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Firepower MST 220i, Operating Manual

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FIREPOWER MST 220i

Manual 0-5343  

         6-1 

REPLACEMENT PARTS

SECTION 6: KEY SPARE PARTS

Torch Part No: 1444-0882

Art# A-12519

5

Figure 6-1

Item 

No.

Description

Part No.

1

MST Nozzle**

MST Nozzle 3/8" 

Bore, Flush

1444-0885

MST Nozzle 1/2" 

Bore, Flush

1444-0886

MST Nozzle 5/8" 

Bore, Flush

1444-0887

MST Nozzle Flux 

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

N/A

4

Universal Conduit Liner*

1444-0883

5

Conductor Tube, Firepower Fusion 

140A/180A/220A MIG Gun, 60 Deg

16201108

Table 6-1: Firepower Fusion 220A MIG Gun Parts

** Patent Pending 

* Refer to your Firepower Catalog for additional  

   options.

6.01  Firepower Fusion 220A MIG Gun

Summary of Contents for MST 220i

Page 1: ...Firepower MST 220i 3 IN 1 Multi Process Welding Systems Operating Manual www Firepower com English Canadien Fran ais Americas Espa ol Revision AA Issue Date May 13 2014 Manual No 0 5343...

Page 2: ...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 desi...

Page 3: ...017 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 publ...

Page 4: ...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 3 1 3 05 Electromagnetic Compatibility 3 4 3 06 Firepower Regulator 3 5 3 07 L...

Page 5: ...8 4 07 TIG GTAW Welding Problems 4 20 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Power Source Problems 5 1 5 02 Routine Service and Calibration Requirements 5 2 5 03 Cle...

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

Page 7: ...Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at...

Page 8: ...f the American Welding Society AWS Miami Florida Guide for Shade Numbers Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded Metal Arc Welding...

Page 9: ...approved covers 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 5 Watch for fire and keep a fire extinguisher nearby 6 B...

Page 10: ...installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negativ...

Page 11: ...EMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 General Safety Information For Victor CS Regulator A Fire...

Page 12: ...he operator E Compressed Gas Cylinders The Department of Transportation DOT approves the design and manufacture of cylinders that contain gases used for welding or cutting operations 1 Place the cylin...

Page 13: ...Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding...

Page 14: ...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 Fee...

Page 15: ...e lectrique peut tuer ou br ler gravement L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les circuits internes de l quipement sont aussi sous...

Page 16: ...entilles Proc d Taille de l lectrode en mm po Courant d arc amp res Gamme d intensit minimum Num ro de teinte recommand e Confort Soudage l arc avec lectrode enrob e proc d SMAW Moins de 2 4 3 32 3 32...

Page 17: ...cuir une chemise paisse un 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloi sons pour prot ger les autres des coups d...

Page 18: ...face l ouverture du robi net de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation 8 Lisez et respectez les consig...

Page 19: ...nt d ter com pl tement le bouchon AVERTISSEMENT AVERTISSEMENT Ce produitcontient des produits chimiques notamment du plomb reconnu par l tatde la Californie pour causerdes malforma tions cong nitalese...

Page 20: ...ien que l oxyg ne elle m me ne br le pas ces substances peuvent devenir extr me ment explosives Elles peuvent prendre feu et br ler violem ment en pr sence d oxyg ne Gardez TOUS les appareils propres...

Page 21: ...2 Placez le bouchon de protection de vanne sur la bouteille chaque fois que vous la d placez ou ne l utilisez pas Ne faites jamais glisser ou rouler d aucune mani re les bouteilles Utilisez un diable...

Page 22: ...e Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed...

Page 23: ...ource Auxiliaire Art A 07639F_AC 115V 15A t t1 t2 X IPM MPM t Fusible D roulement du Fil Alimentation du Fil Vers la Pi ce de Fabrication Hors Tension Dur e de Pr D bit Dur e de Post D bit Dur c du Pu...

Page 24: ...FIREPOWER MST 220i SAFETY INSTRUCTIONS AND WARNINGS 1 18 Manual 0 5343 This Page Intentionally Blank...

Page 25: ...gaining the best efficiency and quality from the Power Source Please read these instructions thoroughly be fore using the unit 2 01 How To Use This Manual To ensure safe operation read the entire manu...

Page 26: ...irs or replacements become necessary it is recommended that such repairs be carried out by ap propriately qualified persons approved by Firepower Advice in this regard can be obtained by contacting an...

Page 27: ...very 10 minute period 20 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool The thermal cut out will operate if the du...

Page 28: ...35 24 4V 90A 60 23 6V 70A 100 22 8V TIG GTAW Welding Output 104 F 10 min 200A 25 18 0V 130A 60 15 2V 101A 100 14 0V 150A 35 16 0V 115A 60 14 6V 90A 100 13 6V 230 VAC 15 208 VAC 15 115 VAC 15 Effectiv...

Page 29: ...ue to in part but not exclusively to any one or more of the following variations or changes in manufactured components installation and conditions and local power grid supply conditions 2 10 Optional...

Page 30: ...5343 2 11 Volt Ampere Curves Voltage Amperage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown Art A 11297 Figu...

Page 31: ...ases D In areas not subjected to abnormal vibration or shock E In areas not exposed to direct sunlight or rain SECTION 3 INSTALLATION OPERATION AND SETUP F Place at a distance of 12 305mm or more from...

Page 32: ...upply input cable plug to 115 V input power Art A 11275 Figure 3 1 115 VAC Adapter Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power supply The input...

Page 33: ...L248 50 Amps 30 Amps Maximum Recommended Fuse or Circuit Breaker Rating Normal Operating UL class K5 Refer to UL248 50 Amps 30 Amps Minimum Recommended Cord Size 12 AWG 12 AWG Maximum Recommended Exte...

Page 34: ...blems in the surrounding area The following shall be taken into account 1 Other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment 2 Radio an...

Page 35: ...nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the work piece to earth may reduce emis sions in some but not all instances Care shou...

Page 36: ...ing Pressure Gauges for Compressed Gas Service b Low pressure gauges must be UL recognized for the class of regulator they are being used on accord ing to UL252A WARNING Do not use a regulator that de...

Page 37: ...regulator For your safety NEVER STAND IN FRONT OF OR BEHIND A REGULATOR WHEN OPENING THE CYLINDER VALVE 9 Slowly and carefully open the cylinder valve Figure 3 5 until the maximum pressure shows on th...

Page 38: ...ice 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...

Page 39: ...Source Controls Indicators And Features 10 Art A 12526 3 4 5 6 7 8 9 11 10 12 13 2 1 14 16 15 21 3A 4T SOFT HARD E S 2 2 9 9 1 1 2 6 4T 4 4 7 7 3 3 6 6 8 8 2 4 8 Figure 3 6 Front and Control Panel Fig...

Page 40: ...of non welding the amperage meter will display a pre set preview value in both STICK and LIFT TIG modes This value can be adjusted by varying the Amperage Control Knob 4 When welding this digital mete...

Page 41: ...ion point for the MIG welding torch Connect the torch by pushing the torch connector into the brass torch adaptor firmly and screwing the plastic torch nut clockwise to secure in position To remove th...

Page 42: ...ut 3 Trigger Switch Input 4 Spool Gun Motor 24V DC 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 c...

Page 43: ...s released ie if the multifunction control knob is set to 5 the unit will ramp down from the present welding current to zero over 5 seconds If no down slope time is selected then the welding output wi...

Page 44: ...age value for a period of approxi mately 10 seconds in all modes The voltage meter will hold the value until 1 any of the front panel controls are adjusted in which case the unit will revert to previe...

Page 45: ...source front panel is set to 50 and the remote control device is set to 100 the maximum achievable output from the unit will be 50 Should 100 output be required the respective front panel control mus...

Page 46: ...on 220A MIG Gun Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and screw ing the plastic torch nut clockwise to secure the MIG torch to the MIG tor...

Page 47: ...e to align the spool alignment pin on the hub with the mating hole in the wire spool 3 Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool NOTE The Hub tension has been...

Page 48: ...lignment pin on the hub with the mating hole in the wire spool 3 Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool NOTE The Hub tension has been pre adjusted at the fa...

Page 49: ...l rotates counter clockwise 3 Then place Flat Washer Large Hole Keyed Washer Spring Flat Washer Small Hole as shown in Figure 3 13 Finally secure with Wire Spool Hub Nut NOTE The Hub tension has been...

Page 50: ...nd into the MIG gun Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 3 14 Remove the contact tip from the MIG gun With the MIG gun lead reasona...

Page 51: ...nsure 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 17 Changing the Feed Roll To c...

Page 52: ...the positive welding terminal If in doubt consult the electrode wire manu facturer Welding current flows from the Power Source via dinse type terminals It is essential however that the male plug is in...

Page 53: ...to prevent falling or tipping CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Remove any packaging material prior to use Do no...

Page 54: ...wever 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 informati...

Page 55: ...let on the rear panel of the Power Source 1 Make sure the welding power source is turned OFF before connecting the welding gun NOTE If the Firepower MST 220 has already been setup for MIG Welding you...

Page 56: ...ust be used to turn the weld current ON OFF as well as providing remote control of the weld current E Fit the welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Sec...

Page 57: ...the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping Note A 26V TIG torch with an 8 pin plug must be used to turn the weld current on off via t...

Page 58: ...that the male plug is inserted and turned securely to achieve a sound electrical connection C Select STICK mode with the process selection control refer to Section 3 10 for further information WARNING...

Page 59: ...ed by heating them with an arc between a continu ous flux filled electrode wire and the work Shielding is obtained through decomposition of the flux within the tubular wire Additional shielding may or...

Page 60: ...lectrode wire Type of gas not applicable for FCAW self shielding wires Gas flow rate not applicable for FCAW self shield ing wires Primary Adjustable Variables These control the process after preselec...

Page 61: ...resulting in a shorter 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...

Page 62: ...FIREPOWER MST 220i BASIC WELDING 4 4 Manual 0 5343 Firepower MIG Lift TIG Stick Wire Selection Chart Art A 12540 Table 4 1 NOTE Please refer to the inside panel of the machine for the same chart...

Page 63: ...o 31 75 CFH 2 Shielding gas cylinder contents and flow gauge Ensure that the shielding gas cylinder is not empty and the flow meter is correctly adjusted to workshop welding 28 35 CFH or outdoors weld...

Page 64: ...applied to the pressure roller adjuster B Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size C Swarf is fed into the conduit liner where it accumu lat...

Page 65: ...ng gas D Insufficient or excessive heat input D Adjust the wirespeed control or the voltage control 6 Weld cracking A Weld beads too small A Decrease travel speed B Weld penetration narrow and deep B...

Page 66: ...e heating 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 applicatio...

Page 67: ...Figure 4 17 Overhead Position Butt Weld Art A 07694 Figure 4 18 Overhead Position Fillet Weld Joint Preparations In many cases it will be possible to weld steel sections without any special preparati...

Page 68: ...ch so that welding can be carried out in the downhand position Make sure that the work clamp is making good electrical contact with the work either directly or through the work table For light gauge m...

Page 69: ...act or touch weld electrodes such as E7014 do not stick in this way and make welding much easier Rate of Travel After the arc is struck your next concern is to maintain it and this requires moving the...

Page 70: ...ular to the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the per pendicular position to prevent slag from running ahead of the weld Refer t...

Page 71: ...iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead posi tion as shown in the sketch The electrode is held at 45 to th...

Page 72: ...does not resume its former shape and the contraction of the new shape exerts a strong pull on adjacent metal Several things can then happen The metal in the weld area is stretched plastic deformation...

Page 73: ...e thus reducing distortion Art A 07707 Figure 4 31 Principle of Presetting Art A 07708 B Preheat Preheat Dotted lines show effect if no preheat is used Weld C Figure 4 32 Reduction of Distortion by Pr...

Page 74: ...etallic particles may be trapped in undercut from previous run A If a bad undercut is present clean slag out and cover with a run from a smaller gauge electrode B Joint preparation too restricted B Al...

Page 75: ...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...

Page 76: ...e welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Electrode an...

Page 77: ...C Current for Mild Steel DC Current for Stainless Steel 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...

Page 78: ...peed 5 Uneven leg length 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 connect ed to positive welding termin...

Page 79: ...ode is being used for the welding job B Select the right electrode type Refer to Firepower Electrode Selection Chart C Gas flow rate is too high C Select the right rate for the welding job Refer to Ta...

Page 80: ...FIREPOWER MST 220i BASIC WELDING 4 22 Manual 0 5343 This Page Intentionally Blank...

Page 81: ...nal fault in power source B Have an Accredited Firepower Service Provider investigate the fault 4 Welding wire continues to feed when torch trigger is released A Trigger mode selection switch is in 4T...

Page 82: ...ower Service Provider Disconnect the Welding Power Source from the Electricity Supply before disassembling Routine Inspection Testing Maintenance The inspection and testing of the power source and ass...

Page 83: ...ed wiring sup plying Firepower welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below 1 For outlets wiring and associated accessories suppl...

Page 84: ...within applicable Firepower power source specifications Output Voltage V to be checked to ensure it falls within applicable Firepower power source specifications Motor Speed RPM of wire drive motors t...

Page 85: ...Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current Warning Disconnect input power before maintaining Each Use Visual check of re...

Page 86: ...Also wipe off or clean the grooves on the upper feed roll After cleaning tighten the feed roll retaining knobs CAUTION Do NOT use compressed air to clean the Welding Power Source Compressed air can fo...

Page 87: ...zzle Flux 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 Hand...

Page 88: ...FIREPOWER MST 220i REPLACEMENT PARTS 6 2 Manual 0 5343 6 02 Power Source Spare Parts Art A 12541 1 2 3 6 7 9 8 10 11 12 14 13 15 16 18 19 4 5 21 22 23 24 25 17 30 31 29 32 33 34 35 28 Figure 6 2...

Page 89: ...005608 Washer Friction Spool Hub 19 W7005609 Spool Hub 20 W7005619 Guide Inlet 023 045 not shown 21 W7004967 Guide Outlet 023 045 22 1444 0920 Front Panel FP MST220i 23 1444 0921 Panel Base FP MST220i...

Page 90: ...FIREPOWER MST 220i REPLACEMENT PARTS 6 4 Manual 0 5343 This Page Intentionally Blank...

Page 91: ...2 MB 1 POT1 1 CR JC QF DY GND 24VDC 3 POT MAX 5VDC 2 WIPER 1 POT MIN RED BLK YEL 1 24VDC 1 1 OUTPUT 3 OUTPUT 8 Pin Remote Control Spool Gun 1 SPOOL GUN 0V 1 TORCH SWITCH 24V 2 TORCH SWITCH RIN 0VDC 3...

Page 92: ...FIREPOWER MST 220i APPENDIX A 2 Manual 0 5343 This page intentionally blank...

Page 93: ...UENTIAL 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 contra...

Page 94: ...This page intentionally blank...

Page 95: ...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...

Page 96: ...aly 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...

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