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APPENDIX

FIREPOWER TIG 200 AC/DC

Manual 0-5370

A-3

Appendix

A-12718

Summary of Contents for TIG 200 AC/DC

Page 1: ...Operating Manual A 12707 Firepower TIG 200 AC DC Inverter Arc Welder English Canadien Fran ais Americas Espa ol Revision AA Issue Date November 13 2014 Manual No 0 5370 www firepoweronline com 115 230...

Page 2: ...r competition through market 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...

Page 3: ...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 accident or any other cause Publication Date November 13 20...

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

Page 5: ...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 Cleaning the Weld...

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

Page 7: ...dy 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 equipment Repair or replace damaged par...

Page 8: ...sion of 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 W...

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...

Page 10: ...d and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental...

Page 11: ...ose also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 GENERAL SAFETY INFORMATION FOR FIREPOWER CS FLOWMETER REGULATOR A Fire Prevention Welding and cutt...

Page 12: ...rtation DOT approves the design and manufacture of cylinders that contain gases used for welding or cutting operations 1 Place the cylinder Figure 1 1 where you will use it Keep the cylinder in a vert...

Page 13: ...C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Societ...

Page 14: ...ative 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 Wi...

Page 15: ...T L ELECTROCUTION PEUT ETRE MORTELLE Une d charge 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...

Page 16: ...ty AWS Miami Florida Guide de teinte des lentilles 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...

Page 17: ...isse 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 recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons pour...

Page 18: ...robinet 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 consignes relatives aux bo...

Page 19: ...orrecte et de l accumulateur AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROI DISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br...

Page 20: ...de la peau et des v tements contre les tincelles et le laitier Gardez col manches et poches boutonn s Il ne faut pas remonter vos manches ou les pantalons revers Quand vous travaillez dans un environ...

Page 21: ...la vanne de bouteille ne vous tenez pas directement devant Op rez toujours cette op ration dans une zone bien ventil e Si une bouteille d ac tyl ne crache un brouillard laissez reposer pendant 15 minu...

Page 22: ...rise Source 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...

Page 23: ...following harmonized standards EN 60974 10 2007Arc Welding Equipment Part 10 Electromagnetic compatibility EMC requirements EN 60974 1 2012 Arc Welding Equipment Part 1 Welding power sources Classific...

Page 24: ...ss 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 system Ther...

Page 25: ...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 26: ...uctors from de energized supply line before moving the welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handle on top of case Use ha...

Page 27: ...nverter Power Source Applicable Standards Approvals CSA E60974 1 00 UL60974 1 IEC 60974 1 Number of Phases 1 Nominal Supply Frequency 50 60Hz Welding Current Range STICK Mode 5 160A DC Stick 10 170A A...

Page 28: ...URVES Voltage Amperage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown 60 70 80 90 100 e volts 200 AC DC 0 10 2...

Page 29: ...3 2 3 01 ENVIRONMENT These units are designed for use in environments with increased hazard of electric shock as outlined in EN 60974 1 Additional safety precautions may be required when using unit in...

Page 30: ...tage 208 230V AC Input Current at Maximum Output 32 Amps Maximum Recommended Fuse or Circuit Breaker Rating Time Delay Fuse UL class RK5 Refer to UL248 50 Amps 50 Amps Maximum Recommended Fuse or Circ...

Page 31: ...red when this 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 m...

Page 32: ...elding equipment 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 weldin...

Page 33: ...0 AC DC Manual 0 5370 3 5 Installation 3 08 200 AC DC Power Source Controls Indicators and Features 17 16 15 14 13 12 1 2 3 4 11 10 9 8 7 6 5 19 18 Figure 3 1 Controls on Front Panel 21 20 A 11232 ON...

Page 34: ...Remote Control 5k ohm Potentiometers Maximum 6 Remote Control 5k ohm Potentiometers Minimum 7 Remote Control 5k ohm Potentiometer Wiper 8 Not used Table 3 2 8 Pin Control Plug Configuration 3 Negativ...

Page 35: ...source is switched back ON turn the power source OFF and have an Accredited Firepower Service Provider check the power source 7 Process Selection Switch The process selection control is used to selec...

Page 36: ...er Release Trigger Crater Current A 11410_AB Figure 3 4 9 Wave Balance Arc Force Indicator This indicator light will illuminate when programming Wave Balance AC HF TIG mode only or Arc Force STICK mod...

Page 37: ...T 4T POST FLOW 17 Mode Switch Press the MODE switch to toggle AC and DC output in all Process modes 18 Digital Ammeter The digital amperage meter is used to display both the pre set current and actual...

Page 38: ...al components are at Mains voltage potential 21 Shielding Gas Inlet Unit has a 5 8 Inert gas fitting suitable for connection of a gas hose to a regulated Shielding Gas Supply The Shielding Gas inlet i...

Page 39: ...STICK mode Arc Force STICK Mode only Arc Force is effective when in STICK Mode only Arc Force control provides and adjustable amount of Arc Force or dig control This feature can be particularly benefi...

Page 40: ...ld porosity at the start of a weld V SEC Hz Volts 0 0 to 1 0 second Initial Current This parameter operates in 4T TIG modes only and is used to set the start current for TIG The Start Current remains...

Page 41: ...the pulse is called the Low Current Amps 5 to 200A DC HF TIG mode 30 to 200A AC LIFT TIG mode 10 to 200A AC HF TIG mode Pulse Width This parameter sets the percentage on time of the PULSE FREQUENCY f...

Page 42: ...e only and is used to set the frequency for the AC weld current V SEC Hz Volts 15 to 150 Hz Wave Balance This parameter operates in AC TIG mode and is used to set the penetration to cleaning action ra...

Page 43: ...electrode touches the work the current defaults to 33 amps If the short exists for more than 1 2 seconds the output is turned off In STICK mode if the electrode touches the work for more than two seco...

Page 44: ...ING DO NOT use a Flowmeter Regulator that delivers pressure exceeding the pressure rating of the downstream equipment unless pro visions are made to prevent over pressurization i e system relief valve...

Page 45: ...E CYLINDER VALVE 8 Slowly and carefully open the cylinder valve Figure 3 9 until the maximum pressure shows on the high pressure gauge Art A 09828 Figure 3 9 Open Cylinder Valve 9 Open the cylinder va...

Page 46: ...f Switch Remote Amperage Control Cartridge in a Sealed Plastic Bag NOTE You will not be able to view the pre set amperage on the power source with this control amperage will not be viewable until the...

Page 47: ...Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in Lift TIG or HF TIG Mode Not...

Page 48: ...Tig Torch A 12720 Negative Welding Terminal Figure 3 10 Setup for TIG Welding NOTE When the 200 AC DC is used with a Remote Foot Control in depress foot control to maximum to allow max current to be p...

Page 49: ...Flowmeter Regulator 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 Flowmeter Regulator and tighten with a wrench Caution DO NOT ov...

Page 50: ...yonet type terminals It is essential however that the male plug is inserted fully and turned clockwise until tight to achieve a sound electrical connection C Select STICK mode with the process selecti...

Page 51: ...ened 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 d...

Page 52: ...thicker 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 issue...

Page 53: ...produce 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...

Page 54: ...on 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...

Page 55: ...te 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 an...

Page 56: ..._AB 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 w...

Page 57: ...at 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...

Page 58: ...s been 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 plas...

Page 59: ...t a 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 D...

Page 60: ...llic 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 g...

Page 61: ...urface 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 elect...

Page 62: ...s produced 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 shield...

Page 63: ...lity 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 coppe...

Page 64: ...7 LPM 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 LP...

Page 65: ...ed 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 connected to...

Page 66: ...A Tungsten 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...

Page 67: ...c 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 check primary circuit 3 Fa...

Page 68: ...es If after 30 minutes Err 001 is displayed and Fault Indicator illuminates when the power source is switched back ON turn the power source OFF and have an Accredited Firepower Service Provider check...

Page 69: ...ble 5 2 Minimum Insulation Resistance Requirements Firepower Inverter Power Sources C Earthing The resistance shall not exceed 1 between any metal of a power source where such metal is required to be...

Page 70: ...epower service provider Testing Requirements Output current A to be checked to ensure it falls within applicable Firepower power source specifications Output Voltage V to be checked to ensure it falls...

Page 71: ...SPARE PARTS FIREPOWER TIG 200 AC DC Manual 0 5370 6 1 Spare Parts SECTION 6 KEY SPARE PARTS 6 01 POWER SOURCE 1 2 3 4 5 6 7 10 13 14 16 9 11 A 11500_AC 15 12 12 25 23 21 8 19 17 18 20 24 28 Figure 6 1...

Page 72: ...0mm 13 W7005568 Control socket 8 pin including wire harness 14 W7005514 Gas outlet front panel 15 W7005515 Switch On Off 16 W7003076 CT output 17 W7005539 Inductor 200AC DC 18 1442 0091 Base Panel 19...

Page 73: ...APPENDIX FIREPOWER TIG 200 AC DC Manual 0 5370 A 1 Appendix APPENDIX 1 CIRCUIT DIAGRAM A 12719 200 AC DC SYSTEM SCHEMATIC 11 07 14...

Page 74: ...FIREPOWER TIG 200 AC DC APPENDIX A 2 Manual 0 5370 Appendix APPENDIX 2 200 AC DC SETUP GUIDE...

Page 75: ...APPENDIX FIREPOWER TIG 200 AC DC Manual 0 5370 A 3 Appendix A 12718...

Page 76: ...FIREPOWER TIG 200 AC DC APPENDIX A 4 Manual 0 5370 Appendix This Page Blank Intentionally...

Page 77: ...This Page Intentionally Blank...

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: ...ment 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 Technol...

Page 80: ...800 Milan Italy 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 6...

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