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ESAB Firepower FP-200, Instruction Manual

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ESAB Firepower FP-200 Instruction Manual Download Page 41

5  OPERATION

 

0463 815 001 

- 41 - 

© ESAB AB 2021

 

5.9 

Wire reel brake 

The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum 

braking. If it is considered necessary, adjustment can be made by turning the thumb screw inside 
the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire 
reel circumference continuing no further than 1/8 in.-3/16 in. (3-5 mm) after release of the trigger. 
The electrode wire should be slack without becoming dislodged from wire spool. 

CAUTION!

 

Overtension of the brake will cause rapid wear of mechanical wire feeder parts, 
overheating of electrical components and possibly more incidences of contact tip 
burnback. 

 

Figure

 

30:

 

Wire

 

reel

 

brake

 

1 Spool hub tension thumb screw 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for Firepower FP-200

Page 1: ...0463 766 001 GB 20210830 Firepower MST 200 3 In 1 Multiprocess Welding System Firepower FP 200 MIG MAG Welding System Instruction manual...

Page 2: ...usion 180 A MIG gun 39 5 7 Feed roller pressure adjustment 39 5 8 Changing the feed roll 40 5 9 Wire reel brake 41 5 10 Setup for MIG GMAW welding with gas shielded MIG wire 42 5 11 Setup for MIG FCAW...

Page 3: ...rce problems 69 8 2 MIG GMAW FCAW welding troubleshooting 70 8 3 MMA SMAW welding troubleshooting only for Firepower MST 200 74 8 4 TIG L GTAW welding problems only for Firepower MST 200 76 8 5 Error...

Page 4: ...t filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders not to watch the arc and not to expose themselv...

Page 5: ...an overloaded welding cable can overheat and create a fire hazard 7 After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fir...

Page 6: ...ing and spraying operations The heat or arc can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases 4 If you develop momentary eye nose or throat irr...

Page 7: ...sure forks are long enough to extend beyond opposite side of unit Keep cables and cords away from moving vehicles when working from an aerial location WARNING EQUIPMENT MAINTENANCE Faulty or improperl...

Page 8: ...tices for Gas Tungsten Arc Welding AWS C5 6 Recommended Practices for Gas Metal Arc welding AWS SP Safe practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutt...

Page 9: ...ble for the purpose be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves Do not wear loose fittin...

Page 10: ...r head out of the fumes Use ventilation extraction at the arc or both to take fumes and gases away from your breathing zone and the general area ARC RAYS Can injure eyes and burn skin Protect your eye...

Page 11: ...dealer or visit us on our website 1 4 California proposition 65 warning WARNING Welding or cutting equipment produces fumes or gases which contain chemicals known in the State of California to cause...

Page 12: ...TWECO connector Ground clamp with 6 AWG 16 mm2 lead and 50mm OKC cable connector 9 ft 3m long Electrode holder with 6 AWG 16 mm2 lead and 50mm OKC cable connector 9 ft 3m long Firepower regulator 0788...

Page 13: ...Permissible load at MIG GMAW 25 duty cycle 90 A 18 5 V 15 duty cycle 200 A 24 V 60 duty cycle 58 A 16 9 V 100 A 19 V 100 duty cycle 45 A 16 3 V 78 A 17 9 V Permissible load at Lift TIG L GTAW 25 duty...

Page 14: ...ion class Firepower FP 200 Input voltage 120 V 15 1 50 60 Hz 230 V 15 1 50 60 Hz Primary current Imax MIG GMAW FCAW 26 A 38 A Open circuit voltage OCV 68 V Setting range MIG GMAW FCAW 30 A 15 5 V 90 A...

Page 15: ...our location NOTE The recommended time delay fuse or circuit breaker size for 120 V is 30 A An individual branch circuit capable of carrying 30 A and protected by fuses or circuit breaker is recommend...

Page 16: ...2 5 lb 8 in wire spool 2 Flat washer small hole 6 Spool hub 3 Spring small hole 4 Plastic nut 1 Remove wire spool hub retaining clip Grasp the loop and pull 2 Place wire spool onto the hub loading it...

Page 17: ...ool hub retaining clip Grasp the loop and pull 2 Place fiber washer and large spring onto the shaft then load the wire spool on the shaft so that the wire will feed off the bottom of the spool as spoo...

Page 18: ...nto the MIG gun Resecure the pressure roller arm 2 and wire drive tension screw and adjust the pressure accordingly Remove the contact tip from the MIG gun With the MIG gun lead reasonably straight fe...

Page 19: ...t pressure stamped on the regulator DO NOT attach the regulator to a system that has a higher pressure than the maximum rated pressure stamped on the regulator 2 The regulator body will be stamped IN...

Page 20: ...e is present Have a qualified repair technician clean the regulator or repair any damage Figure 17 Regulator to cylinder valve 6 Before opening the cylinder valve turn the regulator adjusting screw co...

Page 21: ...equired delivery pressure 3 Close the cylinder valve 4 Turn the adjusting screw knob counter clockwise one turn If the high pressure gauge reading drops there is a leak in the cylinder valve inlet fit...

Page 22: ...lockwise to release the tension on the adjusting spring 5 Check the gauges after a few minutes for verification that the cylinder valve is closed completely When the regulator is not in use and has be...

Page 23: ...ge meter will hold the value until 1 any of the front panel controls are adjusted in which case the unit will revert to preview mode 2 welding is recommenced in which case actual welding amperage will...

Page 24: ...7 MIG polarity lead The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal allowing polarity reversal for different welding applications In general t...

Page 25: ...align keyway insert plug and rotate threaded collar fully clockwise 1 Trigger switch 2 Max CW 3 Min CCW 4 Pot V A WFS 5 Peripheral sense MIG Gun F180TH103035 TIG Torch W4013802 1 Trigger switch 1 Spoo...

Page 26: ...this power source is intended to act as a guide only Some differences may be observed between preview values and actual welding values due to factors including the mode of welding differences in cons...

Page 27: ...selection menu a MIG MAG Sub Menu Parameter Type MIN MAX RIN 10 100 PRG S 0 10 Bb S 0 01 0 1 POG S 0 5 10 Access to sub menu functions is easily performed Press and hold Left hand side Button for 2 se...

Page 28: ...side LED Display Indicates Open Circuit OCV welding voltage V Right hand side LED Display Indicates set welding amperage value A Rotating Right hand side Encoder CW Clockwise will increase welding am...

Page 29: ...as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up 14 Digital voltage meter Left Side LED Display MI...

Page 30: ...performs a dual function It is used to turn the unit ON OFF and it will also trip in the event of a fault 17 Wire Feed Jog switch When installing welding wire press the jog switch to feed the wire th...

Page 31: ...indicator will illuminate if the duty cycle of the power source has been exceeded Should the thermal overload indicator illuminate the output of the power source will be disabled Once the power sourc...

Page 32: ...rol knob adjusts the speed of the wire feed motor which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc The optimum wire speed depends upon the materi...

Page 33: ...of the power source to the appropriate welding accessory such as the MIG gun via the MIG polarity lead TIG torch or work lead Negative welding current flows to the power source via this dinse type te...

Page 34: ...815 001 34 ESAB AB 2021 Spool gun 1 Trigger switch 2 Max CW 3 Min CCW 4 Pot V A WFS 5 Peripheral sense MIG Gun F180TH103035 TIG Torch W4013802 1 Trigger switch MIG Gun TIG Torch 1 Trigger switch 2 10k...

Page 35: ...lue Min and Maximum range see table Right hand side LED display Indicates set welding Wire Feed Speed WFS value Rotating Right hand side Encoder CW Clockwise will increase welding WFS value Rotating R...

Page 36: ...used during the MIG MAG welding process Inductance setting is indicated as IND within Left hand side LED Display with a value shown in Right hand side LED Display The inductance value is adjusted by R...

Page 37: ...review values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip...

Page 38: ...remote switch set to remote the maximum setting of the power source will be determined by the respective front panel control irrespective of the remote control device setting As an example if the out...

Page 39: ...ustable pressure screw These devices should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage If slipping occurs and inspection of the wire contact tip reveal...

Page 40: ...Be sure not to lose key that is located on drive motor shaft This key must align with drive roll groove for proper operation A dual groove feed roller is supplied as standard It can accommodate 0 02...

Page 41: ...ckwise to tighten the brake Correct adjustment will result in the wire reel circumference continuing no further than 1 8 in 3 16 in 3 5 mm after release of the trigger The electrode wire should be sla...

Page 42: ...facturer Welding current flows from the power source via dinse type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 5 Swit...

Page 43: ...rned securely to achieve a sound electrical connection 4 Refer to the weld guide located on the inside of the wire feed compartment door for further information 5 Switch the LOCAL REMOTE switch inside...

Page 44: ...the shielding gas inlet on the rear panel of the power source 1 Make sure the welding power source is turned off before connecting the welding torch NOTE If the power source has already been setup for...

Page 45: ...ON OFF via the TIG torch trigger switch to TIG weld or a foot control with an 8 pin plug must be used to turn the weld current ON OFF as well as providing remote control of the weld current 5 Fit the...

Page 46: ...doubt consult the electrode manufacturer Welding current flows from the power source via dinse type terminals It is essential however that the male plug is inserted and turned securely to achieve a s...

Page 47: ...may be operated automatically and can be machine operated The process can be used to weld thin and fairly thick steels and some non ferrous metals in all positions Figure 38 GMAW process 1 Solidified...

Page 48: ...below CAUTION Do NOT pull the MIG gun back when the arc is established This will create excessive wire extension stick out and make a very poor weld The electrode wire is not energized until the MIG...

Page 49: ...lten pool travels influences the width of the weld and penetration of the welding run MIG welding GMAW variables Most of the welding done by all processes is on carbon steel The items below describe t...

Page 50: ...ld current Decrease in wire feed speed decreases weld current Figure 45 Electrode stick out 1 Tip to work distance 4 Electrode wire 2 Gas nozzle 5 Actual stick out 3 Contact tip tube 6 Average arc len...

Page 51: ...arc Less wire speed will reduce the current and lengthen the arc Increasing the welding voltage hardly alters the current level but lengthens the arc By decreasing the voltage a shorter arc is obtaine...

Page 52: ...trodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace Hydrogen controlled electrodes must be used for this ap...

Page 53: ...Figure 55 Overhead position Fillet weld Joint preparations In many cases it will be possible to weld steel sections without any special preparation For heavier sections and for repair work on casting...

Page 54: ...nt 12 Lap joint 4 Not less than 70 13 Tee joint Fillet both sides of the joint 5 Maximum 1 16 in 1 6 mm 14 Fillet joint 6 1 16 in 1 6 mm 15 Edge joint 7 Not less than 45 16 Corner weld 8 Double vee bu...

Page 55: ...cable and electrode holder is not faulty otherwise you are risking an electric shock Striking an arc Practice this on a piece of scrap plate before going on to more exacting work You may at first expe...

Page 56: ...ot Using a 1 8 in 3 2 mm E7014 electrode at 100 A deposit a run of weld metal on the bottom of the joint Do not weave the electrode but maintain a steady rate of travel along the joint sufficient to p...

Page 57: ...sag towards the base and undercut forms on the vertical leg Multi runs can be made as shown below Weaving in HV fillet welds is undesirable Figure 60 Electrode position for the HV fillet weld Figure 6...

Page 58: ...lectrode should point upwards at an angle of about 45 Overhead welds Apart from the rather awkward position necessary overhead welding is not much more difficult that downhand welding Set up a workpie...

Page 59: ...s not crack stresses will remain Locked up in the structure If the joint material is relatively weak for example a butt joint in 5 64 in 2 0 mm sheet the contracting weld metal may cause the sheet to...

Page 60: ...stresses suitably so that they tend to cancel each other see the figures below for various weld sequences Choice of a suitable weld sequence is probably the most effective method of overcoming distor...

Page 61: ...ts of the structure other than the area to be welded can be sometimes used to reduce distortion Figure Reduction of distortion by preheating shows a simple application By removing the heating source f...

Page 62: ...eat Figure 70 Examples of distortion Dotted lines show the effect if no preheat is used 1Weld Figure 71 Welding sequence Figure 72 Step back sequence Block sequence The spaces between the welds are fi...

Page 63: ...ome circumstances depending on the welding application Figure 75 TIG L GTAW welding application 1 Workpiece 4 Inert gas 2 Gas cup 5 Filler metal 3 Tungsten electrode Workpiece Can be any commercial me...

Page 64: ...life More stable arc Easier starting Wider current range Narrower more concentrated arc Grey NOTE The Firepower MST 200 inverter is not suited for AC TIG welding TIG Welding filler rods Base metal th...

Page 65: ...outline of the TIG welding process is outside the scope of this Instruction Manual 6 BASIC WELDING GUIDE 6 7 Electrode wire size selection The choice of electrode wire size and shielding gas used depe...

Page 66: ...Minimum insulation resistance for in service ESAB inverter power sources shall be measured at a voltage of 500 V between the parts see Minimum insulation resistance requirements ESAB inverter power s...

Page 67: ...s wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition All unsafe accessories shall not be used Repai...

Page 68: ...clean the welding power source open the enclosure and use a vacuum cleaner to remove any accumulated dirt metal filings slag and loose material Keep the shunt and lead screw surfaces clean as accumul...

Page 69: ...ck in conduit liner or contact tip burnback jam Check for clogged kinked MIG gun conduit liner or worn contact tip Replace faulty components Internal fault in the power source Contact an authorised ES...

Page 70: ...e are two main areas where problems occur with GMAW porosity and inconsistent wire feed Porosity When there is a gas problem the result is usually porosity within the weld metal Porosity always stems...

Page 71: ...of inlet outlet guides The liner is blocked with swarf Increased amounts of swarf are produced by the wire passing through the feed roller when excessive pressure is applied to the pressure roller adj...

Page 72: ...w Increase voltage Excessive spatter Voltage is too high Decrease voltage or increase the wire speed control Voltage is too low Increase the voltage or decrease wire speed Irregular weld shape Incorre...

Page 73: ...risp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly The MIG gun has been connected to the wrong voltage polarity on the front panel Connect the MIG polarity c...

Page 74: ...diameter electrode Insufficient gap Allow a wider gap Non metallic particles are trapped in the weld metal Non metallic particles may be trapped in undercut from previous run If a bad undercut is pres...

Page 75: ...t deposit time at the edge of weave Pause for a moment at the edge of the weave to allow weld metal build up The power source is set for MIG GMAW welding Set the power source to MMA SMAW mode Portions...

Page 76: ...struck The TIG torch lead connected to positive welding terminal Connect the TIG torch lead to negative welding terminal No gas flowing to welding region Check the gas lines for kinks or breaks and ga...

Page 77: ...elding Gas cylinder valve OFF or TIG torch hose not connected to regulator Turn ON gas cylinder valve or connect TIG torch hose to regulator 8 5 Error Codes Error codes The error code is used to indic...

Page 78: ...to ensure that the product still complies with the requirements of the above standards Spare parts and wear parts can be ordered through your nearest ESAB dealer see esab com When ordering please stat...

Page 79: ...3 766 Instruction manual The three last digits in the document number of the manual show the version of the manual Therefore they are replaced with here Make sure to use a manual with a serial number...

Page 80: ...16 1 N A Bottom plate FP 200 MST 200 17 1 1444 1114 Hall sensor FP 200 MST 200 18 1 1444 1115 Front PCB FP 200 MST 200 19 1 1444 1116 Aviation socket FP 200 MST 200 20 2 1444 1117 OKC 35 70 FP 200 MS...

Page 81: ...tem Qty Ordering no Denomination Notes 36 1 W7004906 Feedroll retaining thumb screw FP 200 MST 200 37 1 1444 1132 Pressure arm WF FP 200 MST 200 38 1 1444 1135 Outlet wire guide FP 200 MST 200 39 1 14...

Page 82: ...For contact information visit http esab com ESAB AB Lindholmsall n 9 Box 8004 402 77 Gothenburg Sweden Phone 46 0 31 50 90 00 http manuals esab com...

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