MAC TOOLS MW 145 Manuale utente

February

1995

Form:

OM-173

123

Effective

With

Serial

No.

KF800297

OWNERS

MANUAL

MW145



Read

and

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

service

this

unit.

Call

your

distributor

you

not

understand

the

directions.



Give

this

manual

the

operator.

For

help,

call

your

distributor

Too~ﬁ

cover

5/94



ST-

801

021

PRINTED

USA

ARC

WELDING

SAFETY

PRECAUTIONS

WARNING

ARC

WELDING

can

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

Inwelding,

most

jobs,

exposure

certain

hazards

occurs.

Welding

safe

when

precautions

are

taken.

The

safety

information

given

below

only

summary

the

complete

safety

information

that

will

found

the

Safety

Standards

listed

on.the

page.

Read

and

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

QUALIFIED

PEOPLE.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

severe

burns.

The

electrode

and

work

circuit

electrically

live

whenever

the

output

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

on.

semiautomatic

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

improperly

grounded

equipment

hazard.

not

touch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

covers

big

enough

prevent

any

physical

contact

with

the

work

ground.

Disconnect

input

power

stop

engine

before

installing

servicing

this

equipment.

Lockoutltagout

input

poweraccording

OSHA

CFR

1910.147

(see

Safety Standards).

Properly

install

and

ground

this

equipment

according

its

Owners

Manual

and

national,

state,

and

local

codes.

Always

verify

the

supply

ground



check

and

sure

that

input

newer

cord

around

wire

orooerlv

connected

around

terminal

disconnect

box

that

cord

plug

connected

properly

grounded

receptacle

outlet.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

Frequently

inspect

input

powercord

for

damage

bare

wiring



replace

cord

immediately

damaged



bare

wiring

can

kill.

Turn

oft

all

equipment

when

not

use.

10.

not

use

worn,

damaged,

undersized,

poorly

spliced

cables.

11.

not

drape

cables

over

your

body.

12.

earth

grounding

the

workpiece

required,

ground

directly

with

separate

cable



not

use

work

clamp

work

cable.

13.

not

touch

electrode

you

are

contact

with

the

work,

ground,

another

electrode

from

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

replace

damaged

parts

once.

Maintain

unit

according

manual.

15.

Wear

safety

harness

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

workoiece

worktable

as near

the

weld

oractical.

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing;

FLYING

SLAG

SPARKS

can

injure

eyes.

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

metal

slag.

FUMES

AND

GASES

can

hazardous

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

hazardous

your

health.

Keep

your

head

out

the

fumes.

not

breathe

the

fumes.

inside,

ventilate

the

area

and/or

use

exhaust

the

arc

remove

welding

fumes

and

gases.

ventilation

poor,

use

approved

air-supplied

respirator.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.

Wear

welding

helmet

fitted

with

proper

shade

filter

protect

your

face

and

eyes

when

welding

watching

(see

ANSI

Z49.1

and

Z87.1

listed

Safety

Standards).

Wear

approved

safety

glasses

with

side

shields.

Use

protective

screens

barriers

protect

others

from

flash

and

glare;

warn

others

not

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

Work

confined

space

only

well

ventilated,

while

wearing

air-supplied

respirator.

Always

have

trained

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

death.

sure

the

breathing

air

safe.

not

weld

locations

near

degreasing,

cleaning,

spraying

operations.

The

heat

and

rays

the

arc

can

react

with

vapors

form

highly

toxic

and

irritating

gases.

not

weld

coated

metals,

such

galvanized,

lead,

cadmium

plated

steel,

unless

the

coating

removed

from

the

weld

area,

the

area

well

ventilated,

and

necessary,

while

wearing

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

welded.

NOISE

ARC

RAYS

Use

acoroved

ear

plugs

ear

muffs

noise

level

high.

CYLINDERS

can

explode

damaged.

Never

drape

welding

torch

over

gas

cylinder.

Shielding

gas

cylinders

contain

gas

under

high

Never

allow

welding

electrode

touch

any

cylinder.

pressure.

damaged,

cylinder

can

explode.

Since

Never

weld

pressurized

cylinder



explosion

will

result.

gas

cylinders

are

normally

part

the

welding

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

process,

sure

treat

them

carefully.

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

good

condition.

Protect

compressed

gas

cylinders

from

excessive

heat,

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks.

and

arcs.

Keep

protective

cap

place

over

valve

except

when

cylinder

Install

cylinders

upright

position

securing

stationary

use

connected

for

use.

support

cylinder

rack

prevent

falling

tipping.

10.

Read

and

instructions

compressed

gas

cylinders,

Keep

cylinders

away

from

any

welding

other

electrical

associatedequipment,andCGApublicationP-1

listed

Safety

circuits.

Standards.

srl.1.1

2/94

WELDING

can

cause

fire

explosion.

Welding

closed

containers,

such

tanks,

drums,

pipes,

can

cause

them

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

electrode

metal

objects

can

cause

sparks,

explosion,

overheating,

fire.

Check

and

sure

the

area

safe

before

doing

any

welding.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

all

flammables

within

(10.7

the

welding

arc,

this

not

possible,

tightly

cover

them

with

approved

covers.

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

through

small

cracks

and

openings

adjacent

areas.

Watch

for

fire,

and

keep

fire

extinguisher

nearby.

aware

that

welding

ceiling,

floor,

bulkhead,

partition

can

cause

fire

the

hidden

side.

not

weld

closed

containers

such

tanks,

drums,

pipes,

unless

they

are

properly

prepared

according

toAWS

F4.

(see

Safety

Standards).

Connect

work

cable

the

work

the

welding

area

practical

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

not

use

welder

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

cut

off

welding

wire

contact

tip

when

not

use.

11.

Wear

oil-free

protective

garments

such

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

cap.

12.

Remove

any

combustibles,

such

butane

lighteror

matches,

from

your

person

before

doing

any

welding.

ENGINES

can

hazardous.

ENGINE

EXHAUST

GASES

can

kill.

Use

equipment

outside

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

used

closed

area,

away

from

any

building

vent

engine

exhaust

outside

and

intakes.

MOVING

PARTS

can

cause

injury.

Have

only

qualified

people

remove

guards

covers

for

maintenance

and

troubleshooting

necessary.

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

guards

and

doors

when

servicing

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

Always

wear

face

shield

when

working

battery.

EXPLODE;

BATTERY

ACID

can

Stop engine

before

disconnecting

connecting

battery

burn

eyes

and

skin,

cables.

not

allow

tools

cause

sparks

when

working

battery.

Batteries

contain

acid

and

generate

explosive

not

use

welder

charge

batteries

jump

start

vehicles.

gases.

Observe

correct

polarity

and

)

batteries.

STEAM

AND

PRESSURIZED

HOT

the

engine

warm

and

checking

needed,

steps

COOLANT

can

burn

face,

eyes,

and

skin.

Wear

safety

glasses

and

gloves

and

put

rag

over

cap.

ltisbesttocheckcoolantlevelwhenengineiscold

Turn

cap

slightly

and

let

pressure

escape

slowly

before

avoid

scalding.

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safely

We/ding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

33126

Safely

and

Health

Standards,

OSHA

CFR

1910,

from

Superinten

dent

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.

from

American

Welding

ciety,

550

N.W.

LeJeune

Ad,

Miami,

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

02269.

sri

1.1

2/94

Safe

Handling

Compressed

Gases

Cylinders.

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

22202.

Code

for

Safely

Welding

and

Cutting,

CSA

Standard

W117.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

WARNING

ENGINE

FUEL

can

cause

fire

explosion.

Engine

fuel

highly

flammable.

Donotoverf

not

spill

engine.

illtan

fuel.

kallo

fuel

wroomforfuelt

spilled,

clean

oexpand.

before

starting

Stop

engine

and

let

cool

off

before

checking

adding

fuel.

not

add

fuel

while

smoking

unit

near

any

sparks

open

flames.

Moving

parts,

such

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch loose

clothing.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

place.

Stoo

eng

before

installing

connecting

unit.

EMF

INFORMATION

OTE

LI~i~

Considerations

About

Welding

And

The

Effects

Low

Frequency

Electric

And

_____________________

Magnetic

Fields

The

following

quotation

from

the

General

Conclusions

Section

reduce

magnetic

fields

the

workplace,

use

the

following

the

U.S.

Congress,

Office

Technology

Assessment,

Biological

procedures:

Effects

Power

Frequency

Electric

Magnetic

Fields

Keep

cables

together

twisting

taping

them.

Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

there

now

very

Arrange

cables

one

side

and

away

from

the

operator.

large

volume

of scientific

findings

based

experiments

the

not

colt

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

arid 4.

Keep

welding

power

source

and

cables

far

away

produce

changes

in,

biological

systems.

While

most

this

work

very

high

quality,

the

results

are

complex.

Current

scientific

Connect

work

clamp

workpiece

the

weld

understanding

does

not

yet

allow

interpret

the

evidence

possible.

single

coherent

framework.

Even

frustrating,

does

not

yet

About

Pacemakers:

allow

draw

definite

conclusions

about

questions

possible

The

above

procedures

are

among

those

also

normally

risk

ofter

clear

science-based

advice

strategies

minimize

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

avoid

potential

risks.

complete

information.

modlO.1

4/93

TABLE

CONTENTS

SECTION



SAFETY

INFORMATION

SECTION

2

SPECIFICATIONS

2-1.

Volt-Ampere

Curve

2-2.

Duty

Cycle

SECTION

3INSTALLATION

3-1.

In,stalling

The

Running

Gear

3-2.

Installing

Work

Clamp

3-3.

Installing

Gas

Supply

3-4.

Selecting

GMAW

GTAW

Welding

Process

3-5.

Selecting

Gun/Torch

Polarity

3-6.

Installing

Supplied

GMAW

Gun

Optional

MWTIG

Torch

3-7.

Selecting

Location

And

Connecting

Input

Power

3-8.

Installing

Wire

Spool,

Adjusting

Hub

Tension,

And

Threading

Welding

Wire

SECTION

4OPERATION

SECTION

5

MAINTENANCE

TROUBLESHOOTING

5-1.

Overload

Protection

5-2.

Drive

Assembly

Maintenance

5-3.

Gun

Maintenance

5-4.

Troubleshooting

SECTION

ELECTRICAL

DIAGRAMS

SECTION

PARTS

LIST

Figure

7-1.

Main

Assembly

Figure

7-2.

Running

Gear

Figure

7-3.

MWG-160M

Gun

OM-173

1232/95

SECTION

SAFETY

INFORMATION

modl.1

2/93

WARNING

a

CAUTION



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

avoid

injury.



Learn

the

meaning

WARNING

and

CAUTION.

Safety

Alert

Symbol

ELECTRIC

SHOCK

can

kiII.~

MOVING

PARTS

can

injure,



not

touch

live

electrical

parts.



Keep

away

from

moving

parts.



Disconnect

input

power

betoreJj.



Keep

all

panels

and

covers

closed

when

operating.

installing

servicing.

Signal

Word

WARNING

means

possible

death

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

equipment

damage

can

happen.

Statement

Hazard

And

Result

Safety

Instructions

Avoid

Hazard

Symbol

(If

Available)

Safety

Banner

Read

safety

blocks

for

each

sym

shown.

NOTE

Special

instructions

for

best

oper

ation



not

safety.

6~,T~~.1kl~t

READ

SAFETY

BLOCKS

start

Section

3-1

before

proceeding.

NOTE

Turn

Off

switch

when

using

high

frequency.

Figure

1-1.

Safety

Information

SECTION

SPECIFICATIONS

Table

2-1.

Welding

Power

Source

Specifications

Description

Type

Input

Power

Single-Phase;

Hz;

115

Volts

Type

Output

Direct

Current/Constant

Voltage

(DC/CV)

Max.

Open-Circuit

Voltage

Volts

Control

Circuit

Voltage

Gun

Volts

Welding

Processes

Gas

Metal

Arc

(GMAW).

Flux

Cored

Arc

(FCAW),

And

Gas

Tungsten

Arc

(GTAW)

Welding

Calculated

Speed Range

Load

176

817

(4.5

20.8

mpm)

Wire Diameter

Range

.023

.035

(0.58

0.89

mm)

Overall

Dimensions

Length:

18-1/8

(460

mm);

Width:

14-1/4

(362

mm);

Height:

18-1/4

(464

mm)

Weight

Rated

Weld

Output

Net:

(39

kg);

Ship:

(42

kg)

Using

Ampere

Plug

Using

Ampere

Plug

Amperes,

Volts

DC,

40%

Duty Cycle

140

Amperes,

Volts

DC,

40%

Duty

Cycle

Input

Amperes

Rated

Output

115

Input

Amperes

Used

While

Idling

0.54

KVA/KW

Used

Rated

Output

kVA/2.2

4.5

kVA/4

KVNKW

Used

While

Idling

0.06

KVNO.04

0.06

KVA/0.04

Welding

Gun

Rated

Output

(Air-Cooled)

160

Amperes

60%

Duty

Cycle

Using

CO2

Shielding

Gas

Wire

Diameter

.023

And

.035

(0.6

And

0.89

mm)

Hard

And

Flux

Cored

Wires

Cable

Length

(3m)

OM-173

123

Page

2-1.

Volt-Ampere

Curve

Figure

2-1.

Volt-Ampere

Curve

2-2.

Duty

Cycle

~CAUTION

:~~!I~

The

volt-ampere

curves

show

the

minimum

and

maximum

voltage

and

amperage

output

capabilities

the

welding

power

source.

Curves

other

settings

fall

tween

the

curves

shown.

AMPERES

ssbli

10/91



ST-173

778

100

150

200

250

WELDING



not

weld

NGER

THAN

RATED

DUTY

CYCLE

can

damage

unit

gun

and

void

warranty.

ated

load

longer

than

shown

below.

wlwarn8.2

8/93

Figure

2-2.

Duty

Cycle

OM-173

123

Page

SECTION

3-INSTALLATION

-1.

Installing

The

Running

Gear

Tools

Needed:

LIIIIII~J1J

3/8,9/l6in

Figure

3-1.

Installing

The

Running

Gear

Install

running

gear

shown.

See

Parts

List

for

parts

descriptions.

both

ends

chain

are

slots

and

chain

tight

around

cylinder.

Remove

paint

from

axle

grooves

before

installing

retaining

rings.

51-801

025

OM-173

123

Page

3-2.

Installing

Work

Clamp

3-3.

Installing

Gas

Supply

CYLINDERS

can

explode

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

running

gear,

wall,

other

stationary

support.

BUILDUP

SHIELDING

GAS

can

harm

health

kill.



Shut

off

shielding

gas

Supply

when

not

use.

Figure

3-3.

Typical

Regulator/Flowmeter

Installation

Insulator

Bolt

Smaller

Hole

Work

Clamp

Tabs

Bend

tabs

around

work

cable.

Work

Cable

From

Unit

Nut

Tools

Needed:

3/8,7/16

Figure

3-2.

Installing

Work

Clamp

Ret.

ST-025

190-0

warn4.1

9/91

Tools

Needed:

5/8,1-1/8

Argon

Gas

Mixed

Gases

Obtain

gas

cylinder

and

chain

running

gear,

wall,

other

station

ary

support

cylinder

cannot

fall

and

break

off

valve.

Cap

Cylinder

Valve

Remove

cap,

stand

side

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Cylinder

Regulator/Flowmeter

Install

face

vertical.

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Obtain

and

install

gas

hose

between

regulator/flowmeter

and

welding

power

source.

Flow

Adjust

Typical

flow

rate

cfh

(cubic

feet

per

hour).

Check

wire

manufactur

ers

recommended

flow

rate.

CO2

Adapter

0-Ring

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

ssb3.

1 1

2.92



ST-i

697-A

Ref.

ST-

149

827-B

CO2

Gas

OM-173

123

Page

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