Firepower MST-200 3-In-1 Multiprocess Welding System Firepower FP-200 MIG/MAG Welding System Instruction manual 0463 766 001 GB 20210830
TABLE OF CONTENTS 1 2 SAFETY ................................................................................................................................4 1.1 Meaning of symbols ................................................................................................................ 4 1.2 Safety precautions .................................................................................................................. 4 1.3 User responsibility ...........................................
TABLE OF CONTENTS 8 9 TROUBLESHOOTING ........................................................................................................69 8.1 Power source problems ........................................................................................................ 69 8.2 MIG (GMAW/FCAW) welding troubleshooting .................................................................... 70 8.3 MMA (SMAW) welding troubleshooting (only for Firepower MST-200) ........................... 74 8.
1 SAFETY 1 SAFETY 1.1 Meaning of symbols As used throughout this manual: Means Attention! Be Alert! DANGER! Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life. WARNING! Means potential hazards which could result in personal injury or loss of life. CAUTION! Means hazards which could result in minor personal injury.
1 SAFETY FIRES AND EXPLOSIONS Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore: 1. Protect yourself and others from flying sparks and hot metal. 2. Remove all combustible materials well away from the work area or cover the materials with a protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings paper, etc. 3.
1 SAFETY ELECTRIC AND MAGNETIC FIELDS May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 2. Exposure to EMF may have other health effects which are unknown. 3.
1 SAFETY MOVING PARTS Moving parts, such as fans, rotors and belts can cause injury. Therefore: 1. 2. 3. 4. Keep all doors, panels, guards and covers closed and securely in place. Stop engine or drive systems before installing or connecting unit. Have only qualified people remove covers for maintenance and troubleshooting as necessary To prevent accidental starting of equipment during service, disconnect negative (-) battery cable from battery. 5.
1 SAFETY CAUTION! ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding, Cutting and Gouging”, Form 52-529. The following publications are recommended: • • • • • • • • • • 0463 766 001 ANSI/ASC Z49.1 - “Safety in Welding and Cutting” AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding” AWS C5.
1 SAFETY 1.3 User responsibility Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
1 SAFETY ELECTRIC SHOCK - Can kill • Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing • Insulate yourself from work and ground. • Ensure your working position is safe ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health • Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. • Exposure to EMF may have other health effects which are unknown.
1 SAFETY MALFUNCTION - Call for expert assistance in the event of malfunction. PROTECT YOURSELF AND OTHERS! CAUTION! This product is solely intended for arc welding. ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website. 1.
2 INTRODUCTION 2 INTRODUCTION The Firepower MST-200 is a self-contained single phase multi process welding system that is capable of performing MIG (GMAW/FCAW), MMA (SMAW) and LIFT TIG (L-GTAW) welding. The Firepower FP-200 is a self-contained single phase welding system that is capable of performing MIG (GMAW/FCAW) welding. The power sources are equipped with an integrated wire feed unit, digital voltage and amperage meters, and a host of other features. 2.
3 TECHNICAL DATA 3 TECHNICAL DATA Firepower MST-200 120 V ±15% 1~ 50/60 Hz Input voltage 230 V ±15% 1~ 50/60 Hz Primary current Imax MIG (GMAW/FCAW) 26 A 38 A Imax Lift TIG (L-GTAW) 22 A 29 A Imax MMA (SMAW) 26 A 38 A Open circuit voltage (OCV) 68 V Setting range MIG (GMAW/FCAW) 30 A / 15.5 V - 90 A / 18.5 V 30 A / 15.5 V - 200 A / 24 V Lift TIG (L-GTAW) 10 A / 10.4 V - 90 A / 13.6 V 10 A / 10.4 V - 200 A / 18 V MMA (SMAW) 20 A / 20.8 V - 70 A / 22.8 V 20 A / 20.8 V - 170 A / 26.
3 TECHNICAL DATA Firepower MST-200 Effective input current (I1eff) MIG (GMAW) Lift TIG (L-GTAW) MMA (SMAW) Max weld thickness 13 A 11 A 13 A 0.38 in. (9.52 mm) 14.7 A 11.2 A 14.7 A Operating temperature +14 to 104 °F (-10 to +40 °C) Transportation temperature -4 to 131 °F (-20 to +55 °C) Continual sound pressure at no-load <70 dB Dimensions l × w × h 19.2 × 8.7 × 15 in. (488 x 220 x 381 mm) Weight 30.2 lb (13.
3 TECHNICAL DATA Firepower FP-200 Transportation temperature -4 to 131 °F (-20 to +55 °C) Continual sound pressure at no-load <70 dB Dimensions l × w × h 19.2 × 8.7 × 15 in. (488 x 220 x 381 mm) Weight 30.2 lb (13.7 kg) Insulation class transformer F Enclosure class IP21S Application class Supply from power generators The power source can be supplied from different types of generators. However, some generators may not provide sufficient power for the welding power source to operate correctly.
4 INSTALLATION 4 INSTALLATION The installation must be carried out by a professional. CAUTION! This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user's responsibility to take adequate precautions. 4.1 Installing 12.5 lb Spool (8 in. diameter) In order to fit a 12.5 lb spool (8 in. diameter) assemble parts in the sequence shown in the figure below. To install wire spool, refer to the steps below. Figure 12: 12.5 lb (8 in.
4 INSTALLATION 4.2 Installing 2 lb spool (4 in. diameter) In order to fit a 2 lb spool (4 in. diameter) assemble parts in the sequence shown in the figure below. To install wire spool, refer to the steps below. Figure 13: 2 lb (4 in.) spool installation 1 Wire spool hub nut 2 Flat washer small hole 3 Spring small hole 4 2 lb (4 in.) diameter wire spool 5 10mm spacer large hole 6 Fiber washer 1) Remove wire spool hub retaining clip. Grasp the loop and pull.
4 INSTALLATION 4.3 Inserting wire into the wire feed mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension knob (1) in a counter clockwise direction. Then to release the pressure roller arm (2) push the tension screw toward the back of the machine which releases the pressure roller arm (2).
5 OPERATION 5 OPERATION General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment! 5.1 Firepower regulator Pressure regulator attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for welding, cutting, and other applications.
5 OPERATION 4. Be sure that the regulator has the correct pressure rating and gas service for the cylinder used. NOTE! For MIG application, the gas mixture used is 80% argon and 20% carbon dioxide. For MAG application, 100% carbon dioxide is used. 5. Carefully inspect the regulator for damaged threads, dirt, dust, grease, oil, or other flammable substances. Remove dust and dirt with a clean cloth. Be sure the inlet swivel filter is clean and in place. Attach the regulator to the cylinder valve.
5 OPERATION 8. Slowly and carefully open the cylinder valve until the maximum pressure shows on the high pressure gauge. 9. Figure 18: Open cylinder valve On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gauge less 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. 5.
5 OPERATION 5.3 1) 2) 3) 4) 5) When you finish using the regulator Close the cylinder valve. Open the valve on the downstream equipment. This drains all pressure from the system. Close the valve on the downstream equipment. Turn the adjusting screw counter-clockwise to release the tension on the adjusting spring. Check the gauges after a few minutes for verification that the cylinder valve is closed completely.
5 OPERATION 1. Spool gun indicator When the correct ESAB Spool-Gun* is connected, the LED will illuminate. (*Optional Accessory). 2. Thermal overload indicator (fault indicator) This welding power source is protected by a self resetting thermostat. The LED indicator will illuminate if the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled.
5 OPERATION NOTE! The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (dip versus spray transfer).
5 OPERATION 9. Remote control socket The 8 pin remote control socket is used to connect remote control devices to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
5 OPERATION MIG Gun / TIG Torch 1 Trigger switch 2 Max (CW) Spool gun (1027-1397) 3 Min (CCW) 4 Pot Amps 1 Trigger switch SMAW 2 10k Peripheral sense 1 Max (CW) 3 Pot Amps 2 Min (CCW) 10. Multifunction control - Voltage, down slope and arc force The multifunction control knob is used to adjust voltage (MIG mode), down slope (LIFT TIG mode) and arc force (MMA mode) depending on the welding mode selected. NOTE! The preview functionality provided on this power source is intended to act as a guide only.
5 OPERATION When MIG mode is selected Parameter Type Voltage（V） SPOOL GUN /WFS（in/min） SPOOL GUN/WFS（m/min） MIG GUN/WFS（in/min） MIG GUN/WFS（m/min） 120V MIN 12 100 2.5 80 2 230V MAX 20 450 11.2 275 6.8 MIN 12 100 2.5 80 2 MAX 26 600 15 450 11.2 MIG/MAG welding process left side first LED is illuminated Left-hand side LED display Indicates set welding voltage (V). Rotating Left-hand side encoder CW (Clockwise) will increase welding voltage value.
5 OPERATION b) Inductance functions Short pressing Right-hand side Button will access the Inductance functions, Inductance is used during the MIG/MAG welding process. Inductance setting is indicated as “IND” within Left-hand side LED Display with a value shown in Right-hand side LED Display. The inductance value is adjusted by Right-hand side Encoder .This is factory set to “5” adjustment is 1 to 9 (range is 1 to 9) c) MIG Welding Process (2T/4T) i. Under this menu, the 2T/4T LED flashes.
5 OPERATION 11. Arc control (inductance) The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration. Soft means maximum inductance while Hard means minimum inductance. 12.
5 OPERATION 15. Gas inlet (MIG mode only for MIG gun or spool gun operation) The gas inlet connection,5/8-18 UNF female thread is used to supply the appropriate MIG welding gas to the power source. See "Wire reel brake" and "Setup for MIG (GMAW) welding with gas shielded MIG wire" section. WARNING! Only inert shielding gases specifically designed for welding applications should be used. 16. ON / OFF switch This single phase circuit breaker performs a dual function.
5 OPERATION 5.4.2 Firepower FP-200 1. Spool gun indicator When the correct ESAB Spool-Gun* is connected, the LED will illuminate. (*Optional Accessory) 2. Thermal overload indicator (fault indicator) This welding power source is protected by a self resetting thermostat. The LED indicator will illuminate if the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled.
5 OPERATION 3. Digital Wire Feed Speed (WFS) and Welding Amperage (A) (Right side LED display) MIG mode This digital meter is used to display the pre-set (preview) wire feed speed in IPM (inches per minute) in MIG mode and actual welding amperage of the power source when welding. During non-welding, the digital meter will display a pre-set (preview) value of wire feed speed. This value can be adjusted by varying the Wire feed speed control knob (4).
5 OPERATION 7. MIG polarity lead The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal (allowing polarity reversal for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire. When using gasless wire, the polarity lead is generally connected to the negative welding terminal (-).
5 OPERATION Spool gun 1 Trigger switch 4 Pot V-A-WFS 2 Max (CW) 5 Peripheral sense 3 Min (CCW) MIG Gun (F180TH103035) / TIG Torch (W4013802) 1 Trigger switch MIG Gun / TIG Torch 1 Trigger switch 0463 815 001 2 10k Peripheral sense - 34 - © ESAB AB 2021
5 OPERATION SMAW 1. Max (CW) 2. Min (CCW) 3 Pot Amps 10. Voltage control The voltage control knob is used to adjust the voltage in MIG mode. NOTE! The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (dip versus spray transfer).
5 OPERATION a) MIG/MAG Sub-Menu Parameter Type MIN MAX RIN（%） 10 100 PRG（S） 0 10 Bb（S） 0.01 0.1 POG（S） 0.5 10 Access to sub-menu functions is easily performed. Press and hold Left-hand side Button for 2 seconds will access the following functions, then the MIG-LED flashes right now. • Wire Run-In speed: Indicated as “RIN” within Left-hand side LED display Value is adjusted by Right-hand side Encoder and is measured in either as IPM or MPM depending on user choice.
5 OPERATION 4T (Latch mode) This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and released, thus eliminating the need for the operator to hold the torch trigger. 13. Process selection control The process selection control is used to select the MIG (GMAW/FCAW) welding mode.
5 OPERATION 5.5 Firepower MST-200 and Firepower FP-200 features Wiredrive motor circuit breaker The 4A circuit breaker protects the unit from electrical faults and will operate in the event of a motor overload. NOTE! If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button.
5 OPERATION 5.6 Attaching the ESAB fusion 180 A MIG gun Figure 27: Attaching MIG gun 1 MIG gun adapter 2 MIG gun connector 1) Open side panel and loosen thumb screw. 2) Fit the MIG gun to the power source by pushing the MIG gun connector into the MIG gun adapter. 3) Tighten thumb screw and replace side panel. 5.7 Feed roller pressure adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw.
5 OPERATION 5.8 Changing the feed roll To change the feed roll, remove the feed roll retaining screw by turning it in a counter clockwise direction. Once the feed roll is removed, to replace feed roll, simply reverse these directions. NOTE! Be sure not to lose key that is located on drive motor shaft. This key must align with drive roll groove for proper operation. A dual groove feed roller is supplied as standard. It can accommodate 0.02-0.03 in. (0.6-0.8 mm) diameter hard wires.
5 OPERATION 5.9 Wire reel brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the thumb screw inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 1/8 in.-3/16 in. (3-5 mm) after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.
5 OPERATION 5.10 Setup for MIG (GMAW) welding with gas shielded MIG wire 1) Select MIG mode with the process selection control, see " Firepower MST-200, Firepower FP200 controls, indicators and features". 2) Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current flows from the power source via dinse type terminals.
5 OPERATION 5.11 Setup for MIG (FCAW) welding with flux core (gasless) wire 1) Select MIG mode with the process selection control see " Firepower MST-200, Firepower FP200 controls, indicators and features" section. 2) Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current flows from the power source via dinse type terminals.
5 OPERATION 5.12 Setup for spool gun MIG (GMAW) welding with gas shielded MIG wire Select the process selection control to MIG for spool gun welding. For setup and operation of the spool gun, please refer to the spool gun instruction manual. Switch the MIG gun/spool gun switch inside the wire feed compartment to spool gun. Connect the shielding gas for the to the shielding gas inlet on the rear panel of the power source. 1.
5 OPERATION 5.13 Setup for LIFT TIG (L-GTAW) welding (only for Firepower MST-200) 1) Select LIFT TIG mode with the process selection control, see section 5.4.1 " Firepower MST200" 2) Connect the TIG torch to the negative welding terminal (-). Welding current flows from the power source via dinse type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. 3) Connect the work lead to the positive welding terminal (+).
5 OPERATION 5.14 Setup for MMA (SMAW) welding (only for Firepower MST-200) 1) Connect the electrode holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the power source via dinse type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. 2) Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.
6 BASIC WELDING GUIDE 6 BASIC WELDING GUIDE 6.1 MIG (GMAW/FCAW) basic welding Two different welding processes are covered in this section GMAW and FCAW, to provide the very basic concepts in using the MIG mode of welding, where a MIG gun is handheld and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
6 BASIC WELDING GUIDE 6.2 Position of MIG gun The angle of the MIG gun to the weld affects on the width of the weld. 1 Push 3 Drag / Pull 2 Vertical The MIG gun should be held at an angle to the weld joint. (See Secondary adjustment variables below) CAUTION! Do NOT pull the MIG gun back when the arc is established. This will create excessive wire extension (stick-out) and make a very poor weld. The electrode wire is not energized until the MIG gun trigger switch is depressed.
6 BASIC WELDING GUIDE Figure 43: Vertical fillet welds 1 30° to 60° Transverse angle 2 10° Longitudinal angle 3 Direction of travel 4 10° to 20° Longitudinal angle 5 30° to 60° Transverse angle 1 5° to 15° Longitudinal angle 2 30° to 60° Transverse angle 3 Direction of travel 6.3 Distance from the MIG gun nozzle to the workpiece The electrode wire stick out from the MIG gun nozzle should be between 3/8 in. to 3/4 in. (10 to 20 mm).
6 BASIC WELDING GUIDE Primary adjustable variables These control the process after preselected variables have been found. They control the penetration, bead width, bead height, arc stability, deposition rate and weld soundness. They are: • Arc voltage • Welding current (wire feed speed) • Travel speed Secondary adjustable variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation.
6 BASIC WELDING GUIDE Figure 47: Nozzle angle, right handed operator 1 Leading or “pushing” angle (forward pointing) 3 Direction of torch travel 2 Trailing or “pulling” angle (backward pointing) Establishing the arc and making weld beads Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the finished piece. The easiest welding procedure for the beginner to experiment with MIG welding is the flat position.
6 BASIC WELDING GUIDE 6.4 MMA (SMAW) Basic Welding Technique Size of electrode The electrode size is determined by the thickness of metals being joined and by the type of welding machine available. Small welding machines will only provide sufficient current to run the smaller size electrodes. For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the workpiece. Practice will soon establish the most suitable electrode for a given application.
6 BASIC WELDING GUIDE Figure 48: Flat position, Downhand butt weld Figure 49: Flat position, Gravity fillet weld Figure 50: Horizontal position, Butt weld Figure 51: Horizontal-Vertical (HV) position Figure 52: Vertical position, Butt weld Figure 53: Vertical position, Fillet weld Figure 54: Overhead position, Butt weld Figure 55: Overhead position, Fillet weld Joint preparations In many cases, it will be possible to weld steel sections without any special preparation.
6 BASIC WELDING GUIDE Figure 56: Typical joint designs for arc welding 1 Open square butt joint 10 Maximum 1/16 in. (1.6 mm) 2 Gap varies from 1/16 in. (1.6 mm) to 3/16 in. (4.8 11 1/16 in. (1.6 mm) mm) depending on plate thickness 3 Single vee butt joint 12 Lap joint 4 Not less than 70° 13 Tee joint (Fillet both sides of the joint) 5 Maximum 1/16 in. (1.6 mm) 14 Fillet joint 6 1/16 in. (1.
6 BASIC WELDING GUIDE Arc welding technique 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 in. (6.4 mm) thick and a 1/8 in. (3.2 mm) electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the workbench so that welding can be carried out in the downhand position.
6 BASIC WELDING GUIDE 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 20° from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.
6 BASIC WELDING GUIDE not usually necessary to remove this, since it serves a similar purpose to the backing weld in securing proper fusion at the root of the weld. Fillet welds These are welds of approximately triangular cross section made by depositing metal in the corner of two faces meeting at right angles, see figure "Multi-runs in HV fillet weld". A piece of angle iron is a suitable to start or two strips of steel may be tacked together at right angles. Using a 1/8 in. (3.
6 BASIC WELDING GUIDE Figure 62: Single run vertical fillet weld Figure 63: Multi run vertical fillet weld 1 Weaving motion for second and subsequent runs 2 Pause at the edge of the weave Figure 64: Examples of vertical fillet welds ○ • • Correct Pause at the edge of the weave to allow the metal to build up and eliminate undercut. ○ Incorrect Note weld contour when insufficient pause at the edge of weave, see the figure above.
6 BASIC WELDING GUIDE Figure 65: Overhead fillet weld 1 45° to plate 2 Tilted 10° in line of travel 3 Angle tacked to a pipe 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 here.
6 BASIC WELDING GUIDE Figure 66: Parent metal expansion 1 Weld 2 Upsetting 3 Expansion with compression 4 Cool 5 Hot Figure 67: Parent metal contraction 1 Weld 2 Permanent upset Overcoming distortion effects 3 Contraction with tension There are several methods of minimizing distortion effects. • • • • 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.
6 BASIC WELDING GUIDE • Figure 68: Principle of presetting Preheating Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure "Reduction of distortion by preheating" 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.
6 BASIC WELDING GUIDE Figure 69: Reduction of distortion by preheating 1Weld 2Preheat Figure 70: Examples of distortion Dotted lines show the effect if no preheat is used. 1Weld Figure 71: Welding sequence Figure 72: Step back sequence Block sequence. The spaces between the welds are filled in when the welds are cool.
6 BASIC WELDING GUIDE 6.6 TIG (L-GTAW) basic welding technique Gas Tungsten Arc Welding (L-GTAW) or TIG (Tungsten Inert Gas) is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (nonconsumable) electrode and the workpiece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based.
6 BASIC WELDING GUIDE Guide for selecting filler wire diameter Table 16: Filler wire selection guide Electrode diameter DC current range 1/16 in. (1.6 mm) 20-90 A 3/32 in. (2.4 mm) 65-115 A 1/8 in. (3.2 mm) 100-165 A 3/16 in. (5 mm) 200-350 A Tungsten electrode types Table 17: Electrode type (ground finish) Welding application Features Color code Thoriated 2% DC welding of mild steel, stainless steel and copper. Excellent arc starting, Long life, High current carrying capacity.
6 BASIC WELDING GUIDE TIG welding is generally regarded as a specialized process that requires operator competency. While many of the principles outlined in the previous arc welding section are applicable a comprehensive outline of the TIG welding process is outside the scope of this Instruction Manual. 6 BASIC WELDING GUIDE 6.
7 MAINTENANCE 7 MAINTENANCE 7.1 Routine service and calibration requirements Maintain more often if used in unfavorable conditions. WARNING! Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained electrician. WARNING! The mains supply must be disconnected during cleaning and maintenance.
7 MAINTENANCE Due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying ESAB welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below. Due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying ESAB welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below. 1.
7 MAINTENANCE 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. 7.2 Cleaning the welding power source WARNING! Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained electrician.
8 TROUBLESHOOTING 8 TROUBLESHOOTING 8.1 Power source problems Table 22: Power source problems Type of fault Cause Corrective action Electricity supply is ON, the power indicator is illuminated, however, the power source will not start welding when the torch trigger switch is pressed. The power source is not in the correct mode of operation. Set the power source to the correct mode of operation with the process selection switch. Faulty torch trigger. Repair or replace torch trigger switch/lead.
8 TROUBLESHOOTING Type of fault Cause Corrective action No gas flow in MIG mode. The gas hose is damaged Replace or repair. Gas passage contains impurities. Disconnect the gas hose from the rear of the power source and blow out dirt. Gas regulator turned OFF. Turn ON regulator. Empty gas cylinder. Replace gas cylinder. Gas flow continues after the trigger switch has been released (MIG mode). Gas valve has jammed open due to dirt in the gas or the gas line.
8 TROUBLESHOOTING NOTE! To maintain the MIG gun is in good working order do the following: • • • Ensure that the gas holes are not blocked and gas is exiting out of the MIG gun nozzle. Do not restrict gas flow by allowing spatter to build up inside the MIG gun nozzle. Check that the MIG gun O-rings are not damaged. WARNING! Disengage the feed roll when testing for gas flow by ear. Inconsistent wire feed Wire feeding problems can be reduced by checking the following points.
8 TROUBLESHOOTING Basic MIG (GMAW/FCAW) welding troubleshooting Table 25: MIG (GMAW /FCAW) welding problems Type of fault Cause Corrective action Undercut Welding arc voltage is too high. Decrease voltage or increase the wire feed speed. Incorrect MIG gun angle. Adjust angle. Excessive heat input. Increase the MIG gun travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed.
8 TROUBLESHOOTING Type of fault Cause Corrective action Cold weld puddle Loose welding cable connection. Check all welding cable connections. Low primary voltage. Contact supply authority. Fault in power source. Have an accredited ESAB service provider test then replace the faulty component. The arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly The MIG gun has been connected to the wrong voltage polarity on the front panel.
8 TROUBLESHOOTING 8.3 MMA (SMAW) welding troubleshooting (only for Firepower MST-200) Table 26: MMA (SMAW) metal welding troubleshooting Type of fault Cause Corrective action Welding current is varying ARC FORCE is set at a value that causes the welding current to vary excessively with the arc length. Reduce the ARC FORCE until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.
8 TROUBLESHOOTING Type of fault Cause Corrective action Figure 83: Example of insufficient gap or incorrect sequence 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). The welding current is too high. Reduce the welding current. The welding arc is too long. Reduce the length of the welding arc. The angle of the electrode is incorrect. Electrode should not be inclined less than 45° to the vertical face.
8 TROUBLESHOOTING 8.4 TIG (L-GTAW) welding problems (only for Firepower MST-200) Table 27: TIG (L-GTAW) welding problems Type of fault Cause Corrective action Excessive bead build up or poor penetration or poor fusion at edges of weld. The welding current is too low. Increase the weld current and/or faulty joint preparation. Weld bead is too wide and flat or undercut at edges of weld or excessive burn through. The welding current is too high. Decrease the weld current.
8 TROUBLESHOOTING Type of fault Cause Corrective action Arc start is not smooth The tungsten electrode is too large for the welding current. Select the right size electrode. A wrong electrode is being used. Select the right size electrode. Gas flow rate is too high. Select the right rate for the welding task. See "TIG (LGTAW) Basic welding technique" section. Incorrect shielding gas is being used. Select the right shielding gas. Poor work clamp connection to workpiece.
9..ORDERING SPARE PARTS 9 ORDERING SPARE PARTS CAUTION! Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. Firepower MST-200 and Firepower FP-200 are designed and tested in accordance with the Canadian standards CAN/CSA-E60974-1. On completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standards.
APPENDIX APPENDIX ORDERING NUMBERS Ordering number Denomination Type 1444-3200 Firepower MST-200 1444-1200 Firepower FP-200 0463 766 * Instruction manual The three last digits in the document number of the manual show the version of the manual. Therefore they are replaced with * here. Make sure to use a manual with a serial number or software version that corresponds with the product, see the front page of the manual. Technical documentation is available on the Internet at: www.esab.
APPENDIX SPAREPARTS Item Qty Ordering no.
APPENDIX Item Qty Ordering no.
For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.
