Page 1
®
A-13015
Firepower
FP 95
FLUX CORED WELDER
Operating
Manual
Révision : AB Issue Date: April 8, 2016 Manual No.: 0-5122
www.firepoweronline.com
Page 2
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Firepower product. We are proud to have you as our customer and will strive
to provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on
the web at www.firepoweronline.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your Firepower
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.
Page 3
WARNING
!
Firepower FP 95 Flux Cored Welder
Operating Manual Number 0-5122
Published by:
ESAB Group, Inc.
2800 Airport Rd.
Denton, TX 76208
www.repoweronline.com
Copyright 2015 by ESAB
All rights reserved.
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 best judgement,
the Manufacturer assumes no liability for its use.
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.
For Printing Material Specification refer to document 47x1909
Original Publication Date: March 19, 2009
Revision Date: April 8, 2016
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________
Purchase Date:__________________________________ __________
Power Supply Serial #:___________________________ __________
Torch Serial #:___________________________________ __________
Page 4
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be
used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service
advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
Page 5
TABLE OF CONTENTS
SECTION 1: SAFETY ........................................................................................ 1-1
1.0 Safety Precautions .......................................................................................... 1-1
2.0 Précautions de sécurité .................................................................................. 1-3
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Description ..................................................................................................... 2-1
2.05 Specifications ................................................................................................. 2-2
2.06 Volt - Amp Curves .......................................................................................... 2-3
2.07 Duty Cycle ...................................................................................................... 2-3
2.08 MIG Gun Maintenance ................................................................................... 2-3
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Location ......................................................................................................... 3-1
3.02 Safety ............................................................................................................. 3-1
3.03 Grounding ...................................................................................................... 3-1
3.04 Electrical Input Requirements ......................................................................... 3-1
3.05 Requirements for Maximum Output .............................................................. 3-1
3.06 Installing Wire Spool ..................................................................................... 3-1
3.07 Feedrolls ......................................................................................................... 3-2
3.08 Install Wire into the Feedhead ........................................................................ 3-2
3.09 Install Wire into the Welding Gun .................................................................. 3-3
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 General Safety Precautions ............................................................................. 4-1
4.02 Firepower Controls ........................................................................................ 4-1
4.03 Flux Cored Arc Welding (FCAW) .................................................................... 4-3
4.04 Shutdown Procedures .................................................................................... 4-3
4.05 Basic Welding Technique ................................................................................ 4-3
4.06 Welding Gun Positions .................................................................................. 4-4
4.07 Establishing the Arc and Making Weld Beads ................................................ 4-4
4.08 Pre-Weld Procedure ....................................................................................... 4-5
4.09 Welding Procedure ........................................................................................ 4-5
4.10 Reference Table .............................................................................................. 4-5
4.11 Firepower FP 95 FC Welding Setting Selection Guide ..................................... 4-6
SECTION 5:
SERVICE ............................................................................................... 5-1
5.01 Cleaning of the Unit ....................................................................................... 5-1
5.02 Cleaning of the Feed Rolls ............................................................................. 5-1
5.03 Basic Troubleshooting ................................................................................... 5-1
5.04 Welding Problems ......................................................................................... 5-2
5.05 Power Source Problems ................................................................................. 5-3
Page 6
TABLE OF CONTENTS
APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1
APPENDIX 2: POWER SUPPLY REPLACEMENT PARTS ............................................... A-2
APPENDIX 3: FIREPOWER FP 95 FC SYSTEM SCHEMATIC .......................................... A-4
REVISION HISTORY ........................................................................................ A-6
Page 7
SAFETY INSTRUCTIONS FIREPOWER FP 95 FC
SECTION 1: SAFETY
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on
or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply
to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the
standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting equipment.
Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage
to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
Safety Instructions 1-1 Manual 0-5122
Page 8
FIREPOWER FP 95 FC SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your
breathing zone and the general area.
ARC R AYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and filter
lens and wear protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
Arc welding and cutting can be injurious to yourself and others. Take
precautions when welding and cutting. Ask for your employer's safety
practices which should be based on manufacturers' hazard data.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
Do not use the power source for thawing frozen pipes.
WARNING
CAUTION
CAUTION
CAUTION
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 of class A equipment in those locations, due to conducted as well as radiated disturbances.
This product is solely intended for metal removal. Any other use may
result in personal injury and / or equipment damage.
Read and understand the instruction manual before
installing or operating.
!
Manual 0-5122 1-2 Safety Instructinos
Page 9
SAFETY INSTRUCTIONS FIREPOWER FP 95 FC
2.0 Précautions de sécurité
Les utilisateurs du matériel de soudage et de coupage plasma ESAB ont la responsabilité ultime d'assurer que toute personne qui
opère ou qui se trouve dans l'aire de travail observe les précautions de sécurité pertinentes. Les précautions de sécurité doivent répondre aux exigences applicables à ce type de matériel de soudage ou de coupage plasma. Les recommandations suivantes doivent être
observées en plus des règles standard qui s'appliquent au lieu de travail.
Tous les travaux doivent être effectués par un personnel qualifié possédant de bonnes connaissances par rapport au fonctionnement
du matériel de soudage et de coupage plasma. Un fontionnement incorrect du matériel peut produire des situations dangereuses qui
peuvent causer des blessures à l'opérateur ou des dommages au matériel.
1. Toute personne travaillant avec le matériel de soudage ou de coupage plasma doit connaître :
- son fonctionnement;
- l'emplacement des interrupteurs d'arrêt d'urgence;
- sa fonction;
- les précautions de sécurité pertinentes;
- les procédures de soudage et/ou de coupage plasma.
2. L'opérateur doit assurer que :
- seules les personnes autorisées à travailler sur l'équipement se trouvent dans l'aire de travail lors de la mise en
marche de l'équipement;
- toutes les personnes dans l'aire de travail sont protégées lorsque l'arc est amorcé.
3. Le lieu de travail doit être :
- aménagé convenablement pour acquérir le matériel en toute sécurité;
- libre de courants d'air.
4. Équipement de sécurité personnelle
- Vous devez toujours utiliser un équipement de sécurité convenable tels que les lunettes de protection, les
vêtement ininflammables et des gants de protection.
- Vous ne devez jamais porter de vêtements amples, tels que foulards, bracelets, bagues, etc., qui pourraient
se prendre dans l'appareil ou causer des brûlures.
5. Précautions générales :
- Assurez-vous que le câble de retour est bien branché.
- La réparation d'un équipement de haute tension doit être effectuée par un électricien qualifié seulement.
- Un équipement d'extinction d'incendie approprié doit être à proximité de l'appareil et l'emplacement doit être clairement
indiqué.
- Vous ne devez jamais procéder à la lubrification ou l'entretien du matériel lorsque l'appareil est en marche.
Classe de boîtier
Le code IP indique la classe du boîtier, à savoir le niveau de protection offert contre toute pénétration par des objets solides ou de l’eau.
La protection est fournie contre le contact d’un doigt, la pénétration d’objets solides d’une taille supérieure à 12mm et contre l’eau
pulvérisée jusqu’à 60 degrés de la verticale. L’équipement marqué IP21S peut être stocké mais ne doit pas être utilisé à l’extérieur
quand il pleut à moins d’être sous abri.
ATTENTION
Si l’équipement est placé sur une surface
inclinée de plus de 15°, il y a danger de basculement et en conséquence, des blessures
personnelles et/ou des dommages importants à l’équipement.
Inclinaison
maximum
autorisée
15°
Safety Instructions 1-3 Manual 0-5122
Page 10
FIREPOWER FP 95 FC SAFETY INSTRUCTIONS
LE SOUDAGE ET LE COUPAG E À L'ARC PEUVENT CAUSER DES
BLESSURES À L'OPÉRATEUR OU LES AUTRES PERSONNES
SE TROUVANT DANS L'AIRE DE TRAVAIL. ASSUREZ-VOUS
AVERTISSEMENT
CHOC ÉLECTRIQUE - peut être mortel.
- Assurez-vous que l'unité de soudage ou de coupage plasma est installée et mise à la terre conformément
aux normes applicables.
- Ne touchez pas aux pièces électriques sous tension ou les électrodes si vos mains ne sont pas bien
protégées ou si vos gants ou vos vêtements sont humides.
- Assurez-vous que votre corps est bien isolé de la mise à la terre et de la pièce à traiter.
- Assurez-vous que votre position de travail est sécure.
VAPEURS ET GAZ - peuvent être danereux pour la santé.
- Gardez votre tête éloignée des vapeurs.
- Utilisez un système de ventilation et/ou d'extraction à l'arc pour évacuer les vapeurs et les gaz de votre
zone respiratoire.
DE PRENDRE TOUTES LES PRÉCAUTIONS NÉCESSAIRES
LORS D'UNE OPÉRATION DE SOUDAGE OU DE COUPAGE.
DEMANDEZ À VOTRE EMPLOYEUR UNE COPIE DES
MESURES DE SÉCURITÉ QUI DOIVENT ÊTRE ÉLABORÉES À
PARTIR DES DONNÉES DES RISQUE DU FABRICANT.
RAYONS DE L'ARC - peuvent endommager la vue ou brûler la peau.
- Protégez vos yeux et votre corps. Utilisez un écran de soudage/coupage plasma convenable équipé de
lentilles teintées et portez des vêtements de protection.
- Protégez les personnes se trouvant dans l'aire de travail à l'aide d'un écran ou d'un rideau protecteur
convenable.
RISQUE D'INCENDIE
- Les étincelles (projections) peuvent causer un incendie. Assurez-vous qu'il n'y a pas de matériel
inflammable à proximité de l'appareil.
BRUIT - un bruit excessif peut endommager la capacité auditive.
- Protégez vos oreilles. Utilisez des protecteurs d'oreilles ou un autre type de protection auditive.
- Avertissez les personnes se trouvant dans l'aire de travail de ce risque.
FONCTIONNEMENT DÉFECTUEUX - Dans le cas d'un fonctionnement défectueux demandez l'aide d'une
personne qualifiée.
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D'UTILISATION AVANT
D'INSTALLER OU D'OPÉRER L'UNITÉ. PROTÉGEZ-VOUS ET LES AUTRES !
Ce produit est uniquement destiné à la découpe du plasma. Toute autre
ATTENTION
utilisation peut entraîner des blessures ou endommager l’équipement.
ATTENTION
Pour éviter toute blessure personnelle et/
ou endommagement à l’équipement, soulever à l’aide de la méthode et des points
d’attache indiqués ici.
Manual 0-5122 1-4 Safety Instructinos
Page 11
INTRODUCTION FIREPOWER FP 95 FC
!
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part numbers
listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, DANGER,
and NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
NOTE!
An operation, procedure, or background
information which requires additional
emphasis or is helpful in efficient operation
of the system.
CAUTION
!
!
Additional copies of this manual may be purchased by contacting Firepower at the address and phone number in your area
listed on back cover of this manual. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the Firepower web site
listed below
http://www.firepoweronline.com
A procedure which, if not properly followed,
may cause damage to the equipment.
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
WARNING
Gives information regarding possible
electrical shock injury. Warnings will be
enclosed in a box such as this.
DANGER
Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.
2.02 Equipment Identification
The unit’s identification number (specification or part number),
model, and serial number usually appear on a data tag attached
to the rear panel. Equipment which does not have a data tag
such as torch and cable assemblies are identified only by the
specification or part number printed on loosely attached card or
the shipping container. Record these numbers on the bottom of
page i for future reference.
2.03 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 in the inside back cover of this manual.
Include all equipment identification numbers as described above
along with a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when using
bars, hammers, etc., to un-crate the unit.
2.04 Description
The Firepower FP 95 FC Machine is a single-phase input welding
machine and comes equipped with the following:
1. Built-in Wire Feeder and Wire Spool Hub
2. Welding Gun and Cable (6.5' / 2m)
3. Work Cable and Clamp (5' / 1.6m)
4. Input Cord (7' / 2.25m)
5. Operational Manual
6. Spare parts kit (2 contact tips)
7. 0.5 lb Wire spool
The welding system is designed for use with the following
processes:
1. FCAW – Flux-cored arc welding – Does not require the
use of a shielding gas.
Introduction 2-1 Manual 0-5122
Page 12
FIREPOWER FP 95 FC INTRODUCTION
2.05 Specifications
Description Firepower FP 95 FC
Package System Part Number 1444-0322
Power Source Weight 37.15 lb ( 16.8 kg)
Power Source Dimensions HxWxD
Number of Phases 1 Ø
Frequency 60Hz
Flexible Supply Cable Size 7 ft (2.25 m) 14AWG
Supply Lead Plug Type 5-15P
Nominal Input Voltage
Rated Input Current 15A
Rated kVA @ 100% Duty Cycle 1.2kVA
Rated Input Current 15A (60A@20%)
Maximum Input Current 28A (85A@17%)
Generator Requirements 98145.4519
98145.4519 # 3.4kVA
Open Circuit Voltage Range 15 – 27V
Output Current Range 23 – 90A
Duty Cycle Period 10 Minutes
Number of Output Voltage Values 2
Minimum Mains Circuit to suit factory fitted Plug &
Lead (Weld Current @ Duty Cycle)
14"x7"x15"
(355.6 x 177.8 x 381mm)
120V AC
(+) 15A (60A@20%)
Maximum Mains Circuit to suit factory fitted Plug &
Lead (Weld Current @ Duty Cycle)
Wire Size Range (Flux Core)
(+) 28A (85A@17%)
.023” - .030”
(0.6 - 0.8mm)
Table 2-1: System Specifications
∆ The recommended time delay fuse or circuit breaker size is 20 amp. An individual branch circuit capable of carrying 30 amperes and protected by fuses or circuit breaker is recommended for this application. Fuse size is based on not more than 200 percent
of the rated input amperage of the welding power source (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.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components,
installation location and conditions and local power grid supply conditions.
Manual 0-5122 2-2 Introduction
Page 13
INTRODUCTION FIREPOWER FP 95 FC
FP-95 FIREPOWER Vin=115V 60Hz
OUTPUT VOLTAGE
FirePower FP 95 FC at Rated Duty Cycle
91
2.06 Volt - Amp Curves
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
OUTPUT CURRENT
Art # A-09068
Figure 2-1: Volt/Amp curves of the FirePower 95
2.07 Duty Cycle
Duty Cycle is the amount of arc-on time (actual welding time) during any 10 minute period that a machine can operate at it’s rated
output without damaging internal components. For example, the Firepower FP 95 FC is designed for 17% duty cycle at 85 amps. This
means that it has been designed and built to provide the rated amperage, 85 amps, for1.7 minutes out of every 10 minute period.
During the other 8.3 minutes of the 10 minute period, the Firepower FP 95 FC must idle and be allowed to cool. The thermal cutout will
operate if the duty cycle is exceeded.
If the unit overheats and the thermostat opens, wait 15 minutes for unit to cool.
1
0
Figure 2-2: Duty Cycle of Firepower FP 95 FC
2.08 MIG Gun Maintenance
Remove dust and metallic particles from the gun conduit by forcing clean, dry compressed air into the conduit once a week. This will
minimize wire feeding problems.
23
45678
Minu tes
Art # A-09034_AB
0
Introduction 2-3 Manual 0-5122
Page 14
FIREPOWER FP 95 FC INTRODUCTION
This Page Intentionally Blank
Manual 0-5122 2-4 Introduction
Page 15
INSTALLATION FIREPOWER FP 95 FC
SECTION 3:
INSTALLATION
3.01 Location
For best operating characteristics and longest unit life, take care
in selecting the installation site. Avoid locations exposed to high
humidity, dust, high ambient temperature, or corrosive fumes.
Moisture can condense on electrical components, causing corrosion or shorting of circuits. Dirt on components will retain this
moisture and also increases wear on moving parts.
Adequate air circulation is needed at all times in order to assure
proper operation. Provide a minimum of 12” (300mm) of free air
space at both the front and rear of the unit. Make sure that the
ventilation openings are not obstructed.
CAUTION
!
The Firepower FP 95 FC is not suitable for
use in rain.
3.02 Safety
Refer to additional installation instructions under the SAFETY
INSTRUCTIONS AND WARNINGS (Section 1) in this manual.
3.03 Grounding
The internal frame of this welding machine should be grounded
for personal safety. Where grounding is mandatory under state or
local codes, it is the responsibility of the user to comply with all
applicable rules and regulations. Where no state or local codes
exist, it is recommended that the National Electrical Code be
followed.
3.04 Electrical Input Requirements
Plug the input cord into a properly grounded and protected (by
fuse or circuit breaker) mains receptacle capable of handling a
minimum of 20 Amperes. The Firepower FP 95 FC requires a
120VAC supply voltage.
The Firepower FP 95 FC's power cord is equipped with a NEMA
5-15P plug and will only connect to a NEMA 5-15P receptacle.
CAUTION
!
Consult the nameplate for proper input
voltage and input amperage. The method
of installation, conductor size, and overcurrent protection shall conform to the
requirements of the local electrical code. All
installation wiring and machine connection
shall be done by a competent electrician.
NOTE!
The supply wiring for the welding power source
must be capable of handling a minimum of 20
amperes. The welding power source must be
the only load connected to the supply circuit.
Poor unit performance or frequently opening
line fuses or circuit breakers can result from an
inadequate or improper supply..
CAUTION
!
Do not connect the Firepower FP 95 FC to
an input power supply with a rated voltage
that is greater than 120 +10% VAC. Do not
remove the power cord ground prong.
3.05 Requirements for Maximum Output
In order to obtain the maximum output capability of the Firepower FP- 95, a branch circuit capable of 20 amperes at 115 to
125 Volts 60 Hz is required. This generally applies when welding
steel that is equal to or greater than 12 gauge (0.105” 2.5mm) in
thickness.
The rated output with this installation is 85 amperes, 18.25 Volt,
17% duty cycle (1 minute 40 seconds out of every 10 minutes
used for welding).
3.06 Installing Wire Spool
As delivered from the factory, the unit is set with a 4” (102mm)
spool.
Installation of Wire Spool
Assemble parts in sequence (shown in Figure 3-1 from right to
left).
1. Retaining Spring
2. "D" Washer
3. Spool
4. Locking knob (press the two tabs to remove it).
The National Electrical Code (Article 630B) provides standards
for amperage handling capability of supply conductors based on
the duty cycle of the welding power source. The Firepower FP 95
FC has a 17% duty cycle (1 minute and 40 secondss of every 10
minutes can be used for welding).The power cord supplied with
this unit complies with these standards. Ensure that the building
supply and receptacle comply with NEC standards and any additional state and local codes.
Installation 3-1 Manual 0-5122
Page 16
FIREPOWER FP 95 FC INSTALLATION
Hub
Spool
Knob
Pressure Adjust Device
Pressure Arm
Gun Cable
Wire Spool
Locking
D-Ring
Spring
Art # A-09088
3.08 Install Wire into the Feedhead
WARNING
ELECTRIC SHOCK CAN KILL! Make certain
the machine is unplugged from the power
receptacle. Do not plug machine in until told
to do so in these instructions.
If Not Installed Load the Wire Spool per directions in section 3.06
onto the hub so that the wire will feed off the spool as the spool
rotates counter- clockwise.
CAUTION
!
Use care in handling the spooled wire as it
will tend to “unravel” when loosened from
the spool. Grasp the end of the wire firmly
and do not let go of it. Make sure that the
end of the wire is free of any burrs and is
straight.
3.07 Feedrolls
A feedroll consists of two different sized grooves. As delivered
from the factory, the drive roll is installed for .030" (0.8mm)
Firepower FP 95 FC.
The branding inside at the end of the feedroll refers to the size
nearest to the mark
This also applies to optional feedrolls which are available for this
machine.
Figure 3-1: 4" Spool Installation
.030
0.8
Art # A-07963
Figure 3-2 : Feedroll Example
Art # A-09069_AB
Wire Spool
Inlet Wire Guide
Feed Roll
Figure 3-3: Wire Feeder Components
Route the Wire Through the Feedhead
1. Loosen Pressure Adjust Device (Fig. 3-3).
2. Open Pressure Adjust Device (Fig. 3-3).
3. Open Pressure Arm (Fig. 3-4).
4. Place the end of the wire into the Inlet Wire Guide, feeding it over the Feedroll. Make certain that the proper
groove is being used (Fig. 3-5).
5. Pass the wire into the Gun Liner of the Gun Cable End
(Fig. 3-5).
6. Close the Pressure Arm (Fig. 3-5).
7. Close the Pressure Adjust Device. Tighten it to a “snug”
condition (Fig. 3-6).
8. Figure 3-6 shows the result with the wire installed.
Manual 0-5122 3-2 Installation
Page 17
INSTALLATION FIREPOWER FP 95 FC
Pressure Arm
Art # A-09072_AB
!
MAX
Art # A-09073_AB
Art # A-09073_AB
NOTE!
If there is too much pressure on the drive
roll the wire gets locked and the motor
could get damaged, If it is too loose the
wire will not feed properly.
Pressure Adjust Device
Figure 3-6: Wire Installed
3.09 Install Wire into the Welding Gun
1. Plug the Welding Power Source into the 120VAC receptacle.
WARNING
-
Figure 3-4: Opening Pressure Arm
Pressure Adjust Device Pressure Arm
ELECTRIC SHOCK CAN KILL! With the gun
switch (located on the gun) activated,
welding power is applied to the output
terminals, feedroll, ground clamp, gun cable
connection and welding wire. Do not touch
these parts with the gun switch activated.
Wire Spool
Wire
Feed Roll
Figure 3-5: Inserting Wire
2. Turn the welding machine ON with the front panel Voltage Power Switch set to "Min"
MIN
Art # A-09071_AB
Figure 3--7: Power ON
3. Set the wire feed speed to half-way or "5".
MIN
MAX
Figure 3-8: Wire Speed Half-way
4. Straighten the gun cable. Remove the nozzle and con-
Installation 3-3 Manual 0-5122
tact tip from the MIG welding gun (see Section 2.08).
Page 18
FIREPOWER FP 95 FC INSTALLATION
Nozzle
!
WARNING
If ground connection clamp is in place
on the workpiece the electrode wire is
electrically “hot” when the gun switch is
activated.
5. Activate the gun switch until the wire feeds out past the
gun nozzle and deactivate the gun switch.
Contact Tip
Wire
Gun Switch
Art # A-09074
Figure 3-9: Feed Wire Through Gun
6. Set the Voltage Power Switch to "OFF" and unplug the
supply cord.
7. Replace the contact tip and nozzle. Cut the wire within
¼” (6mm) from the nozzle.
WARNING
The drive rollers, when moving, may crush
the fingers. Periodically, check the drive
rollers. Replace them when they are worn
and compromise the regular feeding of the
wire.
CAUTION
!
The Firepower FP 95 FC’s welding torch is
a “live” contact torch and is ALWAYS in the
power on position. Wear eye protection at
all times when handling this torch.
WARNING
ELECTRIC SHOCK CAN KILL! With the gun
switch (located on the gun) activated,
welding power is applied to the output
terminals, feedroll, ground clamp, gun
cable connection and welding wire. Do not
touch these parts while the gun switch is
activated.
Manual 0-5122 3-4 Installation
Page 19
OPERATION FIREPOWER FP 95 FC
!
SECTION 4:
OPERATION
4.01 General Safety Precautions
Read and understand the safety instructions at the beginning of this manual prior to operating this machine.
WARNING
!
Be sure to put on proper protective clothing and eye safeguards (welding coat, apron, gloves, and welding
helmet, with proper lenses installed). See Safety Instructions and Warnings chapter included in this manual.
Neglect of these precautions may result in personal injury.
WARNING
Make all connections to the power source including electrode and work cables, as well as remote control
cables, with the power source turned off. These connections could be electrically live with the power switch
ON.
WARNING
ELECTRIC SHOCK CAN KILL! Do not operate the machine with the door open.
CAUTION
!
Do not pull the machine with the gun. Damage can occur to the gun, gun liner and machine. Avoid bending
the gun cable with a sharp radius. Damage can occur to the gun liner.
4.02 Firepower Controls
Refer to Figure 4-1
1. Power ON / OFF switch turns the power on and off. It also lights when the power supply has gone into overtemp.
2. The Wire Speed Control knob controls the welding current via the electrode wire feed rate (i.e. the speed of the wire feed motor).
3. The Voltage Power Switch selects between MIN and MAX voltage levels to the welding terminals.
CAUTION
!
4. Welding Torch and Cable
5. The Work Cable & Clamp connects to the item being welded.
6. Main Power Cable.
7. The moveable tension knob applies pressure to the grooved roller via screw-adjustable spring pressure. The adjustable spring
The Voltage Power Switch MUST NOT BE SWITCHED during the welding process.
screw should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs,
and inspection of the wire contact tip reveals no wear, distortion or burn-back jam, the conduit liner should be checked for
kinks and clogging by metal flakes and slag. If this is not the cause of slipping, the feedroll pressure can be increased by rotating the adjustable spring screw clockwise. The use of excessive pressure may cause rapid wear of the feed roller, motor shaft
and motor bearings.
CAUTION
!
(8) The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking.
Operation 4-1 Manual 0-5122
Loose welding terminal connections can cause overheating and result in the cables being fused to the
welding terminals.
Page 20
FIREPOWER FP 95 FC OPERATION
Art # A-09064_AD
Wire Speed Control
On / Off Switch
Hi / Low Powe Switch
MIG Welding Torch
Ground Cable & Clamp
Input Power
Cable
Wire Feeder
Pressure Adjust
Welding Wire
Figure 4-1: Firepower Controls
Manual 0-5122 4-2 Operation
Page 21
OPERATION FIREPOWER FP 95 FC
!
4.03 Flux Cored Arc Welding (FCAW)
See Welding Guidelines included in this manual.
1. Make all necessary connections as instructed in the INSTALLATION chapter.
2. Place the WELDING OUTPUT VOLTAGE SELECTOR at the desired setting.
3. Rotate the WIRE SPEED FEED control to the desired setting.
4. Plug the supply cord into a 120 VAC 20 Ampere receptacle.
5. Connect the WORK CLAMP to the workpiece (material to be welded).
6. Extend wire from the gun, and cut to proper stick-out for that type of wire (when welding always maintain this distance).
7. Position gun to where it is at approximately right angles to the workpiece with proper wire stick-out. Lower your welding
helmet and pull the gun trigger switch.
WARNING
Be sure to put on proper protective clothing and eye safeguards (welding coat, apron, gloves, and welding
helmet with proper lenses installed). See Safety Instructions and Warnings chapter included in this manual.
Neglect of these precautions may result in personal injury.
Travel at a speed necessary to maintain a bead width from 1/8" to ¼" (3mm to 6mm) depending on the thickness of the material. For
material that may require larger weldments, either change to a larger diameter filler wire or use multi pass beads. On some applications, it may be necessary to adjust the voltage range to stabilize the arc.
Upon completion of the weld, release the gun trigger switch, raise the welding helmet, and visually examine the weld.
NOTE!
To help you overcome any problems that might arise, you will find useful information in section 4.05 Basic
Welding Techniques.
4.04 Shutdown Procedures
Place the POWER ON/OFF SWITCH in the OFF position.
WARNING
!
After releasing the gun switch, the electrode wire will remain electrically “hot” for several seconds.
4.05 Basic Welding Technique
General
Two different welding processes are covered in this section, with the intention of providing the very basic concepts in using the semiautomatic mode of welding. In this mode, the welding gun is hand-held. The electrode (welding wire) is then fed into a weld puddle and
the arc is shielded by a gas or gas mixture.
Setting of the Power Supply
The settings of the Firepower FP 95 FC requires some practice by the operator in that the welding Power Supply has two control
settings that need to balance. These are the Wire Speed control and the Voltage Control switches. The welding current is determined
by the Wire Speed control (i.e., the current will increase with increased wire speed, resulting in a shorter arc). Slower wire speed will
reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the welding current level, but lengthens the arc.
By decreasing the voltage, a shorter arc is obtained with little change in welding current.
When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire needs more wire
speed to achieve the same current level.
A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the work piece.
If the wire speed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt.
Welding in these conditions normally produces a poor weld due to lack of fusion. If however, the welding voltage is too high, large drops
will form on the end of the electrode wire, causing spatter. The correct setting of voltage and wire speed can be seen in the shape of
the weld deposit and heard by a smooth regular arc sound.
Operation 4-3 Manual 0-5122
Page 22
Art: A-05104
!
30 to 60º
T
Angle
Direction of
T
FIREPOWER FP 95 FC OPERATION
Flux-Cored Arc Welding (FCAW)
This process also known as Open Arc, Innershield, FAB Shield,
etc., is an electric arc welding process which fuses together the
parts to be welded by heating them with an arc between a continuous flux filled electrode wire and the work. Shielding is obtained through decomposition of the flux within the tubular wire.
The process is normally applied semi-automatically; however
the process may be applied automatically or by machine. It is
commonly used to weld large diameter electrodes in the flat and
horizontal position and small electrode diameters in all positions.
The process is used to a lesser degree for welding stainless steel
and for overlay work.
Gas (optional)
Molten Metal
Solid Weld
Metal
Slag
Molten
Slag
Nozzle (optional)
Flux Cored
Electrode
Arc
Figure 4-3: FCAW Process
WARNING
Follow these instructions only after referring to the Safety Instructions and Warnings
chapter of this manual, and the instructions
in the Installation chapter
Check List Before Starting
Wire Feed Speed – 1 to 10
Voltage Range Switch Setting – MIN or MAX
Electrode Wire Stick-out – approx 3/8” (10mm)
4.06 Welding Gun Positions
The welding gun should be held at an angle to the weld joint.
Hold the gun so that the welding seam is viewed at all times.
Always wear the welding helmet with proper filter lenses.
CAUTION
!
The electrode wire is not energized until the gun trigger switch
is depressed. The wire may therefore be placed on the seam or
joint prior to lowering the helmet.
Do not pull the welding gun back when the
arc is established. This will create excessive wire extension (stickout) and make a
very poor weld.
4.07 Establishing the Arc and Making
Before attempting to weld on a finished piece of work, it is
recommended that practice welds be made on a sample metal of
the same material as that of the finished piece.
The easiest MIG welding procedure for the beginner to experiment with, is the flat position. This equipment is capable of flat,
vertical and overhead positions.
For practicing MIG welding, secure some pieces of 16 or 18
gauge (0.06” 1.5mm or 0.08” 2.0mm) mild steel plate 6” x 6”
(150 x 150mm). Use 0.024” (0.6mm) wire.
5º to 15º
Longitudinal
Angle
90º
Transverse
Angle
Figure 4-4: Butt and Horizontal Welds
10º Longitudinal Angle
ransverse
5 to 15º
Longitudinal Angle
ravel
Figure 4-6: Horizontal Fillet Weld
30 to 60º
Transverse Angle
Weld Beads
Direction of
Travel
Art: A-05105
10 to 20º Longitudinal
Angle
Direction of Travel
Figure 4-5: Vertical Weld
30 to 60º
Transverse Angle
Art: A-05107
Direction of Travel
Art: A-05108
Figure 4-7: Overhead
to 60º
30º
Transverse
Angle
Art: A-05106
5 to 15º
Longitudinal
Angle
Manual 0-5122 4-4 Operation
Page 23
OPERATION FIREPOWER FP 95 FC
4.08 Pre-Weld Procedure
1. Check the OPERATION chapter of this manual for details on this equipment.
2. Set the welding voltage range switch at position MIN or MAX.
3. Set the wire feed speed control to about the 2.5 setting. Readjust as necessary.
4. Review standard safe practice procedures in ventilation, eye and face protection, fire, compressed gas and preventative maintenance. See Safety Instructions and Warnings chapter included in this manual.
4.09 Welding Procedure
1. Maintain the tip to work distance (stickout) at 5/16” to 3/8” (8 to 9mm) at all times.
2. For transverse and longitudinal nozzle angles, see section 4.06 Welding Gun Positions.
3. Hold the gun about 3/8” (9mm) from the work, lower the helmet by shaking your head and squeeze the trigger to start the wire
feeding, and establish the arc.
NOTE!
Get in the habit of shaking the helmet down, rather than using the hands. One hand must hold the gun, and
the other is often needed to hold pieces to be tacked or positioned.
4. Make a single down-hand (pulling) stringer weld bead.
5. Practice welding beads. Start at one edge and weld across the plate to the opposite edge.
NOTE!
When the equipment is properly adjusted, a rapidly cracking or hissing sound of the arc is a good indicator
of correct arc length.
6. Practice stopping in the middle of the plate, restarting into the existing weld crater and continuing the weld bead across the
plate.
NOTE!
When the gun trigger is released after welding, the electrode forms a ball on the end. To the new operator, this may
present a problem in obtaining the penetration needed at the start of the next weld. This can be corrected by cutting
the ball off with wire cutters.
4.10 Reference Table
The following table is provided as a user aid when performing FLUX CORED welding.
Result Desired Welding Variable
Welding Current
Arc Voltage
Deeper Penetration 1Increase 3Trailing Max 25° 2Decrease 4Smaller (*)
Shallower
Penetration 1Decrease 3Leading 2Increase 4Larger
Larger Bead 1Increase 2Decrease 3Increase (*)
Smaller Bead 2Decrease 2Increase 3Decrease (*)
Higher Narrower
Bead 1Decrease 2Trailing 3Increase
Flatter Wider Bead 1Increase 290° or Leading 3Decrease
Faster Deposition
Rate 1Increase 2Increase (*) 3Larger
Slower Deposition
Rate 1Decrease 2Decrease (*) 3Smaller
Key: 1 - First Choice, 2 - Second Choice, 3 - Third Choice, 4 - Fourth Choice
(wire speed)
Table 4-1: Welding Reference Table
Travel
Speed Nozzle Angle Stick out Wire size
Operation 4-5 Manual 0-5122
Page 24
FIREPOWER FP 95 FC OPERATION
4.11 Firepower FP 95 FC Welding Setting Selection Guide
Material
Type
Steel
L (MIN)
H (MAX)
24 ga.
(0.6mm)
Wire
Type
Flux Core
E71T-GS
Shielding Gas
and Flow Rate
None
Required
THICKNESS
Voltage
Step
22 ga.
(0.7mm)
L
4
L
2
Figure 4-8 Welding Settings Guide
20 ga.
(0.9mm)
L
6
L
3
Wire
Speed
18 ga.
(1.2mm)
L
L
7
3
Wire Size
(Diameter)
.030" (0.8mm)
.035" (0.9mm)
Art # A-09033_AB
16 ga.
(3mm)
H
L
8
4
(3.2mm)
H
H
1/8"
10
7
Manual 0-5122 4-6 Operation
Page 25
SERVICE FIREPOWER FP 95 FC
SECTION 5:
SERVICE
5.01 Cleaning of the Unit
Periodically remove the right side panel (after disconnecting the supply cord from the receptacle) and blow out the interior with clean,
dry, compressed air of not more than 25 PSI air pressure. Do not strike any components with the air hose nozzle.
5.02 Cleaning of the Feed Rolls
Clean the wire groove on the feed roll at frequent intervals. This cleaning operation can be done by using a small wire brush. To clean
the wire groove, loosen the pressure device and lift the feedroll pressure arm. Remove all wire from the feedhead. Wipe off the bearing
roll (the “top” roll in the feedhead).
5.03 Basic Troubleshooting
The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and without removing the
covers from the Power Source.
If major components are faulty, then the Power Source should be returned to an Accredited ESAB Service Agent for repair.
1. Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within
the molten weld pool which is in the process of escaping during solidification of the molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the
following points:
1. Welding dirty, oily, painted, oxidized or greasy plate.
a. Clean contaminates off the plate.
2. Distance between the MIG torch nozzle and the work piece.
a. Keep the distance between the MIG torch nozzle and the work piece to a minimum.
2. Inconsistent wire feed
Wire feeding problems can be reduced by checking the following points:
1. Wire spool brake is too tight.
a. Feed roller driven by motor in the cabinet will slip.
2. Wire spool brake is too loose.
a. Wire spool can unwind and tangle.
3. Worn or incorrect feed roller size.
a. Use ‘V’ groove drive feed roller matched to the steel wire size you are welding.
4. Misalignment of inlet/outlet guides.
a. Wire will rub against the misaligned guides and reduces wire feedability.
5. Liner blocked with slag.
a. Slag is produced by the wire passing through the feed roller, if excessive pressure is applied to the pressure roller
adjuster. Slag can also be produced by the wire passing through an incorrect feed roller groove shape or size. Slag is
fed into the liner where it accumulates, thus reducing wire feedability.
6. Incorrect or worn contact tip.
a. The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is too large, then arcing
may occur inside the contact tip resulting in the electrode wire jamming in there. When using soft electrode wire such
as aluminum, the wire may become jammed in the contact tip due to expansion of the wire when heated. A contact
tip designed for soft electrode wires should be used.
7. Poor work lead contact to work piece.
a. If the work lead has a poor electrical contact to the work piece, then the connection point will heat up and result in a
reduction of power at the arc.
8. Bent liner.
a. This will cause friction between the wire and the liner thus reducing wire feedability
Service 5-1 Manual 0-5122
Page 26
FIREPOWER FP 95 FC SERVICE
5.04 Welding Problems
FAULT CAUSE REMEDY
Undercut. A Welding arc voltage too
1
high.
B Incorrect torch angle B Adjust angle
C Excessive heat input C Increase the torch travel speed and/or reduce weld-
Lack of penetration. A Welding current too low A Increase welding current by increasing wire feed
2
B Joint preparation too nar-
row or gap too tight
Lack of fusion. Voltage too low Increase voltage by increasing voltage selection
3
Excessive spatter. A Voltage too high A Lower voltage by reducing the voltage selection
4
B Voltage too low B Raise voltage by increasing the voltage selection
Irregular weld shape. A Incorrect voltage and
5
current settings. Convex =
voltage too low. Concave
= voltage too high.
A Reduce voltage by reducing the voltage selection
switch position or increase the wire feed speed.
ing current by reducing the voltage selection switch
position or reducing the wire feed speed.
speed and increasing voltage selection switch position.
B Increase joint angle or gap
switch position.
switch or increase wirespeed control.
switch or reduce wirespeed control.
A Adjust voltage and current by adjusting the voltage
selection switch and the wirespeed control.
B Wire is wandering B Replace contact tip
C Insufficient or excessive
heat input
Weld cracking A Weld beads too small A Decrease travel speed
6
B Weld penetration narrow
and deep
C Excessive weld stresses C Increase weld metal strength or revise design.
D Excessive voltage D Decrease voltage by reducing the voltage selection
E Cooling rate too fast E Slow the cooling rate by preheating part to be
7 Cold weld puddle A Faulty rectifier unit A Have an Accredited ESAB Service Agent to test then
B Loose welding cable con-
nection.
C Low Primary Voltage C Contact supply authority.
D Adjust the wirespeed control or the voltage selec-
tion switch
B Reduce current and voltage and increase MIG torch
travel speed or select a lower penetration shielding
gas.
switch.
welded or cool slowly.
replace the faulty component.
B Check all welding cable connections.
Table 5-1: Welding Problems
Manual 0-5122 5-2 Service
Page 27
SERVICE FIREPOWER FP 95 FC
5.05 Power Source Problems
FAULT CAUSE REMEDY
Primary line voltage is ON.
1
Welding arc can not be
established.
A Primary fuse is blown. A Replace primary fuse.
B Broken connection in primary
circuit.
B Have an Accredited ESAB Service Agent check primary circuit.
Primary line voltage is ON
2
but when the MIG Gun
trigger switch is depressed
nothing happens.
Primary line voltage is ON,
3
no wire feed but gas flows
from the MIG Gun when
the torch trigger switch is
depressed.
Wire feeds when the MIG
4
Gun trigger switch is depressed but arc can not be
established.
Jerky wire feed A Worn or dirty contact tip A Replace
5
MIG Gun trigger switch leads are
disconnected.
A Electrode wire stuck in wire liner
or contact tip (burn-back jam).
B Faulty control PCB B Have an Accredited ESAB Service Agent investigate the fault.
Poor or no work lead connection. Clean work clamp area and ensure good electrical contact.
B Worn feed roller. B Replace
C Excessive back tension from
wire reel hub.
Reconnect.
A Check for clogged / kinked MIG Gun wire liner or worn contact
C Reduce brake tension on spool hub
tip. Replace faulty component(s).
Thermal Overtemp Light
is ON and Fan motor is
6
running
Thermal Overtemp Light
turns on in less than 30
7
seconds during welding.
D Worn, kinked or dirty conduit
liner
The machine duty cycle has
been exceeded.
Fan has stopped running or fuse
on PCB has blown
D Clean or replace conduit liner
Allow the fan to run so machine can cool down. When light
goes out, welding may resume.
Have an Accredited ESAB Service Agent replace the fuse.
Table 5-2: Power Source Problems
Service 5-3 Manual 0-5122
Page 28
FIREPOWER FP 95 FC SERVICE
This Page Intentionally Blank
Manual 0-5122 5-4 Service
Page 29
APPENDIX FIREPOWER FP 95 FC
FEED ROLL INSTALLATION & CONSUMABLE GUIDE
Wire Feed Rolls & MIG Gun Consumable
Wire Feed Roll, Knurle, .023" - .030" /.035"
The branding size at th
end of the feedroll refers
to the size nearest to the mark.
APPENDIX 1: OPTIONS AND ACCESSORIES
Contact your Firepower distributor to order options and accessories. For assistance in locating a Firepower distributor, contact the
Firepower office listed in the inside rear cover that is nearest to you.
Note the model and specification number shown on the equipment nameplate.
Call 1-800-318-6819 Consumable Parts Management Group
Refer to Warranty Schedule.
*
Weld Wires
Description
E71T-GS Flux Cored Wire, .030" (0.8mm), 2 lbs (0.9kg) Spool
E71T-GS Flux Cored Wire, .030" (0.8mm), 10 lbs (4.5kg) Spool
E71T-GS Flux Cored Wire, .035" (0.9mm), 2 lbs (0.9kg) Spool
E71T-GS Flux Cored Wire, .035" (0.9mm), 10 lbs (4.5kg) Spool
1444-0230
1444-0231
1444-0235
Part No.
s
Description
Part No.
1444-0236
(0.6-0.8mm/0.9mm), Hard/Cored
1444-0427
1444-0050 Nozzle
1444-0026 Contact Tip, .030" (0.8mm)
1444-0027 Contact Tip, .035" (0.9mm)
1444-0741 MIG Gun, Complete Assembly
e
.030"
0.8mm
Art # A-09029_AB
Figure A-1: Feed Roll Replacements
Appendix A-1 Manual 0-5122
Page 30
FIREPOWER FP 95 FC APPENDIX
APPENDIX 2: POWER SUPPLY REPLACEMENT PARTS
ITEM DESCRIPTION PART NO.
1 CABLE CLAMP FOR CABLE DIAM.6+ SCREW 1444-0806
2 CABLE CLAMP, FP 95 FC/125/135 1444-0807
3 INPUT POWER CABLE, FP 95 FC/125/135 1444-0433
4 YELLOW PILOT-LIGHT SWITCH 1444-0440
5 CHOKE, FP 95 FC/125 1444-0846
6 CURRENT SWITCH 1444-0438
7 DIVIDING PANEL FP 95 FC + LABEL HELV05000364
8 EARTH CABLE, FP 95 FC HELV43210021
9 EARTH CLAMP, FP 95 FC 1444-0724
10 FRONT FRAME, FP 95 FC 1444-0829
11 HANDLE, FP 95 FC HELV21600036
12 KIT SPOOL HOLDER FOR D.16 SPOOLS - COMP. 1444-0801
13 LEFT SIDE PANEL FP 95 FC W/SILKS. HELV05000363
14 LOWER PANEL FP 95 FC +SILKSCR. HELV05000360
15 MIG GUN, FP 95 FC 1444-0741
16 P.C. BOARD, FP 95 FC 1444-0441
17 POTENTIOMETER KNOB, FP 95 FC 1444-0952
18 RECTIFIER, FP 95 FC 1444-0851
19 RIGHT UPPER PANEL FP 95 FC +SILKSC.+LAB.+HINGES HELV05000361
20 SIDE PANEL.FP 95 FC +SILKS.+LABEL+HINGES HELV05000362
21 SLOW MOTOR D.28 +PINION 1444-0805
22 THERMOSTAT 1444-0443
23 TORCH GROMMET, FP 95 FC 1444-0832
24 TRANSFORMER, FP 95 FC 1444-0845
25 WIRE FEEDER, FP 95 FC 1444-0849
26 FEED ROLL 1444-0842
Table A-1: Replacement Parts
Manual 0-5122 A-2 Appendix
Page 31
APPENDIX FIREPOWER FP 95 FC
20
13
11
23
6
17
4
10
14
8
16
21
19 18 22
12
25
1524
2
3
Art # A-09067_AD
15
9
7
26
Appendix A-3 Manual 0-5122
Figure A-2: FP 95 FC Parts List Callouts
Page 32
FIREPOWER FP 95 FC APPENDIX
Art # A-09025_AB
APPENDIX 3: FIREPOWER FP 95 FC SYSTEM SCHEMATIC
Figure A-3: FP 95 FC Simple System Schematic
Manual 0-5122 A-4 Appendix
Page 33
APPENDIX FIREPOWER FP 95 FC
This Page Intentionally Blank
Appendix A-5 Manual 0-5122
Page 34
FIREPOWER FP 95 FC APPENDIX
Revision History
Date Rev Description
03/19/2009 AA Manual release
04/08/2016 AB Rebrand updates, part number/art updates, schematic updates
Manual 0-5122 A-6 Appendix
Page 35
Page 36
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 4411
Fax: +1 843 664 5748
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone numbers to our distributors in other
countries, please visit our home
page
www.esab.com
www.esab.com
www.firepoweronline.com
©2015 ESAB Welding and Cutting Products
Printed in Italy
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