Firepower MST 220i Operating Manual

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Firepower MST 220i

3-IN-1 Multi Process Welding Systems

Operating Manual

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Revision: AA Issue Date: May 13, 2014 Manual No.: 0-5343

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.

YOU ARE IN GOOD COMPANY!

Firepower is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, efﬁciency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.

If you have any questions or concerns regarding your new Firepower product, please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Firepower.com

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.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: May 13, 2014 Revision Date:

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

TABLE OF CONTENTS

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 General Safety Information For Victor CS Regulator ......................................... 1-5

1.03 Principal Safety Standards .............................................................................. 1-7

1.04 Symbol Chart .................................................................................................. 1-8

1.05 Precautions De Securite En Soudage A L’arc .................................................. 1-9

1.06 Dangers relatifs au soudage à l’arc ................................................................. 1-9

1.07 Informations Générales de Sécurité .............................................................. 1-14

1.08 Principales Normes De Securite ................................................................... 1-16

1.09 Graphique de Symbole .................................................................................. 1-17

SECTION 2: INTRODUCTION ............................................................................. 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identiﬁcation ................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Description ..................................................................................................... 2-1

2.05 Transportation Methods .................................................................................. 2-2

2.06 User Responsibility ......................................................................................... 2-2

2.07 Firepower MST 220i Portable System Package (Part No. 1444-0872) ............ 2-2

2.08 Duty Cycle ....................................................................................................... 2-3

2.09 Speciﬁcations ................................................................................................. 2-4

2.10 Optional Accessories ...................................................................................... 2-5

2.11 Volt-Ampere Curves ........................................................................................ 2-6

SECTION 3: INSTALLATION, OPERATION AND SETUP ................................................ 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Ventilation ....................................................................................................... 3-1

3.04 Electricity Supply ........................................................................................... 3-1

3.05 Electromagnetic Compatibility ........................................................................ 3-4

3.06 Firepower Regulator ....................................................................................... 3-5

3.07 Leak Testing The System ................................................................................ 3-8

3.08 When You Finish Using The Regulator ............................................................ 3-8

3.09 Storage Of The Regulator ............................................................................... 3-8

3.10 Firepower MST 220i Power Source Controls, Indicators And Features ........... 3-9

3.11 Attaching the Firepower Fusion 220A MIG Gun ............................................ 3-16

3.12 Installing 33/44 lb Spool (12" diameter) ...................................................... 3-17

3.13 Installing 12.5 lb Spool ( 8" diameter) .......................................................... 3-18

3.14 Installing 1 lb Spool (4" diameter) ................................................................ 3-19

3.15 Inserting Wire Into The Wire Feed Mechanism ............................................. 3-20

3.16 Feed Roller Pressure Adjustment .................................................................. 3-21

3.17 Changing the Feed Roll ................................................................................. 3-21

3.18 Wire Reel Brake ............................................................................................ 3-22

3.19 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire .................... 3-22

3.20 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire ................... 3-24

3.21 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire 3-25

3.22 Setup For LIFT TIG (GTAW) Welding ............................................................. 3-26

3.23 Setup For STICK (SMAW) Welding .............................................................. 3-28

TABLE OF CONTENTS

SECTION 4:

BASIC WELDING GUIDE ............................................................................. 4-1

4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1

4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-5

4.03 STICK (SMAW) Basic Welding Technique ....................................................... 4-8

4.04 Effects of Arc Welding Various Materials ........................................................ 4-8

4.05 STICK (SMAW) Welding Troubleshooting ..................................................... 4-16

4.06 TIG (GTAW) Basic Welding Technique .......................................................... 4-18

4.07 TIG (GTAW) Welding Problems ..................................................................... 4-20

SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS ............ 5-1

5.01 Power Source Problems ................................................................................. 5-1

5.02 Routine Service and Calibration Requirements ............................................... 5-2

5.03 Cleaning the Welding Power Source ............................................................... 5-5

5.04 Cleaning the Feed Rolls ................................................................................... 5-6

SECTION 6: KEY SPARE PARTS .......................................................................... 6-1

6.01 Firepower Fusion 220A MIG Gun .................................................................... 6-1

6.02 Power Source Spare Parts .............................................................................. 6-2

APPENDIX 1: FIREPOWER MST 220i CIRCUIT DIAGRAM ............................................ A-1

FIREPOWER - LIMITED WARRANTY TERMS ......................................INSIDE REAR COVER

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ................................. REAR COVER

This Page Intentionally Blank

FIREPOWER MST 220i

Manual 0-5343 1-1 SAFETY INSTRUCTIONS AND WARNINGS

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live when

ever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned ON accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn OFF all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In conﬁned spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above ﬂoor level.

15. Keep all panels and covers securely in place.

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.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND

REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

FIREPOWER MST 220i

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5343

WARNING

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.

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.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from ﬂash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, ﬂame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida

Guide for Shade Numbers

Process

Electrode Size in.

(mm)

Arc Current

(Amperes)

Minimum

Protective

Shade

Suggested*

Shade No.

(Comfort)

Shielded Metal Arc Welding (SMAW)

Less than 3/32 (2.4)

3/32-5/32 (2.4-4.0)

5/32-1/4 (4.0-6.4)

More than 1/4 (6.4)

Less than 60

60-160 160-250 250-550

8 10 11

10 12 14

Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW)

Less than 60

60-160 160-250 250-550

7 10 10 10

11 12 14

Gas Tungsten arc Welding (GTAW)

Less than 50

50-150

150-500

8 8

10 12 14

Air Carbon Arc Cutting (CAC-A)

(Light)

(Heavy)

Less than

500

500-1000

10 11

12 14

Plasma Arc Welding (PAW)

Less than 20

20-100 100-400 400-800

8 10 11

6 to 8

10 12 14

Plasma Arc Cutting (PAC)

Less than 20

20-40 40-60 60-80

80-300 300-400 400-800

4 5 6 8 8 9

4 5 6 8

9 12 14

* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufﬁcient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the ﬂux produces a high yellow light, it is desirable to use a ﬁlter lens that absorbs the yellow or sodium line of the visible light spectrum.

FIREPOWER MST 220i

Manual 0-5343 1-3 SAFETY INSTRUCTIONS AND WARNINGS

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a conﬁned space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

WARNING

WELDING can cause ﬁre or explosion. Sparks and spatter fly off from the

welding arc. The ﬂying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause ﬁres and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or ﬁre.

1. Protect yourself and others from ﬂying sparks and hot metal.

2. Do not weld where flying sparks can strike ﬂammable material.

3. Remove all ﬂammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for ﬁre, and keep a ﬁre extinguisher nearby.

6. Be aware that welding on a ceiling, ﬂoor, bulkhead, or partition can cause ﬁre on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

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.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause ﬂying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

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.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and ﬁttings designed for the speciﬁc application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

FIREPOWER MST 220i

SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5343

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

WARNING

ENGINE FUEL can cause ﬁre or explosion. Engine fuel is highly ﬂammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open ﬂames.

3. Allow engine to cool before fuelling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overﬁll tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut ﬁngers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualiﬁed people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is ﬁnished and before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

WARNING

WARNING: This product contains chemicals, includ-

ing lead, known to the State of California to cause birth defects and other reproductive harm.

Wash

hands after handling.

FIREPOWER MST 220i

Manual 0-5343 1-5 SAFETY INSTRUCTIONS AND WARNINGS

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Ofﬁce, May 1989): “...there is now a very large volume of scientiﬁc ﬁndings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic ﬁelds interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientiﬁc understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw deﬁnite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic ﬁelds in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding Power Source and cables as far away from body as practical.

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 cor rectly in the proper environment.

1. The work area must have a ﬁreproof ﬂoor.

2. Work benches or tables used during welding or cutting operations must have ﬁreproof tops.

3. Use heat resistant shields or other approved material to protect nearby walls or unprotected ﬂooring from sparks and hot metal.

4. Keep an approved ﬁre extinguisher of the proper size and type in the work area. Inspect it regularly to ensure that it is in proper working order. Know how to use the ﬁre extinguisher.

5. Move combustible materials away from the work site. If you can not move them, protect them with ﬁreproof covers.

WARNING

NEVER perform welding, heating, or cutting operations on a container that has held toxic, combustible or ﬂammable liquids, or vapors. NEVER perform welding, heating, or cutting operations in an area containing combustible vapors, ﬂam mable liquids, or explosive dust.

B Housekeeping

WARNING

NEVER allow oxygen to contact grease, oil,

or other ﬂam mable substances. Although oxygen by itself will not burn, these sub

stances become highly explosive. They can ignite and burn violently in the pres

ence of oxygen.

Keep ALL apparatus clean and free of grease, oil and other ﬂammable substances.

FIREPOWER MST 220i

SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5343

C Ventilation

WARNING

Ade quately ventilate welding, heating, and cutting work areas to prevent accumula

tion of explosive or toxic concen trations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances. When welding/ brazing, read and understand the Mate

rial Safety Data Sheet for the welding/ brazing alloy.

D Personal Protection

Gas ﬂames produce infrared radiation which may have a harm ful effect on the skin and especially on the eyes. Select goggles or a mask with tempered lenses, shaded 4 or darker, to protect your eyes from injury and provide good visibility of the work.

Always wear protective gloves and ﬂame-resistant clothing to protect skin and clothing from sparks and slag. Keep collars, sleeves, and pockets buttoned. DO NOT roll up sleeves or cuff pants.

When working in a non-welding or cutting environment, always wear suitable eye protection or face shield.

WARNING

Practice the following safety and operation precautions EVERY TIME you use pressure regulation equipment. Deviation from the following safety and operation instructions can result in ﬁre, explosion, damage to equipment, or injury to the operator.

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.

1. Place the cylinder (Figure 1-1) where you will use it. Keep the cylinder in a vertical position. Secure it to a cart, wall, work bench, post, etc.

Art # A-12127

Figure 1-1: Gas Cylinders

WARNING

Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or mis use 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. Contact your gas supplier or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.

NOTE

CGA P-1 publication is available by writing the Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly,VA 20151-2923

2. Place the valve protection cap on the cylinder whenever mov ing it, placing it in storage, or not using it. Never drag or roll cylinders in any way. Use a suitable hand truck to move cylin ders.

3. Store empty cylinders away from full cylinders. Mark them “EMPTY” and close the cylinder valve.

4. NEVER use compressed gas cylinders without a pressure reducing regulator attached to the cylinder valve.

5. Inspect the cylinder valve for oil, grease, and damaged parts.

WARNING

DO NOT use the cylinder if you ﬁnd oil, grease or damaged parts. Inform your gas supplier of this condition immediately.

FIREPOWER MST 220i

Manual 0-5343 1-7 SAFETY INSTRUCTIONS AND WARNINGS

6. Momentarily open and close (called “cracking”) the cylinder valve to dislodge any dust or dirt that may be present in the valve.

CAUTION

Open the cylinder valve slightly. If you open the valve too much, the cylinder could tip over. When cracking the cylinder valve, DO NOT stand directly in front of the cylinder valve. Always perform cracking in a well ventilated area. If an acetylene cylinder sprays a mist when cracked, let it stand for 15 minutes. Then, try to crack the cylinder valve again. If this problem persists, contact your gas supplier.

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 F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

FIREPOWER MST 220i

SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5343

1.04 Symbol Chart

Note that only some of these symbols will appear on your model.

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Dangerous Voltage

Off

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Art # A-04130_AB

115V 15A

IPM

MPM

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld Mode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

4 Step Trigger Operation

2 Step Trigger Operation

See Note

Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides. Cannot be disposed with household garbage.

FIREPOWER MST 220i

Manual 0-5343 1-9 SAFETY INSTRUCTIONS AND WARNINGS

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.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la ﬁn de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.06 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automa

tique avec ﬁl, ce dernier, le rouleau ou la bobine de ﬁl, le logement des galets d’en

trainement et toutes les pièces métalliques en contact avec le ﬁl de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

3 Isolez-vous de la pièce à souder et de la mise à la

terre au moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation aﬁn d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porteélectrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

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12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

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.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

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.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, suscep

tibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec ﬁltre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

AWS F2.2 : 2001 (R2010), Modiﬁé avec l’accord de l’American Welding Society (AWS), Miami, Florida

Guide de teinte des lentilles

Procédé

Taille de l’électrode

enmm (po)

Courant

d’arc

(ampères)

Gamme

d’intensité

minimum

Numéro de teinte

recommandée*

(Confort)

Soudage à l’arc avec électrode enrobée (procédé SMAW)

Moins de 2,4 (3/32)

3/32-5/32 (2,4-4,0)

5/32-1/4 (4,0-6,4)

Plus de 1/4 (6,4)

Moins de 60

60-160 160-250 250-550

8 10 11

10 12 14

Soudage à l’arc sous gaz avec ﬁl plein (procédé GMAW) et soudage avec ﬁl fourré (procédé FCAW)

Moins de 60

60-160 160-250 250-550

7 10 10 10

11 12 14

Soudage à l’électrode réfractaire (procédé GTAW)

Moins de 50

50-150

150-500

8 8

10 12 14

Coupage à l’arc avec électrode de carbone et jet d’air (procédé AAC)

(Clair)

(Sombre)

Moins de 500 500-

1000

10 11

12 14

Soudage à l’arc au plasma (procédé PAW)

Moins de 20

20-100 100-400 400-800

8 10 11

6 à 8

10 12 14

Coupage plasma (procédé PAC)

Moins de 20

20-40 40-60 60-80

80-300 300-400 400-800

4 5 6 8 8 9

4 5 6 8

9 12 14

* En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors dusoudage, du coupage ou du brasage au gaz oxygéné, la torche ou le fondant produit une puissante lumière jaune; il est préférable d’utiliser un ﬁltre qui absorbe cette lumière jaune ou le sodium du spectre de la lumière visible.

Tableau 1-1

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Manual 0-5343 1-11 SAFETY INSTRUCTIONS AND WARNINGS

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des pro

jections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du ﬁl-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inﬂammables.

3. Enlevez toutes matières inﬂammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrezles soigneusement avec des bâches approuvées.

4. Méﬁez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou ﬁssures.

5. Méﬁez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enﬂammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le ﬁl au tube-contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un

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.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les ﬁches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

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SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5343

pantalon revers, des bottines de sécurité et un casque.

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. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protec

teurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre ﬁxe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spéciﬁque; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

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 MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MO

TEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

2. Si vous utilisez ces équipements dans un endroit conﬁné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inﬂammable.

1. Arrêtez le moteur avant de vériﬁer le niveau e carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une ﬂamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vériﬁer le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ven

tilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

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Manual 0-5343 1-13 SAFETY INSTRUCTIONS AND WARNINGS

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

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.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR PEUT BRULER LA PEAU ET LES YEUX.

Les accumulateurs contiennent de l’élec

trolyte acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radia

teur 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. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

AVERTISSEMENT

AVERTISSEMENT: Ce produitcontient des produits

chimiques, notamment du plomb, reconnu par l’Étatde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système reproductif.

Se laver les mains après

manipulation.

REMARQUE

Facteurs relatifs au soudage et aux effets des champs magnétiques et électriques de basse fréquence

Voici une citation tirée du chapitre des conclusions générales du document de base de l’Office of Technology Assessment (bureau des évaluations technologiques) del’U.S. Congress, « Biological Effects of Power Frequency Electric & Magnetic Fields », OTA-BP-E-63 (Washington, DC : U.S. Government Printing Office, mai 1989) : « ... il existe de nos jours, un nombre très élevé de travaux scientiﬁques qui rapportent les résultats d’expériences menées au niveau cellulaire et d’études auprès d’homme et d’animaux qui établissent nettement le rapport entre les champs magnétiques de basse fréquence et les systèmes biologiques, soit par des interactions ou des modiﬁcations. Quoique la plupart de ces travaux soient de très bonne qualité, les résultats sont complexes. Àla lumière des connaissances scientiﬁques actuelles, il nous est encore impossible d’interpréter les évidences en un seul cadre de référence cohérent. La situation est toutefois très contrariante. En effet, il nous est aussi impossible de tirer des conclusions déﬁnitives quant aux risques éventuels ou de proposer des stratégies fondées sur des faits scientiﬁques visant à atténuer ou éviter des risques potentiels ».

Pour atténuer les champs magnétiques sur les lieux detravail, respectez les procédures qui suivent :

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.

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.

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SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5343

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 cor rectement contrôlé.

1. La zone doit comporter un sol ignifugé.

2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement ignifuge.

3. Utilisez des écrans résistants à la chaleur ou en matériau approuvé pour protéger les cloisons proches ou le sol vul nérable des étincelles et du métal chaud.

4. Gardez un extincteur approuvé du bon type et de la bonne taille dans la zone de travail. Inspectez-le régulièrement pour vous assurer qu’il est en état de fonctionner. Apprenez à vous en servir.

5. Enlevez tous les matériaux combustibles de la zone de travail. Si vous ne pouvez pas les enlever, protégez-les avec une cou vre ignifuge.

AVERTISSEMENT

N’effectuez JAMAIS d’opérations de soudage sur un récipient qui a contenu des liquides ou vapeurs toxiques, combusti

bles ou inﬂammables. N’effectuez JAMAIS d’opérations de soudage dans une zone contenant des vapeurs combustibles, des liquides inﬂammables ou des poussières explosives.

B Entretien des Locaux

AVERTISSEMENT

Ne laissez jamais l’oxygène en contact avec la graisse, l’huile ou d’autres subs

tances inﬂammables. Bien que l’oxygène elle même ne brûle pas, ces substances peuvent devenir extrême ment explosives. Elles peuvent prendre feu et brûler violemment en présence d’oxygène.

Gardez TOUS les appareils propres et exempts de graisse, huile ou autres substances inﬂammables.

C Aération

AVERTISSEMENT

Ventilez les zones de soudage, chauffage et découpage de façon adéquate pour éviter l’accumulation de gaz explosifs ou toxiques. Certaines combinaisons de métaux, revêtements et gaz génèrent des fumées toxiques: Utilisez un équipement de protection respiratoire dans ces cir

constances. Si vous soudez ou brasez, lisez et assimilez la ﬁche technique de sécurité de matériau relative à l’alliage de soudage/brasage.

D Protection Personnelle

Les ﬂammes de gaz produisent une radiation infrarouge qui peut avoir un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un masque avec des verres trempés assombris au niveau 4 ou plus sombre, pour protéger vos yeux des dommages et garder une bonne visibilité sur le travail.

Portez en permanence des gants de protection et des vête ments ignifuges pour la protection de la peau et des vêtements contre les étincelles et le laitier. Gardez col, manches et poches boutonnés. Il ne faut pas remonter vos manches ou les pantalons à revers.

Quand vous travaillez dans un environnement non dédié au soudage ou découpage, portez toujours une protection des yeux appropriées ou un masque facial.

AVERTISSEMENT

Mettez en pratique les procédures de sécurité et de mode opératoire suivantes à chaque fois que vous utilisez cet appareil de régulation de pression. Si vous déviez de ces procédures, cela peut entraîner incendie, explosion, dégâts matériels et/ ou blessures corporelles pour l’opérateur.

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Manual 0-5343 1-15 SAFETY INSTRUCTIONS AND WARNINGS

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.

1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la en position verticale. Fixez-la sur un chariot une cloison, un établi, etc.

Art # A-12127

Le schéma 1-1: Cylindres de gaz

AVERTISSEMENT

Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux peuvent résulter d’une mauvaise manu

tention ou d’un mauvais emploi des bouteilles de gaz comprimé. NE faites PAS tomber la bouteille, ne la cognez pas, ne l’exposez pas à une chaleur excessive, aux ﬂammes ou étincelles. NE la cognez PAS contre d’autres bouteilles. Contactez votre fournisseur de gaz ou reportez vous à la publication CGA P-1 “Manipulation sécurisée des gaz comprimés en conteneur” pour plus d’informations sur l’utilisation et la manutention des bouteilles.

AVIS

Ce document CGA p. t peut être obtenu en écrivant à “Compressed Gas Asso

ciation”, 4221 Walney Roed, 5th Floor. Chantilly, VA 20151.2923, USA.

2. Placez le bouchon de protection de vanne sur la bouteille à chaque fois que vous la déplacez ou ne l’utilisez pas. Ne faites jamais glisser ou rouler d’aucune manière les bouteilles. Utilisez un diable approprié pour les déplacer.

3. Entreposez les bouteilles vides à l’écart des bouteilles pleines. Marquez-les “VIDE” et refermez leur vanne.

4. N’utilisez JAMAIS des bouteilles de gaz comprimé sans un régulateur de pression en série sur la vanne de bouteille.

5. Inspectez la vanne de bouteille pour y détecter de l’huile ou de la graisse, ou dès pièces endommagées.

AVERTISSEMENT

N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces endommagées. Informez immédiate ment votre fournisseur de’ gaz de cet état.

6. Ouvrez et fermez momentanément la vanne de la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui pour raient être présentes dans la vanne.

MISE EN GARDE

Ouvrez la vanne de bouteille légèrement. Si vous l’ouvrez trop en grand, la bouteille pourrait se renverser. Quand vous ouvrez/ fermez rapidement la vanne de bouteille, ne vous tenez pas directement devant. Opérez toujours cette opération dans une zone bien ventilée. Si une bouteille d’acé

tylène crache un brouillard, laissez reposer pendant 15 minutes. Essayez de nouveau la vanne. Si le problème persiste, con tactez votre fournisseur de gaz.

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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. National Electrical Code, norme 70 NFPA, National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA

22202. Code for Safety in Welding and Cutting, norme CSA

W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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Soudage á L’arc Avec Electrode Non Fusible (GTAW)

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Haute Température

Force d’Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Tension dangereuse

Hors Tension

SousTension

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

Soudage á L’arc Avec Fil Electrodes Fusible (GMAW)

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Distant

Facteur de Marche

Pourcentage

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de PriseSource Auxiliaire

Art # A-07639F_AC

115V 15A

IPM

MPM

Fusible

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Durée de Pré-Dèbit

Durée de Post-Dèbit

Duréc du Pulse

Soudure Par Point

Appuyez pour démarrer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Purge Du Gaz

Mode Continu de Soudure

Pouces Par Minute

Mètres Par Minute

Torche de Soudage

Probléme de Terre

Maintenez appuyez pour pré-dèbit, relailez pour initier l’arc. Appuyez pour arrêter l’arc, et mainteuir pour pré-dèbit.

Détente à 4-Temps

Détente à 2-Temps

Voir Note

Avis : Pour les environnements avec des risques de choc électrique, le fournisseur d’énergie portant la marque conforme à EN50192 lorsqu’utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à l’hauteur de buse correctement installé. Ne pas déposer avec les déchets ménagers.

Indication d’erreur

1.09 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

FIREPOWER MST 220i

SAFETY INSTRUCTIONS AND WARNINGS 1-18 Manual 0-5343

This Page Intentionally Blank

FIREPOWER MST 220i

Manual 0-5343 2-1 INTRODUCTION

SECTION 2: INTRODUCTION

2.03 Receipt Of Equipment

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. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identiﬁcation numbers as described above along with a full description of the parts in error.

2.04 Description

The Firepower MST 220i is a self contained single phase multi process welding system that is capable of performing MIG (GMAW/FCAW), STICK (SMAW) and LIFT TIG (GTAW) welding processes. The Power Source is equipped with an integrated wire feed unit, digital voltage and amperage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional. The Power Source is also fully compliant to Standard CSA E60974-1, UL 60974-1.

The Firepower MST 220i provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures. The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efﬁciency and quality from the Power Source. Please read these instructions thoroughly before using the unit.

2.01 How To Use This Manual

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

Gives information regarding possible electrical shock injury. Warnings will be enclosed in a box such as this.

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concern

ing certain operating procedures.

You will also notice icons from the safety section appearing throughout the manual. These are to advise you of speciﬁc types of hazards or cautions related to the portion of information that follows. Some may have multiple hazards that apply and would look something like this:

2.02 Equipment Identiﬁcation

The unit’s identiﬁcation number (speciﬁcation or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identiﬁed only by the speciﬁcation or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

FIREPOWER MST 220i

INTRODUCTION 2-2 Manual 0-5343

2.05 Transportation Methods

WARNING

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.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift Power Source with handles built into the top of the front and rear molded panels.

Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place and secure Power

Source on a proper skid before transporting.

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. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualiﬁed persons approved by Firepower. Advice in this regard can be obtained by contacting an Accredited Firepower Distributor.

This equipment or any of its parts should not be altered from standard speciﬁcation without prior written approval of Firepower. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modiﬁcation from standard speciﬁcation, faulty maintenance, damage or improper repair by anyone other than appropriately qualiﬁed persons approved by Firepower.

2.07 Firepower MST 220i Portable System

Package (Part No. 1444-0872)

• Firepower MST 220i Power Source

• Firepower Fusion 12' Mig Gun Euro

• Firepower regulator

• Electrode Holder with 13ft (4m)-20mm

lead

• Work Clamp with 10ft (3.1m)-20mm

lead

• Shielding Gas hose assembly

• 20 to 15A power cord adapter

• Drive Rolls:

.030"/.035" (0.8/0.9mm) V knurled groove/ﬂux cored

• MST Contact Tips (1 each)

.023"(0.6 mm) .030"(0.8 mm) .035"(0.9 mm) (ﬁtted)

• Spring for 8" spools

• Operating Manual

• DVD

Art # A-12523

Figure 2-1: Firepower MST 220i System Packaged 1444-0872

FIREPOWER MST 220i

Manual 0-5343 2-3 INTRODUCTION

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. This means that it has been designed and built to provide the rated amperage (210A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes is 2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

FIREPOWER MST 220i

Welding Current (AMPS)

SAFE OPERATING REGION

(MIG, TIG & STICK)

100

Duty Cycle (PERCENTAGE)

MIG

STICK / TIG

Art # A-12524

Figure 2-2: Firepower MST 220i Duty Cycle on 208/230VAC

Welding Current (AMPS)

Duty Cycle (PERCENTAGE)

Art # A-12525

100

0102030405060708090100 110 120 130140 150

FIREPOWER MST 220i

SAFE OPERATING REGION

(MIG, TIG & STICK)

TIG

STICK

MIG

Figure 2-3: Firepower MST 220i Duty Cycle on 115V AC

FIREPOWER MST 220i

INTRODUCTION 2-4 Manual 0-5343

2.09 Speciﬁcations

Description Firepower MST 220i Multi Process 3 in 1 Welder

Power Source Part No. 1444-0872 Power Source Dimensions H17.12” x W10.47” x D 24.29” (435mm x 266mm x D617mm) Power Source Mass 57.3lb (26.5kg) Cooling Fan Cooled Welder Type Multi Process Welding System Applicable Standard CSA E60974-1-00 / UL60974-1 Number of Phases Single Phase Nominal Supply Voltage 208/230 VAC ± 15% 115VAC± 15% Nominal Supply Frequency 50/60Hz 50/60HZ Welding Current Range

MIG Mode STICK Mode TIG Mode

10-210 Amps 10-200 Amps 10-200 Amps

10-140 Amps 10-110 Amps 10-150 Amps

Wirefeed Speed Range 100 - 600 IPM 100 - 400 IPM MIG Welding Voltage Range 14.5 - 24.5V DC 14.5 - 19.5V DC Nominal OCV 70V DC Single Phase Generator Requirement 7.5 kVA *3.7 kVA

MIG (GMAW/FCAW) Welding Output, 104°F, 10 min. 210A @ 20%,24.5V

122A @ 60%, 20.1V 95A @ 100%, 18.8V

110A @ 45%,19.5V

99A @ 60%, 19.0V

77A @ 100%, 17.9V

STICK (SMAW) Welding Output,1040°F, 10 min. 200A @ 25%,28.0V

130A @ 60%, 25.2V

101A @ 100%, 24.0V

110A @ 35%,24.4V

90A @ 60%, 23.6V

70A @ 100%, 22.8V

TIG (GTAW) Welding Output, 104°F, 10 min. 200A @ 25%,18.0V

130A @ 60%, 15.2V

101A @ 100%, 14.0V

150A @ 35%,16.0V 115A @ 60%, 14.6V 90A @ 100%, 13.6V

230 VAC ± 15% 208 VAC ± 15% 115 VAC ± 15%

Effective Input Current (I1

eff

)

for MIG (GMAW/FCAW) for STICK (SMAW)

for LIFT TIG (GTAW)

11.2A

15.8A

11.5A

14.4A

16.8A

11.7A

15.5A

17.8A

17.4A

Maximum Input Current (I1

max

) for MIG (GMAW/FCAW) for STICK (SMAW)

for LIFT TIG (GTAW)

25.0A

31.6A

22.9A

32.2A

33.6A

23.3A

24.5A

30.1A

29.4A Open Circuit Voltage 70 V Protection Class IP23S

Table 2-1: Firepower MST 220i Speciﬁcations

Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements. Note 2: Motor start fuses or thermal circuit breakers are recommended for this application. Check local re-

quirements for your situation in this regard. Note 3: Generator Requirements at the Maximum Output Duty Cycle. * Some 115 VAC, 15 amp/20 amps electrical outlets ﬁtted with GFCI (Ground Fault Circuit Interrupt) protection

against a nuisance trip with this equipment due to worn or out of tolerance components in the GFCI. In such cases have the 115 VAC, 15 amp/20 amp FGCI electrical outlet replaced by a qualiﬁed electrical trades person.

FIREPOWER MST 220i

Manual 0-5343 2-5 INTRODUCTION

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. Fuse size is based on not more than 200 percent of the rated input amperage of the welding Power Source (Based on Article 630, National Electrical Code)

Firepower continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the speciﬁcations or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the cor

responding changes, updates, improvements or replacement of such items

The values speciﬁed in the table above are optimal values, your values may differ. Individual equipment may differ from the above speciﬁcations due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation and conditions and local power grid supply conditions.

2.10 Optional Accessories

DESCRIPTION PART NUMBER

TIG Torch, 26V, 12.5 ft, 25mm & Accessory Kit 1444-0021 Firepower Spool Gun, 160A, Euro Back End

1444-0894

Firepower Fusion 220A MIG Gun, 12 ft, Euro Back End

1442-0882

Basic Utility Cart

1444-0900

Single Cylinder Cart

1444-0901

Roll Cage

1442-0902

Foot Control, 15 ft, 8 Pin, for remote amperage control when TIG welding

1442-0025

Drive Roll .023"/.035" (0.6/0.9mm) V groove/solid wire

1444-0913

Drive Roll .023"/.030" (0.6/0.8mm) V groove/solid wire

1444-0914

Drive Roll .030"/.035" (0.8/0.9mm) V knurled groove/ﬂux cored [Fitted]

1444-0915

Ground Clamp & Lead Assembly, 6 ft, 25mm

1443-0495

Electrode Holder & Lead Assembly, 13 ft, 50mm

1443-0494

Firepower GF250-50-580 Argon Flowgauge Regulator

0781-9832

Power Adapter - 230V to 115V, 15A

1444-0911

Spring Adaptor for 8" spools

1444-0912

Gas Hose, 6 ft, Male 5/8-18UNF one end [Fitted]

1443-0490

Firepower Parts Storage Box

1421-0098

Table 2-2: Firepower MST 220i Options and Accessories List

FIREPOWER MST 220i

INTRODUCTION 2-6 Manual 0-5343

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.

Art # A-11297

Figure 2-4: Firepower MST 220i Volt-Ampere Curves

FIREPOWER MST 220i

Manual 0-5343 3-1 INSTALLATION/SETUP

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.

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. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator.

3. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.02 Location

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust. B. Ambient temperature between 14° F (0° C) to 104°

F (40° C). C. In areas, free from oil, steam and corrosive gases. D. In areas, not subjected to abnormal vibration or

shock. E. In areas, not exposed to direct sunlight or rain.

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.

G. The enclosure design of this Power Source meets the

requirements of IP23S as outlined in EN 60529. This provides adequate protection against solid objects (greater than 1/2", 12mm) and direct protection from vertical drops. Under no circumstances should the Power Source be operated or connected in a micro environment that will exceed the stated conditions. For further information please refer to EN 60529.

H. Precautions must be taken against the power source

toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

WARNING

This equipment should be electrically con

nected by a qualiﬁed electrician.

3.03 Ventilation

WARNING

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

3.04 Electricity Supply

The Electricity Supply voltage should be within 208/230V AC ± 15% or 115 V AC ± 15%. Too low a supply voltage may cause poor welding performance in STICK mode such as the arc snufﬁng out during welding. Too high a supply voltage will cause components to overheat and possibly fail. The Welding power Source must be:

• Correctly installed, if necessary, by a qualied electrician.

• Correctly earthed (electrically) in accordance with

local regulations.

• Connected to the correct size power point and fuse as

per the Speciﬁcations on page 2-4.

FIREPOWER MST 220i

INSTALLATION/SETUP 3-2 Manual 0-5343

WARNING

The Firepower MST 220i must be electrically connected by a qualiﬁed electrical trades-person. Dam

age 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. Lock-out/

tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting OFF and red-tagging circuit breaker or other disconnecting device.

Power Cords Included With Power Supply

Attached to the power supply is an input power cord with a 208/230Volt 50 Amp NEMA 6-50 P for plug. Supplied adapter allow for connection of the power supply input cable plug to 115 V input power.

Art# A-11275

Figure 3-1: 115 VAC Adapter

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. The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit. The Welding Power Source must be:

Do not connect in input (WHITE or BLACK) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal.

• Correctly installed, if necessary, by a qualied electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point, fuse and primary supply lead based on Table 3-1.

Refer to Figure 3-1 and Table 3-1.

FIREPOWER MST 220i

Manual 0-5343 3-3 INSTALLATION/SETUP

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.

50 / 60 Hz Single Phase Supply

Supply Voltage 208/230V AC 115V AC Input Current at Maximum Output 32 Amps 30 Amps Maximum Recommended Fuse* or Circuit Breaker Rating

* Time Delay Fuse, UL class RK5. Refer to UL248

50 Amps 30 Amps

Maximum Recommended Fuse^ or Circuit Breaker Rating ^Normal Operating, UL class K5. Refer to UL248

50 Amps 30 Amps

Minimum Recommended Cord Size 12 AWG 12 AWG Maximum Recommended Extension Cord Length 50 ft 25 ft Minimum Recommended Grounding Conductor Size 12 AWG 12AWG

Table 3-1: Electrical Service Guide

CAUTION

The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.

Art# A-11240

Primary Power Cable

115

115V,V,

20A,1Ø

15A,1Ø

208/230V, 50A,1Ø

The Adapter enable connection to all these power outlets

115 VAC Adapter

Figure 3-2: Electrical Input Connections

FIREPOWER MST 220i

INSTALLATION/SETUP 3-4 Manual 0-5343

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. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input ﬁlters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer Troublesome.

NOTE

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

B. Assessment of Area

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account.

1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pace-makers and hearing aids.

6. Equipment used for calibration and measurement.

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.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emissions

1. Electricity Supply

Welding equipment should be connected to the Electricity Supply according to the manufacturer’s

recommendations. If interference occurs, it may be necessary to take additional precautions such as ﬁltering of the Electricity Supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

FIREPOWER MST 220i

Manual 0-5343 3-5 INSTALLATION/SETUP

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. Welding Cables The welding cables should be kept as short as possible and should be positioned close together but never

coiled and running at or close to the ﬂoor level.

4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However,

metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing/grounding of the Work Piece Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and

position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems

of interference. Screening the entire welding installation may be considered for special applications.

3.06 Firepower Regulator

Pressure regulator (Figure 3-3) attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for welding, cutting, and other applications.

LOW PRESSURE GAUGE (DELIVERY)

HIGH PRESSURE GAUGE (SUPPLY)

INLET

CONNECTION

OUTLET

CONNECTION

PRESSURE

ADJUSTING

SCREW

A-12435

Figure 3-3: Firepower Regulator

WARNING

Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator for use with any other gas.

FIREPOWER MST 220i

INSTALLATION/SETUP 3-6 Manual 0-5343

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. Wrap pipe threads with Teﬂon tape 1 1/2 to 2 turns to effect a seal. If other sealants are used, they must be compatible with the gas that will be used in the system.

4. If gauges are to be attached to the regulator and the regu lator is stamped and listed by a third party (i.e. “UL” or “ETL”). The following requirements must be met:

a) Inlet gauges over 1000 PSIG (6.87 mPa) shall conform with the requirements of UL 404, “Indicating

Pressure Gauges for Compressed Gas Service.”

b) Low pressure gauges must be UL recognized for the class of regulator they are being used on accord-

ing to UL252A.

WARNING

DO NOT use a regulator that delivers pressure exceeding the pressure rating of the downstream equip

ment unless pro visions are made to prevent over-pressurization (i.e. system relief valve). Make sure the pressure rating of the down stream equipment is compatible with the maximum delivery pressure of the regulator.

5. Be sure that the regulator has the correct pressure rating and gas service for the cylinder used.

6. Carefully inspect the regulator for damaged threads, dirt, dust, grease, oil, or other ﬂammable substances. Remove dust and dirt with a clean cloth. Be sure the inlet swivel ﬁlter is clean and in place. Attach the regulator (Figure 3-4) to the cylinder valve. Tighten securely with a wrench.

WARNING

DO NOT attach or use the regulator if oil, grease, ﬂamma ble substances or damage is present! Have a qualiﬁed repair technician clean the regulator or repair any damage.

Art # A-12436

Figure 3-4: Regulator to Cylinder Valve

FIREPOWER MST 220i

Manual 0-5343 3-7 INSTALLATION/SETUP

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 pres sures. Relief valves are not intended to protect down stream equipment from high pressures.

WARNING

DO NOT tamper with the relief valve or remove it from the regulator.

WARNING

Stand to the side of the cylinder opposite the regulator when opening the cylinder valve. Keep the cyl

inder valve between you and the regulator. For your safety, NEVER STAND IN FRONT OF OR BEHIND A REGULATOR WHEN OPENING THE CYLINDER VALVE!

9. Slowly and carefully open the cylinder valve (Figure 3-5) until the maximum pressure shows on the high pressure gauge.

Art # A-09828

Figure 3-5: Open Cylinder Valve

10. On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gaugeless regulators, the indicator will register the cylinder contents open.

11. On acetylene cylinders, open the valve 3/4 of a turn and no more than 1-1/2.

WARNING

Acetylene delivery pressure must not exceed 15 PSIG (103 kPa) or 30 PSIG (207 kPa). Acetylene can dissociate (decompose with explosive violence) above these pressure limits.

CAUTION

Keep the cylinder valve wrench, if one is required, on the cylinder valve to turn OFF the cylinder quickly, if necessary.

12. Attach the desired downstream equipment.

FIREPOWER MST 220i

INSTALLATION/SETUP 3-8 Manual 0-5343

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 high-

pressure gauge.

b) If the low-pressure gauge drops, there is a leak in the down stream equipment, hose, hose ﬁtting, outlet

ﬁtting or low-pressure gauge. Check for leaks using an approved leak detector solution.

c) If the high-pressure gauge drops and the low-pressure gauge increases at the same time, there is a

leak in the regulator seat.

d) If the regulator requires service or repair, take it to a qualiﬁed repair technician.

5. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve and proceed.

WARNING

If a leak has been detected anywhere in the system, dis continue use and have the system repaired. DO NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under pressure.

3.08 When You Finish Using The Regulator

1. Close the cylinder valve.

2. Open the valve on the downstream equipment. This drains all pressure from the system.

3. Close the valve on the downstream equipment.

4. Turn the adjusting screw counterclockwise to release the ten sion on the adjusting spring.

5. Check the gauges after a few minutes for veriﬁcation that the cylinder valve is closed completely.

3.09 Storage Of The Regulator

When the regulator is not in use and has been removed from the cylinder, it should be stored in an area where it will be pro tected from dust, oil, and grease. The inlet and outlet should be capped to protect against internal contamination and prevent insects from nesting.

FIREPOWER MST 220i

Manual 0-5343 3-9 INSTALLATION/SETUP

3.10 Firepower MST 220i Power Source Controls, Indicators And Features

Art # A-12526

SOFT

HARD

E(S)

Figure 3-6: Front and Control Panel Figure 3-7: Rear Panel Connections

Art # A-10938

Figure 3-8: Wire Feed Compartment Control

FIREPOWER MST 220i

INSTALLATION/SETUP 3-10 Manual 0-5343

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. Once the power source cools down this light will go OFF and the over temperature condition will automatically reset. Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufﬁciently. Do not switch the unit OFF should a thermal overload condition be present.

3. Digital Wirespeed/Amperage Meter (Left Digital Display)

MIG Mode This digital meter is used to display the pre-set (preview) Wirefeed Speed in IPM (Inches per minute) in MIG

mode and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Amperage Control Knob (4).

STICK and LIFT TIG Modes The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual

welding amperage of the power source when welding. At times of non-welding, the amperage meter will display a pre-set (preview) value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Amperage Control Knob (4).

When welding, this digital meter will display actual welding amperage in all modes. At the completion of welding, the digital meter will hold the last recorded amperage value for a period of

approximately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some dif

ferences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.

3A Wirespeed Indicator

The Wirespeed Indicator illuminates when MIG mode is selected to identify that the Digital Wirespeed/Amperage Meter is previewing Wirespeed in IPM (inches per minute).

The Wirespeed Indicator extinguishes when the user is MIG (GMAW/FCAW) welding or depressing the MIG gun trigger and the Digital Wirespeed/Amperage Meter displays actual welding amperage of the power source.

FIREPOWER MST 220i

Manual 0-5343 3-11 INSTALLATION/SETUP

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.

In STICK and LIFT TIG modes, the Wirespeed/Amperage control knob adjusts the amount of amperage (weld current) delivered to the welding arc by the Power Source. It directly adjusts the Power Source to deliver the desired level of weld current.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some dif

5. MIG Torch Adaptor (Euro Style)

The MIG torch adaptor is the connection point for the MIG welding torch. Connect the torch by pushing the torch connector into the brass torch adaptor ﬁrmly and screwing the plastic torch nut clockwise to secure in position. To remove the MIG Torch simply reverse these directions.

6. 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 polarity lead), electrode holder lead or work lead. Positive welding current ﬂows from 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.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the dinse terminal.

7. MIG Polarity Lead

The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal (allowing polarity reversal for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire. When using gasless wire, the polarity lead is generally connected to the negative welding terminal (-). If in doubt, consult the manufacturer of the electrode wire for the correct polarity. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the dinse terminal.

FIREPOWER MST 220i

INSTALLATION/SETUP 3-12 Manual 0-5343

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.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the dinse terminal.

9. Remote Control Socket

The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Trigger Switch

Remote Wirespeed in MIG (GMAW/FCAW) mode

Remote Amps in LIFT TIG (GTAW) mode

Remote Volts in MIG (GMAW/FCAW)

1 2

3 4

5 6

7 8

Negative

Spool Gun Motor

Positive

Art # A-10421_AC

Figure 3-9: Remote Control Socket

Socket Pin

Function

1 Spool Gun Motor Negative 2

Trigger Switch Input

Spool Gun Motor (+24V DC)

5k ohm (maximum) connection to 5k ohm remote control potentiometer.

Zero ohm (minimum) connection to 5k ohm remote control potentiometer.

Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer.

Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.

Table 3- 2

Note that the local/ remote switch (item 18) located in the wirefeed compartment should be set to remote for the amperage/voltage controls to be operative.

10. 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. Some dif

FIREPOWER MST 220i

Manual 0-5343 3-13 INSTALLATION/SETUP

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.

When STICK Mode is Selected

In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneﬁcial in providing the operator the ability to compensate for variability in joint ﬁt-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be achieved. Arc force is increased by turning the control knob clockwise or decreased by turning the knob anti-clockwise

When LIFT TIG Mode is Selected

In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down time at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool is given time to cool sufﬁciently.

Note that when in 2T normal mode (refer item 12), the unit will enter down slope mode as soon as the trigger switch is released (ie if the multifunction control knob is set to 5, the unit will ramp down from the present welding current to zero over 5 seconds). If no down slope time is selected then the welding output will cease immediately. If the unit is set to 4T latch mode, to enter down slope mode the trigger must be held in for the selected time period (ie press and release trigger to commence welding, then press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope phase (4T only), the output will cease immediately.

11. 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.

12. Trigger Mode Control (MIG and LIFT TIG Mode only)

The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal) and 4T (latch mode)

2T (Normal Mode)

In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.

4T (Latch Mode)

This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and released, thus eliminating the need for the operator to hold the torch trigger.

Note that when operating in LIFT TIG mode, the power source will remain activated until the selected downslope time has elapsed (refer Item 10).

FIREPOWER MST 220i

INSTALLATION/SETUP 3-14 Manual 0-5343

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. This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up.

14. Digital Voltage Meter (Right Digital Display)

MIG Mode This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage

of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This value can be adjusted by varying the Multifunction Control Knob (10).

STICK and LIFT TIG Modes This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during

non-welding or welding. This value cannot be adjusted by varying the Multifunction Control Knob (10). When welding, this digital meter will display actual welding voltage in all modes.

At the completion of welding, the digital meter will hold the last recorded voltage value for a period of approximately 10 seconds in all modes. The voltage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some dif

15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation)

The Gas Inlet connection,5/8-18 UNF female thread is used to supply the appropriate MIG welding gas to the Power Source. Refer to section 3.18 or 3.19 for MIG (GMAW/FCAW) set up details

WARNING

Only Inert Shielding Gases speciﬁcally designed for welding applications should be used.

16. ON / OFF Switch

This Single Phase circuit breaker performs a dual function. It is used to turn the unit ON/OFF and it will also trip in the event of a fault.

WARNING

When the front digital displays are lit, the machine is connected to the Electricity Supply and the internal electrical components are at Mains voltage potential.

FIREPOWER MST 220i

Manual 0-5343 3-15 INSTALLATION/SETUP

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. Local / Remote Switch (located in wirefeed compartment)

The local/ remote switch is used only when a remote control device (such as a TIG torch with remote current control) is ﬁtted to the unit via the remote control socket (item 9). When the local/ remote switch is in the remote position, the unit will detect a remote device and work accordingly. When in the local mode, the unit will not detect the remote device and will operate from the power source controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local/ remote switch (ie in both local and remote modes).

Should a remote device be connected and the local/ remote switch set to remote, the maximum setting of the power source will be determined by the respective front panel control, irrespective of the remote control device setting. As an example, if the output current on the power source front panel is set to 50% and the remote control device is set to 100%, the maximum achievable output from the unit will be 50%. Should 100% output be required, the respective front panel control must be set to 100%, in which case the remote device will then be able to control between 0-100% output.

19. Burnback Control (located in wirefeed compartment)

The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG gun after the completion of MIG welding (commonly referred to as stick out). To decrease the burnback time (or lengthen the amount of wire protruding from the MIG gun at the completing of welding), turn the burnback control knob anti-clockwise. To increase the burnback time (or shorten the amount of wire protruding from the torch at the completing of welding), turn the Burnback Control knob clockwise.

20. MIG Gun & Spool Gun Switch

The MIG Gun / Spool Gun switch is used to switch welding mode between MIG Gun functionality and Spool Gun functionality

21. Cooling Fan

The Firepower MST 220i is designed with an intelligent fan control. When the 220i is switched ON the cooling fan will come ON for approximately 3 seconds then automatically switch the fan OFF. The cooling fan will remain OFF until it is required for cooling purposes. 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 in STICK mode the fan operates continuously.

FIREPOWER MST 220i

INSTALLATION/SETUP 3-16 Manual 0-5343

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.

Art # A-12527

MIG Torch Adaptor

MIG Torch Connector

Figure 3-10: Attaching MIG Gun

FIREPOWER MST 220i

Manual 0-5343 3-17 INSTALLATION/SETUP

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. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool.

3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.

NOTE

The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to Sec

tion 3.18

CAUTION

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire ﬁrmly and don’t let go of it.

Wire Spool Hub Nut

Spring

33/44 lb (12") Wire Spool

Retaining Clip Use inner holes on Spool Hub

Flat Washer Small Hole

Fiber Washer

Spool Hub

Keyed Washer

Flat Washer Large Hole

Art # A-12528

Figure 3-11: 33/44 lb (12") Spool Installation

FIREPOWER MST 220i

INSTALLATION/SETUP 3-18 Manual 0-5343

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.

3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.

NOTE

The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to sec

tion 3.18.

CAUTION

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire ﬁrmly and don’t let go of it.

Wire Spool Hub Nut

Spring

12.5 lb (8") Wire Spool

Retaining Clip Use inner holes on Spool Hub

Flat Washer Small Hole

Fiber Washer

Spool Hub

Keyed Washer

Flat Washer Large Hole

Art # A-12529

Figure 3-12: 12.5lb (8") Spool Installation

FIREPOWER MST 220i

Manual 0-5343 3-19 INSTALLATION/SETUP

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. Then place Flat Washer Large Hole, Keyed Washer, Spring, Flat Washer Small Hole as shown in Figure 3-13. Finally secure with Wire Spool Hub Nut.

NOTE

The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to sec

tion 3.18.

CAUTION

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire ﬁrmly and don’t let go of it.

Fiber Washer

Art # A-12530

Wire Spool Hub Nut

Spring

1lb (4") Diameter Wire Spool

Flat Washer Small Hole

Keyed Washer

Flat Washer Large Hole

Large Spring

Figure 3-13: 1 lb (4") Spool Installation

FIREPOWER MST 220i

INSTALLATION/SETUP 3-20 Manual 0-5343

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). With the MIG welding wire feeding from the bottom of the spool (Figure 3-15) pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the MIG gun. Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly (Figure 3-14). Remove the contact tip from the MIG gun. With the MIG gun lead reasonably straight, feed the wire through the MIG gun by depressing the trigger switch. Fit the appropriate Velocity contact tip.

WARNING

Before connecting the work clamp to the work make sure the Electricity Supply is switched OFF. The electrode wire will be at welding voltage potential while it is being feed through the system. Keep MIG gun away from eyes and face.

Wire Drive Tension Knob

Pressure Arm

Outlet Guide

Inlet Guide

Art # A-12531

Figure 3-14: Wire Drive Assembly Components

MIG Welding Wire

Art # A-12532

Figure 3-15: MIG Welding Wire - Installation

FIREPOWER MST 220i

Manual 0-5343 3-21 INSTALLATION/SETUP

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. If it is not the cause of slipping, the feed roll pressure can be increased by rotating the pressure screw clockwise.

WARNING

Before changing the feed roller ensure that the Electricity Supply to the power source is switched OFF.

CAUTION

The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.

3.17 Changing the Feed Roll

To change feed roll remove the feed roll retaining screw by turning in an anti-clockwise direction. Once the feed roll is removed then to replace feed roll simply reverse these directions. Note: Be sure not to lose key that is located on Drive Motor Shaft. This key must align with drive roll groove for proper operation.

A dual groove feed roller is supplied as standard. It can accommodate 0.6/0.8mm diameter hard wires. Select the roller required with the chosen wire size marking facing outward.

GROOVE “B”GROOVE “A”

GROOVE “A” SIZE

GROOVE “B” SIZE

A-09583

Figure 3-16: Dual Groove Feed Roller

Feed Roll Retaining Screw

Art # A-12533

Figure 3-17: Changing the Feed Roll

FIREPOWER MST 220i

INSTALLATION/SETUP 3-22 Manual 0-5343

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.

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip.

Spool Hub Tension Thumb Screw

Art # A-12534

Figure 3-18: Wire Reel Brake

3.19 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 polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manu-

facturer. Welding current ﬂows from the Power Source via dinse type terminals. It is essential, however, that

the male plug is inserted and turned securely to achieve a sound electrical connection. C. Fit the MIG gun to the power source. (Refer to section 3.11 Attaching the Firepower Fusion 220A MIG Gun). D. Connect the work 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. E. Fit the welding grade shielding gas regulator/ﬂowmeter to the shielding gas cylinder (refer to Section 3.06)

then connect the shielding gas hose from the rear of the power source to the regulator/ﬂowmeter outlet. F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information. G. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the

Power Sources Wirespeed and Voltage controls. H. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

FIREPOWER MST 220i

Manual 0-5343 3-23 INSTALLATION/SETUP

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 sta

tionary 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. Do not block the air vents at the front or rear of the Weld

ing Power Source.

Positive Welding Terminal (+)

MIG Polarity Lead

Work Lead

Negative Welding Terminal (-)

Art # A-12535

Shielding Gas Hose Fitted with Quick Connect

MIG Gun

Figure 3-19: Setup for MIG Welding with Gas Shielded MIG Wire

FIREPOWER MST 220i

INSTALLATION/SETUP 3-24 Manual 0-5343

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. Connect the work lead to the positive 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. D. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information. E. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the

Power Sources Wirespeed and Voltage controls.

F. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

WARNING

Before connecting the work clamp to the work make sure the Electricity Supply is switched OFF.

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. Do not block the air vents at the front or rear of the Weld

ing Power Source.

Work Lead

Positive Welding Terminal (+)

Negative Welding Terminal (-)

MIG Polarity Lead

Art # A-12536

MIG Gun

Figure 3-20: Setup for MIG Welding with Gasless MIG Wire

FIREPOWER MST 220i

Manual 0-5343 3-25 INSTALLATION/SETUP

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. Make sure the welding power source is turned OFF before connecting the welding gun.

NOTE

If the Firepower MST 220 has already been setup for MIG Welding you will have to re

move the MIG Gun and retract the welding wire out of the wirefeeder before beginning the next step.

2. Insert the back end of the Spool gun into the MIG Gun connector and tighten the Locking Nut to secure the Spool gun in the MIG Gun Adapter.

3. Connect gas supply ﬁtting and tighten with a wrench.

4. Align Control Plug to panel ﬁtting and tighten securely.

MIG Gun Adaptor

Spool Gun Locking Nut

Art #

A-12537

FIREPOWER MST 220i

INSTALLATION/SETUP 3-26 Manual 0-5343

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 (+). 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.

D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown

below. The TIG torch will require a trigger switch to operate in LIFT TIG Mode.

NOTE

A 26V TIG torch with an 8 pin plug must be used to turn the weld current ON/OFF via the TIG torch trigger switch to TIG weld OR a Foot Control with an 8 pin plug must be used to turn the weld current ON/OFF as well as providing remote control of the weld current.

E. Fit the welding grade shielding gas regulator/ﬂowmeter to the shielding gas cylinder (refer to Section 3.06)

then connect the shielding gas hose from the TIG torch to the regulator/ﬂowmeter outlet. Note that the TIG torch shielding gas hose is connected directly to the regulator/ﬂowmeter. The power source is not ﬁtted with a shielding gas solenoid to control the gas ﬂow in LIFT TIG mode therefore the TIG torch will require a gas valve.

WARNING

Before connecting the work clamp to the work and inserting the electrode in the TIG Torch make sure the Electricity Supply is switched OFF.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Weld

ing Power Source. Loose welding terminal connections can cause overheating and result in the male plug being fused in

the terminal.

F. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the Power Sources Amperage control or REMOTE for remote amperage using a Foot Control.

FIREPOWER MST 220i

Manual 0-5343 3-27 INSTALLATION/SETUP

Positive Welding Terminal (+)

Negative Welding Terminal (-)

Work Lead

TIG Torch

TIG Remote Control

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.

Note: A 26V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current.

Figure 3-22: Setup for TIG Welding

FIREPOWER MST 220i

INSTALLATION/SETUP 3-28 Manual 0-5343

3.23 Setup For STICK (SMAW) Welding

A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manu-

facturer. Welding current ﬂows from the Power Source via dinse type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the work lead to the negative 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.

C. Select STICK mode with the process selection control (refer to Section 3.10 for further information).

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Electricity Supply is switched OFF.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

D. Switch the LOCAL/REMOTE switch inside the wire

feed compartment to LOCAL to use the Power Sources Amperage control or REMOTE for remote amperage control using a Hand Pendant Control.

Positive Welding Terminal (+)

Negative Welding Terminal (-)

Work Lead

Electrode Holder

Art # A-12539

Figure 3-23: Setup for Manual Arc Welding

FIREPOWER MST 220i

Manual 0-5343 4-1 BASIC WELDING

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 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.

GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO

welding, Micro Wire Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid continuous, consumable electrode and the work. Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture. The process is normally applied semi automatically; however the process may be operated automatically and can be machine operated. The process can be used to weld thin and fairly thick steels, and some non-ferrous metals in all positions.

Art # A-8991_AB

Shielding Gas

Molten Weld Metal

Solidiﬁed Weld Metal

Nozzle

Electrode

Arc

Base Metal

GMAW Process

Figure 4-1

FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a continuous ﬂux ﬁlled electrode wire and the work. Shielding is obtained through decomposition of the ﬂux within the tubular wire. Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. The process is normally applied semi automatically; however the process may be applied automatically or by machine. It is commonly used to weld large diameter electrodes in the ﬂat and horizontal position and small electrode diameters in all positions. The process is used to a lesser degree for welding stainless steel and for overlay work.

Art # A-08992_AB

Molten Slag

Nozzle (Optional)

FCAW Process

Flux Cored Electrode

Arc

Shielding Gas

(Optional)

Slag

Molten Metal

Base Metal

Solidiﬁed Weld Metal

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. (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 MIG Gun back when the arc is established. This will create excessive wire extension (stick-out) and make a very poor weld.

The electrode wire is not energized until the MIG Gun trigger switch is depressed. The wire may therefore be placed on the seam or joint prior to lowering the helmet.

Direction of

Travel

5° to 15°

Longitudinal

Angle

90°

Transverse

Angle

Art # A-08993

Figure 4-4

FIREPOWER MST 220i

BASIC WELDING 4-2 Manual 0-5343

Direction of

Travel

5° to 15°

Longitudinal Angle

30° to 60°

Transverse Angle

Art # A-08994

Figure 4-5

Vertical Fillet Welds

Art # A-08995

30° to 60° Transverse

Angle

30° to 60°

Transverse

Angle

Direction of Travel

10°

Longitudinal Angle

10° to 20° Longitudinal

Angle

Figure 4-6

Art # A-08996

30° to 60°

Transverse Angle

Direction of Travel

5° to 15° Longitudinal Angle

Figure 4-7

Distance from the MIG Gun Nozzle to the Work

Piece

The electrode wire stick out from the MIG Gun nozzle should be between 3/8" - 3/4" (10 - 20 mm). This distance may vary depending on the type of joint that is being welded.

Travel Speed

The speed at which the molten pool travels inﬂuences the width of the weld and penetration of the welding run.

MIG Welding (GMAW) Variables

Most of the welding done by all processes is on carbon steel. The items below describe the welding variables in short-arc welding of .023 - 1/4" (0.6 mm - 6.4 mm) mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.

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 for FCAW self shielding

wires)

• Gas ﬂow rate (not applicable for FCAW self shielding wires)

Primary Adjustable Variables

These control the process after preselected variables have been found. They control the penetration, bead width, bead height, arc stability, deposition rate and weld soundness. They are:

• Arc Voltage

• Welding current (wire feed speed)

• Travel speed

Secondary Adjustable Variables

These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are:

1. Sick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 3/8" (10 mm) stick-out

2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed decreases weld current.

Art # A-08997_AD

Gas Nozzle

Electrode Wire

Average Arc Length

Electrode Stick-Out

Tip to

Work Distance

Actual Stick-out

Contact Tip (Tube)

Figure 4-8

3. Nozzle Angle. This refers to the position of the MIG Gun in relation to the joint. The transverse angle is usually one half the included angle between plates forming the joint. The longitudinal angle is the angle between the centre line of the MIG Gun and a line perpendicular to the axis of the weld. The longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading (pushing). Whether the operator is left handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel.

FIREPOWER MST 220i

Manual 0-5343 4-3 BASIC WELDING

Transverse and Longitudinal Nozzle Axes

Art # A-08998_AB

Longitudinal Angle

Axis of Weld

Transverse

Angle

Figure 4-9

Art # A-08999_AC

Nozzle Angle, Right Handed Operator

Direction of Gun Travel

Leading or “Pushing”

Angle

(Forward Pointing)

Trailing or “Pulling”

Angle

(Backward Pointing)

90°

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.

The easiest welding procedure for the beginner to experiment with MIG welding is the ﬂat position. The equipment is capable of ﬂat, vertical and overhead positions.

For practicing MIG welding, secure some pieces of 1/16" or 3/16" (1.6 mm or 5.0 mm) mild steel plate 6" x 6" (150 mm x 150 mm). Use .035" (0.9 mm) ﬂux cored gasless wire or a solid wire with shielding gas.

Setting of the Power Source

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. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the current level, but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with a little change in current level.

When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire needs more Wirespeed to achieve the same current level.

A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece.

If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound. Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup information.

Electrode Wire Size Selection

The choice of Electrode wire size and shielding gas used depends on the following:

• Thickness of the metal to be welded

• Type of joint

• Capacity of the wire feed unit and Power Source

• The amount of penetration required

• The deposition rate required

• The bead prole desired

• The position of welding

• Cost of the wire

FIREPOWER MST 220i

BASIC WELDING 4-4 Manual 0-5343

Firepower MIG, Lift TIG, Stick Wire Selection Chart

Art # A-12540

Table 4-1

NOTE

Please refer to the inside panel of the machine for the same chart.

FIREPOWER MST 220i

Manual 0-5343 4-5 BASIC WELDING

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. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidiﬁcation of the molten metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points.

FAULT/CONDITION CAUSE

1 Shielding gas cylinder contents

and ﬂow meter.

Ensure that the shielding gas cylinder is not empty and the ﬂow meter is correctly adjusted to 31.75 CFH.

2 Shielding gas cylinder contents

and ﬂow gauge.

Ensure that the shielding gas cylinder is not empty and the ﬂow meter is correctly adjusted to workshop welding: 28-35 CFH or outdoors welding: 35-46 CFH.

3 Gas leaks. Check for gas leaks between the regulator/cylinder connec-

tion and in the gas hose to the Power Source.

4 Internal gas hose in the Power

Source.

Ensure the hose from the solenoid valve to the MIG Gun adapter has not fractured and that it is connected to the MIG Gun adapter.

5 Welding in a windy environment. Shield the weld area from the wind or increase the gas ﬂow. 6 Welding dirty, oily, painted,

oxidized or greasy plate.

Clean contaminates off the work piece.

7 Distance between the MIG Gun

nozzle and the work piece.

Keep the distance between the MIG Gun nozzle and the work piece to a minimum.

8 Maintain the MIG Gun in good

working order.

A Ensure that the gas holes are not blocked and gas is exiting

out of the MIG Gun nozzle.

B Do NOT restrict gas ﬂow by allowing spatter to build up inside

the MIG Gun nozzle.

C Check that the MIG Gun O-rings are not damaged.

Table 4-2: Solving Problems beyond the Welding Terminals - Porosity

FIREPOWER MST 220i

BASIC WELDING 4-6 Manual 0-5343

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.

B Replace feed roller if worn.

4 Wire rubbed against the misaligned

guides and reduced wire feed ability.

Misalignment of inlet/outlet guides

5 Liner blocked with swarf A Increased amounts of swarf are produced by the wire

passing through the feed roller when excessive pressure is applied to the pressure roller adjuster.

B Swarf can also be produced by the wire passing

through an incorrect feed roller groove shape or size.

C Swarf is fed into the conduit liner where it accumu-

lates thus reducing wire feed ability.

6 Incorrect or worn contact tip A The Velocity contact tip transfers the weld current

to the electrode wire. If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the wire jamming in the contact tip.

B When using soft wire such as aluminum it may be-

come jammed in the contact tip due to expansion of the wire when heated. A Velocity contact tip designed for soft wires should be used.

7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the

work piece then the connection point will heat up and result in a reduction of power at the arc.

8 Bent liner This will cause friction between the wire and the liner

thus reducing wire feed ability

Table 4-3: Wire Feeding Problems

FIREPOWER MST 220i

Manual 0-5343 4-7 BASIC WELDING

Basic MIG (GMAW/FCAW) Welding Troubleshooting

FAULT CAUSE REMEDY

1 Undercut 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.

2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed speed

and increasing voltage.

B Joint preparation too narrow

or gap too tight

B Increase joint angle or gap.

C Shielding gas incorrect C Change to a gas which gives higher penetration. 3 Lack of fusion Voltage too low Increase voltage. 4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed control.

B Voltage too low B Increase the voltage or decrease wirespeed. 5 Irregular weld shape A Incorrect voltage and

current settings. Convex, voltage too low. Concave, voltage too high.

A Adjust voltage and current by adjusting the voltage

control and the wirespeed control.

B Wire is wandering. B Replace Velocity contact tip.

C Incorrect shielding gas C Check shielding gas.

D Insufﬁcient or excessive

heat input

D Adjust the wirespeed control or the voltage control.

6 Weld cracking A Weld beads too small A Decrease travel speed

B Weld penetration narrow

and deep

B Reduce current and voltage and increase MIG Gun

travel speed or select a lower penetration shielding gas. C Excessive weld stresses C Increase weld metal strength or revise design D Excessive voltage D Decrease voltage. E Cooling rate too fast E Slow the cooling rate by preheating part to be welded

or cool slowly.

7 Cold weld puddle A Loose welding cable con-

nection.

A Check all welding cable connections.

B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited Firepower Service Provider test

then replace the faulty component.

8 Arc does not have a

crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly

The MIG Gun has been connected to the wrong voltage polarity on the front panel.

Connect the MIG Polarity Cable to the positive (+)

welding terminal for solid wires and gas shielded ﬂux

cored wires. Refer to the electrode wire manufacturer

for the correct polarity.

9 Poor weld result from

setup chart parameters

Contact tip has arc marks in the bore causing excessive drag on the wire.

Replace the contact tip with only a Genuine Firepower

Velocity contact tip.

Table 4-4: MIG (GMAW /FCAW) Welding Problems

FIREPOWER MST 220i

BASIC WELDING 4-8 Manual 0-5343

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. A little practice will soon establish the most suitable electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Firepower Distributor.

4.04 Effects of Arc Welding Various Materials

A. 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 may result. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

Hydrogen controlled Electrodes must be used for this application.

B. Austenitic manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

C. Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

D. Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusion of weld and base metal.

Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.

Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in ﬂat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-11 through 4-18.

FIREPOWER MST 220i

Manual 0-5343 4-9 BASIC WELDING

Art # A-07687

Figure 4-11: Flat Position, Down Hand Butt Weld

Art # A-07688

Figure 4-12: Flat Position, Gravity Fillet Weld

Art # A-07689

Figure 4-13: Horizontal Position, Butt Weld

Art # A-07690

Figure 4-14: Horizontal-Vertical (HV) Position

Art A-07691

Figure 4-15: Vertical Position, Butt Weld

Art # A-07692

Figure 4-16: Vertical Position, Fillet Weld

Art# A-07693

Figure 4-17: Overhead Position, Butt Weld

Art # A-07694

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., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-19.

FIREPOWER MST 220i

BASIC WELDING 4-10 Manual 0-5343

Gap varies from 1/16” (1.6mm) to 3/16” (4.8mm) depending on plate thickness

Joint

Open Square Butt

1/16” (1.6mm) max

1/16” (1.6mm)

Single Vee Butt Joint

Not less than

70°

Double Vee Butt Joint

1/16” (1.6mm)

Lap Joint

Tee Joints

(

Fillet both sides of the

joint)

Edge Joint

Fillet Joint

Corner Weld

Plug Weld Plug Weld

Not less than

70°

Single Vee Butt Joint

Not less than

45°

1/16” (1.6mm) max

Art # A-10672

Figure 4-19: Typical Joint Designs for Arc Welding

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" (6.4 mm) thick and a 1/8" (3.2 mm) 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. Make sure that the work clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

The Weldor

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much

work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon

make you feel tired. Relax and you will ﬁnd that the job becomes much easier. You can add much to your peace of

mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting

alight to your clothes. Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder

lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down.

FIREPOWER MST 220i

Manual 0-5343 4-11 BASIC WELDING

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. 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. As soon as the arc is established, maintain a 1/16" -1/8" (1.6 mm - 3.2 mm) gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difﬁculty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Art # A-10673

20°

1/16” (1.6 mm)

Figure 4-20: Striking an Arc

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will ﬁnd that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is ﬂattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidiﬁed in. If this should happen, give the electrode a quick twist back over the weld to detach it. Contact or "touch-weld" electrodes such as E7014 do not stick in this way, and make welding much easier.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1/16" - 3/32" (1.6 mm - 2.4 mm) gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 1/4" (6.4 mm) should have their mating edges beveled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 1/8" (3.2 mm) E7014 electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufﬁcient to produce a well-formed bead. At ﬁrst you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

Art # A-07697_AB

Tack Weld

20°-30°

Electrode

Tack Weld

Figure 4-21: Butt Weld

FIREPOWER MST 220i

BASIC WELDING 4-12 Manual 0-5343

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. 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. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely ﬁlled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular crosssection made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-24.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 1/8" (3.2 mm) E7014 electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) ﬁllet. Strike the arc and immediately bring the electrode to a position perpendicular to the line of the ﬁllet and about 45º from the vertical. Some electrodes require to be sloped about 20º away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-23. Do not attempt to build up much larger than 1/4" (6.4 mm) width with a 1/8" (3.2 mm) electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-24. Weaving in HV ﬁllet welds is undesirable.

Art # A-07699_AB

45° from vertical

60° - 70° from line of weld

Figure 4-23: Electrode Position for HV Fillet Weld

Art # A-07700_AB

Figure 4-24: Multi-runs in HV Fillet Weld

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" (3.2 mm) E7014 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. When the ﬁrst run has been completed de-slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the ﬁrst run and obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 4-26 illustrates multi-run technique and Figure 4-27 shows the effects of pausing at the edge of weave and of weaving too rapidly.

FIREPOWER MST 220i

Manual 0-5343 4-13 BASIC WELDING

Art # A-07701

Figure 4-25: Single Run Vertical Fillet Weld

Art # A-07702

Figure 4-26: Multi Run Vertical Fillet Weld

Art # A-07703

Figure 4-27: Examples of Vertical Fillet Welds

2. Vertical Down

The E7014 electrode makes welding in this

position particularly easy. Use a 1/8" (3.2 mm) 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. The electrode should point upwards at an angle of about 45º.

3. Overhead Welds

Apart from the rather awkward position neces-

sary, 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. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-28). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead ﬁllet welds. Use a 1/8" (3.2 mm) E6013 electrode at 100 amps, and deposit the ﬁrst run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

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.

FIREPOWER MST 220i

BASIC WELDING 4-14 Manual 0-5343

The Cause of Distortion

Distortion is caused by:

A. Contraction of Weld Metal:

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. Therefore, cooling causes the weld metal to ﬂow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in 5/64" (2.0 mm) sheet, the contracting weld metal may cause the sheet to become distorted.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the weld", it meets considerable resistance, and to fulﬁll the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain "locked-up" stresses in the job. Figures 4-29 and 4- 30 illustrate how distortion is created.

Art # A-07705_AB

Hot

Weld

Upsetting

Expansion with compression

Cool

Figure 4-29: Parent Metal Expansion

Art # A-07706_AC

Weld

Permanent Upset

Contraction with tension

Figure 4-30: Parent Metal Contraction

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. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds are methods employed with this in view.

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.

FIREPOWER MST 220i

Manual 0-5343 4-15 BASIC WELDING

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.

Art # A-07707

Figure 4-31: Principle of Presetting

Art # A-07708

PreheatPreheat

Dotted lines show effect if no preheat is used

Weld

Figure 4-32: Reduction of Distortion by Preheating

Art # A-07709

Figure 4-33: Examples of Distortion

Art # A-07710_AB

Block Sequence. The spaces between the welds are ﬁlled in when the welds are cool.

Figure 4-34: Welding Sequence

Figure 4-35: Step back Sequence

Art # A-07428_AB

Figure 4-36: Chain Intermittent Welding

Art # A-07713_AB

Figure 4-37: Staggered Intermittent Welding

FIREPOWER MST 220i

BASIC WELDING 4-16 Manual 0-5343

4.05 STICK (SMAW) Welding Troubleshooting

FAULT CAUSE REMEDY

1 Welding current

varying

ARC FORCE is set at a value that causes the welding current to vary excessively with the arc length.

Reduce the ARC FORCE until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.

2 A gap is left by

failure of the weld metal to ﬁll the root of the weld.

A Welding current too low A Increase welding current. B Electrode too large for

joint.

B Use smaller diameter electrode.

C Insufﬁcient gap. C Allow wider gap.

3 Non-metallic par-

ticles are trapped in the weld metal.

A Non-metallic particles may

be trapped in undercut from previous run.

A If a bad undercut is present clean slag out and

cover with a run from a smaller gauge electrode.

B Joint preparation too

restricted.

B Allow for adequate penetration and room for

cleaning out the slag.

C Irregular deposits allow

slag to be trapped.

C If very bad, chip or grind out irregularities.

D Lack of penetration with

slag trapped beneath weld bead.

D Use smaller electrode with sufﬁcient current to

give adequate penetration. Use suitable tools to remove all slag from comers.

E Rust or mill scale is pre-

venting full fusion.

E Clean joint before welding.

F Wrong electrode for posi-

tion in which welding is done.

F Use electrodes designed for position in which

welding is done, otherwise proper control of slag is difﬁcult.

Art # A-04273

Incorrect sequence

Insufﬁcient gap

Figure

4-38: Example of insufﬁcient gap or incorrect sequence

Table 4-5a:

FIREPOWER MST 220i

Manual 0-5343 4-17 BASIC WELDING

FAULT CAUSE REMEDY

4 A groove has been

formed in the base metal adjacent to the toe of a weld and has not been ﬁlled by the weld metal (undercut).

A Welding current is too

high.

A Reduce welding current.

B Welding arc is too long. B Reduce the length of the welding arc.

C Angle of the electrode is

incorrect.

C Electrode should not be inclined less than 45° to

the vertical face.

D Joint preparation does not

allow correct electrode angle.

D Allow more room in joint for manipulation of the

electrode.

E Electrode too large for

joint.

E Use smaller gauge electrode.

F Insufﬁcient deposit time at

edge of weave.

F Pause for a moment at edge of weave to allow

weld metal buildup.

G Power source is set for

MIG (GMAW) welding.

G Set power source to STICK (SMAW) mode.

5 Portions of the

weld run do not fuse to the surface of the metal or edge of the joint.

A Small electrodes used on

heavy cold plate.

A Use larger electrodes and preheat the plate.

B Welding current is too low. B Increase welding current. C Wrong electrode angle. C Adjust angle so the welding arc is directed more

into the base metal.

D Travel speed of electrode

is too high.

D Reduce travel speed of electrode.

E Scale or dirt on joint

surface.

E Clean surface before welding.

Art # A-04274_AB

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

Lack of side fusion, scale dirt, small electrode, amperage too low

Lack of inter-run fusion

Lack of Root Fusion

Figure 4-39: Example of Lack of Fusion

Table 4-5b: STICK (SMAW) metal welding trouble shooting

FIREPOWER MST 220i

BASIC WELDING 4-18 Manual 0-5343

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. A ﬁller metal may also be added manually in some circumstances depending on the welding application.

Welds Made With or Without

Addition of Filler Metal

Work Piece

Can Be Any Commercial

Metal

Gas Cup Either Ceramic, High-lmpact or

Water Cooled

Metal

Inert Gas

Shields Electrode

and Weld Puddle

Tungsten Electrode

Non-Consumable

Art # A-09658_AC

Figure 4-40: TIG (GTAW) Welding Application Shot

Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30-60 1/16” (1.6mm) 60-115 3/32” (2.4mm) 100-165

1/8” (3.2mm) 135-200

5/32” (4.0mm) 190-280

3/16” (5mm) 250-340

Table 4-6: Current Ranges for Various Tungsten Electrode Sizes

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6mm) 20-90 3/32” (2.4mm) 65-115

1/8” (3.2mm) 100-165

3/16” (5mm) 200-350

Table 4-7: Filler Wire Selection Guide

FIREPOWER MST 220i

Manual 0-5343 4-19 BASIC WELDING

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.

White

Ceriated 2%

AC & DC welding of mild steel, stainless steel, copper, aluminum, magnesium and their alloys

Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc.

Grey

Table 4-8

NOTE

The Firepower MST 220i Inverter is not suited for AC TIG welding.

TIG Welding Filler Rods

Base Metal

Thickness

DC Current

for Mild

Steel

DC Current

for Stainless

Steel

Tungsten

Electrode

Diameter

Filler Rod

Diameter (if

required)

Argon Gas Flow Rate

CFH

Joint Type

0.040”

1.0mm

35-45 40-50

20-30 25-35

0.040”

1.0mm

1/16”

1.6mm

10-15 Butt/Corner

Lap/Fillet

0.045”

1.2mm

45-55 50-60

30-45 35-50

0.040”

1.0mm

1/16”

1.6mm

10-15 Butt/Corner

Lap/Fillet

1/16”

1.6mm

60-70 70-90

40-60 50-70

1/16”

1.6mm

1/16”

1.6mm

15 Butt/Corner

Lap/Fillet

1/8”

3.2mm

80-100 90-115

65-85

90-110

1/16”

1.6mm

3/32”

2.4mm

15 Butt/Corner

Lap/Fillet

3/16”

4.8mm

115-135 140-165

100-125 125-150

3/32”

2.4mm

1/8”

3.2mm

20 Butt/Corner

Lap/Fillet

1/4”

6.4mm

160-175 170-200

135-160 160-180

1/8”

3.2mm

5/32”

4.0mm

20 Butt/Corner

Lap/Fillet

Table 4-9

TIG Welding is generally regarded as a specialized process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual.

FIREPOWER MST 220i

BASIC WELDING 4-20 Manual 0-5343

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.

Travel speed too fast Reduce travel speed.

4 Weld bead too wide or

excessive bead build up or excessive penetration in butt joint.

Travel speed too slow Increase travel speed.

5 Uneven leg length in ﬁllet

joint

Wrong placement of ﬁller rod

Re-position ﬁller rod.

6 Electrode melts or oxidizes

when an arc is struck.

A TIG Torch lead connect-

ed to positive welding terminal.

A Connect TIG Torch lead to negative weld-

ing terminal.

B No gas ﬂowing to weld-

ing region.

B Check the gas lines for kinks or breaks

and gas cylinder contents.

C TIG Torch is clogged

with dust or dirt.

C Clean TIG Torch.

D Gas hose is cut. D Replace gas hose. E Gas passage contains

impurities.

E Disconnect gas hose from the rear of

Power Source then raise gas pressure and blow out impurities.

F Gas regulator turned

OFF.

F Turn ON.

G TIG Torch valve is

turned OFF.

G Turn ON.

H The electrode is too

small for the welding current.

H Increase electrode diameter or reduce the

welding current.

I Power source is set for

MIG welding.

I Set Power Source to LIFT TIG mode.

FIREPOWER MST 220i

Manual 0-5343 4-21 BASIC WELDING

FAULT CAUSE REMEDY

7 Dirty weld pool A Electrode contaminated

by contact with work piece or ﬁller rod material.

A Clean the electrode by grinding off the

contaminates.

B Work piece surface has

foreign material on it.

B Clean surface.

C Gas contaminated with

air.

C Check gas lines for cuts and loose ﬁtting

or change gas cylinder.

8 Poor weld ﬁnish Inadequate shielding

gas.

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

9 Arc start is not smooth. A Tungsten electrode is

too large for the welding current.

A Select the right size electrode. Refer to

Firepower Electrode Selection Chart.

B The wrong electrode

is being used for the welding job.

B Select the right electrode type. Refer to

Firepower Electrode Selection Chart.

C Gas ﬂow rate is too

high.

C Select the right rate for the welding job.

Refer to Table 4-9.

D Incorrect shielding gas

is being used.

D Select the right shielding gas.

E Poor work clamp con-

nection to work piece.

E Improve connection to work piece.

10 Arc ﬂutters during TIG

welding.

Tungsten electrode is too large for the welding current.

Select the right size electrode. Refer to Firepower Electrode Selection Chart.

11 Tungsten blackens due to

lack of shielding gas

A Gas valve on the TIG

Torch has not been turned ON.

A Turn ON TIG Torch gas valve before you

commence welding.

B Gas cylinder valve OFF

or TIG Torch hose not connected to regulator.

B Turn ON gas cylinder valve or connect TIG

Torch hose to regulator.

Table 4-10: TIG (GTAW) Welding Problems

FIREPOWER MST 220i

BASIC WELDING 4-22 Manual 0-5343

This Page Intentionally Blank

FIREPOWER MST 220i

Manual 0-5343 5-1 PROBLEMS AND ROUTINE SERVICE

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 cor-

rect mode of operation with the process selection switch.

B Faulty torch trigger. B Repair or replace torch trigger

switch/lead.

2 Fault Indicator is illumi-

nated and unit will not commence welding when the torch trigger switch is depressed.

Duty cycle of power source has been exceeded.

Leave the power source switched ON and allow it to cool. Note that fault indicator must be extinguished prior to commencement of welding.

3 Unit will not feed wire in

MIG mode.

A Electrode wire stuck in

conduit liner or contact tip (burn-back jam).

A Check for clogged / kinked MIG

gun conduit liner or worn contact tip. Replace faulty components.

B Internal fault in power

source

B Have an Accredited Firepower

Service Provider investigate the fault.

4 Welding wire continues to

feed when torch trigger is released.

A Trigger mode selection

switch is in 4T latch mode.

A Change the trigger mode selec-

tion switch from 4T latch mode to 2T normal mode.

B Torch trigger leads shorted. B Repair or replace torch trigger

switch/lead.

5 Welding arc cannot be

established in MIG mode.

A MIG gun polarity lead is not

connected into a welding output terminal.

A Connect the MIG gun polar-

ity lead to either the positive welding output terminal or the negative welding output terminal as required.

B Poor or no work lead

contact.

B Clean work clamp area and en-

sure good electrical contact.

6 Inconsistent wire feed. A Worn or dirty contact tip. A Replace if necessary.

B Worn feed roll. B Replace. C Excessive brake tension on

wire reel hub.

C Reduce brake tension on spool

hub

D Worn, kinked or dirty con-

duit liner

D Clean or replace conduit liner

7 No gas ﬂow in MIG mode. A Gas hose is damaged. A Replace or repair.

B Gas passage contains

impurities.

B Disconnect gas hose from the

rear of power source and blow out impurities.

C Gas regulator turned OFF. C Turn ON regulator. D Empty gas cylinder. D Replace gas cylinder.

FIREPOWER MST 220i

PROBLEMS AND ROUTINE SERVICE 5-2 Manual 0-5343

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%.

10 TIG electrode melts when

arc is struck.

TIG torch is connected to the (+) VE terminal.

Connect the TIG torch to the (-) VE terminal.

11 Arc ﬂutters during TIG

welding.

Tungsten electrode is too large for the welding current.

Select the correct size of tungsten electrode. Refer to Table 4-7.

Table 5-1: Power Source Problems

5.02 Routine Service and Calibration Requirements

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter 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 before disassembling.

Routine Inspection, Testing & Maintenance

The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is

compliant with Firepower's original specications.

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For ﬁxed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.

A transportable power source is deemed to be any equipment that is not permanently connected and ﬁxed in the position in which it is operated.

B. Insulation Resistance

Minimum insulation resistance for in-service Firepower Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.

FIREPOWER MST 220i

Manual 0-5343 5-3 PROBLEMS AND ROUTINE SERVICE

Components to be Tested

Minimum Insulation

Resistance (MΩ)

Input circuit (including any connected control circuits) to welding circuit (including any connected control circuits)

All circuits to exposed conductive parts

2.5

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage exceeding extra low voltage

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage not exceeding extra low voltage

Separate welding circuit to separate welding circuit

Table 5-2: Minimum Insulation Resistance Requirements: Firepower Inverter Power Sources

C. Earthing

The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and -

1. The earth terminal of a ﬁxed power source; or

2. The earth terminal of the associated plug of a transportable power source

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. General Maintenance Checks

Welding equipment should be regularly checked by an accredited Firepower Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.

3. The Welding System is clean internally, especially from metal ﬁling, slag, and loose material.

E. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used.

F. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited Firepower Service Provider.

FIREPOWER MST 220i

PROBLEMS AND ROUTINE SERVICE 5-4 Manual 0-5343

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. Calibration Requirements

Where applicable, the tests outlined in Table 5-3 below shall be conducted by an accredited Firepower service agent.

Testing Requirements

Output current (A) to be checked to ensure it falls within applicable Firepower power source speciﬁcations Output Voltage (V) to be checked to ensure it falls within applicable Firepower power source speciﬁcations Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Firepower power

source / wire feeder speciﬁcations Accuracy of digital meters to be checked to ensure it falls within applicable Firepower power source speci-

ﬁcations

Table 5-3: Calibration Parameters

Periodic calibration of other parameters such as timing functions are not required unless a speciﬁc fault has been identiﬁed.

C. Calibration Equipment

All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certiﬁcates (NATA certiﬁed laboratories) shall be utilized.

FIREPOWER MST 220i

Manual 0-5343 5-5 PROBLEMS AND ROUTINE SERVICE

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. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current.

Warning! Disconnect input power before maintaining.

Each Use

Visual check of regulator and pressure

Visual check of torch Consumable parts

Weekly

Visually inspect the torch body and consumables

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Replace all broken parts

Bring the unit to an authorized Tweco Service Provider to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

Maintain more often if used under severe conditions

Art # A-10502_AB

FIREPOWER MST 220i

PROBLEMS AND ROUTINE SERVICE 5-6 Manual 0-5343

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 par

ticles to lodge between live electrical parts and earthed metal parts within the Welding Power Source. This may result in arcing between these parts and their eventual failure.

FIREPOWER MST 220i

Manual 0-5343 6-1 REPLACEMENT PARTS

SECTION 6: KEY SPARE PARTS

Torch Part No: 1444-0882

Art# A-12519

Figure 6-1

Item

No.

Description Part No.

MST Nozzle**

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**

MST Contact

Tip, .023"

1444-0890

MST Contact

Tip, .030"

1444-0891

MST Contact

Tip, .035"

1444-0892

MST Contact

Tip, .045"

1444-0893

Handle / Trigger Repair Kit N/A

Universal Conduit Liner*

1444-0883

Conductor Tube, Firepower Fusion 140A/180A/220A MIG Gun, 60 Deg

16201108

Table 6-1: Firepower Fusion 220A MIG Gun Parts

** Patent Pending

* Refer to your Firepower Catalog for additional options.

6.01 Firepower Fusion 220A MIG Gun

FIREPOWER MST 220i

REPLACEMENT PARTS 6-2 Manual 0-5343

6.02 Power Source Spare Parts

Art # A-12541

810

Figure 6-2

FIREPOWER MST 220i

Manual 0-5343 6-3 REPLACEMENT PARTS

Item Part Number Description

1 W7005621 PCB Power, FP MST220i 2 W7005638 PCB Control, FP MST220i 3 W7005602 PCB Display, FP MST220i 4 W7005607 PCB Spool Gun, FP MST220i 5 W7005603 Wiredrive Assembly, FP MST220i 6 W7004906 Thumbscrew,Feedroll Positioner 7 W4014800 DRIVE RL2 Roll, .023/.035 “V” 8 W7005622 Fan Assembly, FP MST220i UL/CSA

9 W7003010 Rectiﬁer Bridge,1000V,50A 10 W7003033 Gas Solenoid Valve Assy 11 W7003215 Gas Inlet Fitting 12 W7004909 Connector Socket,50 Dinse 13 W7004955 Connector Plug,50 Dinse 14 W7003242 Socket,8 Pin,w/ Harness 15 W7005623 Switch CB,Main On-Off 16 W7004911 CT, Output 17 W7005617 Spool Hub Assembly 18 W7005608 Washer,Friction,Spool Hub 19 W7005609 Spool Hub 20 W7005619 Guide,Inlet,.023-.045 (not shown) 21 W7004967 Guide,Outlet,.023-.045 22 1444-0920 Front, Panel, FP MST220i 23 1444-0921 Panel, Base, FP MST220i 24 1444-0922 Center Panel, FP MST220i 25 1444-0923 Rear, Panel, FP MST220i UL/CSA 26 1444-0924 Panel, Cover, FP MST220i (not shown) 27 1444-0925 Panel, Door, FP MST220i (not shown) 28 1444-0926 Panel,Control,FP MST220i 29 W7004972 Knob,1/4” IDx1” ODx0.9” H 30 W7005630 Knob,1/4” IDx1.25” ODx.9” H 31 W7005629 Circuit Breaker,4A 32 W7004943 Switch,250V/2A 33 870734 Knob,1/4” IDx.72” ODx.9” H 34 W7004940 PCB, Burnback Potentiometer 35 W7005632 Shroud, WF Motor 36 1444-0927 Label, Identiﬁcation, FP MST220i (not shown) 37 1444-0928 Setup chart, English version, FP MST220i (not shown) 38 1444-0912

Large Spring, for One Pound Spool (not shown)

39 W7005635

Latch, Door, Slide (not shown)

Table 6-2: Firepower MST 220i Parts

FIREPOWER MST 220i

REPLACEMENT PARTS 6-4 Manual 0-5343

This Page Intentionally Blank

FIREPOWER MST 220i

Manual 0-5343 A-1 APPENDIX

APPENDIX 1: FIREPOWER MST 220i CIRCUIT DIAGRAM

Art # A-11249

ACOUT

DC -

DC +

RED

BLACK

+15V 1

IGBT Driver A 2

IGBT Driver B 3

GND 7

Over Current Signal 6

OT2

Funs

RED

Main Power PCB1

Control PCB2

4 GND

1 +15V

2 -15V

3 Current Feedback

Current Sensor

CONNECTOR LAYOUT DIAGRAM

MWPBFI

FunsDRIVE

FAN

PFC CIRCUIT

GUN

BLACK

POS

NEG

BLACK

WVIN

OT1

DRIVE

IFB

RED

YELLOW

GRAY

WHITE

IGBT Driver B 4

IGBT Driver A 5

1 +15V

2 IGBT Driver A

3 IGBT Driver B

7 GND

6 Over Current Signal

4 IGBT Driver B

5 IGBT Driver A

+24VDC 1

-24VDC 3

GND 2

1 +24VDC

2 GND

3 -24VDC

DY2

SOURCE

MOTOR PWM CONTROL

CIRCUIT

PWM

1 PWM RETURN

2 PWM (MOTOR DRIVER 5VDC PEAK)

ACOUT

SHEETMETAL COVER

60W3

Ω

BR1

BR2

+ +

GAS

SOLENOID

Wirefeeder

Power

Fault

MIG

LIFT TIG

STICK

2T Normal

4T Latch

Process

Trigger

Wirefeed / Amps

Volts

Down Slope / Arc Force(%)

Arc Control

Amps / Wirefeed Display

Volts Display

3456

Front View

8A/250V

Fuse

MIG GUN

SPOOL GUN

GND

OT1

OT2

SOURCE

QF / DY

WVIN

PFC

POT1

QF / DY

GND

+24VDC

3 POT MAX (+5VDC)

2 WIPER

1 POT MIN

RED

BLK

YEL

1 +24VDC

1 - OUTPUT

3 + OUTPUT

8 Pin Remote Control

Spool Gun

SPOOL GUN (0V) 1

TORCH SWITCH (+24V) 2

TORCH SWITCH RIN (0VDC) 3

SPOOL GUN (+2VDC) 4

TORCH SWITCH RIN (0VDC) 5

TORCH SWITCH RIN (0VDC) 6

(REMOVE VOLTAGE) POT WIPER 7

(REMOVE AMPS/WIRESPEED) POT WIPER 8

LOCAL

REMOTE

3 -15VDC

GUN

+24VDC 1

GND

1 +15VDC

GND

DISPLAY DATA &EPROM (D-IN) 1

SEIAL DISPLAY DATA (LOAD) 2

SEIAL DISPLAY DATA (CLK) 3

2T/4T PUSHBUTTON 4

SERIAL DISPLAY DATA (EPROM) 5

STICK 6

+15VDC 9

PROCESS PUSHBUTTON 8

POT3 B 11

POT2 WIPER 12

POT3 A (PANEL DEMAND) 13

POT1 WIPER 14

+15VDC 15

GND

J1 J2

J10J11

J12

J13

J10

J11

J12

J13

RED

WHITE

YELLOW

RED

BLACK

1 +24CDC

GND

+24CDC 1

N/A 2

WHITE

RED

1 +5VDC

2 TO U15 PIN6

INPUT 230V/115V

OUTPUT CONTROL SIGNAL

SPOOL GUN PCB3

W7005607

15V

FUSE

SGM

W7005600

W7005601

W7005602

Display PCB4

J14

DY1

QF/FJ

J15

J16

J17 J18

J19

J20

J21

J22

J23

J24

J25

J26

2J82J72J

J30

J31

J32

J33

J34

J35

RED

BLACK

RED

BLACK

CON3

BURN BACK PCB 5

W7004940

RED

YELLOW

RED

BLACK

INPUT 115/208/230VAC

50/60Hz50/60Hz50/60Hz

FIREPOWER MST 220i

APPENDIX A-2 Manual 0-5343

This page intentionally blank

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. Should any failure to conform to this warranty appear within the time period applicable to the FIREPOWER products as stated below, FIREPOWER shall, upon notiﬁcation thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with FIREPOWER’s speciﬁcations, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at FIREPOWER’s sole option, of any components or parts of the product determined by FIREPOWER to be defective.

FIREPOWER MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: FIREPOWER SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of FIREPOWER with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by FIREPOWER whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of FIREPOWER is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN FIREPOWER’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY FIREPOWER PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date FIREPOWER delivered the product to the authorized distributor.

This page intentionally blank

WARRANTY SCHEDULE

2 Years Parts* and Labor

* 2 years on the Original Main Power Transformer and Inductors not mounted on PC Boards.

* 2 years on Power Supply Components

2 Years Parts / No Labor

Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy

Firepower Regulator for Firepower MST 220i (No labor)

90 days parts / No Labor

Remote Controls

MIG and TIG Torches (Supplied with power sources)

Replacement repair parts

Victor Technologies limited warranty shall not apply to:

Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due normal wear

* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Victor Technologies repair facility within thirty (30) days of the repair.

* No employee, agent, or representative of Victor Technologies is authorized to change this warranty in any way or grant any other warranty, and Victor Technologies shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of Victor Technologies’s obligations to purchaser with respect to the product.

* This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Victor Technologies's sole judgment, impaired the safety or performance of any Victor Technologies product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.

THE AMERICAS

Denton, TX USA U.S. Customer Care

Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph 1-940-381-1212 Fax: 1-940-483-8178

Miami, FL USA Sales Office, Latin America

Ph 1-954-727-8371 Fax: 1-954-727-8376

Oakville, Ontario, Canada Canada Customer Care

Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom Customer Care

Ph +44 1257-261755 Fax: +44 1257-224800

Milan, Italy Customer Care

Ph +39 0236546801 Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia Customer Care

Ph 6221-8990-6095 Fax: 6221-8990-6096

Rawang, Malaysia Customer Care

Ph +603 6092-2988 Fax: +603 6092-1085

Melbourne, Australia Australia Customer Care

Ph 1300-654-674 (tollfree) Ph 61-3-9474-7400 Fax: 61-3-9474-7391

International

Ph 61-3-9474-7508 Fax: 61-3-9474-7488

Shanghai, China Sales Office

Ph +86 21-64072626 Fax: +86 21-64483032

Singapore Sales Office

Ph +65 6832-8066 Fax: +65 6763-5812

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178

INNOVATION TO SHAPE THE WORLD™

T ECHNOLOGIES

™

Firepower MST 220i Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual