FIREPOWER MST 180i 3-IN-1 Multi Process Welding Systems Operating Manual English Canadien Français Americas Español Art# A-12515 Revision: AA Issue Date: March 12, 2014 Manual No.: 0-5339 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 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 0-5339 for: Firepower MST 180i Portable System Package PartNumber:1444-0871 Published by: Victor Technologies International, 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................................................ 4-5 Stick (SMAW) Basic Welding Technique.......................................................... 4-8 Effects of Stick Welding Various Materials............................
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Firepower MST 180i 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 180i 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 180i 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 180i 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 180i ! 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 180i ! 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. 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 180i 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 180i 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 MÉDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPÉRATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET ÉQUIPEMENT.
Firepower MST 180i 15. Fermez solidement tous les panneaux et les capots. 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. AVERTISSEMENT LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. 5.
Firepower MST 180i 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 180i 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 180i 1. Maintenez les câbles l’un près de l’autre en les entrelaçant ou les reliant ensemble au ruban. AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX. Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression. 1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi. 2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter. 3.
Firepower MST 180i 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 180i ! 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.
Firepower MST 180i 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle.
Firepower MST 180i 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.
SECTION 2: INTRODUCTION Firepower MST 180i 2.01 How to Use This Manual 2.03 Receipt of Equipment 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 180i 2.06 User Responsibility This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately.
Firepower MST 180i 2.08 Duty Cycle The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 180 amperes at 23 volts.
Firepower MST 180i 2.09 Specifications DESCRIPTION Firepower MST 180i MULTI PROCESS 3 IN 1 WELDER Power Source System Part No. 1444-0871 Power Source System Dimensions H16.14" x W8.27" x D17.72" (410mm x 210mm x 450mm) Power Source System Weight 32.2lb (14.
Firepower MST 180i NOTE The recommended time delay fuse or circuit breaker size is 50 amp. An individual branch circuit capable of carrying 50 amperes and protected by fuses or circuit breaker is recommended for this application.
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Firepower MST 180i SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment 3.03 Ventilation This Power Source 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 180i Electrical Input Requirements Operate the welding Power Source 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 180i 3.05 Electromagnetic Compatibility 7. The time of day that welding or other activities are to be carried out. 8. The immunity 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 is used in a domestic situation. A.
Firepower MST 180i 5. Earthing of the Workpiece 3.06 Firepower Regulator 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 180i ! ! WARNING DO NOT use a regulator that delivers pressure exceeding the pressure rating of the downstream equipment unless provisions are made to prevent over-pressurization (i.e. system relief valve). Make sure the pressure rating of the downstream equipment is compatible with the maximum delivery pressure of the regulator. WARNING Stand to the side of the cylinder opposite the regulator when opening the cylinder valve. Keep the cylinder valve between you and the regulator.
Firepower MST 180i 3.07 Leak Testing the System 3.08 When You Finish Using the Regulator Leak test the system before putting into operation. 1. Close the cylinder valve. 1. Be sure that there is a valve in the downstream equipment to turn OFF the gas flow. 2. Open the valve on the downstream equipment. This drains all pressure from the system. 2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery pressure. 3. Close the valve on the downstream equipment. 3.
Firepower MST 180i 3.
Firepower MST 180i 1. Power Indicator The power indicator is illuminated when the Electricity Supply is applied to the Power Source and when the ON/OFF switch located on the rear panel is in the ON position. 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 180i 6. MIG Gun 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, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire. When using flux cored (gasless) wire, the polarity lead is generally connected to the negative welding terminal (-).
Firepower MST 180i 9. Multifunction Control - Voltage, Down Slope & Arc Force 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. NOTE The preview functionality provided on this power source is intended to act as a guide only.
Firepower MST 180i Note that when operating in LIFT TIG mode, the Power Source will remain activated until the selected Downslope time has elapsed (refer Control No. 9). 12. Process Selection Control The process selection control is used to select the desired welding mode. Three modes are available, MIG, LIFT TIG and STICK modes. Refer to section 3.15 or 3.16 for MIG (GMAW/FCAW) set up details, section 3.17 for LIFT TIG (GTAW) set-up details or section 3.18 for STICK (SMAW) set-up details.
Firepower MST 180i 17. Intelligent Fan Control The Firepower MST 180i is designed with an intelligent fan control. It automatically switches the cooling fan OFF when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the Power Source. Note that the fan will only operate when required for cooling purposes and will automatically switch OFF when not required.
Firepower MST 180i 3.11 Attaching the Firepower 180A Gun Fit the Firepower MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adaptor and tightening the Locking Nut to secure the MIG Gun in the MIG Gun Adapter.
Firepower MST 180i 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 3-9. 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 180i 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 3-10. 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 180i 3.15 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in an counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 3-11).
Firepower MST 180i 3.16 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 WIREFEED 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 swarf.
Firepower MST 180i 3.18 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 180i 3.20 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire A. Select MIG mode with the process selection control. (Refer to Section 3.10 for further information) B. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals.
Firepower MST 180i 3.21 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 heavy duty bayonet type terminals.
Firepower MST 180i Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) MIG Gun Polarity Lead.
Firepower MST 180i 3.22 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire Set the Process Selection Control to MIG for Spool Gun welding. For setup and operation of the Spool gun, please refer to the spool gun operations manual. Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to SPOOL GUN. Connect the shielding gas for the Spool Gun to the Shielding Gas Inlet on the rear panel of the Power Source. 1.
Firepower MST 180i 3.23 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. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C. Connect the work lead to the positive welding terminal (+).
Firepower MST 180i 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 180i 3.24 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 heavy duty bayonet type terminals. 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 180i 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 180i 10° Longitudinal Angle Direction of Travel 10° to 20° Longitudinal Angle 30° to 60° Transverse Angle 30° to 60° Transverse Angle 30° to 60° Transverse Angle 5° to 15° Longitudinal Angle Direction of Travel Vertical Fillet Welds Art # A-08996 Overhead Weld Art # A-08995 Figure 4-7 Figure 4-6 Distance from the MIG Gun Nozzle to the Work Piece Secondary Adjustable Variables The electrode wire stick-out from the MIG Gun nozzle should be between 3/8" (10mm) to 3/4" (20.0mm).
Firepower MST 180i Transverse Angle Direction of Gun Travel Longitudinal Angle Axis of Weld Transverse and Longitudinal Nozzle Axes Leading or “Pushing” Angle (Forward Pointing) Art # A-08998_AB 90° Trailing or “Pulling” Angle (Backward Pointing) Nozzle Angle, Right Handed Operator Art # A-08999_AC Figure 4-10 Figure 4-9 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 mate
Firepower MST 180i Firepower MIG, Lift TIG, Stick Wire Selection Chart Art # A-12463 Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart BASIC WELDING GUIDE 4-4 Manual 0-5339
Firepower MST 180i 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 180i 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. 2 Wire spool unwinds and tangles. Wire spool brake is too loose. 3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding. B Replace feed roller if worn.
Firepower MST 180i 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 180i 4.03 Stick (SMAW) Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes. For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job.
Firepower MST 180i Art # A-07687 Figure 4-11: Flat Position, Down Hand Butt Weld Art A-07691 Figure 4-15: Vertical Position, Butt Weld Art # A-07688 Figure 4-12: Flat Position, Gravity Fillet Weld Art # A-07692 Figure 4-16: Vertical Position, Fillet Weld Art # A-07689 Figure 4-13: Horizontal Position, Butt Weld Art# A-07693 Figure 4-17: Overhead Position, Butt Weld Art # A-07690 Figure 4-14: Horizontal-Vertical (HV) Position Art # A-07694 Figure 4-18: Overhead Position, Fillet Weld Joint Prepar
Firepower MST 180i Single Vee Butt Joint Open Square Butt Joint Not less than 70° 1/16" (1.6mm) max Gap varies from 1/16" (1.6mm) to 3/16" (4.8mm) depending on plate thickness 1.6mm (1/16”) Single Vee Butt Joint Not less than 45° Double Vee Butt Joint Lap Joint Not less than 70° 1/16" (1.6mm) max 1/16" (1.
Firepower MST 180i Striking the Arc Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck.
Firepower MST 180i 20°-30° Electrode Tack Weld Art # A-07698 Tack Weld Art # A-07697_AB Figure 4-22: Weld Build up Sequence Figure 4-21: Butt Weld 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. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-22.
Firepower MST 180i Art # A-07702 Art # A-07701 Figure 4-26: Multi Run Vertical Fillet Weld Figure 4-25: Single Run Vertical Fillet Weld Art # A-07703 Figure 4-27: Examples of Vertical Fillet Welds 2. Vertical Down The E7014 Stick electrode makes welding in this position particularly easy. Use a 1/8"(3.2mm) electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.
Firepower MST 180i 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 180i D. Presetting It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-31. E.
Firepower MST 180i 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. Reduce the ARC FORCE control knob until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.
Firepower MST 180i FAULT CAUSE REMEDY 5 Portions of the A Small electrodes used on weld run do not heavy cold plate. fuse to the surface B Welding current is too low. of the metal or edge of the joint. C Wrong electrode angle. D Travel speed of electrode is too high. A Use larger electrodes and preheat the plate. B Increase welding current. C Adjust angle so the welding arc is directed more into the base metal. D Reduce travel speed of electrode. E Scale or dirt on joint surface.
Firepower MST 180i 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 180i 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 180i 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 180i 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 180i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT 1 REMEDY Electricity Supply is ON, power in- A Power Source is not in the correct mode of dicator is illuminated however the operation. Power Source will not commence welding when the torch trigger B Faulty torch trigger. switch is depressed. 2 Fault Indicator is illuminated and the Power Source will not commence welding when the torch trigger switch is depressed.
Firepower MST 180i 5.02 Routine Service and Calibration Requirements 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 180i Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying 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 supplying transportable equipment - at least once every 3 months; and 2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months. D.
Firepower MST 180i 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. To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal filings, slag and loose material.
Firepower MST 180i 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. After cleaning, tighten the feed roll retaining knobs. CAUTION Do not use compressed air to clean the Welding Power Source. Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the Welding Power Source.
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Firepower MST 180i SECTION 6: KEY SPARE PARTS 6.01 Firepower 180A MIG Gun Parts Torch Part No: 1444-0881 Item No. Art# A-12519 1 2 Description MST Nozzle** MST Contact Tip** Part No. 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 MST Contact Tip, .023" 1444-0890 MST Contact Tip, .030" 1444-0891 MST Contact Tip, .035" 1444-0892 MST Contact Tip, .
Firepower MST 180i Art # A-12544 6.
Firepower MST 180i Firepower MST 180i 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 43 Manual 0-5339 PART NUMBER W7004962 W7004963 W7003033 W7004970 W7004969 W7004905 W7004906 7977036 W7004947 W7003010 W7003215 W7004909 W7004955 W7004942 W7003053 W7004911 W7004912 1444-0945 1444-0947 W7004922 1444-0948 W7004925 W7004967 1444-0949 1444-0946 870734 W7004972 1444-0950 W7004953 OTWAK/1S W7004961 W7004940 W7004
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Firepower MST 180i APPENDIX: Firepower MST 180i CIRCUIT DIAGRAM IFB J18 J1 DRIVE J16 J3 SOURCE PWM J5 CR J19 J7 FUNS MB CONNECTOR LAYOUT DIAGRAM J8 NTCS QF/DY OT GUN WVIN 1 2 3 4 ON J15 Art # A-11230 APPENDIX 1 Manual 0-5339 J13 J24 J10
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 2 Years Parts* and Labor * 2 years on the Original Main Power Transformer and Inductors not mounted on PC Boards.
THE AMERICAS Denton, TX USA U.S.
