MAC TOOLS KE000000 Owner's manual

MAC TOOLS
Brand
MAC TOOLS
Model
KE000000
Category
Welding System
Type
Owner's manual

This manual is also suitable for

June
1995
Form:
OM-171
108A
OWNERS
MANUAL
MWTIG
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
L._
1~oLsfi
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
cover
5/94
ST-
800 877
PRINTED
IN
USA
SAFETY
PRECAUTIONS
FOR
GTAW
TORCHES
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
QUALIFIED
PEOPLE.
ELECTRIC
SHOCK
can
kill.
1.
Always
wear
dry
insulating
gloves.
2.
Insulate
yourself
from
work
and
ground.
3.
Do
not
touch
live
electrode
or
electrical
parts.
4.
Repair
or
replace
worn,
damaged,
or
cracked
torch
or
cable
insulation.
5.
Turn
off
welding
power
source
before
changing
tungsten
electrode
or
torch
parts.
6.
Keep
all
covers
and
handle
securely
in
I
ARC
RAYS
can
burn
eyes
and
skin.
1.
Wear
welding
helmet
with
correct
shade
of
filter.
2.
Wear
correct
eye
and
body
protection.
3.
Cover
exposed
skin.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
1.
Do
not
weld
near
flammable
material.
2.
Do
not
weld
on
closed
containers.
3.
Watch
for
fire;
keep
extinguisher
nearby.
HOT
SURFACES
can
burn
skin.
1.
Allow
torch
to
cool
before
touching.
2.
Do
not
touch
hot
metal.
3.
Protect
hot
metal
from
contact
by
others.
NOISE
can
damage
hearing;
SOME
APPLICATIONS,
SUCH
AS
PULSING,
are
noisy.
1.
Check
for
noise
level
limits
exceeding
those
specified
by
OSHA.
2.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
3.
Warn
others
nearby
about
noise
hazard.
EMF
INFORMATION
4A
WARNING
GTAW
WELDING
can
be
hazardous.
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
found
in
the
welding
power
source
Owners
Manual.
Read
and
follow
all
safety
precautions.
AND
REPAIR
WORK
PERFORMED
ONLY
BY
A
1.
2.
3.
N
OTE
D~
Considerations
About
We
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
Iding
And
The
Effects
Of
Low
Frequency
Electric
And
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
procedures:
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):.
.
.
there
is
now
a
very
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
large
volume
of
scientific
findings
based
on
experiments
at
the
3.
Do
not
coil
or
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,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
4.
Keep
welding
power
source
and
cables
as
tar
away
as
practical.
5;
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
About
Pacemakers:
allow
us
to
draw
definite
conclusions
about
questions
of
possible
The
above
procedures
are
among
those
also
normally
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
or
avoid
potential
risks.
complete
information.
modlO.1
4/93
sr6
7/93
SECTION
1
-
SAFETY
INFORMATION
6
A~
WARNING
a_CAUTION
U
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
modl.l
2/93
.
1
2
2
~
MOVING
PARTS
can
injure.
I
rr~~&vI
:1~II~c~
~
ELECTRIC
SHOCK
can
klIl.~~
I
Do
not
touch
live
electflcal
parts.
Keep
away
from
moving
parts.
I
Keep
all
panels
and
covers
CO~
i
Disconnect
input
power
before
installing
or
servicing.
when
operating.
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
CAUTION
means
possible
minor
or
serious
injury
can
happen.
injury
or
equipment
damage
can
happen.
3
Statement
Ot
Hazard
And
Result
4
Safety
Instructions
To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
opera
tion
not
related
to
safety.
5
READ
SAFETY
BLOCKS
at start
of
Section
3-1
before
proceeding.
NOTE
127~
Turn
Off
switch
when
using
high
frequency.
1
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Specifications
Specification
Description
Model
Description
GTAW
Torch;
150
Ampere
Rating;
12
ft
(3.7
m)
Direct
Connect,
High-Flex
Cable
With
Handle
Mounted
Switch
Ampere
Rating
At
100%
Duty
Cycle
DCEN
150
Amperes
Using
Argon
Gas
And
Gas
Lens
Collet
Body
Installed
(See
Section
2-1)
Cooling
Method
Air
Cooling
Tungsten
Size
Capacity
1/16
in
(1.6
mm)
Torch
Body
Dimensions
And
Weight
Length:
9-1/2
in
(241
mm);
Handle
Diameter:
1-1/4
in
(34
mm);
Weight:
10
oz
(198
g)
Cable
Length
12
ft
(3.7
m)
Total
Weight
Net:
2.3
lb
(1.1
kg);
Ship:
3.0
lb
(1.4
kg)
OM-171
108
Page
1
Table
2-2.
Recommended
Safe
Operating
Ranges
£~
CAUTION
Figure
2-1.
Duty
Cycle
MW
100
MW
130
MW
150
MW
250
Low
Tap
High
Tap
Low
Mm.
80
A
Range
1
100
A
Range
1
125
A
Range
1
105
A
Range
1
Low
Max.
85
A
Range
2 115
A
Range
2
155
A
Range
2
130
A
Range
2
High
Mm.
105
A
Range
3
135
A
Range
3
*
Range
3
160
A
Range
3
High
Max.
110
A
Range
4
150
A
Range
4
Range
4
*
Range
4
*
Do
not
operate
in
this
range.
~
Range
5
*
.
Range
5
Range
6
*
Range
6
2-1.
Duty
Cycle
WELDING
LONGER
THAN
RATED
DUTY
CYCLE
can
damage
torch
and
void
warranty.
Do
n
ot
weld
at
rated
load
longer
than
shown
below.
wtwam8.1
8/93
0
~
~
10
DefinItion
Duty
Cycle
is
percentage
of
10
minutes
that
torch
can
weld
at
rated
load
without
overheating.
100%
Duty
Cycle
At
150
Amperes
Using
A
rgon
Gas
Minutes
Continuous
Welding
sbl.5
8/93
4
OM-171
108
Page
2
SECTION
3-INSTALLATION
&
OPERATION
3-1.
Required
Torch
Parts
And
Torch
Assembly
Required
Torch
Parts
4
Obtain
the
following
parts
(see
Section
6):
1
Tungsten
Electrode
(See
Section
5)
2
Cup
3
Collet
Body
4
Standard
Collet
Assembiing
Torch
Body
5
Torch
Body
6
Heat
Shield
7
Backcap
(Long
Backcap
Shown)
8
0-Ring
Instaliing
Tungsten
To
adjust
tungsten
position,
loosen
backcap.
Keep
connections
tight.
Replace
cup,
heat
shield,
backcap,
and
0-rings
if
cracked.
3
Assembling
Torch
Parts
7
8
2
4
installing
Tungsten
lighten
Figure
3-1.
Required
Torch
Parts
And
Torch
Assembly
ST-BOO
880
OM-171
108
Page
3
3-2.
Connecting
Torch
READ
SAFETY
BLOCKS
at
beginning
of
manual
before
proceeding.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
shielding
gas
supply
when
not
in
use.
waml.1
9/91
For
Welding
Power
Sources
Using
Friction
Terminai
Lead
Connections
For
Weiding
Power
Sources
Requiring
A
Trigger
Leads
Plug
Adapter
Turn
Off
welding
power
source,
and
disconnect
input
power
before
installing
torch.
Connecting
Trigger
Leads
1
Torch
Trigger
Leads
2
Welding
Power
Source
Trig
ger
Leads
insert
torch
trigger
leads,
one
at
a
time
through
grommet
in
front
pan
el.
Connect
torch
trigger
leads
to
matching
welding
power
source
trigger
leads,
polarity
is
not
impor
tant.
Or
3
Adapter
Plug
Trigger
Leads
Connect
torch
trigger
leads
to
matching
adapter
plug
trigger
leads,
polarity
is
not
important.
4
Torch
Trigger
Plug
insert
into
matching
receptacle
on
welding
power
source,
and
tighten
threaded
collar.
installing
Torch
5
Torch
End
6
Drive
Assembly
7
Torch
Securing
Nut
Insert
torch
end
until
it
bottoms
against
drive
assembly.
Tighten
nut.
ST-800
878-A
/
ST-BOO
879-A
Set
all
welding
power
sources
2
for
straight
polarity.
7
Set
all
welding
power
sources
for
straight
polarity.
Tools
Needed:
~
1/2in
Figure
3-2.
Connecting
Torch
And
Trigger
Leads
OM-171
108
Page
4
SECTION
4
MAINTENANCE
&
TROUBLESHOOTING
NOTE
~
Before
using
troubleshooting
table,
check
selection
and
preparation
of
tungsten
_____________________
electrode
according
to
Section
5.
Trouble
Remedy
Wandering
arc
poor
control
of
direction
of
arc.
~
-
Reduce
gas
flow
rate.
I
Tungsten
electrode
oxidizing
and
not
remaining
I.
~
Shield
weld
zone
from
drafts.
Check
and
tighten
all
gas
fittings.
bright
after
conclusion
of
weld.
I
_________________________________________________________________
Increase
postflow
time
(see
Figure
3-3).
OM-171
108
Page
5
1
Trigger
Press
tngger
to
pull
in
contactor
and
start
gas
flow.
While
trigger
is
pressed,
use
scratch
start
method
to
start
an
arc.
To
extinguish
arc,
md
for
proper
posthow
and
cooling,
momentarily
release
and
repress
trigger
for
aboUt
ten
seconds.
ST-800
877
Figure
3-3.
Operation
Figure
4-1.
Maintenance
Schedule
Table
4-1.
Troubleshooting
5-2.
Preparing
Tungsten
Figure
5-1.
Preparing
Tungsten
For
AC
Or
DC
Electrode
Positive
(DCEP)
Welding
a
CAUTION
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury
and
start
tires.
Shape
tungsten
electrode
only
on
gnnder
with
proper
guards
in
a
safe
location
wearing
proper
face,
hand,
and
body
protection.
Keep
flammables
away.
wam2.1
9/91
Ret.
S-01
61
1
1
Stable
Arc
4
2
2
Flat
Diameter
of
this
flat
determines
amperage
capacity.
3
Grinding
Wheel
4
Straight
Ground
3
Ideal
Tungsten
Preparation
Stable
Arc
Ret.
5-0162
Figure
5-2.
Preparing
Tungsten
For
DC
Electrode
Negative
(DCEN)
Welding
1
Tungsten
Electrode
2
Balled
End
Ball
end
of
tungsten
before
welding
by
applying
either
an
ac
amperage
Electrode
Diameter
mended
for
a
given
electrode
di-
P
O~IIE
1-1/2
Times
slightly
higher
than
what
is
recom
ameter
(see
Table
5-1),
or
a
dc
electrode
positive
amperage.
2
Ref.
S-0161
1
2
1
Tungsten
Electrode
2
Tapered
End
2-1/2
Times
Electrode
Diameter
Grind
end
of
tungsten
on
fine
grit,
hard
abrasive
wheel
before
weld
ing.
Do
not
use
wheel
for
other
jobs
or
tungsten
can
become
contami
nated
causing
lower
weld
quality.
1
2
~i3
1
Arc
Wander
2
Point
3
Grinding
Wheel
4
Radial
Ground
4
Wrong
Tungsten
Preparation
Wandering
Arc
Ref.
S-0162
OM-171
108
Page
7
...4
16
18
171
111
171
113
171
114
171
115
171
117
171
118
171
119
171
124
079
974
171
126
171
127
170
622
SECTION
6-PARTS
LIST
Figure
6-1.
Complete
Assembly
Description
Figure
6-1.
Complete
Assembly
ST-800
881
Quantity
5
9
8
6
20
Item
No.
Part
No.
171
110
..
TORCH
BODY
AIR
COOLED
1
POWER
CABLE
ASSY
12
FT
W/SPEC
FITTINGS
1
BACKCAPSHORT
1
0-RING
FOR
BACK
CAP
1
CUP
GASKET
1
COLLETS,1/16
1
COLLET
BODIES,
1/16
1
CERAMIC
NOZZLE
1
MOMENTARY
CONTACT
MICROSWITCH
1
0-RING,
.500
ID
x
.1O3CS
RBR
2
HANDLE
1
MOMENTARY
CONTACT
SWITCH
w/12
FT
LEADS
1
CABLE,
trigger
1
OM-171
108
Page
8
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  • Page 4 4
  • Page 5 5
  • Page 6 6
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  • Page 10 10
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  • Page 12 12

MAC TOOLS KE000000 Owner's manual

MAC TOOLS
Brand
MAC TOOLS
Model
KE000000
Category
Welding System
Type
Owner's manual
This manual is also suitable for
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