Related Manuals for Firepower TIG 160S
Summary of Contents for Firepower TIG 160S
- Page 1 Firepower TIG 160S Inverter Arc Welder Operating Manual English Canadien Français Americas Español A-12705 A-12705 Revision: AB Issue Date: December 4, 2014 Manual No.: 0-5369 3163339 www.firepoweronline.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 judgement, the Manu- facturer assumes no liability for its use. Operating Manual Number 0-5369 for: Firepower TIG 160S Power Supply Part No. 1442-0037 Firepower TIG 160S System Part No. 1442-0036 Published by: Victor Technologies, Inc.
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Page 4: Table Of Contents
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 Regulator ........1-5 1.03 Principal Safety Standards ................1-7 1.04 Symbol Chart ....................1-8 1.05 Declaration of Conformity ................1-9 SECTION 2: INTRODUCTION .................. - Page 5 Power Source Problems ................5-4 SECTION 6: REPLACEmENT PARTS ................6-1 6.01 Replacement Parts ..................6-1 APPENDIX 1: OPTIONS AND ACCESSORIES ............A-1 APPENDIX 2: SYSTEm SCHEmATIC ..............A-2 FIREPOWER - LImITED WARRANTY TERmS ........INSIDE REAR COVER INTERNATIONAL CONTACT INFORmATION ..........REAR COVER...
- Page 6 Firepower 160S TIG/Stick System Part Number 1442-0036 • Firepower 160S power supply • 17V TIG torch, 12.5ft (3.8m) with accessory kit • Firepower electrode holder, 13ft (4m) lead • Firepower ground clamp, 10ft (3.1m) lead • 4 General Purpose 1/8” (3.2mm) dia. stick electrodes • Firepower CutSkill 2G Flowmeter/Regulator • 230V to 115V adapter • Product family overview DVD • Operating manual...
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Page 7: Safety Instructions And Warnings
SAFETY INSTRUCTIONS FIREPOWER 160S 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 SER- VICING THIS EQUIPMENT. -
Page 8: Safety Instructions
FIREPOWER 160S SAFETY INSTRUCTIONS 5. Use approved ear plugs or ear muffs if noise level is high. WARNING ARC RAYS can burn eyes and skin; NOISE can WARNING damage hearing. Arc rays from the welding FUMES AND GASES can be hazardous to your process produce intense heat and strong health. - Page 9 SAFETY INSTRUCTIONS FIREPOWER 160S 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 WARNING or death. Be sure the breathing air is safe.
- Page 10 FIREPOWER 160S SAFETY INSTRUCTIONS WARNING WARNING SPARKS can cause BATTERY GASES TO ENGINE EXHAUST GASES can kill. EXPLODE; BATTERY ACID can burn eyes and skin. Engines produce harmful exhaust gases. 1. Use equipment outside in open, well-ventilated areas. Batteries contain acid and generate explosive gases.
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Page 11: General Safety Information For Firepower Cs Regulator
Certain combinations of metals, coatings, and 1.02 General Safety Information for gases generate toxic fumes. Use respiratory protection equipment in these circumstances. Firepower CS Regulator When welding/brazing, read and understand A. Fire Prevention the Material Safety Data Sheet for the welding/ Welding and cutting operations use fire or combustion brazing alloy. - Page 12 FIREPOWER 160S SAFETY INSTRUCTIONS WARNING Practice the following safety and operation precautions you use pressure regulation equipment. EVERY TIME Deviation from the following safety and operation instructions can result in fire, explosion, damage to equipment, or injury to the operator.
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Page 13: Principal Safety Standards
SAFETY INSTRUCTIONS FIREPOWER 160S 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. -
Page 14: Symbol Chart
FIREPOWER 160S SAFETY INSTRUCTIONS 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Single Phase Wire Feed Function Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun... -
Page 15: Declaration Of Conformity
• 2004/108/EC The Electromagnetic Compatibility (EMC) Directive hereby declare that Equipment: Welding Power Source Model Name/Number: Firepower 160S 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. - Page 16 FIREPOWER 160S SAFETY INSTRUCTIONS Classification: The equipment described in this manual is Class A and intended for industrial use. 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 difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radi- ated disturbances.
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Page 17: Introduction
INTRODUCTION FIREPOWER 160S SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.03 Receipt of Equipment When you receive the equipment, check it against the This Manual usually applies to the part numbers listed on invoice to make sure it is complete and inspect the page i. -
Page 18: Specifications
(Based on Article 630, National Electrical Code) Firepower continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items. -
Page 19: Installation
INSTALLATION FIREPOWER 160S SECTION 3: INSTALLATION 3.01 Environment These units are designed for use in environments with increased hazard of electric shock. Examples of environments with increased hazard of electric shock are: A. 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. -
Page 20: Electrical Input Connections
FIREPOWER 160S INSTALLATION 3.03 Electrical Input Connections 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. - Page 21 INSTALLATION FIREPOWER 160S 208-230V, 50A, 1Ø Welding Power Supply 20A, 1Ø The Adapters enable connection to all these power outlets 15A, 1Ø Primary Power Cable Art# A-09862 Figure 3-1: Electrical Input Connections Input Power Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors...
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Page 22: Electromagnetic Compatibility
FIREPOWER 160S INSTALLATION The size of the surrounding area to be considered will 3.04 Electromagnetic Compatibility 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. -
Page 23: Setup For Welding
INSTALLATION FIREPOWER 160S 5. Earthing of the Work Piece 3.05 Setup for Welding Where the work piece is not bonded to earth for NOTE electrical safety, nor connected to earth because of its Conventional operating procedures apply size and position, e.g. ship’s hull or building steelwork, when using the Welding Power Source, i.e. -
Page 24: Stick (Smaw) Setup
FIREPOWER 160S INSTALLATION 3.06 STICK (SMAW) Setup Set Welding Current as specified by the Set Process Selection Electrode Manufacturer. Switch to SMAW (Stick) Negative Output Positive Output Terminal Terminal (Dinse™ 50) (Dinse™ 50) Art #: A-09878 Figure 3-2: Setup for STICK (SMAW) Welding STICK (SMAW) Mode Sequence of Operation 3. -
Page 25: Lift Tig (Gtaw) Setup
INSTALLATION FIREPOWER 160S 3.07 LIFT TIG (GTAW) Setup Set Process Selection Switch to GTAW (Lift TIG). Set Welding Current as specified by the Electrode Manufacturer. Negative Output Terminal (Dinse™ 50) Secure the gas cylinder in an Positive Output upright position by chaining it... -
Page 26: Firepower Flowmeter/Regulator
“ETL”). The following requirements must be met: 14. You are now ready to begin TIG Welding. a) Inlet gauges over 1000 PSIG (6.87 mPa) shall conform with the requirements of UL 404, 3.08 Firepower Flowmeter/Regulator “Indicating Pressure Gauges for Compressed Gas Service.” Pressure Flowmeter/Regulator (Figure 3-4) attached b) Low pressure gauges must be UL recognized to the cylinder valve reduce high cylinder pressures to... -
Page 27: Leak Testing The System
INSTALLATION FIREPOWER 160S WARNING 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. Art # A-09828 Figure 3-6: Open Cylinder Valve Art # A-12436 10. On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gaugeless Flowmeter/Regulators, the indicator will register the cylinder contents open. -
Page 28: When You Finish Using The Flowmeter/Regulator
FIREPOWER 160S INSTALLATION 5. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve and proceed. WARNING If a leak has been detected anywhere in the system, dis continue use and have the system repaired. DO NOT use leaking equipment. Do... -
Page 29: Operation
If the Fault Indicator lights up continuously then the primary current into the main transformer has been ex- Front Panel ceeded. Have an Accredited Firepower Service Provider The welding power source is protected by a self re-setting inspect then repair the welder. -
Page 30: Welding Current Control Explanation
FIREPOWER 160S OPERATION 4.02 Welding Current Control 15 Amp Outlet Explanation The mains power 15 Amp circuit breaker or fuse should not trip at this Weld Current value when STICK welding. Output Scale for 115V The environmental conditions that may cause the mains... -
Page 31: Stick (Smaw) Electrode Polarity
OPERATION FIREPOWER 160S Cast Iron 4.03 STICK (SMAW) Electrode Polarity Most types of cast iron, except white iron, are weldable. Stick electrodes are generally connected to the "+" Posi- White iron, because of its extreme brittleness, generally tive Output Terminal and the work lead to the "−" Nega- cracks when attempts are made to weld it. -
Page 32: Gtaw Electrode Polarity
FIREPOWER 160S OPERATION 4.05 GTAW Electrode Polarity Connect the TIG torch to the "-" Negative Output Terminal and the work lead to the "+" Positive Output Terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece. -
Page 33: Tig Welding Parameters For Steel
OPERATION FIREPOWER 160S 4.10 TIG Welding Parameters for Steel DC Current Stainless Base Metal Electrode Filler Rod Argon Gas Flow Mild Steel Steel Thickness Diameter Diameter Rate Joint / Type 35-45 20-30 Butt/Corner 0.040" 1/16" 10 CFH 0.040" (1.0mm) (1.6mm) -
Page 34: Welding Position
FIREPOWER 160S OPERATION 4.12 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. -
Page 35: Joint Preparations
OPERATION FIREPOWER 160S 4.13 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. -
Page 36: Arc Welding Technique
FIREPOWER 160S OPERATION Another difficulty you may meet is the tendency, after the 4.14 Arc Welding Technique arc is struck, to withdraw the electrode so far that the arc A. Word to Beginners is broken again. A little practice will soon remedy both of these faults. -
Page 37: Making Welded Joints
OPERATION FIREPOWER 160S Heavy plate will require several runs to complete the joint. 4.19 Making Welded Joints After completing the first run, chip the slag out and clean Having attained some skill in the handling of an electrode, the weld with a wire brush. It is important to do this to you will be ready to go on to make up welded joints. - Page 38 FIREPOWER 160S OPERATION Art # A-07700_AB Art # A-07702 Figure 4-16: Multi-runs in HV fillet weld C. Vertical Welds Figure 4-18: Multi run vertical fillet weld 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position.
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Page 39: Distortion
OPERATION FIREPOWER 160S cooler, harder metal further away, and tends to bulge (or Art # A-07704 is “upset”). When the weld area begins to cool, the “up- set” 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. - Page 40 FIREPOWER 160S OPERATION 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. Art # A-07710_AB D. Presetting Block Sequence. The spaces between the welds are filled in when the welds are cool.
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Page 41: Service
SERVICE FIREPOWER 160S SECTION 5: SERVICE 5.01 Maintenance and Inspection To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit The only routine maintenance required for the power should also be wiped clean, if necessary; with solvents supply is a thorough cleaning and inspection, with the that are recommended for cleaning electrical apparatus. -
Page 42: Stick (Smaw) Welding Problems
FIREPOWER 160S SERVICE 5.02 STICK (SMAW) Welding Problems Description Possible Cause Remedy 1. Gas pockets or voids in weld metal Electrodes are damp. A. Dry electrodes before use. (Porosity). Welding current is too high. B. Reduce welding current. Surface impurities such as oil, C. -
Page 43: Tig Welding Problems
SERVICE FIREPOWER 160S 5.03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique. Description Possible Cause Remedy 1. Excessive bead build-up or poor Welding current is too low... -
Page 44: Power Source Problems
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to repair unless you are an Accredited Firepower Service Agent and you have had training in power measure- ments and troubleshooting techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Firepower Service Agent for repair. -
Page 45: Replacement Parts
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to repair unless you are an Accredited Firepower Service Agent 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 Agent for repair. - Page 46 FIREPOWER 160S REPLACEMENT PARTS Art#: A-12714 Replacement Parts Manual 0-5199...
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Page 47: Appendix 1: Options And Accessories
1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8" collets; 1/16", 3/32", 1/8" collet bodies; No. 5, 6, 7 Alumina nozzle; short back cap; long back cap Firepower AF210-580 Regulator, Argon-CO2 Flowgauge with 5/8" - 18 UNF connection 0781-4169 Power Adapter-230V,50A Socket (Nema 6-50R) to 115V, 15A Plug (Nema 5-15P) -
Page 48: Appendix 2: System Schematic
FIREPOWER 160s APPENDIX APPENDIX 2: SYSTEM SCHEMATIC J1-2 J9-1 J9-2 J1-1 -24V J2-1 J3-1 J2-2 J3-2 +15V J2-3 J3-3 IGBT Driver A J2-4 J3-4 IGBT Driver B J2-5 J3-5 J2-6 J3-6 Over Current Signal J2-7 J3-7 Over Current Signal J2-8... -
Page 49: Firepower - Limited Warranty Terms
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,... - Page 50 This Page Intentionally Blank...
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Page 51: 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 52 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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