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FP-120, FP-130 and FP-160
MIG Welding System
Instruction Manual
FORM NO. 0056-1842 EFFECTIVE July 2001
Safety and Operating
Instructions
For Your Safety . . .
PLEASE READ
CAREFULLY!
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Table of Contents page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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page FP-120 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 FP-130 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 FP-160 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Firepower Limit
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INTRODUCTION This User’s Guide provides specific information about your Firepower Welding System. This guide provides pertinent information needed to safely and effectively use your Firepower Welding System. The information in this manual applies to specific Firepower Welding System models. It gives instructions on set-up, installation and actual use of your Firepower Welding System. SAFETY PROFILE Tradesmen respect the tools and equipment with which they work. They are also aware that tools and
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Indicates that the helmet must be worn during the step(s) that follow to protect against eye damage and burns due to flash hazard. Indicates that the possibility of toxic gas hazard exists during operation of the step(s) that follow. Indicates that the possibility of being burned by hot slag exists during operation of the step(s) that follow. Indicates that eye protection should be worn to protect against flying debris in the following step(s). Indicates that the possibility of injury or death e
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IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH! Reduce the risk of injury or death from compressed gasses and equipment hazards. Read, understand and follow the following safety instructions. Additionally, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area, understands and follows these safety instructions as well. GENERAL WELDING SAFETY INSTRUCTIONS LOCATION Welding processe
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5. Remove all combustible materials from the work site. If you can not remove them, protect them with fire- proof covers. NEVER perform welding operations on a container that has held toxic, com- bustible or flammable liquids or vapors. NEVER perform welding operations in an area con- taining combustible vapors, flammable liquids or explosive dust. VENTILATION Ventilate welding work areas adequately. Maintain sufficient air flow to prevent accumulation of explosive or toxic concentrations of gas
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HEALTH HAZARDS The welding process can be hazardous to your health. Therefore, follow these precautions: 1. ALWAYS wear protective clothing without pockets and cuffs. Wear a helmet, gloves and shoes with an insu- lating sole. 2. ALWAYS use a welding mask or helmet with the properly tinted protective glass in the shade adequate to the welding operation being performed and to the current intensity. 3. Make certain that bystanders in the welding area are also following these precautions. 4. ALWAYS
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This unit is also capable of welding with either 0.030 inch (0.8 mm) or 0.035 inch (0.9 mm) flux cored weld- ing wire (FCAW) process. The use of shielding gas is not required for this welding process. Please refer to the instructions provided in this manual for proper machine setup. The use of larger diameter wire makes welding difficult. The results cannot be guaranteed. The manufacturer DOES NOT recommend using larger diameter welding wire with this unit. WELDER OPERATING CHARACTERISTICS The d
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SPECIFICATIONS FOR FP 130 WIRE(GMAW/FCAW) WELDING SYSTEM (1444-0306) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 AMP MIG Welding System Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Volt (60 Hz) Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Amps @ 40% Du
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Duty Cycle MIG-GUN 10% DUTY 35% DUTY 60% DUTY 100% DUTY MODEL NO. CYCLE CYCLE CYCLE CYCLE 150 230 amps 205 amps 180 amps 140 amps 200 320 amps 290 amps 250 amps 195 amps 300 500 amps 450 amps 400 amps 275 amps WELDER INSTALLATION POWER SOURCE CONNECTION Power Requirements This welder is designed to operate on a properly grounded 120 volt, 60 HZ, single-phase alternating current (AC) power source fused with a 20 amp time-delayed fuse or circuit breaker. (FP 160 requires 230 Volt, 60 HZ, single ph
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3. Assemble the plastic handle as shown in Figure 1. 4. Tools required: Allen Wrench. Be sure that the welder’s electri- cal power supply cord is not connected while performing this procedure. 5. Install MIG gun per instructions. 6. Install welding wire per instructions. 7. Place the power source in a well ventilated area. DONOT obstruct the air intake and output vents. A reduced air flow can cause a reduced duty cycle and damage internal com- ponents. 8. Insure at least 6 feet of open space on
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INSTALLATION OF THE WELDING WIRE The power source is supplied with a spool of .030 MIG Welding Wire. Install the wire into the feeding system by following the instructions below and referring to Figure 3. MIG (GMAW) welding applications require argon shielding gas. Remove the contact tip and gun nozzle from the MIG gun before starting this pro- cedure. Figure 3: Wire Installation 1. Loosen the nut of the spool holder (brake drum). Remove the spring and the external ring. 2. Remove the plastic pr
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When changing the wire diameter being used, or replacing the wire feed roll, be sure that the correct groove for the wire diameter selected is inside, closest to the machine. The wire is driven by the inside groove. Feed rolls are marked on the side identifying the nearest groove. Feed rolls installed on the FP 120, FP 130, FP 160 are marked "0.6" on one side. When this side is inside, closest to the machine, the groove is suitable for use with 0.023" (0.6mm) hard wire. The other side is mark
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tive pole. When the wire is fed and touches the workpiece, an electric arc is produced. The arc melts the wire that is deposited on the workpiece. MIG welding uses a steel coppered wire as an electrode and an inert gas (CO , CO /Argon mix or pure Argon) 2 2 for protection of the weld pool. The wire can be one of three types: 1. Solid wire - ALWAYS used with a protective gas. 2. Cored wire - Has a core of mineral powders to enhance its characteristics and is used with gas. 3. Gasless cored-wire -
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IMPORTANT 2. Make sure that the polarity of torch and ground cable is correctly set. For gasless welding, the ground cable must be connected to the positive ter- minal (+), while the torch must be connected to the neg- ative terminal (-) (see Figure 4). 3. Connect the ground cable to the workpiece. Make sure that the contact is good. 4. Make sure that the wire-feeding roll is correctly posi- tioned (groove matching the wire diameter). Note that each roll has two grooves. One is marked “.023”/0.6
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REPLACEMENT OF THE WIRE SPOOL The welding power source is supplied with a mini wire spool of about 0.5 Kg of 0.024” (0.6mm) diameter wire. When the wire spool is finished it can be replaced with a wire spool of 2 lbs. or 10 lbs. The wire is pushed by a roll which is moved by a series of mechanisms. The roll has two grooves, one marked by 0.035” (0.9 mm) and the other marked by 0.023” (0.6 mm). It is very important to use the correct groove as explained in “Preparation for Welding” on page 12. Ot
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The torch switch must be pressed thoroughly to perform its three functions: gas flow, wire feed and welding current.) Start welding and decrease the wire speed gradually. Continue to decrease the wire speed and listen to the sound. The sound will change from a crackling noise to a regular and strong buzzing (similar to the sound of frying bacon). This buzzing sound indicates the correct wire speed for the workpiece being welded. When the current regulation is changed, reset the wire speed. ALWAY
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TROUBLESHOOTING INFORMATION Use this chart to assist you in resolving common problems you may encounter. These are not all of the possible solutions. PROBLEM POSSIBLE CAUSE REMEDY 1. Dirty, porous or brittle weld. Plugged welding nozzle. Clean or replace welding nozzle. 2. Arc works but is not feeding wire. Faulty wire speed control assembly. Replace wire speed control assembly. No tension on the drive roller. Adjust the drive tension. Faulty drive motor (very rare). Replace drive motor. 3. When
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GENERAL OPERATING TIPS 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 hose, and other parts of the MIG gun for abrasion, cuts, or undue wear. Replace or repair any parts found deficient. TROUBLESHOOTING GUIDE FOR FIREPOWER FP-200 MIG GUN PROBLEM POSSIBLE CAUSE CORRECTIVE
