ESAB Firepower Air Cooled Mig Gun 180 AMP and 220 AMP User manual

ESAB
Brand
ESAB
Model
Firepower Air Cooled Mig Gun 180 AMP and 220 AMP
Category
Welding System
Type
User manual
Firepower
MIG Gun
Safety and
Operating
Instructions
AIR-COOLED MIG GUN 180 AMP and 220 AMP
Revision: AA Issue Date: August 2, 2014 Manual No.: 0-5357
IMPORTANT: Included inside - special
instructions for liner replacement.
www.firepower.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!
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.Firepower.com
i
!
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
judgment, the Manufacturer assumes no liability for its use.
Firepower MIG Gun
Safety and Operating Instructions
Instruction Guide Number: 0-5357
Published by:
Victor Technologies, Inc.
16052 Swingley Ridge Road,
Suite 300 St. Louis, MO 63017
USA
www.firepower.com
U.S. Customer Care: (800) 426-1888
Canada Customer Care: 905-827-4515
International Customer Care: (940) 381-1212
Copyright © 2014 Victor Technologies International, 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: August 2, 2014
Revision Date:
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
ii
Table of Contents
SECTION 1: SAFETY PRECAUTIONS .........................................................................1
1.01 Safety Precautions ........................................................................... 1
1.02 Mesures de sécurité ......................................................................... 3
SECTION 2: INTRODUCTION ......................................................................................7
2.01 How to Use this Manual ................................................................... 7
2.02 Receipt of Equipment ....................................................................... 7
SECTION 3: FIREPOWER MIG GUN INSTALLATION ....................................................8
3.01 Direct Plug MIG Gun Installation ...................................................... 8
3.02 Duty Cycle ........................................................................................ 9
3.03 Firepower MIG Gun Selection Guide ................................................ 9
SECTION 4: WIRE CONDUIT, TIP, NOZZLE REPLACEMENT.......................................10
4.01 Conduit Identification Firepower Style ............................................ 10
4.02 Conduit Removal ............................................................................ 10
4.03 Conduit Installation - Velocity Contact Tip Style ............................. 10
4.04 Replacing Velocity Contact Tip ...................................................... 11
4.05 Replace Conductor Tube ............................................................... 12
SECTION 5: MAINTENANCE AND TROUBLESHOOTING............................................13
SECTION 6: REPLACEMENT PARTS .........................................................................14
6.01 Firepower MIG Gun Parts .............................................................. 14
FIREPOWER - LIMITED WARRANTY TERMS ...........................................................18
WARRANTY SCHEDULE ...........................................................................................19
GLOBAL CONTACT INFORMATION .................................................Rear Cover
SAFETY AND OPERATING INSTRUCTIONS
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SECTION 1:
SAFETY PRECAUTIONS
1.01 SAFETY PRECAUTIONS
!
WARNING
SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not
properly installed, used, and maintained. Misuse of this equipment and other
unsafe practices can be hazardous. The operator, supervisor, and helper must read
and understand the following safety warnings and instructions before installing
or using any welding or cutting equipment, and be aware of the dangers of the
welding or cutting process. Training and proper supervision are important for a
safe work place. Keep these instructions for future use. Additional recommended
safety and operating information is referenced in each section.
!
WARNING
WARNING: This product contains chemicals, including lead, known to the State
of California to cause birth defects and other reproductive harm. Wash hands
after handling.
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH
Install and maintain equipment in accordance with the National Electrical Code
(NFPA 70) and local codes. Do not service or repair equipment with power
ON. Do not operate equipment with protective insulators or covers removed.
Service or repair to equipment must be done by qualified and/or trained
personnel only.
Do not contact electrically live parts. Always wear dry welding gloves that are in good condition.
Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,
chains, wires, ropes, cranes, and hoists away from any part of the electrical path. All ground
connections must be checked periodically to determine if they are mechanically strong, and
electrically adequate for the required current. When engaged in AC welding/cutting under wet
conditions or where perspiration is a factor, the use of automatic controls for reducing the no
load voltage is recommended to reduce shock hazards. Accidental contact must be prevented
when using open circuit voltage exceeding 80 volts AC, or 100 volts DC by adequate insulation
or other means. When welding is to be suspended for any length of time, such as during lunch
or overnight, all electrode holders and electrodes should be removed from the electrode holder
and the power supply should be turned OFF to prevent accidental contact. Keep MIG Guns,
electrode holders, TIG torches, Plasma torches, and electrodes away from moisture and water.
See safety and operating references 1, 2, and 8.
2
SAFETY AND OPERATING INSTRUCTIONS
0-5357
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Ventilation must be adequate to remove smoke, fumes, and gases during operation
to protect operators and others in the area. Vapors of chlorinated solvents can form
the toxic gas “Phosgene” when exposed to ultraviolet radiation from an electric
arc. All solvents, degreasers, and potential sources of these vapors must be removed
from the operating area. Use air-supplied respirators if ventilation is not adequate
to remove all fumes and gases. Oxygen supports, and vigorously accelerates fire and should
never be used for ventilation.
See safety and operating references 1, 2, 3, and 4.
ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN
Welding and cutting processes produce extreme localized heat and strong
ultraviolet rays. Never attempt to weld/cut without a federally compliant welding
helmet with the proper lens. A number 12 to 14 shade filter lens provides the
best protection against arc radiation. When in a confined area, prevent the
reflected arc rays from entering around the helmet. Approved shielding curtains
and appropriate goggles should be used to provide protection to others in the surrounding area.
Skin should be protected from arc rays, heat, and molten metal. Always wear protective gloves
and clothing. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings,
etc. should be worn for out-of-position welding and cutting, or for heavy operations using large
electrodes. Hightop work shoes provide adequate protection from foot burns. For added protection,
use leather spats. Flammable hair preparations should not be used when welding/cutting. Wear
ear plugs to protect ears from sparks. Where work permits, the operator should be enclosed in
an individual booth painted with a low reflective material such as zinc oxide.
See safety and operating references 1, 2, and 3.
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS
Combustibles reached by the arc, flame, flying sparks, hot slag, and heated
materials can cause fire and explosions. Remove combustibles from the work
area and/or provide a fire watch. Avoid oily or greasy clothing as a spark may
ignite them. Have a fire extinguisher nearby, and know how to use it. If welding/
cutting is to be done on a metal wall, partition, ceiling, or roof, precautions must
be taken to prevent ignition of nearby combustibles on the other side. Do not weld/cut containers
that have held combustibles. All hollow spaces, cavities, and containers should be vented prior
to welding/cutting to permit the escape of air or gases. Purging with inert gas is recommended.
Never use oxygen in a welding torch. Use only inert gases or inert gas mixes as required by the
process. Use of combustible compressed gases can cause explosions resulting in personal injury
or death. Arcing against any compressed gas cylinder can cause cylinder damage or explosion.
See safety and operating references 1, 2, 5, 7, and 8.
NOISE CAN DAMAGE HEARING
Noise from the air carbon-arc process can damage your hearing. Wear protective
hearing devices to ensure protection when noise levels exceed OHSA standards.
Adequate hearing protection devices must be worn by operators and surrounding
personnel to ensure personal protection against noise. See safety and operating
references 1, 2, and 6.
SAFETY AND OPERATING INSTRUCTIONS
30-5357
SAFETY AND OPERATING REFERENCES
1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139,
251, 252, 253, 254 and 1000. U.S. Government Printing Office, Washington, DC 20402.
2. ANSI Z49.1 “Safety in Welding and Cutting”.
3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.
4. ANSI Z88.2. “Standard Practice for Respiratory Protection”. American National
Standards Institute, 1430 Broadway, New York, NY 10018.
5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”.
6. AWS C5.3. “Recommended Practices for Air Carbon-Arc Gouging and Cutting”. The
American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL 33135.
7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes”.
8. NFPA-7. “National Electrical Code”. National Fire Protection Association, Battery Park,
Quincy, MA 02269.
9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes”. Canadian Standards
Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.
DECLARATION OF CONFORMITY
Firepower Products, Inc. declares under our sole responsibility that the product
Hand Held Air/Gas and Water Cooled MIG Welding Torches
To which this declaration relate(s) are in conformance with the following standards:
IEC 60974-7:2005
Following the provisions of the 73/23/EEC directive.
1.02 MESURES DE SÉCURITÉ
!
AVERTISSEMENT
DES BLESSURES GRAVES OU MORTELLES peuvent résulter d’une installation,
d’un usage ou d’un entretien inadéquat de l’équipement de soudage et de
découpage. Une mauvaise utilisation de cet équipement et d’autres pratiques
risquées peuvent être dangereuses. L’opérateur, le superviseur et l’aide doivent
lire et comprendre les avertissements et les instructions de sécurité suivantes
avant d’installer ou d’utiliser tout équipement de soudage ou de découpage et être
conscients des dangers inhérents aux processus de soudage et de découpage.
Une formation et une supervision adaptées sont importantes pour assurer un lieu
de travail sûr. Gardez ces instructions pour une utilisation future. Chaque section
comporte des informations supplémentaires de sécurité et de fonctionnement.
!
AVERTISSEMENT
AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb,
reconnu par l'Étatde la Californie pour causerdes malformations congénitaleset
d'autresdommages touchant le système reproductif. Se laver les mainsaprès
manipulation.
4
SAFETY AND OPERATING INSTRUCTIONS
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UN CHOC ÉLECTRIQUE PEUT CAUSER DES BLESSURES OU LA MORT
L’installation et l’entretien de l’équipement doivent être conformes au Code national
de l’électricité NFPA 70 et aux codes locaux. N’effectuez pas l’entretien ou la
réparation d’équipement en marche. N’opérez pas l’équipement sans isolateurs
ou caches de protection. L’entretien ou la réparation de l’équipement doivent être
effectués uniquement par un technicien qualifié ou par du personnel formé.
Ne touchez pas aux pièces électriques chargées. Portez toujours des gants de soudage au sec
et en bon état. Les vêtements de protection aluminisés peuvent devenir une partie du chemin
électrique. Éloignez les bouteilles d’oxygène, les chaînes, les câbles métalliques, les appareils
de levage, les treuils et les élévateurs de toute partie du circuit électrique. Toutes les liaisons de
terre doivent être vérifiées périodiquement pour déterminer si elles sont solides et appropriées au
courant demandé. En cas de soudage ou de découpage en courant alternatif dans des conditions
d’humidité ou de chaleur où l’opérateur risque de transpirer, il est recommandé d’utiliser des
contrôles automatiques pour réduire la tension à vide et ainsi diminuer les risques de choc
électrique. Lorsque le procédé de soudage et de découpage exige des valeurs de tension en
circuit ouvert dans des machines à courant alternatif supérieur à 80 volts ou dans des machines
à courant continu supérieur à 100 volts, il faut prendre des mesures pour empêcher un contact
accidentel en prévoyant une isolation adéquate ou d autres moyens. Lorsqu’il faut interrompre
les activités de soudage pendant un certain temps, à l’heure du repas ou la nuit, par exemple, il
faut enlever toutes les électrodes du porte-électrode et mettre hors tension l’alimentation pour
éviter tout contact accidentel. Gardez les pistolets MIG, les porte-électrodes, les torches TIG, les
torches à plasma et les électrodes loin de l’humidité et de l’eau. Voir les références en matière
de sécurité et d’utilisation n° 1, 2 et 8.
LA FUMÉE, LES ÉMANATIONS ET LES GAZ PEUVENT ÊTRE DANGEREUX POUR VOTRE SANTÉ
La ventilation doit être suffisante pour enlever la fumée, les émanations et les
gaz pendant le fonctionnement de la torche afin protéger les opérateurs et les
autres personnes présentes dans la zone. Les vapeurs de solvants chlorés peuvent
former un gaz toxique appelé « Phosgène » si elles sont exposées au rayonnement
ultraviolet d un arc électrique. Il faut enlever de la zone de travail tous les solvants,
décapants et sources potentielles de ces vapeurs. Servez-vous d’appareils respiratoires à
adduction d’air si la ventilation n’est pas suffisante pour enlever toutes les émanations et gaz.
L’oxygène alimente les incendies et en accélère la propagation il ne faut jamais l’utiliser à
des fins de ventilation. Voir les références en matière de sécurité et d’utilisation n° 1, 2,
3 et 4.
L LES RAYONS DE L’ARC, LES SCORIES ET LES ÉTINCELLES CHAUDS PEUVENT BLESSER
LES YEUX ET BRÛLER LA PEAU
Les procédés de soudage et de découpage produisent une chaleur extrême
localisée et de puissants rayons ultraviolets. N’essayez jamais de souder ou
de couper sans casque soudage conforme aux normes du gouvernement
fédéral et muni d’une lentille appropriée. Des lentilles à filtre de numéro 12
à 14 fournissent la meilleure protection contre le rayonnement de l’arc. Dans
un endroit confiné, il faut éviter que les rayons reflétés de l’arc n’entrent autour du casque. Il
faut utiliser des rideaux de protection approuvés et des lunettes de protection appropriées pour
protéger les autres personnes se trouvant aux abords. Il faut aussi protéger la peau nue des
rayons de l’arc, de la chaleur et du métal fondu. Portez toujours des gants et des vêtements
de protection. Toutes les poches doivent être fermées et les manchettes, cousues. Il faut porter
un tablier, des manches, des guêtres, etc. en cuir pour effectuer de soudage ou de découpage
et dans le cas des activités intensives nécessitant de grandes électrodes. Les chaussures de
SAFETY AND OPERATING INSTRUCTIONS
50-5357
sécurité montantes fournissent une protection suffisante contre les brûlures aux pieds. Pour
obtenir une plus grande protection, portez des guêtres en cuir. Il ne faut pas utiliser de produits
capillaires inflammables avant d’effectuer des activités de soudage ou de découpage. Portez
des bouchons d’oreilles pour vous protéger les oreilles des étincelles. Lorsqu’il est possible
de le faire dans la zone de travail, l’opérateur doit s’isoler dans une cabine individuelle recouverte
d’un revêtement à faible réflectivité, comme l’oxyde de zinc. Voir les références en matière
de sécurité et d’utilisation n° 1, 2 et 3.
LES ÉTINCELLES DE SOUDAGE PEUVENT CAUSER DES INCENDIES ET DES EXPLOSIONS
Les combustibles atteints par l’arc, les flammes, les vols d’étincelles, les scories
chaudes et les matériaux chauffés peuvent causer des incendies et des explosions.
Enlevez les combustibles de la zone de travail ou mettez en place du personnel
de surveillance. Évitez les vêtements huileux ou graisseux, car une étincelle peut
y mettre le feu. Ayez un extincteur à proximité et sachez comment l’utiliser. Si
l’activité de soudage ou de découpage doit être fait contre un mur, une cloison, un plafond ou un
toit, il faut prendre des précautions pour d’enflammer des combustibles qui se trouveraient à
proximité, de l’autre côté. Ne soudez pas et ne coupez pas de conteneurs ayant contenu des
combustibles. Il faut aérer tous les espaces creux, les cavités et les conteneurs avant de les
soumettre au soudage ou au découpage afin d’évacuer tout l’air ou le gaz qui peut s’y trouver. Il
est recommandé d’effectuer une purge avec du gaz inerte. N’utilisez jamais d’oxygène dans une
tête de soudage. N’utilisez que des gaz inertes ou des mélanges de gaz inertes, conformément
aux exigences du procédé. L’utilisation de gaz combustibles comprimés peut causer des explosions
entraînant des blessures ou la mort. Le fait d’utiliser l’arc sur une bouteille de gaz comprimé peut
endommager la bouteille ou causer une explosion. Voir les références en matière de sécurité
et d’utilisation n° 1, 2, 5, 7 et 8.
LE BRUIT PEUT ENDOMMAGER L’OUÏE
Le bruit du procédé de l’arc avec électrode en carbone et jet d’air peut endommager
l’ouïe. Portez un dispositif de protection de l’ouïe pour vous protéger lorsque le
niveau de bruit dépasse les normes de l’OSHA. Les opérateurs et le personnel aux
abords doivent porter un dispositif de protection de l’ouïe approprié pour les protéger
efficacement contre le bruit. Voir les références en matière de sécurité et
d’utilisation n° 1, 2 et 6.
6
SAFETY AND OPERATING INSTRUCTIONS
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RÉFÉRENCES EN MATIÈRE DE SÉCURITÉ ET D’UTILISATION
1. Code of Federal Regulations (OSHA), section 29, partie 1910.95, 132, 133, 134,
139, 251, 252, 253, 254 et 1000. U.S. Government Printing Office, Washington, DC
20402.
2. ANSI Z49.1 « Safety in Welding and Cutting ».
3. ANSI Z87.1 « Practice for Occupational and Educational Eye and Face Protection ».
4. ANSI Z88.2. « Standard Practice for Respiratory Protection ». American National
Standards Institute, 1430 Broadway, New York, NY 10018.
5. AWS F4.1. « Recommended Safe Practices for Welding and Cutting Containers ».
6. AWS C5.3. « Recommended Practices for Air Carbon-Arc Gouging and Cutting ». The
American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL 33135.
7. NFPA 51B. « Fire Prevention in Cutting and Welding Processes ».
8. NFPA-7. « National Electrical Code » (code national de l’électricité). National Fire
Protection Association, Battery Park, Quincy, MA 02269.
9. CSA W117.2. « Règles de sécurité en soudage, coupage et procédés connexes
». Association canadienne de normalisation, 178 boul. Rexdale, Rexdale, Ontario,
Canada M9W 1R3.
DÉCLARATION DE CONFORMITÉ
TwecoMD Products inc. déclare sous son entière responsabilité que le produit appelé
« Torches de soudage MIG à refroidissement par eau et par air/gaz portatives »
auquel cette déclaration se rapporte respecte les normes suivantes :
IEC 60974-7:2005
conformément aux dispositions de la directive 73/23/CEE.
SAFETY AND OPERATING INSTRUCTIONS
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SECTION 2:
INTRODUCTION
2.01 HOW TO USE THIS MANUAL
To ensure safe operation, read the entire manual, including the chapters on safety instructions
and warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these headings. These special annotations are
easily recognized as follows:
NOTE
NOTE conveys installation, operation, or maintenance information which is
important but not hazard-related.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in injury.
!
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
2.02 RECEIPT OF EQUIPMENT
When you receive the equipment, check it against the invoice to make sure it is complete and
inspect the equipment for possible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information concerning damage claims
or shipping errors to the location in your area, listed on the back cover of this manual. Include
a full description of the parts in error.
If you want additional or replacement copies of this manual, please contact Firepower at the
address and phone number in your area listed on the back cover of this manual. Include the
Manual number (from page i). You may download a copy from our website www.firepower.com.
8
SAFETY AND OPERATING INSTRUCTIONS
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SECTION 3:
FIREPOWER MIG GUN INSTALLATION
NOTE
Be certain that the end user (welder, operator, or helper) reads and understands
these instructions. Be certain that the welder also reads Section 1 “Safety
Precautions.”
!
WARNING
Electric shock can cause injury or death.
Fit the Firepower MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG
Gun Adaptor and tightening the Locking Nut to secure the MIG Gun in the MIG Gun Adapter.
MIG Gun Connect
Tighten Locking Nut
Art #
A-12516
MIG Gun Adaptor
MIG Gun Connector
MIG Gun Locking Nut
Figure 1: Standard MIG Gun Installation
NOTE
When installing or replacing Contact Tip be sure to tighten fully.
3.01 DIRECT PLUG MIG GUN INSTALLATION
Follow the instructions provided with the wire feeder in use for wire installation and MIG Gun
setup .
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3.02 DUTY CYCLE
MIG GUN Duty Cycle
180 AMP 40% Duty Cycle , Mixed Gases
220 AMP 40% Duty Cycle , Mixed Gases
3.03 FIREPOWER MIG GUN SELECTION GUIDE
140 AMP MIG Gun* 180 AMP MIG Gun* 220 AMP MIG Gun*
Rear Connector
(Replacement)
Rear
Connection
Part Number
Stock Number
Part Number
Stock Number
Part Number
Stock Number
Part Number
Stock Number
Tweco
®
F140T-10-3035
1017-1320
F180T-12-3035
1017-1331
F220T-15-3035
1023-1260
350-174H
2035-2110
Miller
®
F140M-10-3035
1017-1319
F180M-12-3035
1017-1330
F220M-15-3035
1023-1259
350-174MH
2035-2111
Lincoln
®
F140L-10-3035
1017-1318
F180L-12-3035
1017-1329
F220L-15-3035
1023-1258
350-174LH
2035-2112
Euro-Kwik
F140X-10-3035
1017-1323
F180X-10-3035
1017-1335
F180X-12-3035
1017-1336
F180X-12-3035
1017-1334
F220X-10-3035
1023-1264
F220X-12-3035
1023-1265
F220X-15-3035
1023-1263
174EX-1
2040-2276
141i
ThermalArc
F140TA-10-3035
1017-1321
-- --
350-174H
2035-2110
181i
ThermalArc
--
F180TA-12-3035
1017-1332
--
211i
ThermalArc
-- --
F220TA-12-3035
1023-1261
*Rear connector supplied as standard
10
SAFETY AND OPERATING INSTRUCTIONS
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SECTION 4:
WIRE CONDUIT, TIP, NOZZLE REPLACEMENT
4.01 CONDUIT IDENTIFICATION FIREPOWER STYLE
The procedure for removal and installation of a wire conduit is similar for all Firepower MIG Guns.
Conduits may be identified by the type of conduit stop and the part number marking on each conduit
stop.
4.02 CONDUIT REMOVAL
1. Lay the MIG Gun out on a table or on the floor in a straight line. Make sure the gun is
fully extended and all twists in the cable are removed.
2. Remove the nozzle and contact tip from the gun assembly. Then loosen the conduit
set screw in the rear connector plug.
NOTE
On Miller
®
Direct Plug MIG Guns, remove the nipple on the end of the connector
plug. On Euro-Kwik connections, remove the conduit retaining cap.
3. Grip the conduit stop and remove the conduit with a twisting motion. On Miller
®
Direct
Plug MIG Guns, twisting the rear of the gun approximately two revolution counter-
clockwise will raise the conduit stop out of the connector plug recess.
4.03 CONDUIT INSTALLATION - VELOCITY CONTACT TIP STYLE
!
WARNING
Failure to follow Conduit Installation Instructions will cause wire feed issues.
1. Uncoil the conduit and lay it in a straight line. Insert the conduit into the rear connector plug.
Push the conduit into the gun with short strokes.
NOTE
If the conduit hangs up gently whip the cable while applying pressure to the
conduit. New liners must be cut to the correct length.
2. When the conduit is completely in the gun, tighten the rear conduit set screw. On Miller
®
guns, reinstall the nipple. On Euro-Kwik guns, reinstall the conduit retaining cap.
SAFETY AND OPERATING INSTRUCTIONS
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IMPORTANT!
3. The new conduit liner will need to be cut to
length. This can be done by trimming the conduit
to the appropriate length.
1/8” (3,2 mm)
Velocity
Conductor Tube
4. File the cut conduit end to remove burrs.
5. Replace the contact tip.
6. Replace the nozzle. Hand tighten
(Nozzle secures tip).
NOTE
For proper operation the nozzle MUST be tight.
The MIG Gun is now ready to be reinstalled on the
feeder.
4.04 REPLACING VELOCITY CONTACT TIP
CAUTION
While nozzle and contact tip are removed, maintain an adequate distance of the
wire from metal objects to avoid burnbacks to conduit or conductor tube.
1. Remove worn nozzle and tip. (Clean nozzle if reusing.)
2. Slide new contact tip into the conductor tube end.
3. Replace the nozzle. Hand tighten (Nozzle secures tip).
NOTE
For proper operation the nozzle MUST be tight.
4. Trim wire to desired stick out.
The MIG Gun is now ready for operation.
12
SAFETY AND OPERATING INSTRUCTIONS
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4.05 REPLACE CONDUCTOR TUBE
Remove the MIG gun from the feeder prior to beginning these steps. The conductor tube is
attached to the Firepower MIG Gun by one set screw on the side of the conductor tube. To remove:
1. Remove the front end consumables from the conductor tube.
2. Lay MIG gun on side, screw side up and remove both handle screws at the front of the
gun handle.
3. Lay the gun back down on its side and untwist the handle back cap.
4. Remove the top handle half being careful to keep all components in place in the lower
handle half.
5. Loosen the socket head cap screw securing the conductor tube in place inside the handle
with a 5/32" Allen wrench.
6. Remove conductor tube.
7. Slide the new tube over the liner and insert into the brass connection within the handle.
Confirm the tube is correctly aligned with the MIG Gun handle and wrench tighten the
socket head cap screw.
8. Re-assemble the handle.
9. Check conductor tube alignment and re-assemble the front end consumables.
The MIG gun is now ready for operation.
1/8”
(3,2 mm)
Handle screws
Back Cap
SAFETY AND OPERATING INSTRUCTIONS
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SECTION 5:
MAINTENANCE AND TROUBLESHOOTING
Contact tips and nozzles should be cleaned frequently. Spatter buildup may cause bridging
between nozzle and tip. This could cause electrical shorting between the nozzle and work
piece as well as poor or improper gas flow. Regularly inspect the conductor tube, handle,
cable, and other parts of the MIG Gun for abrasion, cuts, or undue wear. Replace or repair any
parts found deficient.
Problem Possible Cause Corrective Action
Wire feed inconsistent
or not smooth
1. Loose contact tip. 1. Tighten nozzle.
2. Excessively worn contact tip. 2. Replace contact tip.
3. Spatter buildup on end of
contact tip.
3. Clean or replace contact tip.
4. Sharp bends or kinks in
conduit.
4. Straighten or replace conduit.
5. Dirty or plugged conduit. 5. Replace conduit.
6. Conduit pulled back from
contact tip.
6. Reposition conduit and cable.
7. Machine improperly adjusted. 7. Reset machine per machine
and wire manufacturers’
recommendations.
MIG Gun is running hot
1a. Loose contact tip. 1a. Tighten nozzle.
b. Liner is too long b. Trim liner correctly.
2. Loose power connections. 2. Inspect complete gun for loose
connections and repair.
3. Loose or undersize ground
cable or ground clamp.
3. Tighten or replace as required.
4. Operating gun above
recommended amperage
rating.
4. Readjust machine to correct
setting for size of gun being used.
5. Operating gun above
recommended duty cycle
rating.
5. Readjust machine to correct
setting for size of gun being used.
6. Loose set screw in conductor
tube connector.
6. Tighten set screw.
Porous weld
1. Poor or improper gas flow. 1. Check gas flow out of gun nozzle.
Check for leaks or restrictions in
gas hoses and connections.
2. Dirty or contaminated wire. 2. Change wire.
3. Base metal contaminated. 3. Replace base metal.
Conduit gets hung-up
inside of the gun
1. Burr on the end of the cut
conduit.
2. Conduit liner has kinks.
1. Remove the burr with a file.
2. Replace conduit.
14
SAFETY AND OPERATING INSTRUCTIONS
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SECTION 6: REPLACEMENT PARTS
6.01 FIREPOWER MIG GUN PARTS
Art# A-12519
SAFETY AND OPERATING INSTRUCTIONS
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Item No. Description Part No. Stock No.
1 MST Nozzle**
MST Nozzle 3/8"
Bore, Flush
1444-0885
MST Nozzle 1/2"
Bore, Flush
1444-0886
MST Nozzle 5/8"
Bore, Flush
1444-0887
MST Nozzle Flux
Cored
1444-0888
MST Spot Nozzle,
3/4"
1444-0889
2 Contact Tip**
MST Contact Tip, .023" 1444-0890
MST Contact Tip, .030" 1444-0891
MST Contact Tip, .035" 1444-0892
MST Contact Tip, .045" 1444-0893
3 Velocity 60° Conductor Tube 16201108
4 Universal Conduit Liner* 1444-0883
5a Handle / Trigger Repair Kit
*Refer to Firepower Catalog No. 64-???? for additional options.
** Patent Pending
Additional options
Description Part No. Stock No.
Rear Connector Plugs - Tweco
®
350-174H 2035-2110
Rear Connector Plugs - Miller
®
350-174MH 2035-2111
Rear Connector Plugs - Lincoln
®
350-174LH 2035-2112
MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a registered trademark of ESAB AB; LINCOLN
is a registered trademark of LINCOLN Electric Co.; The aforementioned registered trademarks are no way affiliated
with Tweco Products, Inc. or Victor Technologies, Inc. Firepower is a registered trademark of Victor Technologies, Inc.
16
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ESAB Firepower Air Cooled Mig Gun 180 AMP and 220 AMP User manual

ESAB
Brand
ESAB
Model
Firepower Air Cooled Mig Gun 180 AMP and 220 AMP
Category
Welding System
Type
User manual
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