Firepower MST 140i Operating Manual Download

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TABLE OF CONTENTS

SECTION 4: BASIC WELDING GUIDE .................................................................... 4-1

4.01

MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1

4.02

MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-6

4.03

Stick (SMAW) Basic Welding Technique ......................................................... 4-9

4.04

Effects of Stick Welding Various Materials .................................................... 4-10

4.05

Stick (SMAW) Welding Troubleshooting ....................................................... 4-17

4.06

TIG (GTAW) Basic Welding Technique .......................................................... 4-20

4.07

TIG (GTAW) Welding Problems ..................................................................... 4-22

SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS ............ 5-1

5.01

Power Source Problems ................................................................................. 5-1

5.02

Routine Service............................................................................................... 5-3

5.03

Cleaning the Welding Power Source ............................................................... 5-4

5.04

Cleaning the Feed Rolls ................................................................................... 5-4

5.05

Volt-Ampere Curves ........................................................................................ 5-4

SECTION 6: KEY SPARE PARTS .......................................................................... 6-1

6.01

Firepower 140A MIG Gun Parts ...................................................................... 6-1

6.02

Power Source ................................................................................................. 6-2

6.03

Hardware List ................................................................................................. 6-4

APPENDIX ................................................................................................... A-1

APPENDIX: FIREPOWER MST 140I CIRCUIT DIAGRAM ............................................... A-2

FIREPOWER - LIMITED WARRANTY TERMS ...................................... INSIDE REAR COVER

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ................................. REAR COVER

Summary of Contents for MST 140i

Page 1: ...Art A 12514 Firepower MST 140i 3 IN 1 Multi Process Welding Systems Operating Manual www firepower com English Canadien Français Americas Español Revision AA Issue Date March 12 2014 Manual No 0 5338 ...

Page 2: ...t leading innovation and truly dependable products that will stand the test of time We strive to enhance your productivity efficiency and welding performance enabling you to excel in your craft We design products with the welder in mind delivering advanced features durability ease of use and ergonomic comfort Above all we are committed to a safer working environment within the welding industry You...

Page 3: ...St Louis MO 63017 USA www firepower com Copyright 2014 by Victor Technologies Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence acc...

Page 4: ...10 Options and Accessories 2 4 SECTION 3 INSTALLATION OPERATION AND SETUP 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Ventilation 3 1 3 04 Electricity Supply Voltage 3 1 3 05 Electromagnetic Compatibility 3 3 3 06 Firepower Flowmeter Regulator 3 4 3 07 Leak Testing the System 3 6 3 08 When You Finish Using the Flowmeter Regulator 3 6 3 09 Storage of the Flowmeter Regulator 3 6 3 10 Power Sourc...

Page 5: ...IG GTAW Welding Problems 4 22 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Power Source Problems 5 1 5 02 Routine Service 5 3 5 03 Cleaning the Welding Power Source 5 4 5 04 Cleaning the Feed Rolls 5 4 5 05 Volt Ampere Curves 5 4 SECTION 6 KEY SPARE PARTS 6 1 6 01 Firepower 140A MIG Gun Parts 6 1 6 02 Power Source 6 2 6 03 Hardware List 6 4 APPENDIX A 1 APPENDIX FIREPO...

Page 6: ...This Page Intentionally Blank ...

Page 7: ...rk ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and...

Page 8: ... locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases 7 Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers Process Electrode Siz...

Page 9: ...in use WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag 1 Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cyl...

Page 10: ...adiator can be very hot and under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap WARNING WARNING This product contains chemicals including lead known to the State of California to cause birth defects and other reproductive harm Wash hands after handli...

Page 11: ... highly explosive They can ignite and burn violently in the presence of oxygen Keep ALL apparatus clean and free of grease oil and other flammable substances C Ventilation WARNING Ade quately ventilate welding heating and cutting work areas to prevent accumulation of explosive or toxic concen trations of gases Certain combina tions of metals coatings and gases generate toxic fumes Use respiratory ...

Page 12: ...the cylinder could tip over When cracking the cylinder valve DO NOT stand directly in front of the cylinder valve Always perform cracking in a well ventilated area If an acetylene cylinder sprays a mist when cracked let it stand for 15 minutes Then try to crack the cylinder valve again If this problem persists contact your gas supplier 1 03 Principal Safety Standards Safety in Welding and Cutting ...

Page 13: ... Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow Time Spot Time Spot Weld Mode Continuous Weld Mode Press to initiate wirefeed and welding release to stop Purging Of Gas Inches Per M...

Page 14: ...on dès la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension Un équipement ina déquatement installé ou inadéquatement mis à la terre est dangereux 1 Ne touchez pas à des pièces sous tension 2 Portez des gants et des vêt...

Page 15: ...e est bien ventilée ou que les fumées et les vapeurs sont aspirées à l arc AWS F2 2 2001 R2010 Modifié avec l accord de l American Welding Society AWS Miami Florida Guide de teinte des lentilles Procédé Taille de l électrode en mm po Courant d arc ampères Gamme d intensité minimum Numéro de teinte recommandée Confort Soudage à l arc avec électrode enrobée procédé SMAW Moins de 2 4 3 32 3 32 5 32 2...

Page 16: ...ion est inadequate portez un respirateur à adduction d air approuvé 4 Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux aux produits consummables aux revêtements et aux produits nettoyants 5 Ne travaillez dans un espace confiné que s il est bien ventilé sinon portez un respirateur à adduction d air Les gaz protecteurs de soudage peuvent déplacer l oxygène de l air e...

Page 17: ...nverser de carburant Nettoyez tout carburant renversé avant de faire démarrer le moteur AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pièces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des vêtements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien fermés 2 Avant d inst...

Page 18: ...contrariante En effet il nous est aussi impossible de tirer des conclusions définitives quant aux risques éventuels ou de proposer des stratégies fondées sur des faits scientifiques visant à atténuer ou éviter des risques potentiels Pour atténuer les champs magnétiques sur les lieux de travail respectez les procédures qui suivent 1 Maintenez les câbles l un près de l autre en les entrelaçant ou le...

Page 19: ...s de sécurité et de mode opératoire suivantes à chaque fois que vous utilisez cet appareil de régulation de pres sion Si vous déviez de ces procédures cela peut entraîner incendie explosion dégâts matériels et ou blessures corporelles pour l opérateur E Bouteilles de Gaz Comprimé Le Département des Transports américain DOT approuve la conception et la fabrication des bouteilles qui contiennent les...

Page 20: ...nd Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Supe rintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Wel ding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami ...

Page 21: ...Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 07639_AB 115V 15A t t1 t2 X IPM MPM t Fusible Déroulement du Fil Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Durée de Pré Dèbit Durée de Post Dèbit Duréc du Pulse Soudure Par Point Appuyez pour dèruarer l alimentation du fils et la soudure le relâcher pour arr...

Page 22: ...al requirements Among them are CSA E60974 1 UL 60974 1 and IEC 60974 1 applicable to welding equipment and associated accessories 2002 95 EC RoHS directive Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related indust...

Page 23: ...process welding system that is capable of performing MIG GMAW FCAW STICK SMAW and LIFT TIG GTAW weld ing processes The Power Source System is equipped with an integrated wire feed unit digital voltage and amperage meters and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional The Power Source System is also fully compliant to Standard CSA...

Page 24: ...ture limits of the insulation of the component parts To explain the 10 minute duty cycle period the following example is used Suppose a Welding Power Source System is designed to operate at a 20 duty cycle 100 amperes at 19 volts This means that it has been designed and built to provide the rated amperage 100 A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 ...

Page 25: ...ode 10 90A Wirefeed Speed Range 95 390 IPM MIG Welding Voltage Range 10 19V DC Nominal OCV 53V DC Breaker Size 20A 30A Requires updated Power Cord and Plug Effective Input Current I1eff MIG GMAW FCAW STICK SMAW TIG GTAW 16 8A 16 8A 11 0A 16 1A 11 8A 14 3A Maximum Input Current I1max MIG GMAW FCAW STICK SMAW TIG GTAW 26 2A 28 4A 24 7A 41 5A 30 5A 37A Single Phase Generator Requirement 5 KW 6 KW MIG...

Page 26: ...ffer Individual equipment may differ from the above specifications due to in part but not exclusively to any one or more of the following variations or changes in manufactured components installation location and conditions and local power grid supply conditions The thermal protection switch is rated at 80 C 2 10 Options and Accessories DESCRIPTION PART NUMBER TIG Torch 17V 12 5 ft 25mm Accessory ...

Page 27: ...ter than 1 2 12mm and direct protection from vertical drops Under no circumstances should the Power Source System be operated or connected in a micro environment that will exceed the stated conditions For further information please refer to EN 60529 H Precautions must be taken against the Power Source System toppling over The power source must be located on a suitable horizontal surface in the upr...

Page 28: ...f the welding Power Source 50 60 Hz Single Phase Supply Supply Voltage 115V AC Input Current at Maximum Output 28 4 Amps Maximum Recommended Fuse or Circuit Breaker Rating Time Delay Fuse UL class RK5 Refer to UL248 Maximum Recommended Fuse or Circuit Breaker Rating Normal Operating UL class K5 Refer to UL248 30 Amps 30 Amps Single Phase Generator Requirement 5 KW Minimum Recommended Input Cable S...

Page 29: ...elding or other activities are to be carried out 8 The compatibility of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area...

Page 30: ...lowmeters Regulators supplied with 5 8 18 standard inert gas connections Flowmeters Regulators purchased with open 1 8 1 4 3 8 or 1 2 NPT ports must be assembled to their intended system 1 Note the maximum inlet pressure stamped on the flowmeter regulator DO NOT attach the flowmeter regulator to a system that has a higher pressure than the maximum rated pressure stamped on the flowmeter regulator ...

Page 31: ...n stream equipment from high pressures WARNING DO NOT tamper with the relief valve or remove it from the flowmeter regulator WARNING Stand to the side of the cylinder opposite the flowmeter regulator when opening the cylinder valve Keep the cylinder valve between you and the flowmeter regulator For your safety NEVER STAND IN FRONT OF OR BEHIND A FLOWMETER REGULATOR WHEN OPENING THE CYLINDER VALVE ...

Page 32: ...requires service or repair take it to a qualified repair technician 5 Once leak testing has been performed and there are no leaks in the system slowly open the cylinder valve and proceed WARNING If a leak has been detected anywhere in the system dis continue use and have the system repaired DO NOT use leaking equipment Do not attempt to repair a leaking system while the system is under pressure 3 ...

Page 33: ...OWER SOFT WIRESPEED HARD FAULT DOWNSLOPE S 10 10 2 2 9 9 1 1 ARC FORCE INDUCTANCE 2 6 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Art A 12437 MIG LIFT TIG STICK 4T 2T WIRESPEED INDUCTANCE HARD SOFT DOWNSLOPE S ARC FORCE A V 10 10 2 2 4 4 7 7 9 9 1 1 3 3 6 6 8 8 2 4 6 8 Figure 3 4 Front Panel Art A 10354 16 17 15 Figure 3 5 Rear Panel 18 19 Art A 12438 Figure 3 6 Wire Feed Compartment Control ...

Page 34: ...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 consumables gas mixtures individual welding techniques and the transfer mode of the welding arc ie dip versus spray transfer Where exact settings are required in the case of procedural work it is recommended that alternate measurement ...

Page 35: ...lding terminal when using steel stainless steel or aluminum electrode wire When using flux cored gasless wire the polarity lead is generally connected to the negative welding terminal If in doubt consult the manufacturer of the electrode wire for the correct polarity It is essential however that the Dinse adapter and male plug are inserted and turned securely to achieve a sound electrical connecti...

Page 36: ...Art A 12440 Figure 3 7 Remote Control Socket Socket Pin Function 1 Not used 2 Trigger Switch Input 3 Trigger Switch Input 4 Not used 5 5k ohm maximum connection to 5k ohm remote control potentiometer 6 Zero ohm minimum connection to 5k ohm remote control potentiometer 7 Wiper arm connection to 5k ohm potentiometer for the remote control of the Amperage Weld Current in LIFT TIG mode 8 Wiper arm con...

Page 37: ...dig control This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit up in certain situations with particular electrodes In general increasing the arc force control toward 10 maximum arc force allows greater penetration control to be achieved Arc force is increased by turning the control knob clockwise or decreased by turning the ...

Page 38: ...o cease welding 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the operator can press and release the MIG or TIG Trigger Switch and the output will remain active To deactivate the Power Source the trigger switch must again be depressed and released thus eliminating the need for the operator to hold the MIG or TIG Trigger Switch Note ...

Page 39: ...lding techniques and the transfer mode of the welding arc ie dip versus spray transfer Where exact settings are required in the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate MIG STICK 4T 2T POWER FAULT 6 14 MIG LIFT TIG STICK 4T 2T V 4 7 3 6 4 6 13 14 Fault Indicator This welding Power Source is protected by a self res...

Page 40: ...te device and will operate from the Power Source controls only Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local remote switch ie in both local and remote modes Should a remote device be connected and the local remote switch set to remote the maximum setting of the Power Source will be determined by the respective front panel con...

Page 41: ...MIG Gun Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adapter and tightening the Locking Nut to secure the MIG Gun in the MIG Gun Adapter MIG Gun Connect Tighten Locking Nut Art A 12516 MIG GunAdaptor MIG Gun Connector MIG Gun Locking Nut Figure 3 8 Attaching MIG Gun ...

Page 42: ...Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 3 9 Remove the nozzle and contact tip from the MIG Gun With the MIG Gun lead reasonably straight feed the wire through the MIG Gun by depressing the trigger switch Fit the appropriate contact tip WARNING Before connecting the work clamp to the work piece make sure you have ceased feeding wire ...

Page 43: ...his nut with nylon insert tightens the brake The brake is correctly adjusted when the spool stops within 4 100mm to 8 200mm measured at the outer edge of the spool after MIG Gun trigger is released Wire should be slack without becoming dislodged from the spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical components and possibly an increa...

Page 44: ...n trigger is released Wire should be slack without becoming dislodged from the spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical components and possibly an increased incidence of electrode wire Burnback into contact tip Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in 8 200mm diameter spool NOTE This...

Page 45: ...ssure screw clockwise WARNING Before changing the feed roller ensure that the Electricity Supply to the Power Source is switched off CAUTION The use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing 3 16 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an counterclockwise direction Once the feed roll is removed then to re...

Page 46: ...ockwise to tighten the brake Correct adjustment will result in the wire reel circumference continuing no further than 3 8 10mm 3 4 20mm after release of the trigger The electrode wire should be slack without becoming dislodged from wire spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical components and possibly an increased incidence of e...

Page 47: ...am valve tightly 2 Open downstream equipment valves to drain the lines Bleed gas into a well ventilated area and away from any ignition source 3 After gas is drained completely disengage adjusting screw and close downstream equipment valves 4 Before transporting cylinders that are not secured on a cart designed for such purposes remove flowmeters regulators Put caps on all cylinders that do not ha...

Page 48: ...nary support to prevent falling or tipping CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Art A 12520 Connect Shielding Gas Hose to regulator Primary Cord Work Lead Negative Welding Terminal Positive Welding Terminal MIG Gun Polarity Lead MIG Gun Secure the gas cylinder in an upright position by chaining it to a stationary s...

Page 49: ...e connectors It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection D Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information E Switch the LOCAL REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sources Wirespeed and Voltage controls WARNING Before connecting the work ...

Page 50: ...repower 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 Please refer to 2 10 Options and Accessories E Fit the flowmeter regulator to the shielding gas cylinder refer to Section 3 06 then connect the shielding gas hose from the TIG torch to the flowmeter regulator outlet Note that the TIG torch shielding gas hose ...

Page 51: ...OR a Firepower 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 Connect to shielding gas regulator flow gauge Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping Negative welding terminal 50mm 25mm Adaptor Positive Welding Terminal TIG Torch Work Lead ...

Page 52: ...rs It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Electricity Supply is switched off CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source ...

Page 53: ...rated The process can be used to weld thin and fairly thick steels and some non ferrous metals in all positions Art A 8991_AB Shielding Gas Molten Weld Metal Solidified Weld Metal Nozzle Electrode Arc Base Metal GMAW Process Figure 4 1 FLUX CORED ARC WELDING FCAW This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a continuous flu...

Page 54: ...el 5 to 15 Longitudinal Angle 30 to 60 Transverse Angle Art A 08994 Figure 4 5 Vertical Fillet Welds Art A 08995 30 to 60 Transverse Angle 30 to 60 Transverse Angle Direction of Travel 10 Longitudinal Angle 10 to 20 Longitudinal Angle Figure 4 6 Overhead Weld Art A 08996 30 to 60 Transverse Angle Direction of Travel 5 to 15 Longitudinal Angle Figure 4 7 Distance from the MIG Gun Nozzle to the Work...

Page 55: ...ance between the end of the contact tube tip and the end of the electrode wire Maintain at about 3 8 10mm stick out 2 Wire Feed Speed Increase in wire feed speed increases weld current Decrease in wire feed speed decreases weld current Art A 08997_AD Gas Nozzle Electrode Wire Average Arc Length Electrode Stick Out Tip to Work Distance Actual Stick out Contact Tip Tube Figure 4 8 3 Nozzle Angle Thi...

Page 56: ...e 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 obtained with a little change in current level When changing to a different electrode wire diameter different control settings are required A thinner electrode wire needs more Wirespeed to achieve the same current level A satisfactory weld c...

Page 57: ...Firepower MST 140i Manual 0 5338 4 5 BASIC WELDING GUIDE Firepower MIG Lift TIG Stick Wire Selection Chart Art A 12462 Table 4 1 MIG Lift TIG Stick Welding Set up Chart ...

Page 58: ... connection must seal the shielding gas within the MIG Gun Adapter so the shielding gas flows into the MIG Gun and out thru the MIG Gun nozzle 2 No shielding gas flow Ensure that the shielding gas cylinder is not empty and the flow meter is correctly adjusted to workshop welding 15 25 CFH or outdoors welding 35 46 CFH 3 Gas leaks Check for gas leaks between the regulator cylinder connection and in...

Page 59: ...re is applied to the pressure roller adjuster B Debris can also be produced by the wire passing through an incorrect feed roller groove shape or size C Debris is fed into the conduit liner where it accumu lates thus reducing wire feedability 6 Incorrect or worn contact tip A The contact tip transfers the weld current to the elec trode wire If the hole in the contact tip is too large then arcing ma...

Page 60: ... Concave voltage too high A Adjust voltage and travel speed by adjusting the voltage control and the wirespeed control B Wire is wandering B Check to see if it is near the end of the roll of wire and replace when necessary If the problem continues tighten the nozzle to see if this corrects the problem Then replace contact tip C Incorrect shielding gas C Check shielding gas D Insufficient or excess...

Page 61: ...et up correctly also check polarity shielding gas wire type and size B Contact tip has arc marks in the bore causing excessive drag on the wire B Replace the contact tip with only a genuine MST contact tip Table 4 4 MIG Welding Problems 4 03 Stick SMAW Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the ...

Page 62: ...ing pre heating of heavy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile...

Page 63: ...es being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 19 Gap varies from 1 16 1 6mm to 3 16 4 8mm depending on plate thickness Joint Open Square Butt 1 16 1 6mm max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double Vee Butt Joint 1 16 1 6mm Lap Joint Tee Joints Fillet both sides of the ...

Page 64: ...ined although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in If this should happen give the electrode a quick twist back over the weld to detach it Contact or touch weld electrodes such as E7014 Stick electrodes do not stick in this way and make welding much easier Rate of Travel After the arc is struck your next concern is to maintai...

Page 65: ...a backing bar is used it is not usually necessary to remove this since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld B Fillet Welds These are welds of approximately triangular cross section made by depositing metal in the corner of two faces meeting at right angles Refer to Figure 4 14 A piece of angle iron is a suitable specimen with which to beg...

Page 66: ... Vertical Fillet Weld Art A 07703 Figure 4 27 Examples of Vertical Fillet Welds 2 Vertical Down The E7014 Stick electrode makes welding in this position particularly easy Use a 1 8 3 2mm electrode at 100 amps The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag The electrode shoul...

Page 67: ... the contracting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the weld but when it ...

Page 68: ...ten used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the p...

Page 69: ... particles may be trapped in undercut from previous run A If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode B Joint preparation too re stricted B Allow for adequate penetration and room for clean ing out the slag C Irregular deposits allow slag to be trapped C If very bad chip or grind out irregularities D Lack of penetration with slag trapped beneath...

Page 70: ...ge electrode F Insufficient deposit time at edge of weave F Pause for a moment at edge of weave to allow weld metal buildup G Power Source is set for MIG GMAW welding G Set Power Source to STICK SMAW mode 5 Portions of the weld run do not fuse to the surface of the metal or edge of the joint A Small electrodes used on heavy cold plate A Use larger electrodes and preheat the plate B Welding current...

Page 71: ...lete flux coating 7 Crack occurring in weld metal soon after solidification commences A Rigidity of joint A Redesign to relieve weld joint of severe stresses or use crack resistance electrodes B Insufficient throat thickness B Travel slightly slower to allow greater build up in throat C Weld current is too high C Decrease welding current Not cleaned or incorrect electrode Slag trapped in undercut ...

Page 72: ...n the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High Impact or Water Cooled Metal Inert Gas Shields Electrode and Weld Puddle Tungsten Electrode Non Consumable Art A 10369_AB Figure 4 38 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm 30 60 1 16 ...

Page 73: ...eel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate CFH Joint Type 0 040 1 0mm 35 45 40 50 20 30 25 35 0 040 1 0mm 1 16 1 6mm 10 15 Butt Corner Lap Fillet 0 045 1 2mm 45 55 50 60 30 45 35 50 0 040 1 0mm 1 16 1 6mm 10 15 Butt Corner Lap Fillet 1 16 1 6mm 60 70 70 90 40 60 50 70 1 16 1 6mm 1 16 1 6mm 15 Butt Corner Lap Fillet 1 8 3 2mm 80 100 90 115 65 85 90 110 1 16 ...

Page 74: ...ngth in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts or oxidizes when an arc is struck A TIG Torch lead connected to positive welding terminal A Connect TIG Torch lead to negative welding terminal B No gas flowing to weld ing region B Turn TIG Torch gas valve ON Check the gas lines for kinks or breaks and gas cylinder contents C TIG Torch is clogged with dust...

Page 75: ...e Refer to Table 4 9 Tungsten Electrode Types C Gas flow rate is too high C Select the right rate for the welding job Refer to Table 4 10 D Incorrect shielding gas is being used D Select the right shielding gas E Poor work clamp con nection to work piece E Improve connection to work piece F Tungsten not properly sharpened F Grind tungsten to proper shape 10 Arc flutters during TIG welding Tungsten...

Page 76: ...Firepower MST 140i BASIC WELDING GUIDE 4 24 Manual 0 5338 This Page Intentionally Blank ...

Page 77: ...heck for clogged kinked MIG Gun conduit liner loose nozzle or worn contact tip Replace faulty components B 8 pin gun connector not con nected B Connect 8 pin gun connector C Faulty torch trigger C Repair or replace torch trigger D Wire tension too loose D Tighten wire tension E Brake tension too tight E Loosen brake tension 4 Welding wire continues to feed when torch trigger is released A Trigger ...

Page 78: ...rigger switch has been released MIG mode Gas valve has jammed open due to debris in the gas or the gas line Have an accredited Firepower service provider repair or re place gas valve 9 Power indicator will not illuminate and welding arc cannot be established The Electricity supply is inad equate Ensure that the Electricity Supply voltage is within 95 140 VAC 10 TIG electrode melts when arc is stru...

Page 79: ...ast once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging including the date of the most recent inspection A transportable Power Source is deemed to be any equipment that is not permanently connected and fixed in the posi tion in which it is operated NOTE Please refer to local guidelines for further information B General Mainten...

Page 80: ...d roll After cleaning tighten the feed roll retaining knobs CAUTION Do not use compressed air to clean the Welding Power Source Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the Welding Power Source This may result in arcing between this parts and their eventual failure 5 05 Volt Ampere Curves Voltage Amperage Curves shows maximum vo...

Page 81: ...ux Cored 1444 0888 MST Spot Nozzle 3 4 1444 0889 2 MST Contact Tip MST Contact Tip 023 1444 0890 MST Contact Tip 030 1444 0891 MST Contact Tip 035 1444 0892 MST Contact Tip 045 1444 0893 3 Handle Trigger Repair Kit 4 Universal Conduit Liner 1444 0883 5 Conductor Tube Firepower Fusion 140A 180A 220A MIG Gun 60 Deg 16201108 Table 6 1 Firepower 140A MIG Gun Parts Patent Pending Refer to Firepower Cat...

Page 82: ...Firepower MST 140i KEY SPARE PARTS 6 2 Manual 0 5338 6 02 Power Source Art A 12518 31 ...

Page 83: ...f 250V 16 W7004911 CT Sensor Output MST 140i 17 W7004912 Wire Hub Assy MST 140i 18 1444 0933 Panel Front FP MST 140i 19 1444 0935 Panel Rear FP MST 140i 20 W7004922 Handle MST 140i 21 1444 0936 Side and Top Panels not shown 22 EURO Adapter 23 W7004925 Guide Inlet 023 045 MST 140i 24 W7004967 Guide Outlet 023 045 MST 140i 25 1444 0937 Panel Door FP MST 140i not shown 26 1444 0934 Panel Base FP MST ...

Page 84: ... 6G 3 8 STBK 8 Pin Remote Socket 2 Front PCB 4 7 Nut Hexagon M4 0 7 ST ZP Fan 4 8 SC PHSL M4 0 7 30 ST ZP Fan 4 9 Nut Hexagon M12 1 75 ST ZP Gas Adaptor Inlet 1 10 Washer Flat 7 91 D M8 Wirefeeder Plate 2 11 Washer Spring 7 91 D Wirefeeder Plate 2 12 Screw Hexagon M8 1 25 30 ST ZP Wirefeeder Plate 2 13 Nut Hexagon M8 1 25 ST ZP Wirefeeder Plate 2 14 Screw Hexagon HD 9 32 16 19 Wirefeeder Plate 2 1...

Page 85: ...NTERNAL PANEL SCREW ITEM 5 OFF USED TO SECURE MOULDING TO BASE PANEL 5 2 1 2 2 2 4 1 4 1 4 1 8 4 7 4 4 1 3 1 4 1 3 1 4 1 4 1 3 1 4 1 3 1 4 1 3 1 4 1 6 4 6 2 9 1 SCREW ITEM 5 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL SCREW ITEM 4 2 OFF USED TO SECURE DOOR ASSY TO BASE PANEL 17 1 12 1 11 1 10 1 13 2 14 2 16 1 15 1 4 1 4 1 5 2 Art A 12464 Figure 6 3 ...

Page 86: ...Firepower MST 140i KEY SPARE PARTS 6 6 Manual 0 5338 This Page Intentionally Blank ...

Page 87: ...Firepower MST 140i Manual 0 5338 1 APPENDIX APPENDIX This Page Intentionally Blank ...

Page 88: ...Firepower MST 140i APPENDIX 2 Manual 0 5338 8 I Art A 12517 APPENDIX Firepower MST 140i CIRCUIT DIAGRAM ...

Page 89: ...Firepower MST 140i Manual 0 5338 3 APPENDIX Art A 12517 ...

Page 90: ...EQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of Firepower with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Firepower whether ar...

Page 91: ... claims under this limited warranty must be submitted by an authorized Victor Technologies repair facility within thirty 30 days of the repair No employee agent or representative of Victor Technologies is authorized to change this warranty in any way or grant any other warranty and Victor Technologies shall not be bound by any such attempt Correction of non conformities in the manner and time prov...

Page 92: ... Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626...

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