MAC TOOLS MW260X, Owner'S Manual

Page 1: ... Gun Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source And Wire Feeder For Warranty Claims And Technical Support Contact Milweld Inc National Distributor P O Box 338 Hortonville WI 54944 0338 Tel 920 779 0916 Fax 920 779 0924 ...

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Page 3: ...Polarity For Wire Type 12 2 8 Installing Gas Supply 13 2 9 Installing Wire Spool And Adjusting Hub Tension 13 2 10 Changing Input Voltage From 230 Volts To 200 Volts 14 2 11 Electrical Service Guide 14 2 12 Selecting A Location And Connecting Input Power 15 2 13 Threading Welding Wire 16 SECTION 3 OPERATION 17 3 1 Controls 17 3 2 Weld Parameters 18 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 19 4 1 ...

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Page 5: ... or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conductor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do n...

Page 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Page 7: ...d maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area ...

Page 8: ...s is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting 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 ...

Page 9: ...tion est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement ...

Page 10: ...act D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce ...

Page 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Page 12: ...gnétiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir examiné plus de 500 études qui ont été faites pendant une pé riode de recherche de 17 ans un comité spécial ruban bleu du National Research Council a conclu L accumulation de p...

Page 13: ...8 7 8 in 479 mm D 36 1 2 in 927 mm 185 lb 84 kg 023 045 in 0 6 1 2 mm 030 035 in 0 8 0 9 mm 030 045 in 0 8 1 2 mm While idling 6 Minutes Welding 4 Minutes Resting 2 2 Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes f...

Page 14: ...ous Welding SB1 1 8 93 0 10 Minutes Definition 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 100 Duty Cycle At 200 Amperes Using CO2 100 Duty Cycle At 150 Amperes Using Mixed Gases 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 60 Duty Cycle At 300 Amperes Using CO2 60 Duty Cycle At 200 Amperes Using Mixed Gases 6 Minutes Welding 4 Minutes Resting 2 4 Volt Ampere Curves Volt ampere cu...

Page 15: ...en knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door 3 4 2 1 2 6 Installing Work Clamp 1 Work Cable Route cable out front panel open ing from inside 2 Negative Black Output Terminal Connect cable to terminal 3 Hardware 4 Work Clamp Route cable through clamp handle and secure as shown Close door Ref ST 802 285 B Ref ST 801 566 Tools Needed 1 2 3 4 in 2 1 3 4...

Page 16: ...ity For Wire Type Tools Needed 3 4 in 1 1 Polarity Changeover Label 2 Positive Red Output Terminal 3 Negative Black Output Terminal Always read and follow wire manufacturer s recommended polarity Close door 3 2 Ref ST 802 285 B Ref ST 192 432 ...

Page 17: ...ng has 5 8 18 right hand threads 3 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire man ufacturer s recommended flow rate see Section 3 2 This flow gauge can be adjusted between 5 and 25 cfh 4 CO2 Adapter Customer Supplied 5 O Ring Install adapter with O ring be tween regulator flow gauge and CO2 cylinder 1 1 8 5 8 in 2 9 Installing Wire Spool And Adjusting Hub Tension When a...

Page 18: ...t Voltage 200 230 460 575 Input Amperes At Rated Output 40 35 18 14 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 50 40 20 15 Normal Operating 3 60 50 25 20 Min Input Conductor Size In AWG Kcmil 8 10 14 14 Max Recommended Input Conductor Length In Feet Meters 108 33 94 29 148 45 232 71 Min Grounding Conductor Size In AWG Kcmil 10 10 14 14 Reference 1999 National Electrical Code NE...

Page 19: ...rs Connect directly to line disconnect device if hard wiring is required 5 Line Disconnect Device See Section 2 11 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 2 L1 L2 230 VAC 1 3 L1 L2 Y Always connect grounding conductor first GND PE 5 Y Do not move or operate unit where it could tip 18 in 457 mm of space for airflo...

Page 20: ...nd contact tip Turn On WOOD Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door Open pressure assembly Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire 7 6 1 2 3 5 Hold wire tightly to keep it from unraveling 4 ...

Page 21: ...trols 1 Wire Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The higher the selected number the thicker the material that can be welded see welding guide and Section 3 2 3 Power Switch 1 Ref 195 721 2 3 ...

Page 22: ...55 48 40 26 10 0 0 045 VOLTAGE 7 6 4 4 3 3 2 2 1 2MM WIRESPEED 60 55 50 45 46 40 30 22 030 VOLTAGE 5 5 4 2 2 1 1 0 8MM WIRESPEED 50 58 50 30 20 10 0 E71T GS 035 VOLTAGE 6 5 4 3 2 2 1 1 FLUXCORE 0 9MM WIRESPEED 50 40 38 30 20 10 0 0 045 VOLTAGE 5 5 4 3 2 2 1 2MM WIRESPEED 46 40 30 20 0 0 E71T GS 035 VOLTAGE 7 7 7 6 5 3 FLUXCORE 0 9MM WIRESPEED 80 78 72 68 60 55 75AR 25CO2 045 VOLTAGE 7 7 7 6 5 4 20...

Page 23: ...d apply light coat of oil or grease to drive motor shaft 4 2 Circuit Breakers Ref ST 802 285 B 2 Y Turn Off unit 1 Circuit Breaker CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails If CB1 opens wire feeding stops Check for gun liner blockage or kinks and check for jammed wire or binding drive rolls 2 Circuit Breaker CB2 CB2 protects the trigger circuit from overload If CB2 ope...

Page 24: ...ng Tighten screw 3 Drive Roll Install correct drive roll for wire size and type 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 4 4 Replacing Gun Contact Tip Ref 800 797 C 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 Tools ...

Page 25: ...ghten new liner Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Install adapter contact tip and nozzle Y Disconnect gun from unit first Tools Needed Lay gun cable out straight before installing new liner Head Tube 5 16 in Remove nozzle contact tip and adapter Blow out gun casing Remove liner 10 mm ...

Page 26: ...ecure with handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto new head tube Hand tighten head tube into connector cable 7 Place head tube in vice and tighten until nuts are tight 8 Remove from vice Reposition handle and install switch hous...

Page 27: ...e speed Readjust front panel settings see Section 3 1 Change to correct size drive roll see Section 4 3 Readjust drive roll pressure see Section 2 13 Replace inlet guide contact tip and or liner if necessary see Sections 4 3 4 4 and or 4 5 4 8 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straighten gun cable and or replace damaged p...

Page 28: ...OM 198 781 Page 24 SECTION 5 ELECTRICAL DIAGRAM 197 515 Figure 5 1 Circuit Diagram For Welding Power Source ...

Page 29: ...OM 198 781 Page 25 Notes ...

Page 30: ...98 781 Page 26 SECTION 6 PARTS LIST ST 802 564 Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 Fig 6 2 10 Fig 6 3 11 12 13 14 15 16 17 Fig 6 4 18 19 20 Fig 6 5 Figure 6 1 Main Assembly ...

Page 31: ...0 Fig 6 3 PANEL rear w components 1 11 PLG1 188 911 CORD SET 250V 6 50p 8 10ga 3 c 12ft for 200 230 1 11 PLG1 187 255 CORD SET 250V t tng 8 10ga 3 c 12ft for 230 460 575 1 12 146 161 BASE 1 13 135 390 AXLE 1 14 186 758 WHEEL 2 15 121 614 RING retaining 2 16 008 999 CASTER 2 17 Fig 6 4 PANEL front w components 1 18 146 149 CABLE work 1 19 130 750 CLAMP work 1 20 169 596 GUN M 25 Fig 6 5 1 When orde...

Page 32: ...OM 198 781 Page 28 ST 802 284 C Hardware is common and not available unless listed Figure 6 2 Center Baffle w Components ...

Page 33: ... 1 19 CB1 183 492 CIRCUIT BREAKER man reset 1P 10A 250V 1 20 PC1 171 986 CIRCUIT CARD ASSEMBLY control 1 21 038 618 LINK jumper term bd pri as req 22 TE1 188 910 TERMINAL ASSEMBLY pri 1ph double voltage 200 230 1 22 TE1 192 907 TERMINAL ASSEMBLY pri 1ph triple voltage 230 460 575 1 23 039 046 TERMINAL pwr output black w nut 1 24 039 047 TERMINAL pwr output red w nut 1 25 C7 10 136 735 CAPACITOR 1 ...

Page 34: ...8 809 FAN 9 in 5wg 34 deg 1 3 M 188 706 MOTOR fan 230V 50 60 Hz 1 4 188 709 WINDTUNNEL 9in 1 5 125 785 VALVE 24VAC 2way custom port 1 6 143 810 PANEL rear 1 7 169 654 BRACKET support tank 1 8 188 441 CHAIN safety 1 9 605 227 NUT 750 14 knurled 1 10 178 126 CONN clamp cable 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and...

Page 35: ...KNOB 1 5 035 897 POTENTIOMETER CP 1 T 2W 1K linear wire feed speed 1 6 S2 192 373 SWITCH selector 7 position 1 7 S1 124 511 SWITCH tgl DPST 40A 600 VAC 1 8 144 127 COVER module access 1 9 170 647 BUSHING snap in nyl 1 10 204 413 BUSHING snap in nyl 1 11 048 282 RECEPTACLE W SOCKETS 1 12 198 780 LABEL SET nameplate and sides 1 To maintain the factory original performance of your equipment use only ...

Page 36: ...OM 198 781 Page 32 Ref 800 792 B 1 2 3 4 5 6 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 6 5 M 25 Gun ...

Page 37: ...ING retaining 1 6 170 468 O RING 1 7 169 730 WASHER shock 1 8 169 731 TUBE head 1 9 169 738 NUT locking handle 2 10 194 523 NUT jam 1 11 169 737 HANDLE 2 12 169 741 STRAIN RELIEF cable 2 13 180 433 CORD trigger assembly 1 14 079 974 O RING 500 ID x 103CS rbr 2 15 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 15 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 15 194 012 LINE...

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Page 39: ...accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than manufacturer or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications ...

Page 40: ...rial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department Resources Available Owner s Record Fil...