 page 21 st-155 609-e 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 fig.7−3 − 27 28 29 30 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. Description part no. Item no. Part no. It...

  • Page 26

    Om-154 501 page 22 st-148 529-d 1 2 3 4 5 6 7 8 9 11 10 12 13 15 17 18 19 16 20 21 22 23 14 . Hardware is common and not available unless listed. 24 see table 7-1 for drive roll & wire drive kits figure 7-3. Wire drive and gears (fig 7-2 item 27) description part no. Item no. Part no. Item no. Descr...

  • Page 27

    Om-154 501 page 23 1 110 793 handle assembly 2 110 780 nut, m 10 x 1 3 175 180 head tube 4 175 177 diffusor 5 175 175 holder, tip recessed 5 ♦ 175 176 holder, tip flush 6 ♦ 175 230 contact tip, .025 (10pk) 6 ♦ 175 231 contact tip, .030 (10pk) 6 175 232 contact tip, .035 (10pk) 6 ♦ 175 233 contact ti...

  • Page 29

    Effective january 1, 1998 (equipment with a serial number preface of “kj” or newer) this limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. Limited warranty − subject to the terms and conditions below, warra...

  • Page 30

    Printed in usa model name serial/style number purchase date (date which equipment was delivered to original customer.) distributor address city state zip please complete and retain with your personal records. Always provide model name and serial/style number. Contact your distributor for: welding su...