Firepower MST 140i 3-IN-1 Multi Process Welding Systems Operating Manual English Canadien Français Americas Español Art# A-12514 Revision: AA Issue Date: March 12, 2013 Manual No.: 0-5338 www.firepower.
WE APPRECIATE YOUR BUSINESS! Congratulations on receiving your new Firepower product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network. We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.
! WARNINGS Read and understand this entire Manual and your employer’s safety practices if applicable before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5338 for: Firepower MST 140i Portable system Package Part Number: 1444-0870 Published by: Victor Technologies, Inc. 16052 Swingley Ridge Road, Suite 300 St.
TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS................................................ 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 Arc Welding Hazards........................................................................................ 1-1 General Safety Information for Victor CS Regulator........................................... 1-5 Principal Safety Standards............................................................................... 1-6 Symbol Chart...............
TABLE OF CONTENTS SECTION 4: BASIC WELDING GUIDE ..................................................................... 4-1 4.01 4.02 4.03 4.04 4.05 4.06 4.07 MIG (GMAW/FCAW) Basic Welding Technique................................................ 4-1 MIG (GMAW/FCAW) Welding Troubleshooting................................................ 4-6 Stick (SMAW) Basic Welding Technique.......................................................... 4-9 Effects of Stick Welding Various Materials............................
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Firepower MST 140i SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ! WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/ INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Firepower MST 140 1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching. 1. Keep your head out of the fumes. Do not breathe the fumes. 2. Wear approved safety glasses. Side shields recommended. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 3.
Firepower MST 140i from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. WARNING CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. WARNING WELDING can cause fire or explosion.
Firepower MST 140 2. Do not add fuel while smoking or if unit is near any sparks or open flames. 3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job. WARNING 4. Do not overfill tank — allow room for fuel to expand. STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin. 5. Do not spill fuel. If fuel is spilled, clean up before starting engine. The coolant in the radiator can be very hot and under pressure. 1.
Firepower MST 140i ! ABOUT PACEMAKERS: 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 Prevention Welding and cutting operations use fire or combustion as a basic tool. The process is very useful when properly controlled. However, it can be extremely destructive if not performed correctly in the proper environment. 1.
Firepower MST 140 ! 6. Momentarily open and close (called “cracking”) the cylinder valve to dislodge any dust or dirt that may be present in the valve. WARNING Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or misuse of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, flames or sparks. DO NOT strike it against other cylinders.
Firepower MST 140i 1.03 Principal Safety Standards Safety in Welding and 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 Office, Washington, D.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.
Firepower MST 140 1.04 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
Firepower MST 140i 1.05 Precautions De Securite En Soudage A L’arc ! MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Firepower MST 140 15. Fermez solidement tous les panneaux et les capots. AVERTISSEMENT LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. 3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc. 4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité. 5.
Firepower MST 140i 3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé. 7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril. 4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants. 8.
Firepower MST 140 6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture. 1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés. 7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation. 2. Avant d’installer ou de connecter un système, arrêtez le moteur. 8.
Firepower MST 140i 1. Maintenez les câbles l’un près de l’autre en les entrelaçant ou les reliant ensemble au ruban. 2. Acheminez les câbles à un côté du soudeur, le plus loin possible. AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX. 3. N’enroulez pas de câble autour du corps. 4. Maintenez le bloc d’alimentation du poste de soudage et les câbles aussi loin que possible du corps.
Firepower MST 140 B Entretien des Locaux ! E Bouteilles de Gaz Comprimé Le Département des Transports américain (DOT) approuve la conception et la fabrication des bouteilles qui contiennent les gaz utilisés pour les opérations de soudage ou de découpage. AVERTISSEMENT Ne laissez jamais l’oxygène en contact avec la graisse, l’huile ou d’autres substances inflammables. Bien que l’oxygène ellemême ne brûle pas, ces substances peuvent devenir extrêmement explosives.
Firepower MST 140i ! 1.08 Principales Normes De Securite Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128. AVERTISSEMENT N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces endommagées. Informez immédiatement votre fournisseur de’ gaz de cet état. Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. 6.
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Firepower MST 140i 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle.
Firepower MST 140 1.10 Declaration Of Conformity Manufacturer: Victor Technologies International, Inc. Address: 16052 Swingley Ridge Road, Suite 300 St. Louis, MO 63017 The equipment described in this manual has been designed to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive.
Firepower MST 140i SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.04 Description This Manual usually applies to the part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the word WARNING, CAUTION and NOTE may appear. Pay particular attention to the information provided under these headings.
Firepower MST 140i 2.07 Firepower MST 140i Portable System Package (Part No. 1444-0870) Comes Complete With • Firepower MST 140i Power Source • Firepower 140 Amp MIG Gun • Firepower Argon Regulator/Flowmeter & Hose • Firepower Electrode Holder & Ground Clamp • Drive Rolls & Contact Tips • Shoulder Strap • 20A to 15A Power Cord Adapter • Operator Manual & CD Art # A-12432 2.
Firepower MST 140i 2.09 Specifications DESCRIPTION Power Source System Part No. Power Source System Dimensions Firepower MST 140i MULTI PROCESS 3 IN 1 WELDER 1444-0870 H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm) Power Source System Weight 32.2lb (14.
Firepower MST 140i NOTE The recommended time delay fuse or circuit breaker size is 20 amp. An individual branch circuit capable of carrying 20 amperes and protected by fuses or circuit breaker is recommended for this application.
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Firepower MST 140i SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment This Power Source System is designed for use in environments with increased hazard of electric shock. A. Examples of environments with increased hazard of electric shock are: 1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts. 2.
Firepower MST 140i Electrical Input Requirements Operate the welding Power Source System from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required.
Firepower MST 140i 3.05 Electromagnetic Compatibility 7. The time of day that welding 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. WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source System is used in a domestic situation. A.
Firepower MST 140i 5. Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment.
Firepower MST 140i ! WARNING DO NOT attach or use the flowmeter/ regulator if oil, grease, flammable substances or damage is present! Have a qualified repair technician clean the flowmeter/ regulator or repair any damage. Art # A-09828 Art # A-12436 Figure 3-3: Open Cylinder Valve 9. On all cylinders, open the valve completely to seal the valve packing. On gaugeless flowmeters/ regulators, the indicator will register the cylinder contents open. Figure 3-2: Flowmeter/ Regulator to Cylinder Valve 6.
Firepower MST 140i 3.07 Leak Testing the System 3.08 When You Finish Using the Flowmeter/ Regulator Leak test the system before putting into operation. 1. Be sure that there is a valve in the downstream equipment to turn off the gas flow. 2. With the cylinder valve open, adjust the Flowmeter/ regulator to deliver the maximum required delivery pressure. 1. Close the cylinder valve. 2. Open the valve on the downstream equipment. This drains all pressure from the system. 3.
Firepower MST 140i 3.
Firepower MST 140i 1. Power Indicator The power indicator is illuminated when the Electricity Supply is applied to the Power Source System and when the ON/OFF switch located on the rear panel is in the ON position. 1 Art # A-12??? POWER FAULT V A 2. Digital Wirespeed/Amperage Meter (Left Digital Display) This digital meter displays preview Wirespeed in MIG mode only then actual amperage (weld current) once an arc has been established.
Firepower MST 140i 5. Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG Gun (via the MIG Gun polarity lead), electrode holder lead or work lead. Positive welding current flows from the power source via 25mm Dinse style connector. It is essential, however, that the Dinse adapter and male plug are inserted and turned securely to achieve a sound electrical connection.
Firepower MST 140i 8. Remote Control The 8 pin socket is used to connect the Firepower Velocity MIG Gun, remote control device to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
Firepower MST 140i 9. Multifunction Control - Voltage, Down Slope & Arc Force 6 The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc Force (STICK Mode) depending on the welding mode selected.
Firepower MST 140i 10. Arc Control (Inductance) The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration. Soft means maximum inductance while Hard means minimum inductance. 11.
Firepower MST 140i 13. Digital Voltage Meter (Right Digital Display) The digital voltage meter is used to display the both the preview voltage (MIG mode only) and actual output voltage (all modes) of the Power Source. At times of non-welding, the voltage meter will display a preview value in MIG mode. This value can be adjusted by varying the multifunction control knob (Control No. 9).
Firepower MST 140i 17. Intelligent Fan Control When Power Supply is first turned on it will default in MIG Mode. The Fan will operate for approximately 10 seconds, then shut down. When triggered in MIG mode, fan will not turn on until Power Supply reaches temperatures in which cooling is required. When in Lift TIG mode, as soon as output is enabled, the fan will come on immediately and will not shut down until welding has ceased and Power Supply is at proper operating temperature.
Firepower MST 140i 3.11 Attaching the Firepower 140A 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 Screw to secure the MIG Gun in the MIG Gun Adapter. Connect the 8 pin plug by aligning the keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwise to lock the plug into position.
Firepower MST 140i 3.12 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in a counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm.
Firepower MST 140i 3.13 Installing 4" (100mm) Diameter Spool As delivered from the factory, the Power Source is fitted with a Wire Spool Hub which accepts a 8" (200mm) diameter spools. In order to fit a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 3-11. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake.
Firepower MST 140i 3.14 Installing 8" (200mm) Diameter Spool As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool. In order to re-fit a 8" (200mm) spool assemble parts in the sequence shown below in Figure 3-12. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake.
Firepower MST 140i 3.15 Feed Roller Pressure Adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable 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 reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and debris.
Firepower MST 140i 3.17 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub clockwise 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.
Firepower MST 140i 3.18 Flowmeter/ Regulator Operation With the flowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of flowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal parts. 2. With valves on downstream equipment closed, adjust flowmeter/ regulator to approximate working pressure.
Firepower MST 140i ! WARNING Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so premature arcing will not occur. Secure the shielding gas cylinder in an upright position by chaining it to a suitable stationary 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.
Firepower MST 140i 3.20 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire A. Select MIG mode with the process selection control (refer to Section 3.10.12 for further information). B. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C.
Firepower MST 140i 3.21 Setup for LIFT TIG (GTAW) Welding A. Select LIFT TIG mode with the process selection control (refer to Section 3.10.12 for further information). B. Using the supplied 50mm to 25mm DINSE adapter, connect the TIG torch to the negative welding terminal (-). Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C.
Firepower MST 140i Art # A-12447 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.
Firepower MST 140i 3.22 Setup for STICK (SMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.
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Firepower MST 140i SECTION 4: BASIC WELDING GUIDE 4.01 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the MIG mode of welding, where a welding MIG Gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
Firepower MST 140i The welding Gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the MIG Gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the proper safety equipment. CAUTION Do not pull the welding MIG Gun back when the arc is established. This will create excessive wire extension (stickout) and make a very poor weld.
Firepower MST 140i Preselected Variables Preselected variables depend upon the type of material being welded, the thickness of the material, the welding position, the deposition rate and the mechanical properties. These variables are: • Type of electrode wire • Size of electrode wire • Type of gas (not applicable to self shielding wires FCAW) • Gas flow rate (not applicable to self shielding wires FCAW) Primary Adjustable Variables These control the process after preselected variables have been found.
Firepower MST 140i Direction of Gun Travel 90° Leading or “Pushing” Angle (Forward Pointing) Trailing or “Pulling” Angle (Backward Pointing) Nozzle Angle, Right Handed Operator Art # A-08999_AC Figure 4-10 Establishing the Arc and Making Weld Beads Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the finished piece.
Firepower MST 140i Firepower Velocity MIG, Lift TIG, Stick Wire Selection Chart Art # A-12462 Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart Manual 0-5338 4-5 BASIC WELDING GUIDE
Firepower MST 140i 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG Gun. There are two main areas where problems occur with MIG, Porosity and Inconsistent wire feed Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal.
Firepower MST 140i Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the cabinet slipped Wire spool brake is too tight or drive roll tension not tight enough. 2 Wire spool unwinds and tangles Wire spool brake is too loose. 3 Wire slipping A Worn or incorrect feed roller size. Use a feed roller matched to the size you are welding. B Replace feed roller if worn.
Firepower MST 140i Basic MIG Welding Troubleshooting FAULT 1 Undercut 2 Lack of penetration CAUSE REMEDY A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed. B Incorrect MIG Gun angle B Adjust angle. C Excessive heat input C Increase the MIG Gun travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed. A Welding current too low A Increase welding current by increasing wire feed speed and increasing voltage.
Firepower MST 140i FAULT 7 Cold weld puddle 8 Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly. CAUSE REMEDY A Welding voltage too high A Decrease voltage or increase the wirespeed control. B Loose welding cable connection B Check all welding cable connections. C Low primary voltage C Contact supply authority. D Fault in power source D Have an Accredited Firepower Service Provider to test then replace the faulty component.
Firepower MST 140i 4.04 Effects of Stick Welding Various Materials High Tensile and Alloy Steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks.
Firepower MST 140i Art# A-07693 Figure 4-17: Overhead Position, Butt Weld Art A-07691 Figure 4-15: Vertical Position, Butt Weld Art # A-07694 Figure 4-18: Overhead Position, Fillet Weld Art # A-07692 Figure 4-16: Vertical 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 castings, etc.
Firepower MST 140i Arc Welding Technique - A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 1/4" (6.4mm) thick and a 1/8"(3.2mm) electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position.
Firepower MST 140i 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 deposit a similar weld. 20°-30° Electrode Tack Weld Tack Weld Art # A-07697_AB Figure 4-21: Butt Weld Art # A-07698 Figure 4-22: Weld Build up Sequence Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean the weld with a wire brush.
Firepower MST 140i C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 1/8"(3.2mm) E7014 Stick electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet. The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Figure 4-25. Use a short arc, and do not attempt to weave on the first run.
Firepower MST 140i Art # A-07704 Figure 4-28: Overhead Fillet Weld Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear. The Cause of Distortion Distortion is caused by: A.
Firepower MST 140i Overcoming Distortion Effects There are several methods of minimizing distortion effects. A. Peening This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer. B.
Firepower MST 140i 3 4 2 Art # A-07713_AB 1 Art # A-07711_AB Figure 4-37: Staggered Intermittent Welding Figure 4-35: Step back Sequence Art # A-07428_AB Figure 4-36: Chain Intermittent Welding 4.05 Stick (SMAW) Welding Troubleshooting FAULT 1 Welding current varying CAUSE REMEDY ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length.
Firepower MST 140i FAULT CAUSE REMEDY Art # A-05866_AC Incorrect Sequence Figure 1- Example of insufficient gap or incorrect sequence Insufficient Gap 4 A groove has been A Welding current is too high. formed in the base metal adjacent to B Welding arc is too long. the toe of a weld and has not been C Angle of the electrode is filled by the weld incorrect. metal (undercut). D Joint preparation does not allow correct electrode angle. A Reduce welding current. B Reduce the length of the welding arc.
Firepower MST 140i FAULT 6 Gas pockets or voids in weld metal (porosity) CAUSE REMEDY A High levels of sulfur in steel. A Use an electrode that is designed for high sulfur steels. B Electrodes are damp. B Dry electrodes before use. C Welding current is too high. C Reduce welding current. D Surface impurities such as oil, grease, paint, etc. D Clean joint before welding. E Welding in a windy environment. E Shield the weld area from the wind. F Electrode damaged ie flux coating incomplete.
Firepower MST 140i 4.06 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is 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 shielding gas mixture which is generally Argon based.
Firepower MST 140i Tungsten Electrode Types Electrode Type (Ground Finish) Welding Application Features Color Code Thoriated 2% DC welding of mild steel, stainless steel and copper Excellent arc starting, Long life, High current carrying capacity Red Zirconated 1% High quality AC welding of aluminum, magnesium and their alloys. Self cleaning, Long life, Maintains balled end, High current carrying capacity.
Firepower MST 140i 4.07 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or poor penetration or poor fusion at edges of weld. Welding current is too low Increase weld current and/or faulty joint preparation. 2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through. Welding current is too high Decrease weld current. 3 Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.
Firepower MST 140i FAULT 7 Dirty weld pool CAUSE REMEDY A Electrode contaminated A Clean the electrode by grinding off the conby contact with work taminates. piece or filler rod material. B Work piece surface has B Clean surface. foreign material on it. C Gas contaminated with C Check gas lines for cuts and loose fitting or air. change gas cylinder. 8 Poor weld finish 9 Arc start is not smooth. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems.
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Firepower MST 140i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY 1 Primary Power Supply is A Power Source is not in the correct A Set the Power Source to the corON, power indicator is illumode of operation. rect mode of operation with the minated however the Power process selection switch. Source will not commence B Welding leads, or polarity cable B Connect welding leads or polarwelding when the torch trignot connected. ity cable.
Firepower MST 140i FAULT 7 No gas flow in MIG mode. CAUSE REMEDY A Gas hose is damaged. A Replace or repair. B Gas passage contains debris. B Disconnect gas hose from the rear of Power Source and blow out debris. C Shielding gas cylinder valve shut off. C Turn on the cylinder. D Flowmeter/ Regulator turned off. D Turn on flowmeter/ regulator. E Empty gas cylinder. E Replace gas cylinder. 8 Gas flow continues after the torch trigger switch has been released (MIG mode).
Firepower MST 140i 5.02 Routine Service WARNING There are extremely dangerous voltage and power levels present inside this Power Source. Do not attempt to open or repair unless you are an accredited Firepower Service Provider. Disconnect the Welding Power Source from the Electricity Supply Voltage before disassembling.
Firepower MST 140i 5.03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Electricity Supply Voltage before disassembling. 5.04 Cleaning the Feed Rolls Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on the upper feed roll.
Firepower MST 140i SECTION 6: KEY SPARE PARTS 6.01 Firepower Velocity 140A MIG Gun Parts Torch Part No: ????-1321 Item No. Description Art# A-11672_AB 1 2 Velocity Nozzle** Velocity Contact Tip** 3 Handle / Trigger Repair Kit 4 Conduit Assembly* Part No.
Firepower MST 140i Art # A-12518 6.
Firepower MST 140i Firepower MST 140i POWER SOURCE SPARE PARTS ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Manual 0-5338 PART NUMBER W7006216 W7006227 W7003033 W7006226 W7006209 W7004906 7977036 W7004947 W7003010 W7003215 W7006210 W7004983 W7006224 W7004942 W7003053 W7004911 W7004912 W7006220 W7006223 W7004922 W7004925 W7004967 W7006221 W7006208 870734 W7004972 W7004953 OTWAK/1S W7004961 W7004940 W7006218 W7006219 W7006212 W70
Firepower MST 140i 6.03 Hardware List ITEM DESCRIPTION WHERE USED Qty 1 Nut Lock, M20 25mm Dinse 2 2 Screw Hexagon, M10 × 1.5-20 ST ZP 25mm Dinse 2 3 Washer, M4, ET Lock Handle 2 Side Panel 3 Handle 2 Rear Panel 2 Front Panel 3 Side Panel 3 Door Assy 2 Front Panel 2 Rear Moulding 2 8 Pin Remote Socket 2 Front PCB 4 4 5 6 SC PHCR M4 × 0.7-10 ST ZP SC PHCR M4 × 0.7-16 ST BK SC PHCR ST 6G × 3/8 STBK 7 Nut Hexagon M4 × 0.7 ST ZP Fan 4 8 SC PHSL M4 × 0.
Firepower MST 140i 4 1 4 1 4 1 3 1 4 1 3 1 4 1 6 4 4 1 SCREW ITEM 4, OFF USED TO SECURE MOULDING TO INTERNAL PANEL 8 4 7 4 4 1 6 2 5 2 SCREW ITEM 5, OFF USED TO SECURE MOULDING TO BASE PANEL 2 2 1 2 9 1 4 1 3 1 3 1 4 1 17 1 4 1 3 1 15 1 12 1 11 1 10 1 13 2 5 2 SCREW ITEM 5, 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL 4 1 4 1 14 2 SCREW ITEM 4, 2 OFF USED TO SECURE DOOR ASSY TO BASE PANEL 16 1 Art # A-12464 Figure 6-3 Manual 0-5338 6-5 KEY SPARE PARTS
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Firepower MST 140i APPENDIX: Firepower MST 140i CIRCUIT DIAGRAM I Art # A-12517 8 APPENDIX 2 Manual 0-5338
Firepower MST 140i Art # A-12517 Manual 0-5338 3 APPENDIX
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FIREPOWER - LIMITED WARRANTY TERMS LIMITED WARRANTY: Firepower®, Inc, A Victor Technologies Company, warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material.
WARRANTY SCHEDULE 5 Years Parts* / 3 Years Labor ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster Portafeed, Ultrafeed, Ultima 150, WC 100B * 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards.
THE AMERICAS Denton, TX USA U.S.
