Firepower MST 220i 3-IN-1 Multi Process Welding Systems Operating Manual English Canadien Français Americas Español Revision: AA Issue Date: May 13, 2014 Manual No.: 0-5343 www.Firepower.
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! 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 0-5343 for: Firepower MST 220i Portable system Package Part Number: 1444-0872 Published by: Victor Technologies, Inc. 16052 Swingley Ridge Road, Suite 300 St. Louis, MO 63017 USA www.Firepower.
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 Arc Welding Hazards........................................................................................ 1-1 General Safety Information For Victor CS Regulator.......................................... 1-5 Principal Safety Standards............................................................................... 1-7 Symbol Chart.....................
TABLE OF CONTENTS SECTION 4: BASIC WELDING GUIDE.............................................................................. 4-1 4.01 4.02 4.03 4.04 4.04 4.05 4.06 MIG (GMAW/FCAW) Basic Welding Technique................................................ 4-1 MIG (GMAW/FCAW) Welding Troubleshooting................................................ 4-5 STICK (SMAW) Basic Welding Technique........................................................ 4-8 Effects of Arc Welding Various Materials........................
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FIREPOWER MST 220i 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 220i 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing. 5.
FIREPOWER MST 220i 1. Keep your head out of the fumes. Do not breathe the fumes. 7. Do not weld on closed containers such as tanks or drums. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 8. Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long, possibly unknown paths and causing electric shock and fire hazards. 3. If ventilation is poor, use an approved air-supplied respirator. 9.
FIREPOWER MST 220i 4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery. 8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. ! 5. Keep hands, hair, loose clothing, and tools away from moving parts. WARNING 6. Reinstall panels or guards and close doors when servicing is finished and before starting engine. Engines can be dangerous. WARNING ENGINE EXHAUST GASES can kill.
FIREPOWER MST 220i 1.02 General Safety Information For Victor CS Regulator NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields 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. The following is a quotation from the General Conclusions Section of the U.S.
FIREPOWER MST 220i C Ventilation ! E Compressed Gas Cylinders The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases used for welding or cutting operations. WARNING Adequately ventilate welding, heating, and cutting work areas to prevent accumulation of explosive or toxic concentrations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances.
FIREPOWER MST 220i 6. Momentarily open and close (called “cracking”) the cylinder valve to dislodge any dust or dirt that may be present in the valve. 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. CAUTION Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Open the cylinder valve slightly.
FIREPOWER MST 220i 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 220i 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 220i 12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées. AVERTISSEMENT 13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu. LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
FIREPOWER MST 220i 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés. 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. AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L’arc produit des étincellies et des projections.
FIREPOWER MST 220i pantalon revers, des bottines de sécurité et un casque. 8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous. AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES. Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier. 1.
FIREPOWER MST 220i 1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés. 3. Laissez la pression s’échapper avant d’ôter complètement le bouchon. 2. Avant d’installer ou de connecter un système, arrêtez le moteur. ! 3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.
FIREPOWER MST 220i B Entretien des Locaux ! STIMULATEURS CARDIAQUES : Les procédures décrites ci-dessus sont habituellement celles recommandées pour les porteurs de stimulateurs cardiaques. Pour de plus amples renseignements, consulter un médecin. 1.07 Informations Générales de Sécurité A Prévention D’incendie Les opérations de soudage utilisent le feu ou la combustion comme outil de base. Ce processus est très utile quand il est correctement contrôlé.
FIREPOWER MST 220i 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 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. 1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la en position verticale.
FIREPOWER MST 220i 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. Safety and Health Standards, OSHA 29 CFR 1910, 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, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
FIREPOWER MST 220i 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle.
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FIREPOWER MST 220i SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.03 Receipt Of Equipment To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim.
FIREPOWER MST 220i 2.05 Transportation Methods 2.07 Firepower MST 220i Portable System Package (Part No. 1444-0872) • Firepower MST 220i Power Source WARNING • Firepower Fusion 12' Mig Gun Euro ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source. ! • Firepower regulator • Electrode Holder with 13ft (4m)-20mm2 lead • Work Clamp with 10ft (3.
FIREPOWER MST 220i 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, 210 amperes at 24.5 volts.
FIREPOWER MST 220i 2.09 Specifications Description Firepower MST 220i Multi Process 3 in 1 Welder Power Source Part No. Power Source Dimensions Power Source Mass Cooling Welder Type Applicable Standard Number of Phases Nominal Supply Voltage Nominal Supply Frequency Welding Current Range MIG Mode STICK Mode TIG Mode Wirefeed Speed Range 1444-0872 H17.12” x W10.47” x D 24.29” (435mm x 266mm x D617mm) 57.3lb (26.
FIREPOWER MST 220i NOTE The recommended time delay fuse or circuit breaker size for 115V is 30 amp. An individual branch circuit capable of carrying 30 amperes and protected by fuses or circuit breaker is recommended for this application.
FIREPOWER MST 220i 2.11 Volt-Ampere Curves Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown.
FIREPOWER MST 220i SECTION 3: INSTALLATION, OPERATION AND SETUP F. Place at a distance of 12" (305mm) or more from walls or similar that could restrict natural air flow for cooling. 3.01 Environment This Power Source is designed for use in environments with increased hazard of electric shock. Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock. Please refer to relevant local standards for further information prior to using in such areas.
FIREPOWER MST 220i WARNING The Firepower MST 220i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the Primary Power Cable. WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures.
FIREPOWER MST 220i WARNING An electrical shock or fire hazard is probable if the following electrical service guide recommendations are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding Power Source. Supply Voltage Input Current at Maximum Output Maximum Recommended Fuse* or Circuit Breaker Rating * Time Delay Fuse, UL class RK5. Refer to UL248 Maximum Recommended Fuse^ or Circuit Breaker Rating ^Normal Operating, UL class K5.
FIREPOWER MST 220i 3.05 Electromagnetic Compatibility ! WARNING Extra precautions for Electromagnetic Compatibility may be required 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 manufacturer’s instructions.
FIREPOWER MST 220i 2. Maintenance of Welding Equipment The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding 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.
FIREPOWER MST 220i NOTE Regulators purchased with open 1/8”, 1/4”, 3/8”, or 1/2” NPT ports must be assembled to their intended system. 1. Note the maximum inlet 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” or “HP” at the inlet port. Attach the inlet port to the system supply pressure connection. 3.
FIREPOWER MST 220i 7. Before opening the cylinder valve, turn the regulator adjusting screw counterclockwise until there is no pressure on the adjusting spring and the screw turns freely. 8. Relief Valve (where provided): The relief valve is designed to protect the low pressure side of the regulator from high pressures. Relief valves are not intended to protect downstream equipment from high pressures. ! WARNING DO NOT tamper with the relief valve or remove it from the regulator.
FIREPOWER MST 220i 3.07 Leak Testing The System 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 regulator to deliver the maximum required delivery pressure. 3. Close the cylinder valve. 4. Turn the adjusting screw/knob counterclockwise one turn. a) If the high-pressure gauge reading drops, there is a leak in the cylinder valve, inlet fitting, or highpressure gauge.
FIREPOWER MST 220i 3.
FIREPOWER MST 220i 1. Power Indicator The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/OFF switch located on the rear panel is in the ON position. 2. Thermal Overload Indicator (Fault Indicator) This welding power source is protected by a self resetting thermostat. The 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.
FIREPOWER MST 220i 4. Wirespeed/Amperage Control In MIG mode, the Wirespeed/Amperage control 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 material type and the welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required settings for a basic range of MIG (GMAW/ FCAW) welding applications.
FIREPOWER MST 220i 8. Negative Welding Output Terminal The negative 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 polarity lead), TIG torch or work lead. Negative welding current flows to the power source via this dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
FIREPOWER MST 220i When MIG Mode is Selected In this mode the control knob is used to adjust the output voltage of the unit. The welding voltage is increased by turning the knob clockwise or decreased by turning the knob anti-clockwise. The optimum voltage level required will dependent on the type of welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications.
FIREPOWER MST 220i 13. Process Selection Control The process selection control is used to select the desired welding mode. Three modes are available, MIG (GMAW/FCAW), LIFT TIG (GTAW) and STICK (SMAW) modes. Refer to section 3.19 or 3.20 for MIG (GMAW/ FCAW) set up details, section 3.22 for LIFT TIG (GTAW) set-up details or section 3.23 for STICK (SMAW) set-up details. Note that when the unit is powered OFF the mode selection control will automatically default to MIG mode.
FIREPOWER MST 220i 17. Wiredrive Motor Circuit Breaker The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload. NOTE If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button. 18.
FIREPOWER MST 220i 3.11 Attaching the Firepower Fusion 220A MIG Gun Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor.
FIREPOWER MST 220i 3.12 Installing 33/44 lb Spool (12" diameter) As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 33/44 lb. or 12" diameter. Installation of wire spool, Refer to Figure 3-11. 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull. 2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter clockwise.
FIREPOWER MST 220i 3.13 Installing 12.5 lb Spool ( 8" diameter) In order to fit a 12.5 lb spool (8" diameter) assemble parts in the sequence shown in Figure 3-9. Installation of wire spool: 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull. 2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool. 3.
FIREPOWER MST 220i 3.14 Installing 1 lb Spool (4" diameter) In order to fit a 1 lb spool (4" diameter) assemble parts in the sequence shown in Figure 3-13. Installation of wire spool: 1. Remove Wire Spool 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 spool rotates counter clockwise. 3.
FIREPOWER MST 220i 3.15 Inserting Wire Into The Wire Feed Mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension knob in an anti-clockwise direction. Then to release the pressure roller arm push the tension screw toward the back of the machine which releases the pressure roller arm (Figure 3-14).
FIREPOWER MST 220i 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 220i 3.18 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the Thumb Screw 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 1/8"-3/16" (3-5mm) after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.
FIREPOWER MST 220i ! WARNING Before connecting the work clamp to the work make sure the Electricity Supply is switched OFF. Secure the welding grade 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. Remove any packaging material prior to use.
FIREPOWER MST 220i 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 for further information). B. Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire 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 sound electrical connection. C.
FIREPOWER MST 220i 3.21 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire Select 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 to the Shielding Gas Inlet on the rear panel of the Power Source. 1.
FIREPOWER MST 220i 3.22 Setup For LIFT TIG (GTAW) Welding A. Select LIFT TIG mode with the process selection control (refer to Section 3.10 for further information). B. Connect the TIG Torch to the negative welding terminal (-). 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. C. Connect the work lead to the positive welding terminal (+).
FIREPOWER MST 220i Art # A-12538 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 220i 3.23 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 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.
FIREPOWER MST 220i SECTION 4: BASIC WELDING GUIDE Shielding Gas (Optional) Molten Metal 4.01 MIG (GMAW/FCAW) Basic Welding Technique Base Metal FCAW Process Art # A-08992_AB Figure 4-2 Position of MIG Gun The angle of MIG Gun to the weld has an effect on the width of the weld. Push Vertical Drag/Pull Art # A-07185_AB Figure 4-3 The MIG Gun should be held at an angle to the weld joint.
FIREPOWER MST 220i 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.
FIREPOWER MST 220i Setting of the Power Source Transverse Angle Power source setting requires some practice by the operator, as the welding plant has two control settings that have to balance. These are the Wirespeed control (refer to section 3.06.4) and the welding Voltage Control (refer to section 3.06.10). The welding current is determined by the Wirespeed control, the current will increase with increased Wirespeed, resulting in a shorter arc.
FIREPOWER MST 220i Art # A-12540 Firepower MIG, Lift TIG, Stick Wire Selection Chart Table 4-1 BASIC WELDING 4-4 Manual 0-5343
FIREPOWER MST 220i 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix MIG (GMAW/FCAW) welding problems is to start at the wire spool then work through to the MIG Gun. There are two main areas where problems occur with GMAW; 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 220i Solving Probelms Beyond the Welding Terminals - Inconsistent Wire Feed ! WARNING Disengage the feed roll when testing for gas flow by ear. 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 unwound and tangled. 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.
FIREPOWER MST 220i Basic MIG (GMAW/FCAW) 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 220i 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 220i Art # A-07687 Art# A-07693 Figure 4-11: Flat Position, Down Hand Butt Weld Figure 4-17: Overhead Position, Butt Weld Art # A-07688 Art # A-07694 Figure 4-12: Flat Position, Gravity Fillet Weld Figure 4-18: 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 castings, etc.
FIREPOWER MST 220i 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 1/16” (1.6mm) 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 220i If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock. 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.
FIREPOWER MST 220i 45° from vertical 60° - 70° from line of weld Art # A-07698 Figure 4-22: Weld Build up Sequence Art # A-07699_AB 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 220i 3. Overhead Welds Art # A-07701 Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron 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 sketch.
FIREPOWER MST 220i The Cause of Distortion Upsetting Weld Art # A-07705_AB Distortion is caused by: Expansion with compression A. Contraction of Weld Metal: Hot Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely.
FIREPOWER MST 220i E. Preheating Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-32 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.
FIREPOWER MST 220i 4.04 STICK (SMAW) Welding Troubleshooting FAULT 1 Welding current varying CAUSE REMEDY ARC FORCE is set at a value that causes the welding current to vary excessively with the arc length. 2 A gap is left by A Welding current too low failure of the weld B Electrode too large for metal to fill the joint. root of the weld. C Insufficient gap.
FIREPOWER MST 220i FAULT CAUSE REMEDY 4 A groove has been A Welding current is too formed in the base high. metal adjacent to B Welding arc is too long. the toe of a weld and has not been filled by the weld C Angle of the electrode is incorrect. metal (undercut). D Joint preparation does not allow correct electrode angle. E Electrode too large for joint. A Reduce welding current. B Reduce the length of the welding arc. C Electrode should not be inclined less than 45° to the vertical face.
FIREPOWER MST 220i 4.05 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 220i 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 220i 4.06 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 220i FAULT 7 Dirty weld pool CAUSE REMEDY A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates. 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 air. or 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 220i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY 1 Electricity Supply is ON, power indicator is illuminated however unit will not commence welding when the torch trigger switch is depressed. A Power source is not in the correct mode of operation. A Set the power source to the correct mode of operation with the process selection switch. B Faulty torch trigger. B Repair or replace torch trigger switch/lead.
FIREPOWER MST 220i FAULT CAUSE REMEDY 8 Gas flow continues after the trigger switch has been released (MIG mode). Gas valve has jammed open due to impurities in the gas or the gas line. Have an accredited Firepower service provider repair or replace gas valve. 9 Power indicator will not illuminate and welding arc cannot be established. The Electricity Supply has exceeded voltage limits of the power source. Ensure that the Electricity Supply is within 115V ± 10% or 208/230VAC ± 10%.
FIREPOWER MST 220i Components to be Tested Minimum Insulation Resistance (MΩ) Input circuit (including any connected control circuits) to welding circuit (including any connected control circuits) 5 All circuits to exposed conductive parts 2.
FIREPOWER MST 220i Power Source Calibration A. Schedule Output testing of all Firepower Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below 1. For transportable equipment, at least once every 3 months; and 2. For fixed equipment, at least once every 12 months. B.
FIREPOWER MST 220i 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 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 220i 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.
FIREPOWER MST 220i SECTION 6: KEY SPARE PARTS 6.01 Firepower Fusion 220A MIG Gun Item No. Description Torch Part No: 1444-0882 Art# A-12519 1 2 MST Nozzle** 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 220i 16 14 21 6 33 7 5 35 32 17 13 19 34 18 31 30 29 28 3 12 4 22 25 23 24 10 15 11 8 Art # A-12541 1 9 2 6.
FIREPOWER MST 220i 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 Part Number W7005621 W7005638 W7005602 W7005607 W7005603 W7004906 W4014800 W7005622 W7003010 W7003033 W7003215 W7004909 W7004955 W7003242 W7005623 W7004911 W7005617 W7005608 W7005609 W7005619 W7004967 1444-0920 1444-0921 1444-0922 1444-0923 1444-0924 1444-0925 1444-0926 W7004972 W7005630 W7005629 W7004943 870734 W7004940 W7005632 1444-0927 1444-0928 1444-0912 39 W7005635 Descr
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FIREPOWER MST 220i APPENDIX 1: FIREPOWER MST 220i CIRCUIT DIAGRAM 50/60Hz L2 GND INPUT 115/208/230VAC L1 SHEETMETAL COVER 60W3Ω J14 1 RX ACOUT RED FAN BR1 J23 FJ BR2 ACOUT 1 +24VDC VR 1 BLACK DC - BLACK DC + PFC CIRCUIT RED POT1 BURN BACK PCB 5 W7004940 J15 1 CON3 +24CDC 1 N/A 2 J16 1 DY1 1 Main Power PCB1 75ć J5 1 J6 1 OT2 J1 DRIVE J3 CR ON 1 2 J4 Funs J5 OT2 J10 MB CONNECTOR LAYOUT DIAGRAM J2 SOURCE J13 J11 1 SEIAL DISPLAY DATA (CLK) 3 SEIAL DISPLAY DATA (L
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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.
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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.
