Page 1
160
130
120
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:
Page 2
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.
Page 3
!
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
Copyright
Thermadyne Industries Inc.
®
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident, or
any other cause.
Publication Date: March 19, 2009
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
©
2009 by
i
Page 4
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
Page 5
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
Page 6
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
Page 7
FIREPOWER FP-125, 135, 165 SAFETY INSTRUCTIONS
Welding or Cutting
Operation
Electrode Siz
e
Metal Thickness
or Weldin
g
Current
Filter
Shade
No.
Welding or Cutting
Operation
Electrode Siz
e
Metal Thickness
or Weldin
g
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
12
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
Page 8
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
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.
Page 9
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
Page 10
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
On
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
t
t1
t2
%
X
IPM
MPM
t
V
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
Page 11
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.
Page 12
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
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtre
oculaire
Safety Instructions 1-7 Manual 0-5123
Page 13
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
Page 14
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
Page 15
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
t
t1
t2
%
X
IPM
MPM
t
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
V
1.07 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Manual 0-5123 1-10 Safety Instructinos
Page 16
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
Page 17
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
Page 18
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
5
10
15
20
25
30
35
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
Page 19
FIREPOWER FP-125,135,165 INTRODUCTION
FP-165 FIREPOWER Vin=230V 60Hz
0
5
10
15
20
25
30
35
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
Page 20
INTRODUCTION FIREPOWER FP-125,135,165
FirePower 125 at Rated Duty Cycle
0
1
2 3
4 5 6 7 8
Min ute s
9 10
Art # A-09058
FirePower 135 at Rated Duty Cycle
0
1
2 3
4 5 6 7 8
Min ute s
9 10
Art # A-09059
FirePower 165 at Rated Duty Cycle
0
1
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
Page 21
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
Page 22
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
Page 23
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
Page 24
INSTALLATION FIREPOWER FP-125, 135, 165
1
Art # A-07965
Cap
2
Shielding
Gas
“Cracking”
3
Shielding
Gas
Regulator and
Flow Meter
4
Shielding
Gas
Shielding
Gas
1 1/8”
5
Gas Hose
Figure 3-1 Gas Cylinder Installation for Reference Only!
Installation 3-3 Manual 0-5123
Page 25
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
Page 26
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
Page 27
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
Page 28
INSTALLATION FIREPOWER FP-125, 135, 165
1
2
3
4
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
Page 29
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
Page 30
INSTALLATION FIREPOWER FP-125, 135, 165
LOW1
2
COARSEFINE
HIGH
v
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
2
COARSEFINE
HIGH
v
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
Page 31
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
Page 32
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
Page 33
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
Page 34
OPERATION FIREPOWER FP-125, 135, 165
LOW1
2
COARSEFINE
HIGH
FP-125
v
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
12
11
9
7
6
5
3
2
1
4
8
10
Art # A-09065
3
13
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
12
11
9
7
6
5
3
2
1
4
8
10
Art # A-09066
13
Figure 4-1: FirePower FP-125 Controls
Figure 4-2: FirePower FP-135 and 165 Controls
Operation 4-3 Manual 0-5123
Page 35
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
Page 36
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
Page 37
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
Page 38
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
Page 39
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
Page 40
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
Page 41
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%
L1
L1
L1
5
L1
3.5
L1
3.5
5
3.5
L1
L1
L1
5 6 6 7.5
5
4
8
5
6
4.5
3
7
4
4
4
7
4
3
5
3.5
L2 L2 H1
H1
H1
H1
H1
H1
8
6
5
8.5
7.5
6.5
H2
H2
H2
H2
H2
H2
6
7.5
6.5
H2
H2
H2
H1
L2
L2
L1
L1
L2
3
L2
L2
L1
L1
5 64
L1
3
L1
7.5
643
H1
6.5
H2L1L1
L2
L2
H2
H2
8.5
7.5
H2
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
1
2
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
Page 42
OPERATION FIREPOWER FP-125, 135, 165
Art # A-09031
Stainless
Steel
Stainless
Steel
ER 308L
98% Ar
35cfh
2% CO
2
.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%
CO
2
25cfh
.023" (0.6mm)
.030" (0.8mm)
.035" (0.9mm)
.023" (0.6mm)
.030" (0.8mm)
.035" (0.9mm)
75% Ar
25cfh
CO
2
25%
2
1
1
3.5
2
2.5
2
2.5
3
2
2
1
1
3.5 4.5 5.5 6
3
3.5
5.5
4
3.5
3
2.5
5
3.5
3
2.5
3
3
2.5
3
2
2 2 3
2
3
2
2
2
7.5
4.5
5
7.5
5.5
5
4
3
4
3
3
3
6
4.5
8
7
7
8
4
4
4
4
4
4
7
7
4
4
2
2
2
2
2
2
2.5
1
1
1
1
4 62.5
1
2
1
2
1
7 8.5
53.51.5
3
7
4
8
4
8
421
8.5
1
3
1
1
3 3 5 5.5
4
4
3.5
2.5
3
2.5
2
1 2 2
2
2
7.5
5.5
5.5
3
3
3
8
7
6.5
4
4
4
7
6.5
4
4
2
1
1
1
6.5
4
2
3
4
4
4
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
1
2
3
4
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
Page 43
FIREPOWER FP-125, 135, 165 OPERATION
Art # A-09032
Stainless
Steel
Stainless
Steel
ER 308L
98% Ar
35cfh
2% CO
2
.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%
CO
2
25cfh
.023" (0.6mm)
.030" (0.8mm)
.035" (0.9mm)
.023" (0.6mm)
.030" (0.8mm)
.035" (0.9mm)
75% Ar
25cfh
CO
2
25%
1
1
1
3
3
1
1
1
1
3 3 3.5 5
3
2
5
3.5
3
2
1.5
4
2
2.5
2
3
2
1.5
3
1
1 2 2
2
2
2
2
2
6
5
4
7
5.5
4.5
3
3
3
3
3
3
7
6.5
6
7.5
7
6.5
4
4
4
4
4
4
6
8
6.5
4
4
4
1
1
2
1
2
1
1
1
1
1
1
1.5 1.5 3.5
1
5 6
32.52.5
2
4
3
5
3
7
422
7.5 7.5
7.5
4
1
1
4
3
1
1
4 4 4 5.5
4
3
3
2
3
1.5
3
1 1 2
2
2
7
5.5
4
3
3
3
7.5
7
6
4
4
4
7
6
4
4
1
1
1
1
1
1.5
1
1.5
7.5
4
6
4
1
2
3
3
4
4
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
1
2
3
4
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
Page 44
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 Short
ER70S-X Short
ER70S-X Spray
See Note 1 Short
See Note 1 Short
See Note 1 Spray
See Note 1 Short
Transfer
Mode
Circuit
Circuit
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
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
Page 45
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
Page 46
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
Page 47
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
Page 48
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-
es
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
8
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.
9
Thermal overtemperature
light illuminatesduring
welding, but fan motor
continues to run.
10
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
Page 49
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
Page 50
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
Page 51
APPENDIX FIREPOWER FP-125, 135, 165
This Page Intentionally Blank
Appendix A-3 Manual 0-5123
Page 52
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
Page 53
APPENDIX FIREPOWER FP-125, 135, 165
Figure A-4: FP-125-135-165 Replacement Parts Callout
Appendix A-5 Manual 0-5123
Page 54
FIREPOWER FP-125, 135, 165 APPENDIX
Art # A-09022
APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC
Manual 0-5123 A-6 Appendix
Page 55
APPENDIX FIREPOWER FP-125, 135, 165
Art # A-09023
APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC
Appendix A-7 Manual 0-5123
Page 56
FIREPOWER FP-125, 135, 165 APPENDIX
Art # A-09024
APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC
Manual 0-5123 A-8 Appendix
Page 57
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 notication thereof and substantiation that
the product has been stored, installed, operated, and maintained in accordance with Thermal
Arc’s specications, 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 prots 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 fulllment
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.
Page 58
WARRANTY SCHEDULE
January 2009
SAFETY EQUIPMENT W
ARRANTY PERIOD
L
ABOR
Auto-Darkening Welding Helmet (Electronic Lens)
2 years 2 years
Harness Assembly
1 month 1 month
ENGINE DRIVEN WELDERS W
ARRANTY PERIOD
L
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
L
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
L
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
L
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
L
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
L
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.
Page 59
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
Page 60
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
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