Tweco FP-165 User Manual

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Art # A-09075

FP-125 FP-135 FP-165

MINI MIG

PORTABLE MIG WELDER

Operating Manual

Revision: AA Issue Date: March 19, 2009 Manual No.: 0-5123 Operating Features:

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc 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 call 1-800-752-7621, or visit us on the web at www.Thermalarc.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc 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.

Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, 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 develop technologically advanced products to achieve a safer working environment within the welding industry.

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 best judgement, the Manufacturer assumes no liability for its use.

Operating Manual Number 0-5123 for: FirePower 125 Mini MIG System MIG Welder Part No. 1444-0324 FirePower 135 Mini MIG System MIG Welder Part No. 1444-0326 FirePower 165 Mini MIG System MIG Welder Part No. 1444-0328

Published by: Thermadyne Industries Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

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: March 19, 2009

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

2009 by

TABLE OF CONTENTS

SECTION 1:SAFETY INSTRUCTIONS AND WARNINGS ................................................ 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 Principal Safety Standards .............................................................................. 1-4

1.03 Symbol Chart .................................................................................................. 1-5

1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6

1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole .................................................................................. 1-10

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 General ........................................................................................................... 2-1

2.05 Speciﬁcations ................................................................................................. 2-2

2.06 Volt - Amp Curves .......................................................................................... 2-3

2.07 Duty Cycle ...................................................................................................... 2-5

2.08 MIG Gun Maintenance ................................................................................... 2-6

2.09 Handle / Feet Assembly ................................................................................... 2-6

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 .............................................................. 3-2

3.06 Installation of Shielding Gas (GMAW) Process .............................................. 3-2

3.07 Attaching the Gun and Cable Assembly to the Power Source ........................ 3-5

3.08 Polarity Changeover ....................................................................................... 3-6

3.09 Installing Wire Spool ..................................................................................... 3-7

3.10 Feedrolls ......................................................................................................... 3-7

3.11 Install Wire into the Feedhead ........................................................................ 3-7

3.12 Install Wire into the Welding Gun .................................................................. 3-9

SECTION 4:OPERATION .................................................................................... 4-1

4.01 General Safety Precautions ............................................................................. 4-1

4.02 FirePower Controls ........................................................................................ 4-2

4.03 Gas Metal Arc Welding (GMAW) .................................................................... 4-4

4.04 Flux Cored Arc Welding (FCAW) .................................................................... 4-4

4.05 Shutdown Procedures .................................................................................... 4-4

4.06 Basic Welding Technique ............................................................................... 4-5

4.07 Welding Gun Positions .................................................................................. 4-6

4.08 MIG Welding (GMAW) Variables .................................................................... 4-7

4.09 Establishing the Arc and Making Weld Beads ................................................ 4-8

4.10 Pre-Weld Procedure ....................................................................................... 4-8

4.11 Welding Procedure ........................................................................................ 4-8

4.12 Reference Tables ............................................................................................ 4-9

TABLE OF CONTENTS

4.13 FirePower 125 Welding Setting Selection Guide ........................................... 4-10

4.14 FirePower 135 Welding Setting Selection Guide ........................................... 4-11

4.15 FirePower 165 Welding Setting Selection Guide ........................................... 4-12

4.16 Gas Selection for Gas Metal Arc Welding ...................................................... 4-13

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 Solving Problems Beyond the Welding Terminals .......................................... 5-1

5.05 Welding Problems ......................................................................................... 5-3

APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1

APPENDIX 2: REPLACEMENT PARTS ................................................................... A-4

APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC ................................................. A-6

APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC ................................................. A-7

APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC ................................................. A-8

LIMITED WARRANTY .........................................................................................9

WARRANTY SCHEDULE .................................................................................... 10

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ........................... Inside Rear Cover

SAFETY INSTRUCTIONS FIREPOWER FP-125, 135, 165

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,

OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In conﬁned spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above ﬂoor level.

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a welding helmet ﬁtted with a proper shade of ﬁlter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from ﬂash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, ﬂame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

Safety Instructions 1-1 Manual 0-5123

FIREPOWER FP-125, 135, 165 SAFETY INSTRUCTIONS

Welding or Cutting

Operation

Electrode Siz

Metal Thickness

or Weldin

Current

Filter

Shade

No.

Welding or Cutting

Operation

Electrode Siz

Metal Thickness

or Weldin

Filter

Shade

No.

Torch soldering 2

Gas metal-arc welding (MIG)

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting

Non-ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding

Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6

Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc

welding

(stick) electrodes

Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in.,

4 to 6.4 mm

Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

WARNING

FUMES AND GASES can be hazardous to your health. Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a conﬁned space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

WARNING

WELDING can cause ﬁre or explosion. Sparks and spatter ﬂy off from the welding arc. The ﬂying

sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause ﬁres and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or ﬁre.

1. Protect yourself and others from ﬂying sparks and hot metal.

2. Do not weld where ﬂying sparks can strike ﬂammable material.

3. Remove all ﬂammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for ﬁre, and keep a ﬁre extinguisher nearby.

6. Be aware that welding on a ceiling, ﬂoor, bulkhead, or partition can cause ﬁre on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and ﬁre hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

Manual 0-5123 1-2 Safety Instructinos

SAFETY INSTRUCTIONS FIREPOWER FP-125, 135, 165

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause ﬂying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and ﬁttings designed for the speciﬁc application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

WARNING

ENGINE FUEL can cause ﬁre or explosion.

Engine fuel is highly ﬂammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open ﬂames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overﬁll tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut ﬁngers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualiﬁed people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is ﬁnished and before starting engine.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

Safety Instructions 1-3 Manual 0-5123

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

FIREPOWER FP-125, 135, 165 SAFETY INSTRUCTIONS

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

The following is a quotation from the General Conclusions Section of the U.S. Congress, Ofﬁce of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Ofﬁce, May

1989): “...there is now a very large volume of scientiﬁc ﬁndings based

on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic ﬁelds interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientiﬁc understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw deﬁnite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Manual 0-5123 1-4 Safety Instructinos

SAFETY INSTRUCTIONS FIREPOWER FP-125, 135, 165

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Dangerous Voltage

Off

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Art # A-04130

115V 15A

IPM

MPM

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld Mode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

4 Step Trigger Operation

2 Step Trigger Operation

1.03 Symbol Chart

Note that only some of these symbols will appear on your model.

Safety Instructions 1-5 Manual 0-5123

FIREPOWER FP-125, 135, 165 SAFETY INSTRUCTIONS

1.04 Precautions De Securite En Soudage A L’arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la ﬁn de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.05 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semiautomatique avec ﬁl, ce dernier, le rouleau ou la bobine de ﬁl, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le ﬁl de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen

de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation aﬁn d’éviter une mise en marche accidentelle.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces conﬁnés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

AVERTISSEMENT

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

Manual 0-5123 1-6 Safety Instructinos

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

SAFETY INSTRUCTIONS FIREPOWER FP-125, 135, 165

1. Portez une casque de soudeur avec ﬁltre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les ﬁches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace conﬁné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm) 2 ou 3

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

épais plus de 6 po. (150 mm) 5 ou 6

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

ﬁltre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec ﬁl plein (GMAW)

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atomique (AHW)

Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

ﬁltre

oculaire

Safety Instructions 1-7 Manual 0-5123

FIREPOWER FP-125, 135, 165 SAFETY INSTRUCTIONS

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du ﬁl-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inﬂammables.

3. Enlevez toutes matières inﬂammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méﬁez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou ﬁssures.

5. Méﬁez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enﬂammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre ﬁxe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spéciﬁque; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identiﬁée dans la liste de documents ci-dessous.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le ﬁl au tube-contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

2. Si vous utilisez ces équipements dans un endroit conﬁné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inﬂammable.

1. Arrêtez le moteur avant de vériﬁer le niveau e carburant ou de faire le plein.

Manual 0-5123 1-8 Safety Instructinos

SAFETY INSTRUCTIONS FIREPOWER FP-125, 135, 165

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une ﬂamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vériﬁer le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualiﬁées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction.

Il faut se laver les mains après toute manipulation.

(Code de Californie de la sécurité et santé, paragraphe

25249.5 et suivants)

1.06 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR PEUT BRULER LA PEAU ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safety Instructions 1-9 Manual 0-5123

FIREPOWER FP-125, 135, 165 SAFETY INSTRUCTIONS

Soudage á L’arc Avec Electrode Non Fusible (GTAW)

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Tension dangereuse

Hors Tension

Sous Tension

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

Soudage á L’arc Avec Fil Electrodes Fusible (GMAW)

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Distant

Facteur de Marche

Pourcentage

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de PriseSource Auxiliaire

Art # A-07639

115V 15A

IPM

MPM

Fusible

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Durée de Pré-Dèbit

Durée de Post-Dèbit

Duréc du Pulse

Soudure Par Point

Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Purge Du Gaz

Mode Continu de Soudure

Pouces Par Minute

Mètres Par Minute

Torch de

Soudage

Probléme de Terre

Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.

Détente à 4-Temps

Détente à 2-Temps

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Manual 0-5123 1-10 Safety Instructinos

INTRODUCTION FIREPOWER FP-125,135,165

SECTION 2:

INTRODUCTION

2.01 How to Use This Manual

This Operating Manual usually applies to the part numbers listed on page i. If none are underlined, they are all covered by this manual. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the word WARNING, CAUTION and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

Gives information regarding possible personal injury. Warnings will be enclosed in a box such as this.

CAUTION

Refers to possible equipment damage. Cautions will be shown in bold type.

NOTE

Offers helpful information concerning certain operating procedures. Notes will be shown in italics

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside 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 Thermal Arc web site listed below and clicking on the Literature Library link:

http://www.thermalarc.com

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.

2.04 General

The FirePower FP-125, 135, 165 Machines are singlephase input welding machines and come equipped with the following:

1. Built-in Wire Feeder and Wire Spool Hub

2. Welding Gun and Cable

3. Work Cable and Clamp

4. Regulartor/Flow Meter (FP-125 optional)

5. Input Cord

6. 2 Spare Contact Tips

7. Operational Manual

8. 0.5 lb. Spool of Wire

9. Gas Hose

The welding system is designed for use with the following processes:

1. GMAW - Gas metal arc welding (MIG). Requires the use of a shielding gas and regulator.

2. FCAW – Flux-cored arc welding – Does not require the use of a shielding gas.

2.02 Equipment Identiﬁcation

The unit’s identiﬁcation number (speciﬁcation or part number), model, and serial number usually appear on a nameplate attached to the machine. Equipment which does not have a nameplate attached to the machine is identiﬁed only by the speciﬁcation or part number printed on the shipping container. Record these numbers for future reference.

Introduction 2-1 Manual 0-5123

FIREPOWER FP-125,135,165 INTRODUCTION

2.05 Speciﬁcations

Description FP-125 FP-135 FP-165

Package System Part Number 1444-0324 1444-0326 1444-0328 Power Source Weight 47.4 lb (21.5 kg) 52.9 lb (24.0kg) 58.1 lb (26.4 kg) Power Source Dimensions HxWxD 12 x 9.75 x 17.5" ( 304.8 x 247.7 x 444.5mm) Number of Phases 1 Ø Frequency 60Hz Flexible Supply Cable Size 7 ft (2.2 m) 14AWG 7 ft (2.2 m) 14AWG 7.5 ft (2.5 m) 14AWG Supply Lead Plug Type 5-15P 5-15P 6-50P Nominal Input Voltage

Rated kVA @ 100% Duty Cycle 5kVA 6kVA 7kVA Rated Input Current 15A (60A@40%) 15A (60A@60%) 22.5A (120A@25%) Maximum Input Current 38A (110A@10%) 50A (120A@13%) 35A (155A@15%) Generator Requirements # 5kVA # 6kVA # 7kVA Supply VA @ max. output # 4.6kVA # 5kVA # 6.8kVA Open Circuit Voltage Range 16 – 30V 16 – 32V 15 – 30V Output Current Range 40 – 125A 39 – 135A 36 – 165A Duty Cycle Period 10 Minutes Number of Output Voltage Values 4 Minimum Mains Circuit to suit factory ﬁtted

Plug & Lead (Weld Current @ Duty Cycle) Maximum Mains Circuit to suit factory ﬁtted

Plug & Lead (Weld Current @ Duty Cycle)

Steel

Stainless Steel

Flux Core

120V AC 120V AC 230V AC

15A (60A@40%) 15A (60A@60%) 22.5A (120A@25%)

38A (110A@10%) 50A (120A@13%) 35A (155A@15%)

Wire Size Range

.023” - .030” - .035"

(0.6 - 0.8 - 0.9mm)

.030” - .035”

(0.8 - 0.9mm)

.023” - .030” - .035"

(0.6 - 0.8 - 0.9mm)

.030” - .035”

(0.8 - 0.9mm)

.023” - .030” - .035"

(0.6 - 0.8 - 0.9mm)

.030” - .035”

(0.8 - 0.9mm)

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)

Thermal Arc 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 0-5123 2-2 Introduction

INTRODUCTION FIREPOWER FP-125,135,165

FP-125 FIREPOWER Vin=115V 60Hz

5.0

10.0

15.0

20.0

25.0

30.0

35.0

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140

OUTPUT CURRENT

OUTPUT VOLTAGE

Art # A-09076

FP-135 FIREPOWER Vin=115V 60Hz

0 10 20 30 40 50 60 70 80 90 100 110 120 130

OUTPUT CURRENT

OUTPUT VOLTAGE

Art # A-09077

2.06 Volt - Amp Curves

Figure 2-1: Volt/Amp curves of the FirePower 125

Introduction 2-3 Manual 0-5123

Figure 2-1: Volt/Amp curves of the FirePower 135

FIREPOWER FP-125,135,165 INTRODUCTION

FP-165 FIREPOWER Vin=230V 60Hz

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190

OUTPUT CURRENT

OUTPUT VOLTAGE

Art # A-09078

Figure 2-1: Volt/Amp curves of the FirePower 165

Manual 0-5123 2-4 Introduction

INTRODUCTION FIREPOWER FP-125,135,165

FirePower 125 at Rated Duty Cycle

2 3

4 5 6 7 8

Min ute s

9 10

Art # A-09058

FirePower 135 at Rated Duty Cycle

2 3

4 5 6 7 8

Min ute s

9 10

Art # A-09059

FirePower 165 at Rated Duty Cycle

2 3

4 5 6 7 8

Min ute s

9 10

Art # A-09060

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-135 is designed for 20% duty cycle at 117 amps. This means that it has been designed and built to provide the rated amperage, 117 amps, for 2 minutes out of every 10 minute period. During the other 8 minutes of the 10 minute period, the FirePower FP-135 must idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.

The FirePower FP-125 is designed for 19% duty cycle at 90 Amps.

The FirePower FP-135 is designed for 20% duty cycle at 117 Amps.

The FirePower FP-165 is designed for 18% duty cycle at 140 Amps.

If the unit overheats and the thermostat opens, wait 15 minutes for unit to cool.

Figure 2-5: Duty Cycle of FirePower125

Figure 2-6: Duty Cycle of FirePower135

Figure 2-7: Duty Cycle of FirePower165

Introduction 2-5 Manual 0-5123

FIREPOWER FP-125,135,165 INTRODUCTION

Art # A-09094

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.

2.09 Handle / Feet Assembly

Manual 0-5123 2-6 Introduction

INSTALLATION FIREPOWER FP-125, 135, 165

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 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.

CAUTION

Consult the nameplate for proper input voltage and input amperage. The method of installation, conductor size, and over-current protection shall conform to the requirements of the local electrical code. All installation wiring and machine connection shall be done by a competent electrician.

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-125 has a 19% duty cycle (1 minute 54 seconds of every 10 minutes can be used for welding). The FirePower FP-135 has a 20% duty cycle (2 minutes of every 10 minutes can be used for welding). The FirePower FP-165 has an 18% duty cycle (1 minute 48 seconds of every 10 minutes can be used for welding). The power cords supplied with these units comply with these standards. Ensure that the building supply and receptacle comply with NEC standards and any additional state and local codes.

NOTE

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. Firepower FP-125 & FP-135 requires a 120VAC supply voltage and the Firepower FP-165 requires a 230VAC supply voltage.

The Firepower FP-125 & FP-135's power cord is equipped with a NEMA 5-15P plug and will only connect to a NEMA 5-15P receptacle.

Except for some early models, the Firepower FP-165's power cord is equipped with a NEMA 6-50P plug and will only connect to a NEMA 6-50P receptacle.

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-125 or 135 to an input power supply with a rated voltage that is greater than 120 +10% VAC. Do not remove the power cord ground prong.

CAUTION

Do not connect the FirePower FP-165 to an input power supply with a rated voltage that is greater than 230 + 10% VAC. Do not remove the power cord ground prong.

Installation 3-1 Manual 0-5123

FIREPOWER FP-125, 135, 165 INSTALLATION

3.05 Requirements for Maximum Output

In order to obtain the maximum output capability of the FirePower FP-125 a branch circuit capable of 40 amperes at 115 to 125 Volts 60 Hz is required. In order to obtain the maximum output capability of the FirePower FP-135 a branch circuit capable of 50 amperes at 115 to 125 Volts 60 Hz is required. In order to obtain the maximum output capability of the FirePower FP-165 a branch circuit capable of 30 amperes at 208 to 230 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.

3.06 Installation of Shielding Gas (GMAW) Process

Refer to Figure 3-1.

NOTE

Shielding Gas is not required if the unit is using self-shielded FCAW (ﬂux cored arc welding) wires.

1. Cylinder Positioning: Chain the cylinder to a wall or other support to prevent the cylinder from falling over. If an optional portable mounting arrangement is used, follow the instructions that are provided with it.

CAUTION

KEEP FACE WELL AWAY FROM THE CYLINDER VALVE DURING “CRACKING”. Never “crack” a fuel gas cylinder valve near other welding works, sparks or open ﬂames. Ensure that the surrounding area is well ventilated.

4. Fit Regulator/Flowmeter to Cylinders:

Screw the regulator into the appropriate cylinder. The nuts on the regulator and hose connections are right hand (RH) threaded and need to be turned in a clockwise direction in order to tighten. Tighten with a wrench.

CAUTION

Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.

5. Attach Supplied Gas Line: Attach supplied gas line between the regulator output and the desired input at the rear of the power supply depending on Spool Gun or MIG Gun use.

2. Remove Cylinder Cap: Remove the large metal cap on top of the cylinder by rotating counter clockwise. Next remove the dust seal.

3. Cracking: Position yourself so the valve is pointed away from you and quickly open and close the valve for a burst of gas. This is called “Cracking” and is done to blow out any foreign matter that may be lodged in the ﬁtting.

Manual 0-5123 3-2 Installation

INSTALLATION FIREPOWER FP-125, 135, 165

Art # A-07965

Cap

Shielding Gas

“Cracking”

Shielding Gas

Regulator and Flow Meter

Shielding Gas

1 1/8”

Gas Hose

Figure 3-1 Gas Cylinder Installation for Reference Only!

Installation 3-3 Manual 0-5123

FIREPOWER FP-125, 135, 165 INSTALLATION

Art # A-07280

Adjusting Regulator

Adjust control knob of regulator to the required ﬂow rate, indicated on gauge dial. (Refer to Figure 3-2 and data charts. Approx. 20 CFH)

The gas ﬂow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas ﬂow rates may cause turbulence and weld porosity.

Argon or argon based gas ﬂow rates:

- Workshop welding: 20-30 CFH

- Outdoors welding: 30-40 CFH

Helium based or CO2 gas ﬂow rates:

- Workshop welding: 30-40 CFH

- Outdoors welding: 40-50 CFH

NOTE

All valves downstream of the regulator must be opened to obtain a true ﬂow rate reading on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.

Figure 3-2: Adjusting flow rate. Illustration for

Reference Only.

Refer to section 4.15 for suggested gas / ﬁller metal combinations.

NOTE

The regulator/ﬂowmeters used with argonbased and carbon dioxide shielding gases are different. The regulator/ﬂow meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide regulator/ﬂow meter will need to be ﬁtted.

Two types of gas are generally used with Gas Metal Arc Welding (GMAW) of thin gauge sheet steel. A mixture of 75% Argon and 25% Carbon Dioxide (CO2) is recommended, Carbon Dioxide (CO2) can also be used.

Manual 0-5123 3-4 Installation

INSTALLATION FIREPOWER FP-125, 135, 165

Gun Switch Plug/Socket

Gas Tube

Art # A-09079

3.07 Attaching the Gun and Cable Assembly to the Power Source

The Firepower FP-125, FP-135, FP-165 are supplied with a 80A MIG gun. The 80A MIG gun is designed with an ergonomic handle and fewer parts to eliminate performance problems. The 80A MIG gun uses standard readily available TWECO consumable parts.

1. Open the door to the machine.

2. Connect the gun cable to the power source by ﬁrst

routing the switch lead through the access hole in the front panel followed by the gun cable (see Figure 3-3).

NOTE:

Turn the cable end to align the gas hose nipple on the connector plug with the keyway located in the bottom of the front panel access hole.

3. Loosen the screws and insert the gun cable end as far

as it will go. Tighten thumbscrew (see Figure 3-3).

4. Insert the gun switch plug into the gun switch socket

(see Figure 3-3).

5. If shielding gas is being used, push the gas hose on

to the gas hose nipple and secure it with the hose clamp.

6. To remove the gun, simply reverse these directions.

CAUTION

When disconnecting gun switch leads from the machine, grab the connectors and pull. Do not pull on the wires.

Figure 3-3: Attaching Gun and Cable

Installation 3-5 Manual 0-5123

FIREPOWER FP-125, 135, 165 INSTALLATION

Polarity Terminal Leads

Polarity Terminal Knobs

Gas Hose Normally Connected

Art # A-09080

Gas Tube Normally Disconnected

Polarity Terminal Leads

Polarity Terminal Knobs

Art # A-09081

3.08 Polarity Changeover

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

As delivered from the factory, the output polarity is set to the polarity which matches the welding wire supplied with the unit. The output terminals are located on the interior panel of the welding power source if you need to change polarity.

PROCESS POLARITY CABLE CONNECTIONS

CABLE TO GUN CABLE TO WORK

1. GMAW – Solid Wire 1. DCEP – Reverse Polarity 1. Connected to (+) Pos. output terminal

1. Connected to (-)

Neg. output terminal

2. FCAW – Self-shielding Wire

2. DCEN – Straight Polarity 2. Connected to (-)

– no Shielding Gas

Table 3-1: Process Cable Connections

Connection for GMAW (reverse polarity DCEP)

1. Open the door to the machine.

2. Remove the polarity terminal knobs.

3. Set up the polarity (as per Table 3-1 above) by

removing the leads from the terminals and reversing them if necessary. Refer to Figure 3-4.

4. Replace the polarity terminal knobs.

NOTE

Ensure that the polarity terminal knobs are tightly secured and that there is no connection between positive and negative terminals.

Connection for FCAW (straight polarity DCEN)

2. Connected to (+)

Neg. output terminal

Pos. output terminal

Figure 3-4: Connection for GMAW (reverse polarity

DCEP)

1. Open the door to the machine.

2. Remove the polarity terminal knobs.

3. Set up the polarity (as per Table 3-1 above) by

removing the leads from the terminals and reversing them if necessary. Refer to Figure 3-5.

4. Replace the polarity terminal knobs.

NOTE

Ensure that polarity terminal knobs are tightly secured and that there is no connection between positive and negative terminals.

Figure 3-5: Connection for FCAW (straight polarity

DCEN)

Manual 0-5123 3-6 Installation

INSTALLATION FIREPOWER FP-125, 135, 165

Art # A-09082

.030

0.8

Art # A-07963

3.09 Installing Wire Spool

3.10 Feedrolls

As delivered from the factory, the unit is set for an 4” (102mm) spool.

Installation of Wire Spool

Assemble parts in sequence (shown in Figure 3-6 from right to left).

1. Spool 4” (102mm)

2. External Ring

3. Retaining Spring

4. Nut

NOTE

Nut is tightened until a slight force is required to turn the spool\

A feedroll consists of two different sized grooves, .023” (0.6mm) and .030” / .035” (0.8mm / 0.9mm).

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 3-7 : Feedroll Example

3.11 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.

1. Loosen the nut of the spool holder (brake drum). Remove the spring and the external ring.

Figure 3-6: 4" Spool Installation

2. Remove the plastic protection from the spool. Place it on the spool holder again. Mount the external ring , the spring and the plastic lock nut again. These parts form the braking system for the wire spool. Tighten nut to appropriate tightness. Excessive pressure strains the wire feeding motor. Too little pressure does not allow the immediate stop of the wire spool at the end of the welding.

Installation 3-7 Manual 0-5123

FIREPOWER FP-125, 135, 165 INSTALLATION

Wire Spool

Inlet Wire Guide Feedroll

Pressure Adjust Device

Pressure Arm

Gun Cable End

Art # A-09083

Pressure Adjust Device

Pressure Arm

Art # A-09084

Pressure Adjust Device

Pressure Arm

Spool

Wire Guide

Wire

Feedroll

Gun Cable End

Art # A-09085

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.

Figure 3-9: Opening Pressure Arm

Figure 3-8: Wire Feeder Components

Route the Wire Through the Feedhead

1. Loosen Pressure Adjust Device (Fig. 3-9).

2. Open Pressure Adjust Device (Fig. 3-9).

3. Open Pressure Arm (Fig. 3-9).

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. 3-10).

5. Pass the wire into the Gun Liner of the Gun Cable End (Fig. 3-10).

6. Close the Pressure Arm (Fig. 3-10).

7. Close the Pressure Adjust Device. Tighten it to a “snug” condition (Fig. 3-10).

8. Figure 3-11 shows the result with the wire installed.

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.

Figure 3-10: Inserting Wire

Figure 3-11: Wire Installed

Manual 0-5123 3-8 Installation

INSTALLATION FIREPOWER FP-125, 135, 165

LOW1

COARSEFINE

HIGH

Art # A-09061

Wire Feed Speed

Voltage Control Switch

Power ON OFF Switch

Art # A-09062

Wire Feed Speed

Voltage Control Switch

Power ON OFF Switch

LOW1

COARSEFINE

HIGH

Art # A-09061

Wire Feed Speed

Voltage Control Switch

Power ON OFF Switch

Art # A-09062

Wire Feed Speed

Voltage Control Switch

Power ON OFF Switch

3.12 Install Wire into the Welding Gun

1. Plug the Welding Power Source into the 120VAC receptacle for the FirePower FP-125 and FP-135, and into the 230VAC receptacle for the FirePower FP-165.

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 with the gun switch activated.

2. Turn the welding machine ON with the front panel Voltage Control Switch set to "1".

3. Set the wire feed speed to half-way or "5".

Figure 3-14: FP-125 Wire Speed Half-way

Figure 3-15: FP-135, 165 Wire Speed Half-way

Figure 3--12: FP-125 Power ON

Figure 3--13: FP-135, 165 Power ON

Installation 3-9 Manual 0-5123

FIREPOWER FP-125, 135, 165 INSTALLATION

Contact Tip

Nozzle

Gun Switch

Wire

Art # A-09087

4. Straighten the gun cable. Remove the nozzle and contact tip from the MIG welding gun (see Section

2.08).

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.

Figure 3-15: Feed Wire Through Gun

6. Deactivate the gun switch and set the Power Control Switch to "0 / OFF" and unplug the supply cord.

7. Replace the contact tip and nozzle. Cut the wire within ¼” (6mm) from the nozzle.

Manual 0-5123 3-10 Installation

OPERATION FIREPOWER FP-125, 135, 165

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.

Operation 4-1 Manual 0-5123

FIREPOWER FP-125, 135, 165 OPERATION

4.02 FirePower Controls

Refer to Figure 4-1 and 4-2.

1. Power ON / OFF switch turns the power on and off. It also lights when the power supply has gone into overtemp.

10 The Gun Switch Connector is provided for con-

nection of the Gun Switch Leads.

11. Negative (-) Welding Terminal.

12. Positive (+) Welding Terminal.

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 Control Switch(s) sets the voltage level to the welding terminals. There are 4 positions available.

CAUTION

The Voltage Control Switch MUST NOT BE SWITCHED during the welding process. Some internal electrical components are at Mains voltage potential with this switch in the OFF position.

4. MIG Gun cable end and Gun Switch Leads are routed through this opening.

5. The Work Cable & Clamp connects to the item being welded.

6. The gas inlet nipple is used to connect the gas hose to the gas regulator for GMAW. Use the hose clamp to secure the hose to the gas nipple.

CAUTION

Loose welding terminal connections can cause overheating and result in the cables being fused to the welding terminals.

13. The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the wire reel hub. Clockwise rotation will tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than ¾” (20mm) after release of the Torch Trigger Switch. The wire should be slack without becoming dislodged from the reel.

CAUTION

Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, overheating of electrical components and possibly an increased incidence of wire burnback into the contact tip.

7. Main Power Cable.

8. The moveable tension knob applies pressure to the grooved roller via screw-adjustable spring pressure. The adjustable spring 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.

NOTE

Genuine TWECO contact tips should be used.

9 The Gun Adaptor connects the MIG Gun to the

feedhead assembly.

Manual 0-5123 4-2 Operation

OPERATION FIREPOWER FP-125, 135, 165

LOW1

COARSEFINE

HIGH

FP-125

RATED OUTPUT

VOLTS 15 AMP 110 DUTY CYCLE 13% MAX OCV 30 AMP RANGE 40-110

CSA

21 60 40% 30 40-110

120V Wire Feed Welder

Welds 24 gauge to 3/16"(4.8mm) Mild Steel

Art # A-09065

FP-135

RATED OUTPUT

VOLTS 18 AMPS 120 DUTY CYCLE 20% MAX OCV 32 AMP RANGE 39-120

CSA

21 60 60% 32 39-120

120V Wire Feed Welder

Welds 24 gauge to 1/4"(6.4mm) Mild Steel

Art # A-09066

Figure 4-1: FirePower FP-125 Controls

Figure 4-2: FirePower FP-135 and 165 Controls

Operation 4-3 Manual 0-5123

FIREPOWER FP-125, 135, 165 OPERATION

4.03 Gas Metal Arc Welding (GMAW)

See Welding Guidelines included in this manual.

Make all necessary connections as instructed in the INSTALLATION chapter.

Place the WELD VOLTAGE RANGE SWITCH at the desired setting.

CAUTION

Do not turn the WELD VOLTAGE RANGE SWITCH clockwise past position 4, as damage to the switch may occur.

Plug the supply cord into a 120 VAC 40 Ampere receptacle for the FP-125, 120 VAC 50 Ampere receptacle for the 135 and into a 230 VAC 30 Ampere receptacle for the FP-165.

Open the gas cylinder valve to supply shielding gas to the gun. (optional gas regulator required on the FP-125)

Connect the WORK CLAMP to the workpiece (material to be welded).

To help you overcome any problems that might arise, you will ﬁnd useful information in section 4.06 Basic Welding Techniques.

4.04 Flux Cored Arc Welding (FCAW)

Follow the same general procedure as with the GMAW process above. Shielding gas is not required for self shielded type wires. For differences in the process see section 4.06 Basic Welding Techniques. Also included is information to solve any problem related to the FCAW process.

4.05 Shutdown Procedures

Close the cylinder valve (GMAW process only). Press gun switch to vent gas line (GMAW process only). Place the POWER ON/OFF SWITCH in the OFF position.

After releasing the gun switch, the electrode wire will remain electrically “hot” for several seconds.

NOTE

WARNING

Rotate the WIRE SPEED control to the desired setting.

Extend wire from the gun, and cut to proper stick-out for that type of wire (when welding always maintain this distance).

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.

Manual 0-5123 4-4 Operation

OPERATION FIREPOWER FP-125, 135, 165

Base Metal

Arc

Electrode

Nozzle

Shielding Gas

Weld Metal Solidiﬁed Weld Metal

Art: A-05103

Arc

Flux Cored Electrode

Nozzle (optional)

Gas (optional)

Molten Metal

Molten Slag

Solid Weld Metal

Slag

Art: A-05104

4.06 Basic Welding Technique

GAS METAL ARC WELDING (GMAW)

General

Two different welding processes are covered in this section, with the intention of providing the very basic concepts in using the semi-automatic 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 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.

This process, also known as MIG welding, CO2 welding, Micro Wire Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid, continuous, consumable electrode and the work. Shielding is obtained from an externally supplied gas or gas mixture. The process is normally applied semi-automatically; however the process may be operated automatically and can be machine operated. The process can be used to weld thin and fairly thick steels, and some non-ferrous metals in all positions.

Figure 4-3: GMAW Process

FLUX CORED ARC WELDING (FCAW)

This process also known as Open arc, Innershied, 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.

Figure 4-4: FCAW Process

Operation 4-5 Manual 0-5123

FIREPOWER FP-125, 135, 165 OPERATION

Direction of Travel

90º Transverse Angle

5º to 15º Longitudinal Angle

Art: A-05105

Direction of Travel

30º

to 60º Transverse Angle

10 to 20º Longitudinal Angle

30 to 60º Transverse Angle

10º Longitudinal Angle

Art: A-05106

5 to 15º Longitudinal Angle

30 to 60º Transverse Angle

Direction of Travel

Art: A-05107

Direction of Travel

30 to 60º Transverse Angle

5 to 15º Longitudinal Angle

Art: A-05108

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

POLARITY – DCEP (Direct Current Electrode Positive) or DCEN (Direct Current Electrode Negative)

WIRE FEED SPEED – 1 to 10

VOLTAGE RANGE SWITCH SETTING – 1 to 4 for FP-135, 165 an two switches and1-2 and Low-High for FP-125.

GAS FLOW RATE – 15 to 25 CFH (If shielding gas is required)

ELECTRODE WIRE STICK-OUT – approx 3/8” (10mm)

4.07 Welding Gun Positions

The welding gun should be held at an angle to the weld joint (see Secondary Adjustment Variables in Section 4.08). Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper ﬁlter lenses.

CAUTION

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.

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.

Figure 4-5: Butt and Horizontal Welds

Figure 4-7: Horizontal Fillet Weld

Manual 0-5123 4-6 Operation

Figure 4-6: Vertical Weld

Figure 4-8: Overhead

OPERATION FIREPOWER FP-125, 135, 165

Gas Nozzle

Tip to Work Distance

Contact Tip (Tube)

Electrode Wire

Actual Stickout

Average Arc Length

Art: A-05109

Longitudinal Angle

Transverse Angle

Axis of Weld

Art: A-05110

Direction of Gun Travel

90º

Leading or "Pushing" Angle (Forehand)

Trailing or "Pulling" Angle (Backhand)

Art # A-05111

4.08 MIG Welding (GMAW) Variables

Most of the welding done by all processes is on carbon steel. The following items describe the welding variables in short-arc welding of 24 gauge (0.024”, 0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.

Pre-selected Variables

Pre-selected variables depend upon the type of material being welded, the thickness of the material, the welding position, the deposition rate and the mechanical properties. These variables are:

1. Type of electrode wire

2. Size of electrode wire

3. Type of gas (not applicable to self-shielding wires FCAW)

4. Gas ﬂow rate (not applicable to self-shielding wires FCAW)

2. Wire Feed Speed. Increase in wire feed speed increases weld current. Decrease in wire feed speed decreases weld current.

3. Nozzle Angle. (Figures 4-9 and 4-10) This refers to the position of the welding gun in relation to the joint. The transverse angle is usually one half the included angle between plates forming the joint. The longitudinal angle is the angle between the center line of the welding gun and a line perpendicular to the axis of the weld. The longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading (pushing). Whether the operator is left-handed or right-handed has to be considered to realize the effects of each angle in relation to the direction of travel.

Primary Adjustable Variables

These control the process after Pre-selected Variables have been found. They control the penetration, bead width, bead height, arc stability, deposition rate and weld soundness. They are:

1. Arc Voltage

2. Welding Current (wire feed speed)

3. Travel Speed

Secondary Adjustable Variables

These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are:

1. Stickout—distance between the end of the contact tube (tip) and the end of the electrode wire. Keep this at about 3/8” (10mm) stickout (as shown in Figure 4-8).

Figure 4-10: Transverse and Longitudinal Nozzle Axes

Figure 4-11: Nozzle Angle, Right-Handed Operator

Figure 4-9: Electrode Stick-Out

Operation 4-7 Manual 0-5123

FIREPOWER FP-125, 135, 165 OPERATION

4.09 Establishing the Arc and Making

4.11 Welding Procedure

Weld Beads

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 and 75% Argon / 25% CO2 shielding gas.

4.10 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 1 or 2.

3. Set the wire feed speed control to about the 2.5 setting. Readjust as necessary.

4. Adjust the gas ﬂow rate to about 20 cubic feet per hour (15 - 20 lpm).

5. 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.

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 4.07 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.

Manual 0-5123 4-8 Operation

OPERATION FIREPOWER FP-125, 135, 165

4.12 Reference Tables

The following tables are provided as user aids when performing MIG or FLUX CORED welding.

Type of Gas Typical Mixtures Primary Uses Carbon Dioxide (CO2) Mild and low alloy steels Argon (Ar) - Carbon Dioxide (CO2) 75% Ar – 25% CO2 Mild and low alloy steelsStainless Steel Argon (Ar) Aluminum

Table 4-1: Type of Gas

Result Desired Welding Variable

Arc

Voltage

Deeper

Penetration 1Increase

Shallower

Penetration 1Decrease 3Leading 2Increase 5Larger

Larger Bead 1Increase 2Decrease

Smaller Bead 2Decrease 2Increase

Higher Narrower

Bead 1Decrease 2Trailing 3Increase

Flatter Wider

Bead 1Increase 290° or Leading 3Decrease

Faster

Deposition Rate 1Increase

Welding Current

(wire speed)

Travel

Speed Nozzle Angle Stick out

3Trailing Max

25° 2Decrease

3Increase

(*)

3Decrease

(*)

2Increase

(*) 3Smaller

5Smaller

Wire

size

(*) 4CO2

Gas

Type

4Ar CO2

mix

Slower

Deposition Rate 1Decrease

Key: (1) First Choice, (2) Second Choice, (3) Third Choice, (4) Fourth Choice, (5) Fifth Choice

Table 4-2: Welding Variables

NOTE

Same adjustment is required for wire feed speed.

* When these variables are changed, the wire feed speed must be adjusted so that the welding current remains constant. See DEPOSITION RATE in the WELDING VARIABLES section. This change is especially helpful on materials of 20 gauge (.04” 1mm approximately) and smaller in thickness.

Operation 4-9 Manual 0-5123

2Decrease

(*) 3Larger

FIREPOWER FP-125, 135, 165 OPERATION

Art # A-09030

Steel

Flux Core

E71T-GS

None

Required

.030" (0.8mm)

.035" (0.9mm)

Steel

ER70S-6

Solid

(or hard)

100%

CO2

25cfh

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

75% Ar

25cfh

CO225%

3.5

5 6 6 7.5

4.5

3.5

L2 L2 H1

8.5

7.5

6.5

7.5

6.5

5 64

7.5

643

6.5

H2L1L1

8.5

7.5

24 ga. (0.6mm)

22 ga. (0.7mm)

20 ga. (0.9mm)

18 ga. (1.2mm)

16 ga. (3mm)

1/8" (3.2mm) 3/16" (4.8mm)

Wire Speed

Voltage Step

THICKNESS

FINE

COARSE

LOW

HIGH

Material Type

Wire Type

Shielding Gas

and Flow Rate

Wire Size

(Diameter)

4.13 FirePower 125 Welding Setting Selection Guide

Figure 4-12: FP-125 Selection Guide

Manual 0-5123 4-10 Operation

OPERATION FIREPOWER FP-125, 135, 165

Art # A-09031

Stainless

Steel

Stainless

Steel

ER 308L

98% Ar

35cfh

2% CO

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

Steel

Flux Core

E71T-GS

None

Required

.030" (0.8mm)

.035" (0.9mm)

Steel

ER70S-6

Solid

(or hard)

100%

25cfh

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

75% Ar

25cfh

25%

3.5

2.5

3.5 4.5 5.5 6

3.5

5.5

3.5

2.5

3.5

2.5

2 2 3

7.5

4.5

7.5

5.5

4.5

2.5

4 62.5

7 8.5

53.51.5

421

8.5

3 3 5 5.5

3.5

2.5

1 2 2

7.5

5.5

6.5

24 ga. (0.6mm)

22 ga. (0.7mm)

20 ga. (0.9mm)

18 ga. (1.2mm)

16 ga. (3mm)

1/8" (3.2mm) 3/16" (4.8mm) 1/4" (6.4mm) 5/16" (7.9mm)

Wire Speed

Voltage Step

THICKNESS

Material Type

Wire Type

Shielding Gas

and Flow Rate

Wire Size

(Diameter)

4.14 FirePower 135 Welding Setting Selection Guide

Operation 4-11 Manual 0-5123

Figure 4-13: FP-135 Selection Guide

FIREPOWER FP-125, 135, 165 OPERATION

Art # A-09032

Stainless

Steel

Stainless

Steel

ER 308L

98% Ar

35cfh

2% CO

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

Steel

Flux Core

E71T-GS

None

Required

.030" (0.8mm)

.035" (0.9mm)

Steel

ER70S-6

Solid

(or hard)

100%

25cfh

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

.023" (0.6mm)

.030" (0.8mm)

.035" (0.9mm)

75% Ar

25cfh

25%

3 3 3.5 5

3.5

1.5

2.5

1.5

1 2 2

5.5

4.5

6.5

7.5

6.5

1.5 1.5 3.5

5 6

32.52.5

422

7.5 7.5

7.5

4 4 4 5.5

1.5

1 1 2

5.5

7.5

1.5

7.5

24 ga. (0.6mm)

22 ga. (0.7mm)

20 ga. (0.9mm)

18 ga. (1.2mm)

16 ga. (3mm)

1/8" (3.2mm) 3/16" (4.8mm) 1/4" (6.4mm) 5/16" (7.9mm)

Wire Speed

Voltage Step

THICKNESS

Material Type

Wire Type

Shielding Gas and Flow Rate

Wire Size (Diameter)

4.15 FirePower 165 Welding Setting Selection Guide

Manual 0-5123 4-12 Operation

Figure 4-14: FP-165 Selection Guide

OPERATION FIREPOWER FP-125, 135, 165

4.16 Gas Selection for Gas Metal Arc Welding

Metal Type

Carbon

Steel

Low Alloy

and

High Alloy

Steel

Base Plate

Thickness

Greater

than

22 gauge

(.030”)

Greater

than

22 gauge

(.030”)

Greater

than

22 gauge

(.030”)

Greater

than

10 gauge

Greater

than

22 gauge

(.030”)

Greater

than

22 gauge

(.030”)

Greater

than

3/32”

Greater

than

14 gauge

(.075”)

Filler

Metal

ER70S-X Short

ER70S-X Spray

See Note 1 Short

See Note 1 Spray

See Note 1 Short

Transfer

Mode

Circuit

Transfer

Circuit

Globular

Circuit

transfer

Circuit

Suggested

Shielding Gas

100% CO2All Position

75% Argon

25% CO2

92% Argon

8% CO2

92% Argon

8% CO2

75% Argon

25% CO2

92% Argon

8% CO2

92% Argon

8% CO2

98% Argon

2% CO2

Welding

Positions Comments

Welding

All Position

Welding

All Position

Welding

Flat & HV

Fillet

All Position

Welding

All Position

Welding

Flat & HV

Fillet

All Position

Welding

High welding speeds. Good penetration and

pool control.

Suitable for high-current and high-speed

welding.

Higher deposition rates without melt-through.

Minimum distortion and spatter. Good pool

control for out-of-position welding.

Good arc stability, weld soundness, and

increasing width of fusion.

High welding speeds. Good penetration and

pool control. Applicable for out-of-position

welds. Suitable for high-current and high-

speed welding.

Good coalescence and bead contour. Good

mechanical properties.

Reduces undercutting. Higher deposition rates

and improved bead wetting. Deep penetration

and good mechanical properties.

Good control of melt-through and distortion.

Used also for spray arc welding. Pool ﬂuidity

sometimes sluggish depending on the base

alloy.

Stainless

Steel

Aluminum Greater

Greater

than

22 gauge

(.030”)

Greater

than

3/32”

than

18 gauge

(.045”)

Note 1: Contact your Filler Metal Supplier for recommended ﬁller metal for the base metal to be welded.

ER308-X ER309-X ER316-X

ER4043 ER5356

Short

Circuit

Spray

Transfer

Spray

Transfer

90% Helium

7.5% Argon

2.5% CO2 or 81% Argon

18% Helium

1 % CO2

90% Helium

7.5% Argon

2.5% CO2 or 81% Argon

18% Helium

1 % CO2

Argon All Position

All Position

Welding

Flat & HV

Welding

Fillet

Low CO2 percentages in Helium mix minimizes

carbon pickup, which can cause intergranular

corrosion with some alloys. Helium improves

wetting action and contour. CO2 percentages

above 5% should be used with caution on some

alloys.

Good arc stability. Produces a ﬂuid but

controllable weld pool, good coalescence,

and bead contour. Minimizes undercutting on

heavier thickness.

Excellent cleaning action. Provides more stable

arc than helium-rich mixtures.

Table 4-3: Gas Selection GMAW

Operation 4-13 Manual 0-5123

SERVICE FIREPOWER FP-125, 135, 165

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 THERMAL ARC Service Agent for repair.

1. Gas cylinder contents and ﬂow meter.

a. Ensure that the gas cylinder is not empty and

the ﬂow meter is correctly adjusted to 20CFM (15 liters per minute).

2. Gas leaks

a. Check for gas leaks between the regulator/cyl-

inder connection and in the gas hose to the Power Source.

3. Internal gas hose in the Power Source.

a. Ensure the hose from the solenoid valve to the

MIG torch adaptor has not fractured and that it is connected to the MIG torch adaptor.

4. Welding in a windy environment.

a. Shield the weld area from the wind or increase

the gas ﬂow.

5. Welding dirty, oily, painted, oxidized or greasy plate.

a. Clean contaminates off the plate.

6. Distance between the MIG torch nozzle and the work piece.

5.04 Solving Problems Beyond the Welding Terminals

The general approach to ﬁx Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW:

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:

a. Keep the distance between the MIG torch nozzle

and the work piece to a minimum.

7. Maintain the MIG torch in good working order.

a. Ensure that the gas holes are not blocked and

gas is exiting out of the torch nozzle. Refer to WARNING below.

b. Do not restrict gas ﬂow by allowing spatter to

build up inside the MIG torch nozzle.

WARNING

Disengage the drive roll when testing for gas ﬂow by ear.

Service 5-1 Manual 0-5123

FIREPOWER FP-125, 135, 165 SERVICE

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 ‘U’ groove drive feed roller matched to

the aluminum wire size you are welding. Use ‘V’ groove drive feed roller matched to the steel wire size you are welding. Use ‘knurled V’ groove drive feed roller matched to the ﬂux cored 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

Manual 0-5123 5-2 Service

SERVICE FIREPOWER FP-125, 135, 165

5.05 Welding Problems

FAULT CAUSE REMEDY 1 Undercut.

A Welding arc voltage

too high.

B Incorrect torch angle B Adjust angle

C Excessive heat input C Increase the torch travel speed and/or reduce

A Reduce voltage by reducing the voltage se-

lection switch position or increase the wire feed speed.

welding current by reducing the voltage selection switch position or reducing the wire feed speed.

2 Lack of penetration. A Welding current too

low

B Joint preparation too

narrow or gap too

C Shielding gas incor-

rect

3 Lack of fusion. Voltage too low Increase voltage by increasing voltage selec-

4 Excessive spatter. A Voltage too high A Lower voltage by reducing the voltage selec-

B Voltage too low B Raise voltage by increasing the voltage selec-

5 Irregular weld shape. A Incorrect voltage and

current settings. Convex = voltage too low. Concave = voltage too high.

A Increase welding current by increasing wire

feed speed and increasing voltage selection switch position.

B Increase joint angle or gap

C Change to a gas which gives higher penetra-

tion

tion switch position.

tion switch or increase wirespeed control.

tion 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 Incorrect shielding

gas

D Insufﬁcient or exces-

sive heat input

Table 5-1a: Welding Problems

Service 5-3 Manual 0-5123

C Check shielding gas

D Adjust the wirespeed control or the voltage

selection switch

FIREPOWER FP-125, 135, 165 SERVICE

FAULT

CAUSE REMEDY

6 Weld cracking A Weld beads too small A Decrease travel speed

B Weld penetration nar-

row and deep

B Reduce current and voltage and increase MIG

torch travel speed or select a lower penetration shielding gas.

C Excessive weld stress-

C Increase weld metal strength or revise de-

sign

D Excessive voltage D Decrease voltage by reducing the voltage

selection switch.

E Cooling rate too fast E Slow the cooling rate by preheating part to be

welded or cool slowly.

7 Cold weld puddle

A Faulty rectiﬁer unit A Have an Accredited THERMAL ARC Service

Agent to test then replace the faulty component.

B Loose welding cable

B Check all welding cable connections.

connection.

C Low Primary Voltage C Contact supply authority

Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly.

The MIG torch has been

connected to the wrong voltage polarity on the front panel.

Connect the MIG torch to the positive (+) welding

terminal for solid wires and gas shielded ﬂux cored wires. Refer to the electrode wire manufacturer for the correct polarity.

Thermal overtemperature light illuminatesduring welding, but fan motor continues to run.

Thermal overtemperature light illuminates in less than 30 seconds during welding

The machine duty cycle has been exceeded.

Fan has stopped running or fuse on PCB has blown.

Allow the fan to run, to allow the machine to cool down.

Have an accredited THERMAL ARC Service Agent replace the fan motor or fuse.

Manual 0-5123 5-4 Service

APPENDIX FIREPOWER FP-125, 135, 165

Art # A-09026

FEED ROLL INSTALLATION & CONSUMABLE GUIDE

Part No.

Wire Feed Rolls &

MIG Gun Consumables

Description

1444-0427

Wire Feed Roll, Knurle, .023" - .030" /.035" (0.6- 0.8mm/0.9mm), Hard/Cored

1444-0050

Nozzle

1444-0025

Contact Tip, .023" (0.6mm)

1444-0026

Contact Tip, .030" (0.8mm)

1444-0027

Contact Tip, .035" (0.9mm)

1444-0489

Gas Diffuser

1444-0741

MIG Gun, Complete Assembly

.030"

0.8mm

Weld Wires

Part No.

Description

1444-0210

1444-0211

1444-0215

1444-0216

1444-0220

1444-0221

ER70S-6 Mild Steel Wire, .023" (0.6mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .023" (0.6mm), 11 lbs. (5kg) Spool

ER70S-6 Mild Steel Wire, .030" (0.8mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .030" (0.8mm), 11 lbs. (5kg) Spool

ER70S-6 Mild Steel Wire, .035" (0.9mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .035" (0.9mm), 11 lbs (5kg) Spool

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

1444-0236

The branding size at the end of the feedroll refers to the size nearest to the mark.

APPENDIX 1: OPTIONS AND ACCESSORIES

• Contact your Thermal Arc distributor to order options and accessories. For assistance in locating a Thermal Arc distributor, contact the Thermadyne ofﬁce listed in the inside rear cover that is nearest to you.

• Note the model and speciﬁcation number shown on the equipment nameplate.

For Tweco/Victor Inquiries and Orders:

Call 1-800-318-6819 Consumable Parts Management Group

Replacement Torch Catalog number 1444-0741

Figure A-1: FP-125 Feed Roll and Consumables Chart

Appendix A-1 Manual 0-5123

FIREPOWER FP-125, 135, 165 APPENDIX

FEED ROLL INSTALLATION & CONSUMABLE GUIDE FP-135

Wire Feed Rolls & MIG Gun Consumables

Part No.

Description

1444-0427

Wire Feed Roll, Knurle, .023" - .030" /.035"

(0.6- 0.8mm/0.9mm), Hard/Cored

1444-0050

Nozzle

1444-0025

Contact Tip, .023" (0.6mm)

1444-0026

Contact Tip, .030" (0.8mm)

1444-0027 Contact Tip, .035" (0.9mm)

1444-0489

Gas Diffuser

1444-0741

MIG Gun, Complete Assembly

.030"

0.8mm

Weld Wires

Part No.

Description

1444-0210

1444-0211

1444-0215

1444-0216

1444-0220

1444-0221

ER70S-6 Mild Steel Wire, .023" (0.6mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .023" (0.6mm), 11 lbs. (5kg) Spool

ER70S-6 Mild Steel Wire, .030" (0.8mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .030" (0.8mm), 11 lbs. (5kg) Spool

ER70S-6 Mild Steel Wire, .035" (0.9mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .035" (0.9mm), 11 lbs (5kg) Spool

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

1444-0236

The branding size at the

end of the feedroll refers

to the size nearest to the mark.

FEED ROLL INSTALLATION & CONSUMABLE GUIDE FP-165

Wire Feed Rolls & MIG Gun Consumables

Part No.

Description

1444-0427

Wire Feed Roll, Knurle, .023" - .030" /.035"

(0.6- 0.8mm/0.9mm), Hard/Cored

1444-0050

Nozzle

1444-0025

Contact Tip, .023" (0.6mm)

1444-0026

Contact Tip, .030" (0.8mm)

1444-0027 Contact Tip, .035" (0.9mm)

1444-0489

Gas Diffuser

1444-0741

MIG Gun, Complete Assembly

.030"

0.8mm

Weld Wires

Part No.

Description

1444-0210

1444-0211

1444-0215

1444-0216

1444-0220

1444-0221

ER70S-6 Mild Steel Wire, .023" (0.6mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .023" (0.6mm), 11 lbs. (5kg) Spool

ER70S-6 Mild Steel Wire, .030" (0.8mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .030" (0.8mm), 11 lbs. (5kg) Spool

ER70S-6 Mild Steel Wire, .035" (0.9mm), 2 lbs. (0.9kg) Spool

ER70S-6 Mild Steel Wire, .035" (0.9mm), 11 lbs (5kg) Spool

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

1444-0236

The branding size at the

end of the feedroll refers

to the size nearest to the mark.

Figure A-2: FP-135 Feed Roll and Consumables Chart

Figure A-3: FP-165 Feed Roll and Consumables Chart

Manual 0-5123 A-2 Appendix

APPENDIX FIREPOWER FP-125, 135, 165

This Page Intentionally Blank

Appendix A-3 Manual 0-5123

FIREPOWER FP-125, 135, 165 APPENDIX

APPENDIX 2: REPLACEMENT PARTS

Item DESCRIPTION

1 TORCH GROMMET 1444-0477 1444-0477 1444-0477

2 FRONT PANEL FP-125 SILK-SCREEN PRINTED 1444-0815 1444-0816 1444-0817

3 PLASTIC HINGE FOR SIDE PANEL 1444-0435 1444-0435 1444-0435

4 SWITCH KNOB, FP-135/165 - 1444-0808

5 POTENTIOMETER KNOB, FP-125/135/165 1444-0543 1444-0543 1444-0543

6 YELLOW PILOT-LIGHT SWITCH 1444-0440 1444-0440 1444-0440

7 RIGHT COVER PANEL FP-125-135-165 1444-0821 1444-0821 1444-0821

8 FRONT FRAME, FP-125/135/165 1444-0833 1444-0833 1444-0833

9 CAP D.36 FOR MIG 100 LOUVER 1444-0831 1444-0831 1444-0831

10 INPUT POWER CABLE 1444-0433 1444-0433 1444-0463

11 EARTH CLAMP, FP-125/135/165 1445-0966 1445-0966 1445-0966

12 EARTH CABLE, FP-125/135/165 1444-0843 1444-0843 1444-0843

13 LOUVER MIG 100 1444-0830 1444-0830 1444-0830

14 CABLE CLAMP FOR CABLE DIAM.6+ SCREW 1444-0806 1444-0806 1444-0806

15 MIG GUN, FP-125/135/165 1444-0741 1444-0741 1444-0741

16 FEMALE CONNECTOR, 9/16"X18 - 1444-0839 1444-0839

17 GAS REGULATOR, FP-135/165 - 1444-0838 1444-0838

18 GAS HOSE 1,5M + CONN. 9/16" + CLAMPS 1444-0809 1444-0809 1444-0809

19 P.C. BOARD 1444-0483 1444-0483 1444-0465

20 MOTOR & GEARBOX, FP-135 - 1444-0803 W7004002

21 RECTIFIER 1444-0836 1444-0836 1444-0837

22 THERMOSTAT, RECTIFIER 1444-0456 1444-0456 1444-0443

23 FAN KIT 1444-0486 1444-0486 W7004008

24 CABLE CLAMP 1444-0807 1444-0807 1444-0428

25 PLASTIC FOOT 1444-0495 1444-0495 1444-0495

26 TRANSFORMER 1444-0844 1444-0462 1444-0469

27 CHOKE 1444-0846 1444-0847 1444-0728

28 SWITCH 17A - 1444-0852 1444-0835

29 HOSE CONNECTOR D.4-HOSEHOLDER D.6 + NUTS 1444-0840 1444-0840 1444-0840

30 SPOOL HOLDER 1444-0800 1444-0800 1444-0800

31 MILD STEEL WIRE REEL 1444-0500 1444-0500 1444-0500

32 HANDLE, FP-125/135/165 1444-0828 1444-0828 1444-0828

33 WIRE FEEDER 1444-0848 1444-0850 1444-0491

34 WIRE FEED ROLL - 1444-0427 1444-0427

34b WIRE FEEDING D.28 + PINION 1444-0804 - -

35 KIT GAS/NO GAS CHANGE BOARD 1444-0802 1444-0802 1444-0802

36 DIVIDING PANEL FP + LABELS 1444-0825 1444-0826 1444-0826

37 DOOR LATCH 1444-0426 1444-0426 1444-0426

38 SIDE PANEL FP SILK+LAB+HINGE+LOCK 1444-0822 1444-0823 1444-0824

39 LOWER PANEL, FP-125/135/165 1444-0490 1444-0490 1444-0490

40 SWITCH 16A, FP-125 1444-0834 - -

41 THERMOSTAT, XFMER - - 1444-0470

42 CONTACTOR *Not shown in art 1444-0498 1444-0498 -

43 BACK PANEL FP SILK-SCREEN PRINTED 1444-0818 1444-0819 1444-0820

FP-125 FP-135 FP-165

Model Part No.

Table A-1: FP-125 Replacement Parts List

Manual 0-5123 A-4 Appendix

APPENDIX FIREPOWER FP-125, 135, 165

Figure A-4: FP-125-135-165 Replacement Parts Callout

Appendix A-5 Manual 0-5123

FIREPOWER FP-125, 135, 165 APPENDIX

Art # A-09022

APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC

Manual 0-5123 A-6 Appendix

APPENDIX FIREPOWER FP-125, 135, 165

Art # A-09023

APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC

Appendix A-7 Manual 0-5123

FIREPOWER FP-125, 135, 165 APPENDIX

Art # A-09024

APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC

Manual 0-5123 A-8 Appendix

LIMITED WARRANTY

This information applies to Thermal Arc products that were purchased in the USA and Canada.

November 2007

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company (“Thermal Arc”), warrants to customers of authorized distributors (“Purchaser”) that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the

warranty period stated below, Thermal Arc shall, upon notication thereof and substantiation that

the product has been stored, installed, operated, and maintained in accordance with Thermal

Arc’s specications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or damage, correct such defects by suitable

repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty of merchantability,

tness for any particular purpose, or other warranty of quality, whether

express, implied, or statutory.

Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect,

incidental, or consequential damages, including but not limited to lost prots and business

interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of

Thermal Arc with respect to any contract, or anything done in connection therewith such as the

performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any

goods covered by or furnished by Thermal Arc, whether arising out of contract, tort, including negligence or strict liability, or under any warranty, or otherwise, shall not exceed the price of the goods upon which such liability is based.

No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulllment of thermal’s obligations to purchaser with respect to the product.

This warranty is void, and seller bears no liability hereunder, if purchaser used replacement

parts or accessories which, in Thermal Arc’s sole judgment, impaired the safety or performance of any Thermal Arc product. Purchaser’s rights under this warranty are void if the product is sold

to purchaser by unauthorized persons.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event

shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s discovery of any defect. Thermal Arc shall pay no transportation costs of any kind under this

warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s

risk and expense. This warranty dated July 1st 2007 supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered Trademark of Thermal Arc, Inc.

WARRANTY SCHEDULE

January 2009

SAFETY EQUIPMENT W

ARRANTY PERIOD

ABOR

Auto-Darkening Welding Helmet (Electronic Lens)

2 years 2 years

Harness Assembly

1 month 1 month

ENGINE DRIVEN WELDERS W

ARRANTY PERIOD

ABOR

Scout, Raider, Explorer

Original Main Power Stators and Inductors 3 years 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years 3 years All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors 1 year 1 year

Engines and associated components are NOT warranted by Thermal Arc, although most are warranted by the engine

See the Engine Manufactures’

Warranty for Details

GMAW/FCAW (MIG) WELDING EQUIPMENT W

ARRANTY PERIOD

ABOR

Firepower FP-95, FP-125, FP-135, FP-165 Fabricator 140, 180, 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P, 320SP; 400SP; 500SP; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed

Original Main Power Transformer and Inductor 5 years 3 years Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors 3 years 3 years All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors. 1 year 1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT W

ARRANTY PERIOD

ABOR

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400MST, 300MST, 400MSTP

Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors 3 years 3 years All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors. 1 year 1 year

PLASMA WELDING EQUIPMENT W

ARRANTY PERIOD

ABOR

Ultima 150

Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors 3 years 3 years Welding Console, Weld Controller, Weld Timer 3 years 3 years All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. 1 year 1 year

SMAW (Stick) WELDING EQUIPMENT W

ARRANTY PERIOD

ABOR

Thermal Arc 95 S

Original Main Power Magnetics 1 year 1 year Original Main Power Rectifiers, Control P.C. Boards 1 year 1 year All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans 1 year 1 year

160S, 300S, 400S

Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years 3 years All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors 1 year 1 year

GENERAL ARC EQUIPMENT W

ARRANTY PERIOD

ABOR

Water Recirculators 1 year 1 year

Plasma Welding Torches 180 days 180 days Gas Regulators (Supplied with power sources) 180 days Nil

MIG and TIG Torches (Supplied with power sources) 90 days Nil Replacement repair parts 90 days Nil

MIG, TIG and Plasma welding torch consumable items Nil Nil

This information applies to Thermal Arc products that were purchased in the USA and Canada.

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-36546801 Fax: (39) 02-36546840

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 FAX:

(636) 728-3010

Email: sales@thermalarc.com

www.thermalarc.com

Tweco FP-165 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.03 Symbol Chart

1.04 Precautions De Securite En Soudage A L’arc

1.05 Dangers relatifs au soudage à l’arc

1.06 Principales Normes De Securite

1.07 Graphique de Symbole

2.01 How to Use This Manual

2.03 Receipt of Equipment

2.04 General

2.06 Volt - Amp Curves

2.07 Duty Cycle

2.08 MIG Gun Maintenance

2.09 Handle / Feet Assembly

3.01 Location

3.02 Safety

3.03 Grounding

3.04 Electrical Input Requirements

3.05 Requirements for Maximum Output

3.06 Installation of Shielding Gas (GMAW) Process

3.07 Attaching the Gun and Cable Assembly to the Power Source

3.08 Polarity Changeover

3.09 Installing Wire Spool

3.10 Feedrolls

3.11 Install Wire into the Feedhead

3.12 Install Wire into the Welding Gun

4.01 General Safety Precautions

4.02 FirePower Controls

4.03 Gas Metal Arc Welding (GMAW)

4.04 Flux Cored Arc Welding (FCAW)

4.05 Shutdown Procedures

4.06 Basic Welding Technique

4.07 Welding Gun Positions

4.08 MIG Welding (GMAW) Variables

4.11 Welding Procedure

4.10 Pre-Weld Procedure

4.12 Reference Tables

4.13 FirePower 125 Welding Setting Selection Guide

4.14 FirePower 135 Welding Setting Selection Guide

4.15 FirePower 165 Welding Setting Selection Guide

4.16 Gas Selection for Gas Metal Arc Welding

5.01 Cleaning of the Unit

5.02 Cleaning of the Feed Rolls

5.03 Basic Troubleshooting

5.04 Solving Problems Beyond the Welding Terminals

5.05 Welding Problems

APPENDIX 1: OPTIONS AND ACCESSORIES

APPENDIX 2: REPLACEMENT PARTS

APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC

APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC

APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION