Firepower TIG 140 AC/DC Operating Manual Download Page 26 | Manualshive

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FIREPOWER TIG 140 AC/DC SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS AND WARNINGS

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Manual 0-5355

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Summary of Contents for TIG 140 AC/DC

Page 1: ...FIREPOWER TIG 140 AC DC Operating Manual 3163339 English Canadien Fran ais Americas Espa ol Revision AA Issue Date August 8 2014 Manual No 0 5355 www firepower com...

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: ...ngley Ridge Road Suite 300 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 permissio...

Page 4: ...1 2 05 User Responsibility 2 2 2 06 Transporting Methods 2 2 2 07 Packaged Items 2 2 2 08 Duty Cycle 2 3 2 09 Specifications 2 4 2 10 Optional Accessories 2 5 2 11 Volt Ampere Curves 2 6 SECTION 3 INS...

Page 5: ...15 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Basic Troubleshooting 5 1 5 02 Power Source Problems 5 1 5 03 Routine Service and Calibration Requirements 5 2 5 04 Cleani...

Page 6: ...This page left blank intentionally...

Page 7: ...not wrap cables around your body 10 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 equipmen...

Page 8: ...an 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 SMAW Less t...

Page 9: ...lf and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible ti...

Page 10: ...ot spill fuel If fuel is spilled clean up before starting engine WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 K...

Page 11: ...perator 3 Do not coil or drape cable around the body 4 Keep welding Power Source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recom...

Page 12: ...se pressure regulation equipment Deviation from the following safety and operation instructions can result in fire explosion damage to equipment or injury to the operator E Compressed Gas Cylinders Th...

Page 13: ...nd Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Off...

Page 14: ...ncy Negative 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 Func...

Page 15: ...ION D ENTRETIEN ET D ESSAI 1 06 Dangers relatifs au soudage l arc AVERTISSEMENT L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler gravement L lectrode et le circuit de soud...

Page 16: ...ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Sh...

Page 17: ...v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque 2 Portez des lunettes de s curit approuv es Des crans lat raux sont...

Page 18: ...pe ments et les pi ces connexes doivent tre maintenus en bon tat 6 Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille...

Page 19: ...UR ET LE LIQUIDE DE REFROID ISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 1 N tez pas le bouchon de r...

Page 20: ...travail Si vous ne pouvez pas les enlever prot gez les avec une cou vre ignifuge AVERTISSEMENT N effectuez JAMAIS d op rations de soudage sur un r cipient qui a contenu des liquides ou vapeurs toxique...

Page 21: ...portez vous lapublication CGAP 1 Manipulations curis edesgazcompri m s en conteneur pour plus d informations sur l utilisationetlamanutentiondesbouteilles AVIS Ce document CGA p t peut tre obtenu en c...

Page 22: ...50 N W LeJeune 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...

Page 23: ...ositif Courant 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 D roulement du Fi...

Page 24: ...nd associated accessories 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...

Page 25: ...is Class A and intended for industrial use Warning This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply syst...

Page 26: ...FIREPOWER TIG 140 AC DC SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS AND WARNINGS 1 20 Manual 0 5355...

Page 27: ...instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source Please read these instructions thoroughly befor...

Page 28: ...le responsibility for any malfunction which results from improper use or unauthorized modifica tion from standard specification faulty maintenance damage or improper repair by anyone other than ap pro...

Page 29: ...te at a 20 duty cycle 200 amperes at 18 0 volts This means that it has been designed and built to provide the rated amperage 200A for 2 minutes i e arc welding time out of every 10 minute period 20 of...

Page 30: ...de 10 90A Welding Current Range TIG Mode 10 140A Nominal Supply Voltage 120V Effective Input Current I1eff See Note 1 STICK TIG 16 9A 18 5A Maximum Input Current I1max STICK TIG 37 8A 41 0A Single Pha...

Page 31: ...C DC INTRODUCTION Manual 0 5355 2 5 INTRODUCTION 2 10 Optional Accessories 17 Style TIG Torch Part No 1442 0022 Basic Utility Cart Part No 1444 0900 Foot Control Part No 1442 0025 Tweco Helmet USA Onl...

Page 32: ...s maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown 0 20 40 60 80 100 0 20 40 60 80 100 120 140 AC Volts AC Amps TIG AC Volt A...

Page 33: ...TION 0 10 20 30 40 50 60 70 80 0 20 40 60 80 100 120 DC Volts DC Amps STICK DC Volt Amp Curve Art A 12606 0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 80 90 AC Voltage AC Amps STICK AC Volt Amp Curve...

Page 34: ...INTRODUCTION FIREPOWER TIG 140 AC DC INTRODUCTION 2 8 Manual 0 5355 This page left blank intentionally...

Page 35: ...tions on page 3 2 3 01 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in IEC 60974 1 Additional safety precautions may be required whe...

Page 36: ...Phase Supply Supply Voltage 115 Volt 10 Input Current at Maximum Output 41 0 Amps Maximum Recommended Fuse or Circuit Breaker Rating Time Delay Fuse UL class RK5 Refer to UL248 20 Amps 20 Amps Maximum...

Page 37: ...is Welding Power Source is used in a domestic situation A Installation and Use Users Responsibility The user is responsible for installing and using the welding equipment according to the manufacturer...

Page 38: ...ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions 3 Welding Cables The welding cables sho...

Page 39: ...Features 8 1 2 3 4 Art A 12636 Weld Current A MODE 2T 4T TRIGGER 22 ga 0 8 mm 18 ga 1 2 mm 16 ga 1 6 mm 1 8 3 2 mm 3 16 4 7 mm 1 4 6 4 mm PROCESS LIFT TIG HF TIG STICK TIG AC Aluminum Amps DC Mild St...

Page 40: ...ontrol Plug Configuration 3 Negative Welding Terminal Negative Welding Terminal 2 50 mm Dinse Welding current flows from the Power Source terminals It is essential however that the male plug is insert...

Page 41: ...active Press and hold the torch trigger to activate the power source weld Release the torch trigger switch to cease welding NOTE When operating in GTAW HF and LIFT TIG modes the power source will rem...

Page 42: ...splays are lit the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential 12 Shielding Gas Inlet Unit has a 5 8 Inert gas fitting suitab...

Page 43: ...uminum Amps DC Mild Stainless Steel 25 40 65 125 140 STICK 70 90 Amps Art A 12637 Figure 3 6 LIFT TIG and HF TIG Mode 3 11 Short Circuit Protection While Welding To prolong the useful life of a TIG tu...

Page 44: ...system supply pressure connection 3 If gauges are to be attached to the regulator and the regu lator is stamped and listed by a third party i e UL or ETL The following requirements must be met a Inle...

Page 45: ...ow pressure side of the regulator from high pres sures Relief valves are not intended to protect down stream equipment from high pressures WARNING DO NOT tamper with the relief valve or remove it from...

Page 46: ...igid Head Remote Control Cartridge Potentiometer with integrated on off switch installed Art A 12641 NOTE The additional switches controls below are interchangeable with the installed control in the T...

Page 47: ...ve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal D Connect the TIG torch trigger switch...

Page 48: ...6 mm 1 8 3 2 mm 3 16 4 7 mm 1 4 6 4 mm PROCESS LIFT TIG HF TIG STICK TIG AC Aluminum Amps DC Mild Stainless Steel 25 40 65 125 140 STICK 70 90 Amps Art A 12638 Figure 3 10 Setup for TIG Welding NOTE...

Page 49: ...ulator please refer to 3 18 and tighten with a wrench 6 Connect one end of the supplied gas hose to the outlet of the Argon regulator and tighten with a wrench Caution DO NOT over tighten 7 Connect th...

Page 50: ...rode manufacturer Welding current flows from the power source via 50mm Dinse type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical con...

Page 51: ...d 2 0 0 A 8 Negative Welding Terminal Positive Welding Terminal A MODE 2T 4T TRIGGER 22 ga 0 8 mm 18 ga 1 2 mm 16 ga 1 6 mm 1 8 3 2 mm 3 16 4 7 mm 1 4 6 4 mm PROCESS LIFT TIG HF TIG STICK TIG AC Alumi...

Page 52: ...INSTALLATION OPERATION AND SETUP 3 18 Manual 0 5355 FIREPOWER TIG 140 AC DC INSTALLATION SETUP This page left blank intentionally...

Page 53: ...d zone and under bead cracks in the weld area may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode depo...

Page 54: ...icker steel than E6013 Especially suitable sheet metal lap joints and fillet welds general purpose plate welding Mild Steel E7018 A low hydrogen all position electrode used when quality is an issueorf...

Page 55: ...oduce sound joints In general surfaces 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 9 Ga...

Page 56: ...of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the arc is established maintain a 1 16 1 6mm to 1 8 3 2mm gap between th...

Page 57: ...this The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc To complete the joint in thin plate turn the job over clean the slag out of the back and d...

Page 58: ...45 from vertical 60 70 from line of weld Figure 4 13 Electrode Position for HV Fillet Weld Art A 07700_AB 1 2 3 4 5 6 Figure 4 14 Multi runs in HV Fillet Weld C Vertical Welds 1 Vertical Up Tack weld...

Page 59: ...right angles to another piece of angle 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 position as shown in the sk...

Page 60: ...een upset it 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...

Page 61: ...similar rate thus reducing distortion Art A 07707 Figure 4 21 Principle of Presetting Art A 07708 B Preheat Preheat Dotted lines show effect if no preheat is used Weld C Figure 4 22 Reduction of Dist...

Page 62: ...c par ticles are trapped in the weld metal A Non metallic 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 gaug...

Page 63: ...ace 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 is too low B Increase welding current C Wrong electrod...

Page 64: ...roduced by an electric arc that is established between a single tungsten non consumable electrode and the work piece Shielding is obtained from a welding grade shielding gas or welding grade shielding...

Page 65: ...y AC weld ing of aluminium magnesium and their alloys Self cleaning Long life Maintains balled end High current car rying capacity White Ceriated 2 AC DC welding of mild steel stainless steel copper a...

Page 66: ...PM Butt Corner Lap Fillet 1 8 3 2mm 80 100 90 115 65 85 90 110 1 16 1 6mm 3 32 2 4mm 15 CFH 7 LPM Butt Corner Lap Fillet 3 16 4 8mm 115 135 140 165 100 125 125 150 3 32 2 4mm 1 8 3 2mm 21 CFH 10 LPM B...

Page 67: ...vel speed too slow Increase travel speed 5 Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts or oxidises when an arc is struck A Torch lead conne...

Page 68: ...ungsten electrode is too large for the weld ing current A Select the right size tungsten electrode Refer to Table 4 3 Tungsten Electrode Selection Chart B The wrong electrode is being used for the wel...

Page 69: ...not lit and welding arc cannot be established A B Primary control fuse is blown Broken connection in primary circuit A B Replace primary control fuse Have an Accredited Firepower Service Provider che...

Page 70: ...pection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of IEC ANSI 60974 1 Safety in Welding and Allied Processes Part 2 Electrical This i...

Page 71: ...ng the integrity of fixed 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 assoc...

Page 72: ...o ensure it falls within applicable Firepower power source specifications Accuracy of digital meters to be checked to ensure it falls within applicable Firepower power source specifi cations Table 5 3...

Page 73: ...RE PARTS FIREPOWER TIG 140 AC DC Manual 0 5355 6 1 KEY SPARE PARTS SECTION 6 KEY SPARE PARTS 6 01 Power Source 1 2 3 4 5 6 7 10 13 14 16 9 11 15 12 12 25 23 21 8 19 17 18 20 24 28 Art A 12612 Figure 6...

Page 74: ...763 Dinse Socket 50mm 13 W7003606 Control socket 8 pin including wire harness 14 W7006767 Gas outlet front panel 15 W7005515 Switch On Off 16 W7003076 CT output 17 W7006769 Inductor 140 AC DC 18 1442...

Page 75: ...APPENDIX FIREPOWER TIG 140 AC DC Manual 0 5355 A 1 APPENDIX APPENDIX 1 CIRCUIT DIAGRAM Art A 12613...

Page 76: ...FIREPOWER TIG 140 AC DC APPENDIX APPENDIX A 2 Manual 0 5355 APPENDIX 2 FIREPOWER TIG 140 AC DC SETUP GUIDE...

Page 77: ...APPENDIX FIREPOWER TIG 140 AC DC Manual 0 5355 A 3 APPENDIX Art A 12643...

Page 78: ...QUENTIAL 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 contr...

Page 79: ...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 80: ...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 Mel...

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