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8 TROUBLESHOOTING

0463 766 001

8.4 TIG (L-GTAW) welding problems

(only for Firepower MST-200)

Table 27: TIG (L-GTAW) welding problems

Type of fault

Cause

Corrective action

Excessive bead build up or poor
penetration or poor fusion at
edges of weld.

The welding current is too low.

Increase the weld current
and/or faulty joint preparation.

Weld bead is too wide and flat or
undercut at edges of weld or
excessive burn through.

The welding current is too high.

Decrease the weld current.

Weld bead is too small or
insufficient penetration or ripples
in bead are widely spaced apart.

The travel speed is too fast.

Reduce the travel speed.

Weld bead is too small or
insufficient penetration or ripples
in bead are widely spaced apart.

The travel speed is too slow.

Increase the travel speed.

Uneven leg length in fillet joint

Wrong placement of filler the
rod.

Re-position filler rod.

Electrode melts or oxidizes when
an arc is struck.

The TIG torch lead connected
to positive welding terminal.

Connect the TIG torch lead to
negative welding terminal.

No gas flowing to welding
region.

Check the gas lines for kinks or
breaks and gas cylinder
contents.

The TIG torch is clogged with
dust or dirt.

Clean the TIG torch.

The gas hose is cut.

Replace the gas hose.

Gas passage contains dirt.

Disconnect the gas hose from
the rear of power source then
raise the gas pressure and
blow out dirt.

Gas regulator turned OFF.

Turn ON.

TIG torch valve is turned OFF.

Turn ON.

The electrode is too small for
the welding current.

Increase the electrode diameter
or reduce the welding current.

The power source is set for
MIG welding.

Set the power source to LIFT
TIG mode.

Dirty weld pool

Electrode contaminated by
contact with workpiece or filler
rod material.

Clean the electrode by grinding
off the contaminates.

Work piece surface has foreign
material on it.

Clean the surface.

Gas contaminated with air.

Check the gas lines for cuts
and loose fitting or change gas
cylinder.

Poor weld finish

Inadequate shielding gas.

Increase the gas flow or check
the gas line for gas flow
problems.

Содержание Firepower FP-200

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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