115 230 Firepower T I G 2 0 0 A C / D C Inverter Arc Welder Operating Manual English Canadien Français Americas Español A-12707 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 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 WARNING out of service. ELECTRIC SHOCK can kill. 7. Use fully insulated electrode holders. Never dip Touching live electrical parts can cause fatal holder in water to cool it or lay it down on the ground shocks or severe burns. The electrode and or the work surface. Do not touch holders connected work circuit is electrically live whenever the to two welding machines at the same time or touch output is on. The input power circuit and other people with the holder or electrode. machine internal circuits are also live when 8. Do not use worn, damaged, undersized, or poorly power is on. In semi-automatic or automatic spliced cables. wire welding, the wire, wire reel, drive roll 9. Do not wrap cables around your body. housing, and all metal parts touching the 10. Ground the workpiece to a good electrical (earth) welding wire are electrically live. Incorrectly ground. installed or improperly grounded equipment 11. Do not touch electrode while in contact with the work is a hazard. (ground) circuit. 1. Do not touch live electrical parts. 12. Use only well-maintained equipment. Repair or replace damaged parts at once. 2. Wear dry, hole-free insulating gloves and body protection. 13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a 3. Insulate yourself from work and ground using dry voltage reducer. Use equipment with DC output. insulating mats or covers. 14. Wear a safety harness to prevent falling if working 4. Disconnect input power or stop engine before above floor level. installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses 15. Keep all panels and covers securely in place. so power cannot be turned on accidentally. 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 arc. WARNING 4. Wear protective clothing made from durable, ARC RAYS can burn eyes and skin; NOISE flame-resistant material (wool and leather) and foot can damage hearing. Arc rays from the protection. welding process produce intense heat and 5. Use approved ear plugs or ear muffs if noise level strong ultraviolet rays that can burn eyes is high. and skin. Noise from some processes can damage hearing. 1. Wear a welding helmet fitted with a proper shade WARNING of filter (see ANSI Z49.1 listed in Safety Standards) FUMES AND GASES can be hazardous to to protect your face and eyes when welding or your health. watching. Welding produces fumes and gases. 2. Wear approved safety glasses. Side shields Breathing these fumes and gases can be recommended. hazardous to your health. AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida Guide for Shade Numbers Minimum Suggested* Electrode Size in. Arc Current Process Protective Shade No. (mm) (Amperes) Shade (Comfort) Less than 3/32 (2.4) Less than 60 7 - Shielded Metal Arc Welding 3/32-5/32 (2.4-4.0) 60-160 8 10 (SMAW) 5/32-1/4 (4.0-6.4) 160-250 10 12 More than 1/4 (6.4) 250-550 11 14 Less than 60 7 - Gas Metal Arc Welding (GMAW) 60-160 10 11 and Flux Cored Arc Welding 　 160-250 10 12 (FCAW) 250-550 10 14 Less than 50 8 10 Gas Tungsten arc Welding 　 50-150 8 12 (GTAW) 150-500 10 14 Less than (Light) 10 12 Air Carbon Arc Cutting (CAC-A) 500 (Heavy) 11 14 500-1000 Less than 20 6 6 to 8 20-100 8 10 Plasma Arc Welding (PAW) 　 100-400 10 12 400-800 11 14 Less than 20 4 4 20-40 5 5 40-60 6 6 Plasma Arc Cutting (PAC) 　 60-80 8 8 80-300 8 9 300-400 9 12 400-800 10 14 * As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum. Manual 0-5370 1-2 Safety Instructions SAFETY INSTRUCTIONS FIREPOWER TIG 200 AC/DC 1. Keep your head out of the fumes. Do not breathe 7. Do not weld on closed containers such as tanks or the fumes. drums. 2. If inside, ventilate the area and/or use exhaust at the 8. Connect work cable to the work as close to the arc to remove welding fumes and gases. welding area as practical to prevent welding current 3. If ventilation is poor, use an approved air-supplied from travelling long, possibly unknown paths and respirator. causing electric shock and fire hazards. 4. Read the Material Safety Data Sheets (MSDSs) 9. Do not use welder to thaw frozen pipes. and the manufacturer’s instruction for metals, 10. Remove stick electrode from holder or cut off consumables, coatings, and cleaners. welding wire at contact tip when not in use. 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 WARNING injury or death. Be sure the breathing air is safe. FLYING SPARKS AND HOT METAL can cause 6. Do not weld in locations near degreasing, cleaning, injury. or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and Chipping and grinding cause flying metal. As irritating gases. welds cool, they can throw off slag. 7. Do not weld on coated metals, such as galvanized, 1. Wear approved face shield or safety goggles. Side lead, or cadmium plated steel, unless the coating shields recommended. is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air- 2. Wear proper body protection to protect skin. supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. WARNING CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under WARNING high pressure. If damaged, a cylinder can WELDING can cause fire or explosion. explode. Since gas cylinders are normally Sparks and spatter fly off from the welding part of the welding process, be sure to treat arc. The flying sparks and hot metal, weld them carefully. spatter, hot workpiece, and hot equipment 1. Protect compressed gas cylinders from excessive can cause fires and burns. Accidental contact heat, mechanical shocks, and arcs. of electrode or welding wire to metal objects 2. Install and secure cylinders in an upright position by can cause sparks, overheating, or fire. chaining them to a stationary support or equipment 1. Protect yourself and others from flying sparks and cylinder rack to prevent falling or tipping. hot metal. 3. Keep cylinders away from any welding or other 2. Do not weld where flying sparks can strike flammable electrical circuits. material. 4. Never allow a welding electrode to touch any 3. Remove all flammables within 35 ft (10.7 m) of the cylinder. welding arc. If this is not possible, tightly cover them 5. Use only correct shielding gas cylinders, Flowmeter/ with approved covers. Regulators, hoses, and fittings designed for the 4. Be alert that welding sparks and hot materials from specific application; maintain them and associated welding can easily go through small cracks and parts in good condition. openings to adjacent areas. 6. Turn face away from valve outlet when opening 5. Watch for fire, and keep a fire extinguisher nearby. cylinder valve. 6. Be aware that welding on a ceiling, floor, bulkhead, 7. Keep protective cap in place over valve except when or partition can cause fire on the hidden side. 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 4. To prevent accidental starting during servicing, gas cylinders, associated equipment, and CGA disconnect negative (-) battery cable from publication P-1 listed in Safety Standards. battery. ! 5. Keep hands, hair, loose clothing, and tools away from moving parts. WARNING 6. Reinstall panels or guards and close doors when Engines can be dangerous. servicing is finished and before starting engine. WARNING WARNING ENGINE EXHAUST GASES can kill. SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes Engines produce harmful exhaust gases. and skin. 1. Use equipment outside in open, well-ventilated Batteries contain acid and generate explosive gases. areas. 2. If used in a closed area, vent engine exhaust outside 1. Always wear a face shield when working on a battery. and away from any building air intakes. 2. Stop engine before disconnecting or connecting battery cables. 3. Do not allow tools to cause sparks when working WARNING on a battery. ENGINE FUEL can cause fire or explosion. 4. Do not use welder to charge batteries or jump start vehicles. Engine fuel is highly flammable. 5. Observe correct polarity (+ and –) on batteries. 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. WARNING 3. Allow engine to cool before fuelling. If possible, check and add fuel to cold engine before beginning STEAM AND PRESSURIZED HOT COOLANT job. can burn face, eyes, and skin. 4. Do not overfill tank — allow room for fuel to expand. The coolant in the radiator can be very hot 5. Do not spill fuel. If fuel is spilled, clean up before and under pressure. starting engine. 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 WARNING removing cap. MOVING PARTS can cause injury. 3. Allow pressure to escape before completely removing cap. Moving parts, such as fans, rotors, and belts can cut NOTE fingers and hands and catch loose clothing. Considerations About Welding And The 1. Keep all doors, panels, covers, and guards Effects of Low Frequency Electric and Mag- closed and securely in place. netic Fields 2. Stop engine before installing or connecting unit. 3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. Manual 0-5370 1-4 Safety Instructions