Firepower MST 140i Service Manual
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Firepower MST 140i Service Manual

3-in-1 multi process welding systems
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FIREPOWER MST 140i
3-IN-1 Multi Process
Welding Systems
Service
Manual
Revision: AB
Issue Date: January 5, 2015
Art# A-12514
Manual No.: 0-5363
www.firepower.com

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  • Page 1 FIREPOWER MST 140i 3-IN-1 Multi Process Welding Systems Service Manual Art# A-12514 Revision: AB Issue Date: January 5, 2015 Manual No.: 0-5363 www.firepower.com...
  • Page 2 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.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Service Manual Number 0-5363 for: Firepower MST 140i Portable System Package Part Number 1444-0870 Published by: Victor Technologies International, Inc.

  • Page 4: Table Of Contents

    Description ..................... 2-1 2.05 Transportation Methods .................. 2-1 2.06 User Responsibility ..................2-2 2.07 FIREPOWER MST 140i Portable System Package (Part No. 1444-0870) ..2-2 SECTION 3: SAFETY AND INSTALLATION ............... 3-1 3.01 Duty Cycle ....................... 3-1 3.02 Specifications ....................3-2 3.03...
  • Page 5 Installing Control PCB2 and Clear Protective Sheet ........8-5 8.05 Installing Case ....................8-7 SECTION 9: KEY SPARE PARTS ................9-1 9.01 Firepower 140A MIG Gun Parts ..............9-1 9.02 Power Source ....................9-2 9.03 Hardware List ....................9-4 SECTION 10: OPTIONS AND ACCESSORIES ..............10-1...
  • Page 6 TABLE OF CONTENTS FIREPOWER - LIMITED WARRANTY TERMS ........INSIDE REAR COVER INTERNATIONAL CONTACT INFORMATION ..........REAR COVER...

  • Page 7: Safety Instructions And Warnings

    FIREPOWER MST 140i 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.
  • Page 8 FIREPOWER MST 140i 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot ARC RAYS can burn eyes and skin; NOISE can damage hearing.
  • Page 9 FIREPOWER MST 140i 6. Be aware that welding on a ceiling, floor, bulkhead, 1. Keep your head out of the fumes. Do not breathe or partition can cause fire on the hidden side. the fumes. 7. Do not weld on closed containers such as tanks or 2.
  • Page 10 FIREPOWER MST 140i 6. Turn face away from valve outlet when opening 2. Stop engine before installing or connecting unit. cylinder valve. 3. Have only qualified people remove guards or 7. Keep protective cap in place over valve except when covers for maintenance and troubleshooting as cylinder is in use or connected for use.

  • Page 11: General Safety Information For Firepower Cs Regulator

    FIREPOWER MST 140i 1.02 General Safety Information for Firepower CS Regulator WARNING Fire Prevention WARNING: This product contains chemicals, including Welding and cutting operations use fire or combustion lead, known to the State of California to cause birth as a basic tool. The process is very useful when properly defects and other reproductive harm.
  • Page 12 FIREPOWER MST 140i Ventilation Compressed Gas Cylinders The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases WARNING used for welding or cutting operations. Ade quately ventilate welding, heating, and 1. Place the cylinder (Figure 1-1) where you will cutting work areas to prevent accumula- use it.

  • Page 13: Principal Safety Standards

    FIREPOWER MST 140i 4. NEVER use compressed gas cylinders without 1.03 Principal Safety Standards a pressure reducing regulator attached to the cylinder valve. Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., 5. Inspect the cylinder valve for oil, grease, and Miami, FL 33126.

  • Page 14: Symbol Chart

    FIREPOWER MST 140i 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun...

  • Page 15: Precautions De Securite En Soudage A L'arc

    FIREPOWER MST 140i 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).
  • Page 16 FIREPOWER MST 140i 9. N’enroulez pas de câbles électriques autour de votre corps. 10. N’utilisez qu’une bonne prise de masse pour la mise AVERTISSEMENT à la terre de la pièce à souder. LE RAYONNEMENT DE L’ARC PEUT BRÛLER 11. Ne touchez pas à l’électrode lorsqu’en contact avec LES YEUX ET LA PEAU;...
  • Page 17 FIREPOWER MST 140i 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés. AVERTISSEMENT 3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de LE SOUDAGE PEUT CAUSER UN INCENDIE l’éblouissement;...
  • Page 18 FIREPOWER MST 140i 8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, AVERTISSEMENT identifiée dans la liste de documents ci-dessous. LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.
  • Page 19 FIREPOWER MST 140i 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT AVERTISSEMENT CAUSER DES BLESSURES. LA VAPEUR ET LE LIQUIDE DE REFROI- Des pièces en mouvement, tels des ventila- DISSEMENT BRULANT SOUS PRESSION teurs, des rotors et des courroies peuvent PEUVENT BRULER LA PEAU ET LES YEUX.

  • Page 20: Informations Générales De Sécurité

    FIREPOWER MST 140i fondées sur des faits scientifiques visant à atténuer ou éviter des risques potentiels ». AVERTISSEMENT Pour atténuer les champs magnétiques sur les lieux de travail, respectez les procédures qui suivent : N’effectuez d’opérations de soudage JAMAIS sur un récipient qui a contenu des liquides ou 1.
  • Page 21 FIREPOWER MST 140i manches et poches boutonnés. Il ne faut pas remonter AVIS vos manches ou les pantalons à revers. Ce document CGA p. t peut être obtenu en Quand vous travaillez dans un environnement non écrivant à “Compressed Gas Association”, dédié...

  • Page 22: Principales Normes De Securite

    FIREPOWER MST 140i 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, Supe- rintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 23: Graphique De Symbole

    FIREPOWER MST 140i 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique Soudage...
  • Page 24 FIREPOWER MST 140i This page is left blank intentionally. 1-18 Manual 0-5363 SAFETY INSTRUCTIONS AND WARNINGS...

  • Page 25: Introduction

    WARNING 2.04 Description Gives information regarding possible per- The Firepower MST 140i is a self contained single sonal injury. Warnings will be enclosed in a phase multi process welding system that is capable of box such as this.

  • Page 26: User Responsibility

    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.

  • Page 27: Safety And Installation

    8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. Fabricator 141i Safe Operating TIG (GTAW) Region STICK (SMAW) / MIG (GMAW/ FCAW) Art # A-11276_AB Welding Current (amps) Figure 3-1: FIREPOWER MST 140i Duty Cycle Manual 0-5363 SAFETY AND INSTALLATION...

  • Page 28: Specifications

    FIREPOWER MST 140i 3.02 Specifications DESCRIPTION Firepower MST 140i MULTI PROCESS 3 IN 1 WELDER Power Source System Part No. 1444-0870 Power Source System Dimensions H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm) Power Source System Weight 32.2lb (14.6kg)

  • Page 29: Environment

    (Based on Article 630, National Electrical Code) Firepower continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the speci fications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

  • Page 30: Ventilation

    • Correctly earthed (electrically) in accordance with local regulations. • Connected to the correct size power point and fuse as per the Specifications on page 3-2. WARNING The FIREPOWER MST 140i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 140 VAC or higher is applied to the Primary Power Cable. WARNING ELECTRIC SHOCK can kill;...
  • Page 31 FIREPOWER MST 140i Do not connect an input (WHITE or BLACK) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal. • Correctly installed, if necessary, by a qualified electrician. • Correctly earthed (electrically) in accordance with local regulations. • Connected to the correct size power point, fuse and primary supply lead based on Table 3-2. Refer to Table 3-2. WARNING An electric shock or fire hazard is probable if the following electrical service guide recommendations are not followed.

  • Page 32: Electromagnetic Compatibility

    FIREPOWER MST 140i 5. The health of people around, e.g. the use of 3.07 Electromagnetic Compatibility pacemakers and hearing aids. 6. Equipment used for calibration and measurement. WARNING 7. The time of day that welding or other activities are Extra precautions for Electromagnetic to be carried out.

  • Page 33: Firepower Flowmeter/ Regulator

    SCREW A-12435 the workpiece to earth may reduce emissions Figure 3-1: Firepower CS Flowmeter/ Regulator in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage WARNING to other electrical equipment.
  • Page 34 FIREPOWER MST 140i valves are not intended to protect down stream equipment from high pressures. WARNING DO NOT use a flowmeter/ regulator that delivers WARNING pressure exceeding the pressure rating of the downstream equipment unless pro visions DO NOT tamper with the relief valve or remove are made to prevent over-pressurization (i.e.

  • Page 35: Volt-Ampere Curves

    Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. Firepower MST 140i Safe Operating TIG (GTAW) Region STICK (SMAW) / MIG (GMAW/ FCAW) Art # A-12434 Welding Current (amps) Figure 3-2: FIREPOWER MST 140i Volt-Ampere Curves Manual 0-5363 SAFETY AND INSTALLATION...
  • Page 36 FIREPOWER MST 140i Notes 3-10 Manual 0-5363 SAFETY AND INSTALLATION...

  • Page 37: Operation

    FIREPOWER MST 140i SECTION 4: OPERATION 4.01 Power Source Controls, Indicators and Features POWER FAULT LIFT TIG STICK STICK SOFT HARD SOFT HARD DOWNSLOPE (S) DOWNSLOPE (S) ARC FORCE (%) WIRESPEED INDUCTANCE WIRESPEED ARC FORCE (%) INDUCTANCE Art # A-12437...
  • Page 38 MIG Gun Adapter within the Wire Feed Compartment to secure the Firepower MIG Gun in position. Failure to properly lock the Firepower MIG Gun into the MIG Gun Feedplate will result in the MIG Gun being pushed out of the MIG Gun Feedplate by the MIG welding wire or lack of shielding gas (porosity in the weld) at the weld zone.
  • Page 39 Dinse connector. 8. Remote Control The 8 pin socket is used to connect the Firepower MIG Gun, remote control device to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. Trigger Switch...
  • Page 40 FIREPOWER MST 140i Socket Pin Function Not used Trigger Switch Input Trigger Switch Input Not used 5k ohm (maximum) connection to 5k ohm remote control potentiometer. Zero ohm (minimum) connection to 5k ohm remote control potentiometer. Wiper arm connection to 5k ohm potentiometer for the remote control of the Amperage (Weld Current) in LIFT TIG mode.
  • Page 41 FIREPOWER MST 140i When LIFT TIG Mode is Selected In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down time of the amperage at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool is given time to cool sufficiently.
  • Page 42 FIREPOWER MST 140i 13. Digital Voltage Meter (Right Digital Display) The digital voltage meter is used to display the both the preview voltage (MIG mode only) and actual output voltage (all modes) of the Power Source. At times of non-welding, the voltage meter will display a preview value in MIG mode. This value can be adjusted by varying the multifunction control knob (Control No.
  • Page 43 17. Intelligent Fan Control The FIREPOWER MST 140i is designed with an intelligent fan control. It automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the Power Source.

  • Page 44: Attaching The Firepower 140A Mig Gun

    FIREPOWER MST 140i 4.02 Attaching the Firepower 140A MIG Gun Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adapter and tightening the Locking Nut to secure the MIG Gun in the MIG Gun Adapter.

  • Page 45: Inserting Wire Into The Wire Feed Mechanism

    FIREPOWER MST 140i 4.03 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in a counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm.

  • Page 46: Installing 4" (100Mm) Diameter Spool

    FIREPOWER MST 140i 4.04 Installing 4" (100mm) Diameter Spool As delivered from the factory, the Power Source is fitted with a Wire Spool Hub which accepts a 8" (200mm) diameter spools. In order to fit a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 4-8.

  • Page 47: Installing 8" (200Mm) Diameter Spool

    FIREPOWER MST 140i 4.05 Installing 8" (200mm) Diameter Spool As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool. In order to re-fit a 8" (200mm) spool assemble parts in the sequence shown below in Figure 4-9.

  • Page 48: Feed Roller Pressure Adjustment

    FIREPOWER MST 140i 4.06 Feed Roller Pressure Adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and debris.

  • Page 49: Wire Reel Brake

    FIREPOWER MST 140i 4.08 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake.

  • Page 50: Flowmeter/ Regulator Operation

    FIREPOWER MST 140i 4.09 Flowmeter/ Regulator Operation With the flowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of flowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal parts.

  • Page 51: Setup For Mig (Gmaw) Welding With Gas Shielded Mig Wire

    C. Fit the MIG Gun to the Power Source. (Refer to Section 4.02 Attaching the Firepower 140A MIG Gun). D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
  • Page 52 FIREPOWER MST 140i Art # A-12520 Connect Shielding Gas Hose to regulator Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping. Positive Welding Terminal (+) MIG Gun Negative Welding...

  • Page 53: Setup For Mig (Fcaw) Welding With Flux Core (Gasless) Wire

    FIREPOWER MST 140i 4.11 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire A. Select MIG mode with the process selection control (refer to Section 4.01.12 for further information). B. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
  • Page 54 FIREPOWER MST 140i Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) MIG Gun Polarity Lead. Art# A-12521 Work Lead Figure 4-14: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire 4-18 Manual 0-5363 OPERATION...

  • Page 55: Setup For Lift Tig (Gtaw) Welding

    NOTE A Firepower 17V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Firepower Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current.
  • Page 56 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Firepower Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing...

  • Page 57: Setup For Stick (Smaw) Welding

    FIREPOWER MST 140i 4.14 Setup for STICK (SMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
  • Page 58 FIREPOWER MST 140i This page is left blank intentionally. 4-22 Manual 0-5363 OPERATION...

  • Page 59: Theory Of Operation

    FIREPOWER MST 140i SECTION 5: THEORY OF OPERATION 5.01 Inverter Design What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC.
  • Page 60 FIREPOWER MST 140i Notes Manual 0-5363 THEORY OF OPERATION...

  • Page 61: Troubleshooting

    FIREPOWER MST 140i SECTION 6: TROUBLESHOOTING 6.01 Pre-Power Up Checks It is best to perform the following Pre-Power Up test procedures in order to prevent blowing Primary Line Fuses or causing further damage to the power supply. Checking Unit Before Applying Power The following safety information shall be read before starting troubleshooting and servicing: 1.
  • Page 62 FIREPOWER MST 140i Power Up Problems B. Preset current can’t be adjusted. NOTE 1. Defective Display PCB3 In the event that either an individual indicator a) Replace Display PCB3. will not come on,or if a segment on the either 2. Defective Control PCB2...
  • Page 63 FIREPOWER MST 140i G. Fan doesn’t run B. The power source does not feed wire when torch trigger is depressed. 1. Defective fan 1. Defective torch trigger a) Measure the voltage between pin 1 and pin 2 of Funs connectors. If voltage is 20-24V, replace a) Check the torch trigger switch and replace it.
  • Page 64 FIREPOWER MST 140i 1. Fouled contact tip 1. TIG Torch is connected to the (+) polarity terminal a) Replace contact tip if necessary. a) Connect the TIG Torch to the (-) polarity termi- 2. Drive roll tension not tight enough nal.

  • Page 65: Case Removal

    FIREPOWER MST 140i 6.04 Case Removal WARNING Read and follow safety information in Section 6.02 before proceeding. 1. Cover Remove Screws Lossen Screws Front & Rear Art # A-10456 a) Remove the two top screws from the front & rear mouldings.

  • Page 66: Clear Protective Sheet Removal

    FIREPOWER MST 140i 6.05 Clear protective Sheet Removal WARNING Read and follow safety information in Section 6.02 before proceeding. 1. Clear protective sheet Take out clear protective sheet. Art # A-12170 6.06 Visually Inspect Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, transformers, switches, or rectifier when a failure occurs.

  • Page 67: Preliminary Dc Bus Measurement Of The Main Pcb1

    FIREPOWER MST 140i 6.07 Preliminary DC Bus Measurement of the Main PCB1 WARNING Read and follow safety information in Section 6.02 before proceeding. Art # A-12171 DC Bus Testing Multimeter Lead Placement Voltage with SW1 OFF Negative meter lead to testpoint1...
  • Page 68 FIREPOWER MST 140i IGBT Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 9 IGBT 1 0.2 – 0.8 VDC Negative meter lead to testpoint 10 Positive meter lead to testpoint 11 IGBT 2 0.2 – 0.8 VDC...

  • Page 69: Check Main On / Off Switch

    FIREPOWER MST 140i 6.08 Check Main ON / OFF Switch Art # A-10459 Power Switch Testing Multimeter Lead Placement Impedance Positive meter lead to testpoint 23 Switch ON 0 to 1 Ω Negative meter lead to testpoint 24 Positive meter lead to testpoint 25 Switch ON 0 to 1 Ω...

  • Page 70: Dc Bus Voltage Measurement

    FIREPOWER MST 140i 6.10 DC Bus Voltage Measurement Apply voltage to the Power Source. WARNING There are extremely dangerous voltage and power levels present inside these Power Sources. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

  • Page 71: Pcb Connectors

    FIREPOWER MST 140i 6.11 PCB Connectors 1. Main PCB1 NTCS QF/FJ AC OUT CIN1 AC OUT OUT+ OUT- COUT1 COUT2 T13-1 T20-1 T17-1 T16-1 T15-1 T14-1 R102 R100 R101 C100 Art # A-12172 IN Header Pin Pin Function Signal +15V...
  • Page 72 FIREPOWER MST 140i NTCS Header Pin Pin Function Signal Power source for NCT circuitry 12VDC between Pin 1 and Pin 2 Power source for NCT circuitry Table 6-12 NTCS Header Pin Function (Connects to NTCS header on Control PCB2) DY2 Header Pin...
  • Page 73 FIREPOWER MST 140i Control PCB2 Vmin WVIN QF/DY IGBT OT Imin Imax NTCS FUNs SOURCE DRIVE Art # A-12173 GUN Header Pin Pin Function Signal +23V~25VDC (0V +24V Trigger positive when Trigger closed) Trigger Common Table 6-16 GUN Header Pin Function (Connects to GUN1 header on Remote Interface PCB4)
  • Page 74 FIREPOWER MST 140i DRIVE Header Pin Pin Function Signal +15V +15 VDC IGBT1 ,4 PWM Driver Signal 5VDC Vpk IGBT2 ,5 PWM Driver Signal 5VDC Vpk IGBT2 ,5 PWM Driver Signal 5VDC Vpk IGBT1 ,4 PWM Driver Signal 5VDC Vpk...
  • Page 75 FIREPOWER MST 140i NTCS Header Pin Pin Function Signal Power source for NCT circuitry 12VDC between Pin 1 and Power source for NCT circuitry pin 2 Table 6-26 NTCS Header Pin Function (Connects to NTCS header on Main PCB1) MB Header Pin...
  • Page 76 FIREPOWER MST 140i J1 Header Pin Pin Function Signal Serial display date& EPROM (D-IN) 5VDC digital Serial display data(LOAD) 5VDC digital Serial display data (CLK) 5VDC digital 2T/4T push button 0VDC Serial display EPROM (D-OUT) 5VDC digital Not used Chip select...
  • Page 77 FIREPOWER MST 140i 15V Header pin Pin Function Signal +15VDC +15V power source Table 6-31 15V Header Pin Function R-G Header Pin Pin Function Signal +23V-25VDC, +24V trigger positive 0V@ trigger closed Trigger switch RTN -12VDC Pot Max -12VDC +12VDC Pot Min...
  • Page 78 FIREPOWER MST 140i Serial display data (CLK) 5VDC digital 2T/4T push button 0VDC Serial display EPROM (D-OUT) 5VDC digital w h e n MIG/ LIFT TIG/ STICK Selection Button depressed Chip select 5VDC digital MODEpush button 0VDC +15VDC 15VDC Not used 0-10 kΩ...
  • Page 79 FIREPOWER MST 140i 6. Header Pin Function FUSE Header Pin Pin Function Signal 10A Fuse connector Closed Table 6-37 FUSE Header Pin Function (Connects to 10A Motor Fuse) PP Header Pin Pin Function Signal Closed when Remote Local/ Remote switch connector...

  • Page 80: Dip Switch Settings, Control Pcb2

    Art # A-12173 Art # A-12221 SW0 position Function Set to OFF for FIREPOWER MST 140i Set to OFF for FIREPOWER MST 140i Set to OFF for FIREPOWER MST 140i Set to OFF for FIREPOWER MST 140i Table 6-41 SW0 Dip Switch functions...

  • Page 81: Calibration

    FIREPOWER MST 140i 6.13 Calibration Calibration Vmin Imax Imin Art # A-12224 Set SW0-1 to ON, SW0-2 to ON, SW0-3 to ON, SW0-4 to OFF to allow calibration of output volts & amps, and calibra- tion of wire feed speed.
  • Page 82 FIREPOWER MST 140i Output Voltage Calibration Select MIG mode on the front panel. Remove the load from the output terminals. Set front panel VOLTS potentiometer to minimum. Adjust Vmin trimpot until output volts is 10.0V +/- 0.2V Set front panel VOLTS potentiometer to maximum.
  • Page 83 FIREPOWER MST 140i Wire Speed Testpoint Waveforms Select MIG mode on the front panel and remove the load from output terminals. Adjust the wirespeed control knob to the max and the digital amperage meter will display a preview value 390.

  • Page 84: Main Circuit Description

    FIREPOWER MST 140i 6.14 Main Circuit Description WARNING Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage. 6-24 Manual 0-5363 TROUBLESHOOTING...
  • Page 85 FIREPOWER MST 140i The mains supply voltage is connected via a double pole switch to the input rectifier BR1 &BR2. Overvoltage protec- tion is provided by varistor CY1. The rectifier output charges the main capacitor bank (C16, C18, C18-1) to high voltage. Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.

  • Page 86: Circuit Diagram

    FIREPOWER MST 140i 6.15 Circuit Diagram 6-26 Manual 0-5363 TROUBLESHOOTING...

  • Page 87: Disassembly Procedure

    FIREPOWER MST 140i SECTION 7: DISASSEMBLY PROCEDURE 7.01 Safety Precautions for Disassembly WARNING Read and follow safety information in Section 6.02 before proceeding. WARNING STATIC (ESD) can damage PC boards. Unplug unit before beginning Disassembly procedure. Manual 0-5363 DISASSEMBLY PROCEDURE...

  • Page 88: Control Pcb2 Removal

    FIREPOWER MST 140i 7.02 Control PCB2 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly. Remove case (refer to 6.04) before removing Control PCB2. 1. M4 Screw. Remove 4 screws from Control panel. 2 Disconnect DRIVE harness from DRIVE connector.

  • Page 89: Display Pcb3 Removal

    FIREPOWER MST 140i WVIN QF/DY IGBT OT SOURCE NTCS FUNs DRIVE A-10018 7.03 Display PCB3 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove Control Panel screws. 2. Disconnect the harness from the connectors.
  • Page 90 FIREPOWER MST 140i Art # A-12181 Manual 0-5363 DISASSEMBLY PROCEDURE...

  • Page 91: Front Panel Assembly Removal

    FIREPOWER MST 140i 7.04 Front Panel Assembly Removal Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove the five screws on front panel. 2 Unscrew Negative output terminal bolts. 3. Unscrew torch cable terminal bolts.

  • Page 92: Rear Panel Removal

    FIREPOWER MST 140i 7.05 Rear Panel Removal Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove the rear panel screws. 2. Disconnect the gas tube. 3. Disconnect Input Cord ground wire. 4. Disconnect the four wires from the switch.

  • Page 93: On/ Off Switch Sw1 And Power Cord Removal

    FIREPOWER MST 140i 7.06 ON/ OFF Switch SW1 and Power Cord Removal Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Gas inlet. Remove gas inlet from rear panel. 2. SW1 locking tabs Squeeze the locking tabs and push SW1 out from the rear panel.

  • Page 94: Base Panel Removal And Main Pcb1 Disassembly

    FIREPOWER MST 140i 7.07 Base Panel Removal and Main PCB1 Disassembly Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove Wire Feeder Screws. 2. Remove Inductor Screws. 3. Remove Central Panel Screws. 4. Remove Main PCB1 assembly Screws.

  • Page 95: Assembly Procedures

    FIREPOWER MST 140i SECTION 8: ASSEMBLY PROCEDURES 8.01 Installing Base panel 1. Main PCB1 assembly. 2. Heatsink on Main PCB1 assembly. 3. Install the feet of Main PCB1 assembly. 4. Install Rectifiers (torque 15 kgfcm). 5. Install Inductor. 6. Install Main PCB1 assembly screws.

  • Page 96: Installing Rear Panel

    FIREPOWER MST 140i 8.02 Installing Rear panel 1. Install gas inlet. 2. Install ON/OFF switch 3. Install wire cord and 2 screws. 4. Reconnect Input Wire on the ON/OFF switch. 5. Install fan. 6. Install plastic inserts into rear panel feet and install panel screws.

  • Page 97: Installing Front Panel

    FIREPOWER MST 140i 8.03 Installing Front Panel 1. Reinstall output terminals on front panel with 27mm wrench. 2. Place Display PCB3 and Remote Interface PCB4 assembly into front panel and install screws. POWER FAULT LIFT TIG STICK STICK SOFT HARD...
  • Page 98 FIREPOWER MST 140i 6. Reconnect the harness to the connectors on Display PCB3 and Remote Interface PCB4. Art # A-12183 Manual 0-5363 ASSEMBLY PROCEDURE...

  • Page 99: Installing Control Pcb2 And Clear Protective Sheet

    FIREPOWER MST 140i 8.04 Installing Control PCB2 and Clear Protective Sheet 1. Install 4 screws. 2 Plug harness into DRIVE connector. 3. Plug harness into SOURCE connector. 4. Plug harness into CR connector. 5. Plug harness into FUNs connector 6. Plug harness into NTCs connector.
  • Page 100 FIREPOWER MST 140i Art # A-12184 Manual 0-5363 ASSEMBLY PROCEDURE...

  • Page 101: Installing Case

    FIREPOWER MST 140i 8.05 Installing Case 1. Install Case. 2. Install Ground Screw, which connects the ground wire to the cover. 3. Install Screws. Tighten screws. Install Screws Tighten Screws Front & Rear Art # A-12092 Manual 0-5363 ASSEMBLY PROCEDURE...
  • Page 102 FIREPOWER MST 140i Notes Manual 0-5363 ASSEMBLY PROCEDURE...

  • Page 103: Section 9: Key Spare Parts

    Trigger Repair Universal Conduit Liner* 1444-0883 Conductor Tube, Firepower 16201108 140A/180A/220A MIG Gun, 60 Deg Table 9-1: Firepower 140A MIG Gun Parts ** Patent Pending * Refer to Firepower Catalog No. for additional options. Figure 9-1 Manual 0-5363 KEY SPARE PARTS...

  • Page 104: Power Source

    FIREPOWER MST 140i 9.02 Power Source Figure 9-2 Manual 0-5363 KEY SPARE PARTS...
  • Page 105 W7004961 Thermistor, NTC, K45 47K, MST 140i W7004940 PCB Burnback Potentiometer 1444-0939 Label, Setup Chart - English Version, FP MST 140i, (not shown) Label, Setup Chart, FP MST 140i, French (not shown) W7006212 Inductor, MST 140i (not shown) W7004951 Spool Hub, MST 140i...

  • Page 106: Hardware List

    Screw Hexagon HD 9/32 × 16 ×19 Wirefeeder Plate Screw Skt Set M4 × 0.7 Firepower No. 4 Torch Adaptor Screw Hexagon M6 × 1.0-10 ST ZP Firepower No. 4 Torch Adaptor Nut Hexagon M10 × 1. 5 ST ZP Firepower No.
  • Page 107 FIREPOWER MST 140i SCREW ITEM 4, OFF USED TO SECURE MOULDING TO INTERNAL PANEL SCREW ITEM 5, OFF USED TO SECURE MOULDING TO BASE PANEL SCREW ITEM 5, 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL SCREW ITEM 4, 2 OFF USED...
  • Page 108 FIREPOWER MST 140i Notes Manual 0-5363 KEY SPARE PARTS...

  • Page 109: Options And Accessories

    1443-0491 Firepower electrode clamp with 16 mm lead and 25 mm Dinse, 9ft (2.7m) 1443-0490 Firepower GF250-50-580 Argon Flowgauge Regulator 0781-9832 Power Adapter, 115V, 20A- 15A 1444-0910 Table 10-1: FIREPOWER MST 140i Options and Accessories List Manual 0-5363 10-1 ACCESSORIES...
  • Page 110 “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 rec-...

  • Page 111: Warranty Schedule

    * 2 years on Power Supply Components 2 Years Parts / No Labor Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy Firepower Regulator for Firepower MST 220i (No labor) 90 days parts / No Labor Remote Controls MIG and TIG Torches (Supplied with power sources)
  • Page 112 THE AMERICAS Denton, TX USA U.S. Customer Care Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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