A-12707
Firepower TIG 200 AC/DC
115
230
Inverter Arc Welder
Operating
Manual
English
Canadien Français
Americas Español
Revision: AA Issue Date: November 13, 2014 Manual No.: 0-5370
www.firepoweronline.com
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!
The Brand of Choice for Contractors and Fabricators Worldwide.
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.Firepoweronline.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 judgement, the
Manufacturer assumes no liability for its use.
Welding Power Supply
Operating Manual Number 0-5370 for:
Firepower TIG 200 AC/DC, Machine Only Part Number 1442-0033
Firepower TIG 200 AC/DC, System Part Number 1442-0032
Published by:
Victor Technologies, Inc.
16052 Swingley Ridge Road,
Suite 300 St, Louis, MO 63017
USA
www.firepoweronline.com
Copyright © 2014 by
Victor Technologies, Inc.
All rights reserved.
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: November 13, 2014
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
ii
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 General Safety Information for firepower CS Flowmeter/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 .............................................................. 1-13
1.08 Principales Normes De Securite ................................................................... 1-15
1.09 Graphique de Symbole .................................................................................. 1-16
1.05 Declaration of Conformity ............................................................................. 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 User Responsibility ......................................................................................... 2-2
2.06 Transporting Methods ..................................................................................... 2-2
2.07 Packaged Items .............................................................................................. 2-2
2.08 Duty Cycle ....................................................................................................... 2-2
2.09 Specifications ................................................................................................. 2-3
2.10 Optional Accessories ...................................................................................... 2-4
2.11 Volt-Ampere Curves ........................................................................................ 2-4
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 Mains Supply Voltage Requirements .............................................................. 3-1
3.05 High Frequency Introduction .......................................................................... 3-2
3.06 High Frequency Interference ........................................................................... 3-3
3.07 Electromagnetic Compatibility ........................................................................ 3-3
3.08 200 AC/DC Power Source Controls, Indicators and Features .......................... 3-5
3.09 200 AC/DC - STICK Programming Mode ...................................................... 3-10
3.10 200 AC/DC – LIFT TIG and HF TIG Programming Mode .............................. 3-11
3.11 Short Circuit Protection While Welding ......................................................... 3-15
3.12 Firepower Flowmeter/Regulator .................................................................... 3-15
3.13 Specification for TIG Torch ........................................................................... 3-17
3.14 SETUP FOR TIG (GTAW) WELDING .............................................................. 3-19
3.15 Setup for STICK (SMAW) Welding .............................................................. 3-22
TABLE OF CONTENTS
SECTION 4:
BASIC WELDING GUIDE ............................................................................ 4-1
4.01 STICK (SMAW) Basic Welding Technique ....................................................... 4-1
4.02 STICK (SMAW) Welding Troubleshooting ..................................................... 4-10
4.03 TIG (GTAW) Basic Welding Technique .......................................................... 4-12
4.04 TIG (GTAW) Welding Problems ..................................................................... 4-15
SECTION 5: POWER SOURCE PROBLEMS
AND ROUTINE SERVICE REQUIREMENTS ........................................................ 5-1
5.01 Basic Troubleshooting .................................................................................... 5-1
5.02 Power Source Problems ................................................................................. 5-1
5.03 Routine Service and Calibration Requirements ............................................... 5-2
5.04 Cleaning the Welding Power Source ............................................................... 5-4
SECTION 6:
KEY SPARE PARTS ................................................................................... 6-1
6.01 Power Source ................................................................................................. 6-1
APPENDIX 1 : CIRCUIT DIAGRAM ........................................................................ A-1
APPENDIX 2 : 200 AC/DC SETUP GUIDE ................................................................ A-2
LIMITED WARRANTY TERMS ....................................................... INSIDE REAR COVER
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER
This Page Intentionally Blank
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
!
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.
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 whenever 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.
Safety Instructions
1-1
Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
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.
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.
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.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
Process
Shielded Metal Arc Welding
(SMAW)
Gas Metal Arc Welding (GMAW)
and Flux Cored Arc Welding
(FCAW)
Gas Tungsten arc Welding
(GTAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
Electrode Size in.
(mm)
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)
(Light)
(Heavy)
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.
Arc Current
(Amperes)
Less than 60
60-160
160-250
250-550
Less than 60
60-160
160-250
250-550
Less than 50
50-150
150-500
Less than
500
500-1000
Less than 20
20-100
100-400
400-800
Minimum
Protective
Shade
7
8
10
11
7
10
10
10
8
8
10
10
11
6
8
10
11
Suggested*
Shade No.
(Comfort)
10
12
14
11
12
14
10
12
14
12
14
6 to 8
10
12
14
Plasma Arc Cutting (PAC)
* 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.
Manual 0-5370
1-2
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
10
4
5
6
8
8
9
4
5
6
8
9
12
14
Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
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.
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
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.
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, Flowmeter/
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.
Safety Instructions
1-3
Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
!
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.
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.
NOTE
Considerations About Welding And The
Effects of Low Frequency Electric and Magnetic Fields
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
Manual 0-5370
1-4
Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
!
!
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, OTABP-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.
1.02 GENERAL SAFETY INFORMATION
FOR FIREPOWER CS
FLOWMETER/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 extin guisher.
5. Move combustible materials away from the work
site. If you can not move them, protect them
with fireproof covers.
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.
WARNING
NEVER perform welding, heating, or cutting operations on a container that has held
toxic, combustible or flammable liq uids, 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 substances
become highly explosive. They can ignite
and burn violently in the presence of oxygen.
Keep ALL apparatus clean and free of grease, oil and
other flammable substances.
Safety Instructions
1-5
Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
!
!
!
!
C. Ventilation
WARNING
Ade quately ventilate welding, heating, and
cutting work areas to prevent accumulation 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 Material 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.
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 201512923
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.
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 Flowmeter/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.
6. Momentarily open and close (called “cracking”)
the cylinder valve to dislodge any dust or dirt that
may be present in the valve.
Manual 0-5370
1-6
Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
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.
Safety Instructions
1-7
Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Hertz (cycles/sec)
Frequency
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preflow Time
Postflow Time
2 Step Trigger
Operation
t1
Press to initiate wirefeed and
welding, release to stop.
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
115V 15A
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.
Receptacle RatingAuxiliary Power
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
V
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
IPM
MPM
S
S
4 Step Trigger
Operation
Burnback Time
Inches Per Minute
Meters Per Minute
See Note
See Note
Art # A-04130_AB
Manual 0-5370
1-8
Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
!
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-automatique
avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement
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 porteélectrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre
avec l’électrode ou le porte-électrode.
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.
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FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
11. Ne touchez pas à l’électrode lorsqu’en contact avec
le circuit de soudage (terre).
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.
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, susceptibles 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
AVERTISSEMENT
Procédé
Soudage à l’arc avec
électrode enrobée (procédé
SMAW)
Soudage à l’arc sous gaz
avec fil plein (procédé
GMAW) et soudage avec fil
fourré (procédé FCAW)
Soudage à l’électrode
réfractaire (procédé GTAW)
Coupage à l’arc avec
électrode de carbone et jet
d’air (procédé AAC)
Soudage à l’arc au plasma
(procédé PAW)
Coupage plasma (procédé
PAC)
Taille de l’électrode
enmm (po)
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)
(Clair)
(Sombre)
Courant
d’arc
(ampères)
Moins de 60
60-160
160-250
250-550
Moins de 60
60-160
160-250
250-550
Moins de 50
50-150
150-500
Moins de
500 500-
1000
Moins de 20
20-100
100-400
400-800
Moins de 20
20-40
40-60
60-80
80-300
300-400
400-800
Gamme
d’intensité
minimum
7
8
10
11
7
10
10
10
8
8
10
10
11
6
8
10
11
4
5
6
8
8
9
10
Numéro de teinte
recommandée*
(Confort)
10
12
14
11
12
14
10
12
14
12
14
6 à 8
10
12
14
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
dusoudage, 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.
Manual 0-5370
Tableau 1-1
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Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
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.
LE SOUDAGE PEUT CAUSER UN INCENDIE
OU UNE EXPLOSION
L’arc produit des étincellies et des projections. 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 couvrez-les 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 pantalon
revers, des bottines de sécurité et un casque.
AVERTISSEMENT
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Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
8. Lisez et respectez les consignes relatives aux
bouteilles de gaz comprimé et aux équipements
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES
BLESSURES.
connexes, ainsi que la publication P-1 de la CGA,
identifiée dans la liste de documents ci-dessous.
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 protecteurs 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.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
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 ventilateurs, des rotors et des courroies peuvent
couper doigts et mains, ou accrocher des
vêtements amples.
Manual 0-5370
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Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
!
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’électrolyte 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.
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.
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, combustibles ou inflammables. N’effectuez JAMAIS d’opérations de soudage dans une zone contenant des vapeurs
combustibles, des liquides inflammables ou
des poussières explosives.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION
PEUVENT BRULER LA PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur
peut être brûlant et sous pression.
Safety Instructions
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Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
!
!
!
!
B. Entretien des Locaux
AVERTISSEMENT
AVERTISSEMENT
Ne laissez jamais l’oxygène en contact avec
la graisse, l’huile ou d’autres substances
inflammables. Bien que l’oxygène elle même
ne brûle pas, ces substances peuvent devenir extrême ment explosives. Elles peuvent
prendre feu et brûler violem ment 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 circonstances. Si vous
soudez ou brasez, lisez et assimilez la fiche
technique de sécurité de matériau relative à
l’alliage de soudage/brasage.
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.
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
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
Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux
peuvent résulter d’une mauvaise manutention
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.
Manual 0-5370
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Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
!
AVIS
Ce document CGA p. t peut être obtenu en
écrivant à “Compressed Gas Association”,
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.
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.
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’acétylène crache
un brouillard, laissez reposer pendant 15
minutes. Essayez de nouveau la vanne. Si
le problème persiste, con tactez votre fournisseur de gaz.
Safety Instructions
1-15
Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
SousTension
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
X
%
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Distant
Facteur de Marche
Pourcentage
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Haute Température
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Torche de Soudage
Purge Du Gaz
Mode Continu de
Soudure
Soudure Par Point
Duréc du Pulse
t
t1
Appuyez pour démarrer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Maintenez appuyez pour pré-dèbit,
relailez pour initier l’arc. Appuyez
pour arrêter l’arc, et mainteuir pour
pré-dèbit.
Durée de Pré-Dèbit
Durée de Post-Dèbit
t2
Détente à 2-Temps
Détente à 4-Temps
Probléme de Terre
t
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
115V 15A
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.
Classement de PriseSource Auxiliaire
Manual 0-5370
Indication d’erreur
Force d’Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
Tension
V
1-16
IPM
MPM
S
Pouces Par Minute
Mètres Par Minute
Voir Note
Voir Note
Art # A-07639F_AC
S
Safety Instructions
SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC
1.05 Declaration of Conformity
Declaration of Conformity
We Victor Technologies International Inc.
of 16052 Swingley Ridge Road
Suite 300
Chestereld, MO 63033 U.S.A.
in accordance with the following Directive(s):
•2006/95/EC The Low Voltage Directive
•2004/108/EC The Electromagnetic Compatibility (EMC) Directive
hereby declare that:
Equipment: Welding Power Source
Model Name/Number: Firepower 200 AC/DC
Market Release Date: January 16, 2014
is in conformity with the applicable requirements of the following harmonized standards:
•EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC)
requirements
•EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
Classification: The equipment described in this document is Class A and intended for industrial use.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc.
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: November 13, 2014
Steve Ward
(Full Name)
V.P. Europe and General Manager
(Position)
(Signature)
This Class A equipment is not intended for use in residential locations where the electrical power
is provided by the public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
Safety Instructions
!
WARNING
1-17
Manual 0-5370
FIREPOWER TIG 200 AC/DC SAFETY INSTRUCTIONS
Classication:TheequipmentdescribedinthismanualisClassAandintendedforindustrialuse.
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical
power is provided by the public low-voltage supply system. There may be potential difculties in ensuring electromagnetic compatibility in those locations, due to conducted as well
as radiated disturbances.
Manual 0-5370
1-18
Safety Instructions
INTRODUCTION FIREPOWER TIG 200 AC/DC
!
SECTION 2:
INTRODUCTION
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
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning 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:
2.03 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 back cover of this manual.
Include all equipment identification numbers as described above along with a full description of the parts
in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
2.04 DESCRIPTION
The Firepower 200 AC/DC is a single phase constant
current welding inverter capable of performing SMAW
(STICK), GTAW (HF TIG) and GTAW (LIFT TIG) welding
processes. The unit is equipped with digital amperage
and voltage meters, and a host of other features in order
to fully satisfy the broad operating needs of the modern
user. The unit is also fully compliant to Standard CSA E
60974-1-00 and UL 60974.1.
The 200 AC/DC 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.
2.02 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, or bottom of the machine. 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 ii for future reference.
Introduction
2-1
Manual 0-5370
FIREPOWER TIG 200 AC/DC INTRODUCTION
A-12708
2.05 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 PACKAGED ITEMS
• 200AC/DCInverterPowerSource
• Firepower 200 AmpElectrode Holderwith 13ft
(4m) Lead
• Firepower200AmpWorkClampwith10ft(3m)
Lead
• 26 TIG Torch13ft (4m)Lead withIntegrated
Controls & Accessory
• 9ft (2.75m) PowerCordandNEMA6-50P 230V
AC Plug
• ArgonFlowGauge&12.5ft(3.8m)Hose
• 4GeneralPurposeStickElectrodes(E6013)
• ShoulderStrap
• OperatingManual&CD
• FirepowerCap
2.06 TRANSPORTING METHODS
This unit is equipped with a handle for carrying purposes.
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.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.
WARNING
Figure 2-1: 200 AC/DC Packaged System
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, 200 amperes
at 18.0 volts. This means that it has been designed
and built to provide the rated amperage (200A) 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 be allowed to cool. The
thermal cut out will operate if the duty cycle is exceeded.
Manual 0-5370
2-2
Introduction
INTRODUCTION FIREPOWER TIG 200 AC/DC
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
Welding Current (AMPS)
SAFE OPERATING REGION
(TIG & STICK)
0
0
10
20
30
40
60
70
50
80
100
90
Duty Cycle (PERCENTAGE)
GTAW (TIG)
SMAW (STICK)
A-11493
186 AC/DC
Figure 2-2: 200 AC/DC Duty Cycle
2.09 SPECIFICATIONS
Part Number 1442-0033
Power Source Weight 48.4lbs (22 kg)
Power Source Dimensions H15.75"xW9.45"xD18.7"
Cooling Fan Cooled (Runs Continually)
Welder Type Inverter Power Source
Applicable Standards / Approvals CSA E60974-1-00 / UL60974-1 / IEC 60974-1
Number of Phases 1
Nominal Supply Frequency 50/60Hz
Welding Current Range (STICK Mode) 5 - 160A (DC Stick) 10-170A (AC Stick)
Welding Current Range (TIG Mode) 5 - 200A (DC TIG) 30-200A (AC LIFT TIG)
Nominal Supply Voltage 208V 230V
Effective Input Current (I1eff) (See Note 1)
STICK
TIG
Maximum Input Current (I1max)
STICK
TIG
Single Phase Generator Requirement (See Note 2) 9.5KVA (7KW)
STICK (SMAW)
Welding Output, 40ºC, 10 min.
TIG (GTAW)
Welding Output, 40ºC, 10 min.
Open circuit voltage 70.3 VDC / 50VAC
Protection Class IP23S
Description Firepower 200 AC/DC INVERTER
(H 400mm x W 240mm x D 475mm)
10-200A (AC HF TIG)
16.4A
16.5A
35.6A
35.4A
Table 2-1: 200 AC/DC Specification
170A @ 15%, 26.8V
100A @ 60%, 24.0V
80A @ 100%, 23.2V
200A @ 20%, 18V
116A @ 60%, 14.6V
90A @ 100%, 13.6V
15.5A
14.1A
34.9A
32.4A
Introduction
2-3
Manual 0-5370
FIREPOWER TIG 200 AC/DC INTRODUCTION
e
Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements.
Note 2: Generator Requirements at the Maximum Output Duty Cycle.
2.10 OPTIONAL ACCESSORIES
26 Style TIG Torch with Remote Current Control ..... Part No. 1442-0050
Basic Utility Cart .......................................................... Part No. 1444-0900
Foot Control ................................................................. Part No. 1442-0025
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.
100
90
80
200 AC/DC
70
60
(volts)
50
TIG
Output Voltag
40
30
20
10
STICK
0
020406080 100 120 140 160180 200 220 240
Figure 2-3: 200 AC/DC Volt-Amp Curves
Manual 0-5370
Welding Current (AMPS)
2-4
A-11583
Introduction
INSTALLATION FIREPOWER TIG 200 AC/DC
!
SECTION 3:
INSTALLATION, OPERATION AND SETUP
3.01 ENVIRONMENT
These units are designed for use in environments with
increased hazard of electric shock as outlined in EN
60974.1. 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.
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 0.5" (12mm)), and direct protection
from vertical drops. Under no circumstances
should the unit 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
connected by a qualified electrician.
3.03 VENTILATION
3. In wet or damp hot locations where humidity
or perspiration considerable 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 0° C to 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.
F. Place at a distance of 12" (300 mm) or more from
walls or similar that could restrict natural air flow
for cooling.
WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.
3.04 MAINS SUPPLY VOLTAGE
REQUIREMENTS
The Mains supply voltage
should be within ± 15% of the rated mains supply
voltage. Too low a voltage may cause poor welding
performance. Too high a supply voltage will cause
components to overheat and possibly fail.
The Welding Power Source must be:
• Correctly installed,if necessary, by aqualied
electrician.
• Correctlyearthed(electrically)inaccordancewith
local regulations.
• Connectedtothecorrectsizepowerpointandfuse
as per the Specifications on page 3-2.
Installation
3-1
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
!
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.
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
Input Current at Maximum Output 32 Amps
Maximum Recommended Fuse* or Circuit Breaker Rating
* Time Delay Fuse, UL class RK5. Refer to UL248
Maximum Recommended Fuse^ or Circuit Breaker Rating
^Normal Operating , UL class K5. Refer to UL248
Minimum Recommended Cord Size 12 AWG
Maximum Recommended Extension Cord Length 50 ft
Minimum Recommended Grounding Conductor Size 12 AWG
Table 3-1: Electrical Service Guide
50 Amps
50 Amps
3.05 HIGH FREQUENCY INTRODUCTION
The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference
due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following
information is intended as a guide for personnel installing high frequency welding machines.
The high frequency section of this machine has an output similar to a radio transmitter. The machine
should NOT be used in the vicinity of blasting operations due to the danger of premature firing
It is also possible that operation close to computer installations may cause computer malfunction.
Manual 0-5370
WARNING EXPLOSIVES
WARNING COMPUTER
3-2
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
3.06 HIGH FREQUENCY INTERFERENCE
Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways.
1. Direct Radiation: Radiation from the machine can occur if the case is metal and is not properly grounded. It
can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power
Source will prevent direct radiation if the equipment is properly grounded.
2. Transmission via the Supply Lead: Without adequate shielding and filtering, high frequency energy may be
fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation
and conduction. Adequate shielding and filtering is provided in the Power Source.
3. Radiation from Welding Leads: Radiated interference from welding leads, although pronounced in the
vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimise this type
of interference. Looping and suspending of leads should be avoided wherever possible.
4. Re-Radiation from Unearthed Metallic Objects: A major factor contributing to interference is re-radiation from
unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation
in most cases.
3.07 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.
Installation
3-3
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
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.
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.
Manual 0-5370
3-4
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
3.08 200 AC/DC Power Source Controls, Indicators and Features
18
17
16
15
14
13
12
19
5
6
7
8
9
10
11
20
21
1
2
Figure 3-1: Controls on Front Panel
ON
OFF
3 4
22
Installation
A-11232
Figure 3-2: Rear Panel
3-5
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
1. Positive Welding Terminal
Positive Welding Terminal (50mm) dinse. Welding current flows from the Power Source via heavy duty bayonet
type terminals. It is essential, however, that the male plug is inserted fully and turned clockwise until tight to
achieve a sound electrical connection.
2. 8 Pin Control Socket
The 8 pin receptacle is used to connect a trigger switch or remote control to the welding Power Source circuitry:
To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket information
is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface
with the 8 pin receptacle.
NOTE
When not using a Remote, disconnect any remote control device or it may limit the preview and actual
output current range.
Socket Pin Part Number / Description
1 Not used
2 Trigger Switch Input
3
Trigger Switch Input
4 Not used
5 Remote Control 5k ohm Potentiometers Maximum
6 Remote Control 5k ohm Potentiometers Minimum
7 Remote Control 5k ohm Potentiometer Wiper
8 Not used
Table 3-2: 8 Pin Control Plug Configuration
2
1
5
4
3
8
7
6
A-11228
3. Negative Welding Terminal
Negative Welding Terminal 50 mm dinse. Welding current flows from the Power Source via heavy duty bayonet
type terminals. It is essential, however, that the male plug is inserted fully and turned clockwise until tight to
achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
4. Shielding Gas Outlet
The Shielding Gas Outlet located on the front panel is a 5/8-18 UNF female gas fitting and is utilized for the
connection of a suitable TIG Torch.
5. Power ON Indicator
The POWER ON indicator illuminates when the ON/OFF switch (20) is in the ON position and the correct mains
voltage is present.
6. Fault Indicator (Thermal Overload or Primary Circuit Overcurrent)
The Fault Indicator will illuminate in conjunction with an “Err 001” displayed on the ammeter and voltmeter
digital displays if either of the following two conditions exists
Manual 0-5370
3-6
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
1. Thermal Overload
This is due to the duty cycle of the power source being exceeded. Once the power source cools sufficiently
it will automatically reset and the Fault Indicator and Err 001 will go off and the power source is then able
to continue welding. During the time of cooling the power source should remain ON such that the fan
continues to operate allowing the unit to cool sufficiently. If after 30 minutes with the fan running the Fault
Indicator has not gone OFF then have an Accredited Firepower Service Provider check the power source.
2. Primary Circuit Overcurrent
This is due to primary circuit component(s) malfunctioning which results in excessive primary circuit
current. Switch OFF the power source immediately to allow all components to cool down for at least 30
minutes. If after 30 minutes “Err 001” is displayed and Fault Indicator illuminates when the power source
is switched back ON turn the power source OFF and have an Accredited Firepower Service Provider check
the power source.
7. Process Selection Switch
The process selection control is used to select the desired welding mode. Three modes are available, GTAW
(LIFT TIG), GTAW (HF TIG) and SMAW (Stick) modes.
Note that when the unit is powered off the mode selection control will automatically default to LIFT TIG 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.
8. Trigger Mode Control Switch (HF TIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality 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.
NOTE
When operating in GTAW (HF and LIFT TIG modes), the power source will remain active until the
selected down slope time has elapsed.
High
Low
Installation
Figure 3-3
3-7
A-11409
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
AMPS
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 realized, thus eliminating the need for the operator to hold the
torch trigger.
Note that when operating in GTAW (HF and LIFT TIG modes), the power source will remain activated until the
selected down slope time has elapsed
NOTE
This Up Slope operates in (4T) TIG modes only and is used to set the time for the weld current to ramp up,
after the torch trigger switch has been pressed then released, from Initial Current to High or Weld Current.
High
Current
Weld
Current
Initial
Current
Arc Ignited
Pre
Flow
Up
Slope
Crater
Current
Down
Slope
Arc Terminated
TIME
Post
Flow
Press & hold
Trigger
Release
Trigger
9. Wave Balance / Arc Force Indicator
This indicator light will illuminate when programming Wave Balance (AC HF TIG mode only) or Arc Force
(STICK mode only).
10. Forward Programming Button
Pressing this button will advance to the next step in the programming sequence.
11. Multifunction Control
The multifunction control knob is used to adjust welding current.
It is also used to adjust parameters when in programming mode.
12. Back Programming Button
Pressing this button will go back to the previous step in the programming sequence.
13. AC frequency Indicator
This indicator light will illuminate when programming AC Frequency (AC HF TIG mode only).
14. Purge Switch
Figure 3-4
Press & hold
Trigger
Release
Trigger
A-11410_AB
Press the PURGE switch to purge the gas line in LIFT TIG and HF TIG modes. To PURGE the shielding gas
line in LIFT TIG and HF TIG modes press the PURGE switch and release. The indicator will illuminate and
shielding gas will purge for a preset period of 15 seconds. (This cannot be adjusted). To stop shielding gas
from purging within this time press the PURGE switch and release and the purge indicator will extinguish and
shielding gas will cease.
Manual 0-5370
3-8
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
15. Pulse Switch
Press the PULSE switch to toggle Pulse On and OFF in LIFT TIG and HF TIG modes
16. Programming Parameter Indicators (Front Panel Display Indicators)
The Front Panel LED indicators serve two purposes. First, they show what process and what parameter is
selected and the value of that parameter. The AMP DISPLAY shows only amperage values measured in AMPS,
the VOLT DISPLAY can indicate Voltage, Time, Percentage, or Frequency. The UNITES lights indicate the unit
of measurement for the reading on the VOLT DISPLAY: Volts (V), Seconds (SEC), Percent (%),Hertz (HZ). Only
the parameters that are applicable to a specific PROCESS, MODE, or TRIGGER SELECTION will light when
using the FORWARD or BACK programming switches. Secondly, during the welding process, the following
sequence indicators will light to indicate the specific phase of the weld process which is active:
TIG STICK
PREFLOW WELD CURRENT
HOT START
INITIAL CURRENT (4T)
UPSLOPE (4T)
WELD CURRENT (PULSING OFF)
HIGH CURRENT (PULSING ON)
LOW CURRENT (PULSING ON)
DOWNSLOPE
CRATER CURRENT (4T)
POST FLOW
17. Mode Switch
Press the MODE switch to toggle AC and DC output in all Process modes
18. Digital Ammeter
The digital amperage meter is used to display both the pre-set current and actual output current of the power
source.
At times of non-welding, the amperage meter will display a pre-set (preview) amperage value. This value can
be adjusted by varying the multifunction control when the Programming Parameter Indicator light shows
WELD CURRENT.
NOTE: You will not be able to view the pre-set amperage on the power source with this control, amperage will
not be viewable until the arc is initiated. The all-in-one on/off with rotary current control cannot provide preview.
When welding, the amperage meter will display actual welding current.
Should a remote device be connected 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 power
source front panel control must be set to 100%, in which case the remote device will then be able to control
between 0-100% output.
Installation
3-9
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
Adjust programming parameter Press to go forward / go back between
programming status LED’s
A-12716
19. Digital Voltmeter / Parameter meter
The digital volt meter is used to display the actual output voltage of the power source. It is also used to display
Parameters in Programming Mode.
Depending on the Programming Parameter selected, the status indictor adjacent to the volt meter will illuminate
to show the units of the programming parameter.
When welding, the volt meter will display actual welding voltage.
20. ON / OFF Switch
This Switch is located on the rear of the Power Source and turns mains power off and on.
!
WARNING
When the front digital displays are lit, the machine is connected to the Mains supply voltage and the
internal electrical components are at Mains voltage potential
21. Shielding Gas Inlet
Unit has a 5/8" Inert gas fitting suitable for connection of a gas hose to a regulated Shielding Gas Supply. The
Shielding Gas inlet is located on the rear of the Power Source.
22. Cooling Fan
The 200 AC/DC is fitted with a cooling fan that will operate continuously when the ON/OFF switch on the rear
panel is switched to the ON position.
3.09 200 AC/DC - STICK PROGRAMMING MODE
Press the PROCESS SELECTION button to select STICK mode.
Press the MODE switch to toggle between AC and DC welding output.
Press FORWARD or BACK to cycle through available programming functions.
Use the Multi Function Control to adjust the Parameter selected.
While welding the Multi Function Control directly controls the WELD CURRENT.
Figure 3-5: Stick Programming Mode
Manual 0-5370
3-10
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
Programming Parameter Adjustment Device Display
Hot Start
This parameter operates in all weld modes
except LIFT TIG mode and is used to heat up
the weld zone in TIG modes or improve the
start characteristics for stick electrodes the
peak start current on top of the WELD current.
0 to 70A (max 170A weld current)
e.g. HOT START current = 130 amps when
WELD = 100 amps & HOT START = 30 amps
Weld Current
This parameter sets the TIG WELD current
when PULSE is OFF. This parameter also sets
the STICK weld current.
5 to 170A (DC STICK mode)
10 to 170A (AC STICK mode)
Arc Force (STICK Mode only)
Arc Force is effective when in STICK Mode
only. Arc Force control provides and adjustable
amount of Arc 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 100% (maximum
Arc Force) allows greater penetration control to
be achieved.
Table 3-3
Amps
Amps
V
SEC
%
Hz
Volts
0 to 100%
3.10 200 AC/DC – LIFT TIG AND HF TIG PROGRAMMING MODE
Press the PROCESS SELECTION switch to select LIFT TIG or HF TIG mode.
Press the MODE switch to toggle between AC and DC welding output.
Press FORWARD or BACK to cycle through available programming functions.
Use the Multi Function Control to adjust the parameter selected.
Installation
3-11
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
Adjust programming parameter using
the Multi Function Control knob
Press to go forward / go back between
programming status LED’s
A-12717
Figure 3-6: LIFT TIG and HF TIG Programming Mode
Programming Parameter Adjustment Device Display
Pre-Flow
This parameter operates in
TIG modes only and is used to
provide gas to the weld zone
prior to striking the arc, once
the torch trigger switch has been
pressed. This control is used to
dramatically reduce weld porosity
at the start of a weld.
Initial Current
This parameter operates in (4T)
TIG modes only and is used to
set the start current for TIG. The
Start Current remains on until the
torch trigger switch is released
after it has been depressed.
Note: The maximum initial current
available will be limited to the set
value of the weld current.
Up Slope
This parameter operates in (4T)
TIG modes only and is used to
set the time for the weld current
to ramp up, after the torch trigger
switch has been pressed then
released, from Initial Current to
High or Weld current.
Manual 0-5370
5 to 200 Amps (DC TIG mode)
30 to 200 Amps (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
0.0 to 15.0 seconds
3-12
Volts
0.0 to 1.0 second
Amps
Volts
V
SEC
%
Hz
V
SEC
%
Hz
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
Programming Parameter Adjustment Device Display
Weld Current
This parameter sets the TIG
WELD current when PULSE is
OFF. This parameter also sets the
STICK weld current.
5 to 200A (DC TIG mode)
30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
High Current
This parameter sets the High weld
current when in PULSE mode.
10 to 200A (DC TIG mode)
30 to 200A (AC TIG mode)
Low Current
The lowest point in the pulse is
called the Low Current.
Amps
Amps
Pulse Width
This parameter sets the
percentage on time of the PULSE
FREQUENCY for High weld
current when the PULSE is ON.
Pulse Frequency
This parameter sets the PULSE
FREQUENCY when the PULSE is
ON.
Down Slope
This parameter operates in TIG
modes only and is used to set
the time for the weld current
to ramp down, after the torch
trigger switch has been pressed,
to crater current. This control is
used to eliminate the crater that
can form at the completion of a
weld.
Amps
5 to 200A (DC HF TIG mode)
30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
V
SEC
%
Hz
Volts
15 to 80%
V
SEC
%
Hz
Volts
0.5 to 200 Hz
V
SEC
%
Hz
Volts
0.0 to 25.0 seconds
Installation
3-13
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
Programming Parameter Adjustment Device Display
Crater Current
This parameter operates in (4T)
TIG modes only and is used to
set the finish current for TIG.
The CRATER Current remains
ON until the torch trigger switch
is released after it has been
depressed.
Note: The maximum crater
current available will be limited to
the set value of the weld current.
Post Flow
This parameter operates in TIG
modes only and is used to adjust
the post gas flow time once
the arc has extinguished. This
control is used to dramatically
reduce oxidation of the tungsten
electrode.
AC Frequency
This parameter operates in AC
TIG mode only and is used to
set the frequency for the AC weld
current.
5 to 200A (DC TIG mode)
30 to 200A (AC TIG mode)
10 to 200A (AC HF TIG mode)
0.0 to 60.0 seconds
Amps
Volts
Volts
V
SEC
%
Hz
V
SEC
%
Hz
15 to 150 Hz
Wave Balance
This parameter operates in AC
TIG mode and is used to set the
penetration to cleaning action
ratio for the AC weld current.
Generally WAVE BALANCE is set
to 50% from the factory for AC
Volts
10 to 65%
TIG Welding. The WAVE BALANCE
control changes the ratio of
penetration to cleaning action of
the AC TIG welding arc. Maximum
weld penetration is achieved
when the WAVE BALANCE control
is set to 10%. Maximum cleaning
of heavily oxidized aluminium or
magnesium alloys is achieved
when the WAVE BALANCE control
is set to 65%.
Table 3-4
WAVE BALANCE is used for aluminium welding in AC HF TIG or AC LIFT TIG mode
It is used to set the ratio of penetration to cleaning action for the AC TIG welding arc.
V
SEC
%
Hz
Maximum weld penetration is achieved when the WAVE BALANCE is set to 10%. Maximum cleaning of heavily
oxidized aluminium or magnesium alloys is achieved when the WAVE BALANCE is set to 65%.
Manual 0-5370
3-14
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
LOW PRESSURE
GAUGE (DELIVERY)
HIGH PRESSURE
GAUGE (SUPPLY)
INLET
CONNECTION
OUTLET
CONNECTION
PRESSURE
ADJUSTING
SCREW
A-12435
!
Wave Balance = 50% Wave Balance = 10% Wave Balance = 65%
10%50% 65%
(+)(+) (+)
(-)(-) (-)
90%50% 35%
Balanced with 50% penetration
and 50% cleaning
3.11 SHORT CIRCUIT PROTECTION WHILE WELDING
Maximum Penetration and
reduced cleaning
Table 3-5: AC TIG Wave Balance
Maximum Cleaning and
reduced penetration
A-11223
To prolong the useful life of a TIG tungsten electrode and eliminate tungsten contamination to welding point, the
200 AC/DC incorporates special circuitry.
In all TIG processes, after the welding arc has established, if the tungsten electrode touches the work the current
defaults to 33 amps. If the short exists for more than 1-2 seconds, the output is turned off.
In STICK mode, if the electrode touches the work for more than two seconds the welding current is reduced to
0 Amps.
3.12 FIREPOWER FLOWMETER/REGULATOR
Pressure Flowmeter/Regulator (Figure 3-7) attached to the cylinder valve reduce high cylinder pressures to suitable
low working pressures for welding, cutting, and other applications.
Use the Flowmeter/Regulator for the gas and pressure for which it is designed. NEVER alter a Flowmeter/
Regulator for use with any other gas.
Installation
Figure 3-7: Firepower CS Flowmeter/Regulator
WARNING
3-15
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
!
!
NOTE
Flowmeter/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 Flowmeter/Regulator. DO NOT attach the Flowmeter/
Regulator to a system that has a higher pressure than the maximum rated pressure stamped on the
Flowmeter/Regulator.
2. The Flowmeter/Regulator body will be stamped “IN" or “HP" at the inlet port. Attach the inlet port to the
system supply pressure connection.
3. If gauges are to be attached to the Flowmeter/Regulator and the Flowmeter/Regulator 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 Flowmeter/Regulator they are being used
on according to UL252A.
DO NOT use a Flowmeter/Regulator that delivers pressure exceeding the pressure rating of the
downstream equipment 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 Flowmeter/Regulator.
4. Be sure that the Flowmeter/Regulator has the correct pressure rating and gas service for the cylinder used.
5. Carefully inspect the Flowmeter/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 Flowmeter/Regulator (Figure 3-9) to the cylinder valve. Tighten securely with a wrench.
DO NOT attach or use the Flowmeter/Regulator if oil, grease, flamma ble substances or damage is
present! Have a qualified repair technician clean the Flowmeter/Regulator or repair any damage.
WARNING
WARNING
Art # A-12436
Figure 3-8: Flowmeter/Regulator to Cylinder Valve
6. Before opening the cylinder valve, turn the Flowmeter/Regulator adjusting screw counterclockwise until
there is no pressure on the adjusting spring and the screw turns freely.
Manual 0-5370
3-16
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
!
!
7. Relief Valve (where provided): The relief valve is designed to protect the low pressure side of the Flowmeter/
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 Flowmeter/Regulator.
WARNING
Stand to the side of the cylinder opposite the Flowmeter/Regulator when opening the cylinder valve.
Keep the cylinder valve between you and the Flowmeter/Regulator. For your safety, NEVER STAND IN
FRONT OF OR BEHIND A Flowmeter/Regulator WHEN OPENING THE CYLINDER VALVE!
8. Slowly and carefully open the cylinder valve (Figure 3-9) until the maximum pressure shows on the high
pressure gauge.
Art # A-09828
Figure 3-9: Open Cylinder Valve
9. Open the cylinder valve completely to seal the valve packing. On gaugeless Flowmeter/Regulators, the
indicator will register the cylinder contents open.
CAUTION
Keep the cylinder valve wrench, if one is required, on the cylinder valve to turn off the cylinder quickly,
if necessary.
10. Attach the desired downstream equipment.
3.13 SPECIFICATION FOR TIG TORCH
1. SPECIFICATION FOR TIG TORCH PART NO: W4013600 TO SUIT Firepower 200AC/DC
TIG Torch Contents include:
1 x 26 TIG Torch with Long Back Cap, 12.5 ft lead length, 10.5" gas hose length, 9.5" control lead with 8 pin
plug and Rigid Head.
Remote Control Cartridge, Potentiometer with integrated on/off switch (installed).
Installation
3-17
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
A-12703
roller potentiometer and
A-12704
NOTE: The additional switches/controls below are interchangeable with the installed control in the TIG torch.
ART# A-11587
Control module with
push button on/o
switch only.
Control module with
push button on/o switch
with roller potentiometer.
Control module with
integrated on/o switch.
Additional On/Off Switch Cartridge in a Sealed Plastic Bag.
Additional On/Off Switch-Remote Amperage Control Cartridge in a Sealed Plastic Bag (NOTE: You will not be
able to view the pre-set amperage on the power source with this control, amperage will not be viewable until the
arc is initiated).
1 x Accessory Kit containing 1 x Short Back Cap, 1 x Collet Body 1/8" (3.2mm),
1 x Collet Body 3/32" (2.4mm), 1 x Collet Body 1/16" (1.6mm), 1 x Collet 1/8" (3.2mm), 1 x Collet 3/32" (2.4mm),
1 x Collet 1/16" (1.6mm), 1 x Nozzle Alumina No5, 1 x Nozzle Alumina No6, 1 x Nozzle Alumina No7, 1 x Tungsten
Electrode 1/8" (3.2mm) Thoriated Type (red band), 1 x Tungsten Electrode 3/32" (2.4 mm) Thoriated Type (red
band) and 1 x Tungsten Electrode 1/16" (1.6mm) Thoriated Type (red band).
Manual 0-5370
3-18
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
3.14 SETUP FOR TIG (GTAW) WELDING
A. Select Lift TIG or HF TIG mode with the process selection control (refer to Section 3.08.7 for further information).
B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via
heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely
to achieve a sound electrical connection.
C. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source
via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted fully and turned
clockwise until tight to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the bayonet terminal.
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 or HF TIG Mode.
Note: See Appendix A3 for TIG torch contents and trigger switch options.
NOTE
If the TIG torch has a remote TIG torch current control fitted then it will require to be connected to the
8 pin socket. (Refer to section 3.08.2 Remote Control Socket for further information).
E. Fit the welding grade shielding gas Flowmeter/Regulator/flowmeter to the shielding gas cylinder (refer to Section
3.12) then connect the shielding gas hose from the Flowmeter/Regulator/flowmeter outlet to the gas INLET on
the rear of the 200 AC/DC Power Source. Connect the gas hose from the TIG torch to the gas OUTLET on the
front of the 200 AC/DC Power Source.
!
WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable
stationary support to prevent falling or tipping.
Installation
3-19
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
Positive Welding
Terminal (+)
8
Work Lead
8 Pin Control Socket
Tig Torch
A-12720
Negative Welding
Terminal (-)
When the 200 AC/DC is used with a Remote Foot Control in, depress foot control to maximum to allow
max current to be previewed/adjusted on the front panel. To avoid premature arcing, please ensure the
TIG Torch is located away from your work piece.
Manual 0-5370
Figure 3-10: Setup for TIG Welding
NOTE
3-20
Installation
INSTALLATION FIREPOWER TIG 200 AC/DC
LIFT TIG (GTAW) Sequence of Operation
CAUTION
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Connect the ground (work) clamp cable to positive output terminal. It is essential that the male plug is inserted
and turned fully clockwise until connector locks in place to achieve reliable electrical connection.
3. Connect the TIG torch as follows:
a) Place the TIG torch into the negative output terminal. It is essential that the male plug is inserted and turned
fully clockwise until connector locks in place to achieve reliable electrical connection;
b) Place the 8 pin plug into the 8 pin socket. To make connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
c) Place the TIG torch gas hose to the gas outlet and tighten with a wrench. Caution: DO NOT over tighten.
4. Using a secured Argon cylinder, slowly crack open then close the cylinder valve while standing off to the side
of the valve. This will remove any debris that may be around the valve & Flowmeter/Regulator seat area.
5. Install the Flowmeter/Regulator (for details of Firepower Flowmeter/Regulator, please refer to 3.18) and tighten
with a wrench.
6. Connect one end of the supplied gas hose to the outlet of the Argon Flowmeter/Regulator and tighten with a
wrench. Caution: DO NOT over tighten.
7. Connect the other end of the supplied gas hose to the gas inlet fitting on the rear panel of the welder and tighten
with a wrench. Caution: DO NOT over tighten.
8. Open the Argon Cylinder Valve to the fully open position.
9. Connect the ground (work) clamp to your work piece.
10. Set the DOWN SLOPE control knob to the desire weld current ramp down time.
11. Set the weld current control knob to the desired amperage.
12. The tungsten must be ground to a blunt point in order to achieve optimum welding results. It is critical to grind
the tungsten electrode in the direction the grinding wheel is turning.
13. Install the tungsten with approximately 1/8" (3.2mm) to ¼" (6.0mm) sticking out from the gas cup, ensuring
you have correct sized collet.
14. Tighten the back cap.
15. Plug the power cable into the appropriate outlet, and turn the switch to the “ON" position. The power L.E.D.
light should illuminate. Set the “Process Selection Switch" to LIFT TIG.
16. You are now ready to begin TIG Welding.
When the 200 AC/DC is used with a Remote Foot Control in, depress foot control to maximum to allow
max current to be previewed/adjusted on the front panel. To avoid premature arcing, please ensure the
TIG Torch is located away from your work piece.
Installation
NOTE
3-21
Manual 0-5370
FIREPOWER TIG 200 AC/DC INSTALLATION
8
Positive Welding
Terminal (+)
Electrode Holder
Work Lead
A-12721
200A
Negative Welding
Terminal (-)
3.15 SETUP FOR STICK (SMAW) WELDING
A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode
manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is
essential, however, that the male plug is inserted fully and turned clockwise until tight 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 heavy duty bayonet type terminals. It is essential, however,
that the male plug is inserted fully and turned clockwise until tight to achieve a sound electrical connection.
C. Select STICK mode with the process selection control (refer to Section 3.08.7 for further information)
!
WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder
make sure the mains power 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.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the bayonet terminal.
Figure 3-11: Setup for Stick Welding.
Manual 0-5370
3-22
Installation
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
SECTION 4:
BASIC WELDING GUIDE
4.01 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.
Effects of Stick 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. 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.
B. 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 pre-heating of heavy sections
necessary to give proper fusion of weld and base metal.
E. Types of Electrodes
Arc Welding electrodes are classified into a number of groups depending on their applications. There are a
great number of electrodes used for specialized industrial purposes which are not of particular interest for
everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for
welding large diameter pipes, etc The range of electrodes dealt with in this publication will cover the vast
majority of applications likely to be encountered; are all easy to use.
Basic Welding Guide
4-1
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
Art # A-07688
Art # A-07689
Art # A-07690
Metal Being Joined Electrode Comments
Mild Steel E6011 This electrode is used for all-position welding or for welding
on rusty, dirty, less-than-new metal. It has a deep, penetrating
arc and is often the first choice for repair or maintenance work.
Mild Steel E6013 This all-position, electrode is used for welding clean, new sheet
metal. Its soft arc has minimal spatter, moderate penetration and
an easy-to-clean slag.
Mild Steel E7014 All positional, ease to use electrode for use on thicker steel than
E6013. Especially suitable sheet metal lap joints and fillet welds,
general purpose plate welding.
Mild Steel E7018 A low-hydrogen, all-position electrode used when quality is an
issue or for hard-to-weld metals. It has the capability of producing
more uniform weld metal, which has better impact properties at
low temperatures.
Cast Iron Eni-Cl Suitable for joining all cast irons except white cast iron.
Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy work etc.
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 4-5 through 4-12.
Art # A-07687
Figure 4-1: Flat Position, Down Hand Butt Weld
Figure 4-2: Flat Position, Gravity Fillet Weld
Figure 4-3: Horizontal Position, Butt Weld
Art A-07691
Figure 4-5: Vertical Position, Butt Weld
Art # A-07692
Figure 4-6: Vertical Position, Fillet Weld
Art# A-07693
Figure 4-4: Horizontal-Vertical (HV) Position
Manual 0-5370
4-2
Figure 4-7: Overhead Position, Butt Weld
Basic Welding Guide
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
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
Art # A-07694
Figure 4-8: 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 4-9.
Figure 4-9: Typical Joint Designs for Arc Welding
Basic Welding Guide
4-3
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
20°
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" (6.0mm) thick and a 1/8" (3.2mm) electrode. Clean any paint, loose scale
or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand
position. 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 Welder
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.
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.
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" (1.6mm) to 1/8" (3.2mm) 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-07696_AB
1.6 mm (1/16”)
Figure 4-10: 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.
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.
Manual 0-5370
4-4
Basic Welding Guide
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
20°-30°
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 4-11, allowing 1/16" (1.6mm) to 3/32" (2.4mm)
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" (6.0mm) should have their mating edges
bevelled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root.
Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a wellformed 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.
Electrode
Tack Weld
Tack Weld
Art # A-07697_AB
Figure 4-11: Butt Weld
Art # A-07698
Figure 4-12: 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 4-12. 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.
Basic Welding Guide
4-5
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
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
4-4.
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. 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 4-13. Do not attempt
to build up much larger than 1/4" (6.4mm) width
with a 1/8" (3.2mm) 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 4-14. Weaving in HV fillet welds
is undesirable.
45° from
vertical
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to
your work bench in an upright position. 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 4-15. 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
4-16 illustrates multi-run technique and Figure
4-17 shows the effects of pausing at the edge
of weave and of weaving too rapidly.
Art # A-07701
60° - 70° from line
of weld
Art # A-07699_AB
Figure 4-13: Electrode Position for HV Fillet Weld
Art # A-07700_AB
6
3
1
5
2
4
Figure 4-`14: Multi-runs in HV Fillet Weld
Figure 4-15: Single Run Vertical Fillet Weld
Art # A-07702
Figure 4-16: Multi Run Vertical Fillet Weld
Manual 0-5370
4-6
Basic Welding Guide
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
Art # A-07703
Figure 4-17: Examples of Vertical Fillet Welds
2. Vertical Down
Use a 1/8" (3.2mm) electrode at 100 amps. The tip of the electrode is held in light contact with the work
and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.
The electrode should point upwards at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead welding is not much more difficult that
downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right
angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in
a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode
is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-18). 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.
Art # A-07704
Figure 4-18: 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.
Basic Welding Guide
4-7
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
Upsetting
Weld
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" (2.0mm) 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 fulfil 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 4-19 and
4- 20 illustrate how distortion is created.
Hot
Weld
Hot
Expansion with
compression
Cool
Art # A-07705_AB
Figure 4-19: Parent Metal Expansion
Art # A-07706_AC
Permanent Upset
Contraction
with tension
Figure 4-20: 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 4-20 through 4-23 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 4-21.
Manual 0-5370
4-8
Basic Welding Guide
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
Art # A-07708
E. Preheating
Suitable preheating of parts of the structure other
than the area to be welded can be sometimes used
to reduce distortion. Figure 4-22 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 4-21: Principle of Presetting
B
Weld
C
PreheatPreheat
Art # A-07710_AB
4
Art # A-07711_AB
Figure 4-25: Step Back Sequence
1
2
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
3
Figure 4-24: Welding Sequence
1
2
3
Dotted lines show effect if no preheat is used
Figure 4-22: Reduction of Distortion by Preheating
Art # A-07709
Figure 4-23: Examples of Distortion
Art # A-07428_AB
Figure 4-26: Chain Intermittent Welding
Art # A-07713_AB
Figure 4-27: Staggered Intermittent Welding
Basic Welding Guide
4-9
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
Art: A-04971
4.02 STICK (SMAW) WELDING TROUBLESHOOTING
FAULT CAUSE REMEDY
1 Welding current
varying
2 A gap is left by
failure of the weld
metal to fill the
root of the weld.
3 Non-metallic par-
ticles are trapped
in the weld metal.
ARC FORCE control knob
is set at a value that
causes the welding current
to vary excessively with
Reduce the ARC FORCE control knob until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece
when you “dig" the electrode into the workpiece.
the arc length.
A Welding current too low A Increase welding current.
B Electrode too large for
B Use smaller diameter electrode.
joint.
C Insufficient gap. C Allow wider gap.
A Non-metallic particles may
be trapped in undercut
A If a bad undercut is present clean slag bout and
cover with a run from a smaller gauge electrode.
from previous run.
B
Joint preparation too
restricted.
C Irregular deposits allow
B Allow for adequate penetration and room for
cleaning out the slag.
C If very bad, chip or grind out irregularities.
slag to be trapped.
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-
E Clean joint before welding.
venting full fusion.
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.
Figure 1 - Example of insufficient gap or incorrect sequence
Manual 0-5370
4-10
Basic Welding Guide
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
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).
5 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.
A Welding current is too
A Reduce welding current.
high.
B Welding arc is too long. B Reduce the length of the welding arc.
C Angle of the electrode is
incorrect.
D Joint preparation does not
allow correct electrode
C Electrode should not be inclined less than 45° to
the vertical face.
D Allow more room in joint for manipulation of the
electrode.
angle.
E Electrode too large for
E Use smaller gauge electrode.
joint.
F Insufficient deposit time at
edge of weave.
A Small electrodes used on
F Pause for a moment at edge of weave to allow
weld metal buildup.
A Use larger electrodes and preheat the plate.
heavy cold 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
D Reduce travel speed of electrode.
is too high.
6 Gas pockets or
voids in weld
metal (porosity)
E Scale or dirt on joint
E Clean surface before welding.
surface.
Art: A-04972
Figure 2: Example of Lack of Fusion
A High levels of sulphur in
steel.
A Use an electrode that is designed for high sul-
phur steels.
B Electrodes are damp. B Dry electrodes before use.
C Welding current is too
C Reduce welding current.
high.
D Surface impurities such as
D Clean joint before welding.
oil, grease, paint, etc.
E Welding in a windy envi-
E Shield the weld area from the wind.
ronment.
F Electrode damaged i.e. flux
coating incomplete.
F Discard damaged electrodes and only use elec-
trodes with a complete flux coating.
Basic Welding Guide
4-11
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
FAULT CAUSE REMEDY
7 Crack occurring in
weld metal soon
after solidification
commences
A Rigidity of joint. A Redesign to relieve weld joint of severe stresses
or use crack resistance electrodes.
B Insufficient throat thick-
ness.
B Travel slightly slower to allow greater build up in
throat.
C Weld current is too high. C Decrease welding current.
Art: A-04973
Figure 3: Example of Slag Inclusion
Table 4-2: Welding Problems SMAW (STICK)
4.03 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.
Art # A-09658_AC
Can Be Any Commercial
Welds Made With or Without
Addition of Filler Metal
Tungsten Electrode Current Ranges
Electrode Diameter DC Current (Amps)
0.040" (1.0mm) 30-60
Gas Cup
Either Ceramic,
Work Piece
Metal
High-lmpact or
Water Cooled
Metal
Inert Gas
Shields Electrode
and Weld Puddle
Figure 4-28: TIG Welding Application Shot
1/16" (1.6mm) 60-115
3/32" (2.4mm) 100-165
Tungsten Electrode
Non-Consumable
1/8" (3.2mm) 135-200
5/32" (4.0mm) 190-280
3/16" (4.8mm) 250-340
Table 4-3: Current Ranges for Various Tungsten Electrode Sizes
Manual 0-5370
4-12
Basic Welding Guide
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
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" (4.8mm) 200-350
Table 4-4: Filler Wire Selection Guide
Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
Base
Metal
Thickness
1/16"
1.6mm
1/8"
3.2mm
Welding Application Features Color Code
DC welding of mild
steel, stainless steel
and copper
High quality AC welding of aluminium,
magnesium and their
alloys.
AC & DC welding of
mild steel, stainless
steel, copper, aluminium, magnesium and
their alloys
AC Current for
Aluminium
60-80
70-90
125-145
140-160
Excellent arc starting,
Long life, High current
carrying capacity
Self cleaning, Long
life, Maintains balled
end, High current carrying capacity.
Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.
Table 4-5 Tungsten Electrode Types
Tungsten
Electrode
Filler Rod Diameter
(if required)
Diameter
1/16"
1.6mm
3/32"
2.4mm
1/16"
1.6mm
1/16"-3/32"
1.6mm - 2.4mm
Argon Gas
Flow Rate
15 CFM
7 LPM
17 CFM
8 LPM
Red
White
Grey
JOINT
TYPE
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
Basic Welding Guide
Table 4-6 Aluminium Welding Material
4-13
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
Base Metal
Thickness
0.040"
1.0mm
0.045"
1.2mm
1/16"
1.6mm
1/8"
3.2mm
3/16"
4.8mm
1/4"
6.4mm
DC Current
for Mild
Steel
35-45
40-50
45-55
50-60
60-70
70-90
80-100
90-115
115-135
140-165
160-175
170-200
DC Current
for Stainless
Steel
20-30
25-35
30-45
35-50
40-60
50-70
65-85
90-110
100-125
125-150
135-160
160-180
Tungsten
Electrode
Diameter
0.040"
1.0mm
0.040"
1.0mm
1/16"
1.6mm
1/16"
1.6mm
3/32"
2.4mm
1/8"
3.2mm
Filler Rod
Diameter (if
required)
1/16"
1.6mm
1/16"
1.6mm
1/16"
1.6mm
3/32"
2.4mm
1/8"
3.2mm
5/32"
4.0mm
Argon Gas Flow
Joint Type
Rate
10 CFH(5 LPM) Butt/Corner
Lap/Fillet
13 CFH(6 LPM) Butt/Corner
Lap/Fillet
15 CFH(7 LPM) Butt/Corner
Lap/Fillet
15 CFH(7 LPM) Butt/Corner
Lap/Fillet
21 CFH(10 LPM) Butt/Corner
Lap/Fillet
21 CFH(10 LPM) Butt/Corner
Lap/Fillet
Table 4-7: Welding Rate
TIG Welding is generally regarded as a specialised 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. For further information please refer to www.firewpower.
com or contact Firepower.
Manual 0-5370
4-14
Basic Welding Guide
BASIC WELDING GUIDE FIREPOWER TIG 200 AC/DC
4.04 TIG (GTAW) WELDING PROBLEMS
FAULT CAUSE REMEDY
1 Excessive bead build up or
poor penetration or poor
fusion at edges of weld.
2 Weld bead too wide and
flat or undercut at edges
of weld or excessive burn
through.
3 Weld bead too small or
insufficient penetration or
ripples in bead are widely
spaced apart.
4 Weld bead too wide or
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet
joint
6 Electrode melts or oxidises
when an arc is struck.
Welding current is too
low
Welding current is too
Increase weld current and/or faulty joint
preparation.
Decrease weld current.
high
Travel speed too fast Reduce travel speed.
Travel speed too slow Increase travel speed.
Wrong placement of
Re-position filler rod.
filler rod
A. Torch lead connected
to positive welding
A. Connect torch lead to negative welding
terminal.
terminal.
B. No gas flowing to weld-
ing region.
C. Torch is clogged with
B. Check the gas lines for kinks or breaks
and gas cylinder contents.
C. Clean torch.
dust or dirt.
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 Flowmeter/Flow-
F. Turn on.
meter/Regulator turned
off.
G. The electrode is too
small for the welding
G. Increase electrode diameter or reduce the
welding current.
current.
H. Power source is set for
STICK welding.
H. Set Power Source to LIFT TIG or HF TIG
mode.
Basic Welding Guide
4-15
Manual 0-5370
FIREPOWER TIG 200 AC/DC BASIC WELDING GUIDE
FAULT CAUSE REMEDY
7 Dirty weld pool A. Electrode contaminated
by contact with work
piece or filler rod material.
B. Work piece surface has
foreign material on it.
C. Gas contaminated with
air.
8 Poor weld finish Inadequate shielding
gas.
9 Arc start is not smooth. A. Tungsten electrode is
too large for the welding current.
B. The wrong electrode
is being used for the
welding job.
C. Gas flow rate is too
high.
A. Clean the electrode by grinding off the
contaminates.
B. Clean surface.
C. Check gas lines for cuts and loose fitting
or change gas cylinder.
Increase gas flow or check gas line for
gas flow problems.
A. Select the right size tungsten electrode.
Refer to Table 4-3 Tungsten Electrode
Selection Chart.
B. Select the right tungsten electrode type.
Refer to Table 4-5 Tungsten Electrode
Selection Chart.
C. Select the right rate for the welding job.
Refer to Table 4-7.
10 Arc flutters during TIG
welding.
D. Incorrect shielding gas
is being used.
E. Poor work clamp con-
nection to work piece.
Tungsten electrode is
too large for the welding current.
D. Select the right shielding gas.
E. Improve connection to work piece.
Select the right size tungsten electrode.
Refer to Table 4-3 Tungsten Electrode
Selection Chart.
Manual 0-5370
4-16
Basic Welding Guide
SERVICE FIREPOWER TIG 200 AC/DC
SECTION 5: POWER SOURCE PROBLEMS
AND ROUTINE SERVICE REQUIREMENTS
5.01 BASIC TROUBLESHOOTING
!
WARNING
There are extremely dangerous voltage and power levels present inside this product. Do not attempt
to open or repair unless you are a qualified electrical tradesperson and you have had training in power
measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an accredited
Firepower Service Provider for repair. The basic level of troubleshooting is that which can be performed without
special equipment or knowledge. Refer also to section 4 for solving welding problems.
5.02 POWER SOURCE PROBLEMS
FAULT CAUSE REMEDY
1. Mains supply voltage is
ON, power indicator is
illuminated however unit
will not commence welding
when the torch trigger
switch is depressed.
2. Mains supply voltage is
ON. Indicator light is not lit
and welding arc cannot be
established.
3. Fault Indicator is illuminated
and unit will not commence
welding when the torch
trigger switch is depressed.
4. Welding output continues
when torch trigger released
5. Welding output voltage
is present when the
torch trigger switch is
depressed but arc cannot be
established.
6. Welding output voltage is
not present when torch
trigger depressed
7. TIG electrode melts when
arc is struck.
8. Arc flutters during TIG
welding.
9. No HF output in HF mode HF Circuit faulty Have an Accredited Firepower
A.
Power source is not in the
correct mode of operation.
B.
Faulty torch trigger.
A. B.Primary control fuse is blown.
Broken connection in primary
circuit.
Duty cycle of power source has
been exceeded.
A.
Trigger mode selection is in 4T
(LATCH) mode
B.
Torch trigger leads shorted
Poor or no work lead contact. Clean work clamp area and ensure
Faulty trigger switch / lead Repair or replace Torch / trigger
TIG torch is connected to
the (+) VE terminal.
Tungsten electrode is too
large for the welding current.
A.
Set the power source to the
correct mode of operation with
the process selection switch.
B.
Repair or replace torch trigger
switch/lead.
A. B.Replace primary control fuse.
Have an Accredited Firepower
Service Provider check primary
circuit.
Leave the power source
switched ON and allow it to
cool. Note that fault indicator
must be extinguished prior to
commencement of welding.
A.
Change to 2T (NORMAL) mode
B.
Repair or replace Torch / trigger
lead
good electrical contact.
lead
Connect the TIG torch to the (-)
VE terminal.
Select the correct size of tungsten
electrode.
Service Provider check HF circuit.
Service
5-1
Manual 0-5370
FIREPOWER TIG 200 AC/DC SERVICE
!
FAULT CAUSE REMEDY
Error Code “Err 001” is
displayed on the digital
displays in conjunction
with the Fault Indicator
Illuminating.
A. Thermal Overload This is due to the duty cycle of
the power source being exceeded.
Once the power source cools
sufficiently it will automatically
reset and the Fault Indicator and
Err 001 will go off and the power
source is then able to continue
welding. During the time of
cooling the power source should
remain ON such that the fan
continues to operate allowing the
unit to cool sufficiently. If after 30
minutes with the fan running the
Fault Indicator has not gone OFF
then have an Accredited Firepower
Service Provider check the power
source.
B.
Primary Circuit Overload This is due to primary circuit
component(s) malfunctioning
which results in excessive primary
circuit current. Switch the power
source to OFF immediately to
allow all components to cool
down for at least 30 minutes.
If after 30 minutes “Err 001” is
displayed and Fault Indicator
illuminates when the power
source is switched back ON turn
the power source OFF and have
an Accredited Firepower Service
Provider check the power source.
Table 5-1: Power Source Problem
5.03 Routine Service and Calibration Requirements
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 Mains Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out in accordance with
Section 5 of EN 60974.1: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Firepower original specifications.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in
EN 60974.1, then the above tests should be carried out prior to entering this location.
Manual 0-5370
WARNING
5-2
Service
SERVICE FIREPOWER TIG 200 AC/DC
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
Components to be Tested
Input circuit (including any connected control circuits) to welding circuit
(including any connected control circuits)
All circuits to exposed conductive parts
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
Minimum Insulation
Resistance (MΩ)
5
2.5
10
1
1
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.
Service
5-3
Manual 0-5370
FIREPOWER TIG 200 AC/DC SERVICE
!
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.
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.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined
in EN 60974.1, then the above tests should be carried out prior to entering this location.
B. Calibration Requirements
Where applicable, the tests outlined in Table 5-3 below shall be conducted by an accredited Firepower service
provider.
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
Accuracy of digital meters to be checked to ensure it falls within applicable Firepower power source specifications
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.
5.04 Cleaning the Welding Power Source
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 Mains Supply Voltage before disassembling.
To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated
dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign
material may reduce the welders output welding current.
Manual 0-5370
WARNING
5-4
Service
SPARE PARTS FIREPOWER TIG 200 AC/DC
SECTION 6:
KEY SPARE PARTS
6.01 POWER SOURCE
24
21
15
23
12
1
13
12
14
7
19
5
6
16
2
3
11
4
25
28
17
9
A-11500_AC
20
10
8
Spare Parts
Figure 6-1
6-1
18
Manual 0-5370
FIREPOWER TIG 200 AC/DC SPARE PARTS
200 AC/DC Spare Parts
Item Part Number Description
1 W7005500 PCB display
2 W7005503 PCB aux power supply
3 W7005502 PCB HF
4 W7005504 PCB 200ACDC
5 W7005505 PCB AC output drive
6 W7005506 PCB control
7 W7005507 PCB secondary rectifier
8
9 W7005509 Coil coupling HF
10 W7005520 Fan assembly
11
12
13
14 W7005514 Gas outlet, front panel
15 W7005515 Switch, On/Off
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31 1442-0093 Front Control, Label (now shown)
1442-0090 Side Panel
W7003033 Gas solenoid assembly
W7005513 Dinse Socket 50mm²
W7005568 Control socket 8 pin (including wire harness)
W7003076 CT, output
W7005539 Inductor 200AC/DC
1442-0091 Base Panel
W7005531 Front panel
W7005516 Rear panel
1442-0092 Panel, Top Cover
W7003215 Gas inlet fitting(not shown)
W7005537 Control knob, (25mm
2
OD)
W7005536 Handle
W7004952 CT, primary
W7005501 Shroud, Knob, Front Panel (not shown)
W7004930 Shielding Gas Hose Assy (not shown)
W7005511 Transformer
831761 Set-Up Guide, English (not shown)
831762 Set-Up Guide, French (not shown)
Table 6-1
Manual 0-5370
6-2
Spare Parts
APPENDIX FIREPOWER TIG 200 AC/DC
APPENDIX 1 : CIRCUIT DIAGRAM
11/07/14
200 AC/DC SYSTEM SCHEMATIC
Appendix
A-1
A-12719
Manual 0-5370
FIREPOWER TIG 200 AC/DC APPENDIX
APPENDIX 2 : 200 AC/DC SETUP GUIDE
Manual 0-5370
A-2
Appendix
APPENDIX FIREPOWER TIG 200 AC/DC
A-12718
Appendix
A-3
Manual 0-5370
FIREPOWER TIG 200 AC/DC APPENDIX
This Page Blank Intentionally
Manual 0-5370
A-4
Appendix
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.
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 Flowmeter/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.
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Ph 1-800-426-1888 (tollfree)
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