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

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

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

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 #:

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.

SAFETY AND OPERATING INSTRUCTIONS

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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

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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.

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

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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.

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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.

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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.

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

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.

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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.

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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

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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.

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

150-5357

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.

SAFETY AND OPERATING INSTRUCTIONS

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

Brand: ESAB

Model: Firepower Air Cooled Mig Gun 180 AMP and 220 AMP

Category: Welding System

Type: User manual

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