Tweco FP-235DC User Manual

FP-100, FP-235 and FP-235AC/DC

Arc Welding System

Instruction Manual

FORM NO. 0056-1841 EFFECTIVE July 2001

Safety and Operating

Instructions

For Your Safety . . .

PLEASE READ

CAREFULLY!

Table of Contents

page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Welding Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Personal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Health Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Welder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Welder Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Internal Thermal Overload Protection (FP-100 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Specifications for FP-100 Arc(SMAW) Welding System (1443-0402) . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Specifications for FP-235 Arc(SMAW) Welding System (1443-0404) . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Specifications for FP-235 AC/DC Arc(SMAW) Welding System (1443-0406) . . . . . . . . . . . . . . . . . . . . . .6

Welder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Power Source Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Connection to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Extension Cords (applies to FP-100 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Welder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ARC Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

AC Output Connections (FP-235 and FP-235 AC/DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

DC Output Operations (FP-235 AC/DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Selecting AC or DC Welding Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

AC Current Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Direct Current Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Adjusting Amperage/Increasing Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Lowering the Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Preparations for Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Welding Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Preparing the Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Ground Clamp Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Selecting the Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

High vs. Low Voltage Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Selecting the Proper Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Welding Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

AC Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

DC Straight Polarity Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

DC Reverse Polarity Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Striking the Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

page

Learning to Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Arc Welding Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Types of Commonly Used Weld Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Stringer Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Weave Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Finishing the Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Special Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Burning Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Recognizing Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Magnetic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Color Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Additional Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Firepower Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Table of Illustrations

page

Figure 1: Wheel and Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Figure 2: Welding Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Figure 3: Workpiece Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Figure 4: Shielded Metal Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Figure 5: Bead Heat Requirement Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 6: Weld Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 7: Weld Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 8: Stringer Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 9: Weave Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 10: Triple Pass Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 11: Triple Pass Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 12: FP-100 Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Figure 13: FP-235 Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Figure 14: FP-235 AC/DC Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Figure 15: FP-100 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Figure 16: FP-235 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Figure 17: FP-235 AC/DC Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

INTRODUCTION

This User’s Guide provides specific information about your Firepower Welding System. This guide provides pertinent information needed to safely and effectively use your Firepower Welding System. The information in this manual applies to specific Firepower Welding System models. It gives instructions on set-up, installation and actual use of your Firepower Welding System.

SAFETY PROFILE

Tradesmen respect the tools and equipment with which they work. They are also aware that tools and equipment are dangerous if used improperly or abused.

Read this guide prior to using your welding system. It enables you to do a better and safer job. You will also learn the machine’s application, limitations and the specific potential hazards related to welding.

SAFETY INFORMATION

The following safety information is provided to you as a guideline. Use it to operate your new Firepower Welding System under the safest possible conditions. Any equipment that uses electrical power is potentially dangerous to use when the safety or safe handling instructions are not known and/or are not followed. This safety information gives you the necessary information for safe use and operation.

Items in this manual that significantly affect safety are identified with the following headings. Please read and understand this manual. Pay special attention to items identified with these headings.

- Means there is a possibility of injury or death to yourself or others if the proper

safety precautions are not followed.

- Means there is the possibility of damage to the Firepower Welding System or

other property.

- Indicates points of interest for more efficient and convenient installation or opera-

tion. It may be used before or after a procedure to highlight or better explain the step.

READ ALL SAFETY AND WARNING INSTRUCTIONS CAREFULLY before attempting to install, operate or service this welding unit. Your failure to comply with the instructions could result in personal injury and/or property damage.

RETAIN THESE INSTRUCTIONS FOR YOUR FUTURE REFERENCE.

SAFETY SYMBOLS

Familiarize yourself with the warning symbols listed on the following pages. These symbols identify important safety messages in this manual. When you see one of these symbols, be alert to the possibility of personal injury and carefully read the message that follows.

Indicates that the possibility of electric shock hazard exists during the operation of the step(s) that follow.

Indicates that the possibility of fire hazard exists during the operation of the step(s) that follow.

Indicates that the helmet must be worn during the step(s) that follow to protect against eye damage and burns due to flash hazard.

Indicates that the possibility of toxic gas hazard exists during operation of the step(s) that follow.

Indicates that the possibility of being burned by hot slag exists during operation of the step(s) that follow.

Indicates that eye protection should be worn to protect against flying debris in the following step(s).

Indicates that the possibility of injury or death exist due to improper handling and maintenance of compressed gas cylinders or regulators.

ELECTRIC SHOCK CAN KILL! Reduce the risk of death or serious injury from shock. Read, understand and follow the following safety instructions. Additionally, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area, understands and follows these safety instructions as well.

FIRE OR EXPLOSION CAN CAUSE DEATH, INJURY AND PROPERTY DAMAGE! Reduce the risk of death, injury or property damage from fire or explosion. Read, understand and follow the following safety instructions. Additionally, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area, understands and follows these safety instructions as well. Remember, welding by nature produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can start fires, burn skin and damage eyes.

ARC RAYS CAN INJURE EYES AND BURN SKIN! Reduce the risk of injury from arc rays. Read, understand and follow the following safety instructions. Additionally, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area, understands and follows these safety instructions as well.

FUMES, GASSES AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS AND DEATH! Reduce the risk of discomfort, illness or death. Read, understand and follow the following safety instructions. Additionally, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area, understands and follows these safety instructions as well.

IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH! Reduce the risk of injury or death from compressed gasses and equipment hazards. Read, understand and follow the following safety instructions. Additionally, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area, understands and follows these safety instructions as well.

GENERAL WELDING SAFETY INSTRUCTIONS

LOCATION

Welding processes of any kind can be dangerous not only to the operator but to

any person situated near the equipment, if safety and operating rules are not strictly observed.

PERSONAL PROTECTION

1. Wear closed, non-flammable protective clothing, without pockets or turned up trousers and pro-

tective gloves for welding.

2. Wear a non-flammable welding helmet to shield the neck, face and sides of the head. Keep the protective

lens clean. Replace the protective lens if broken or cracked. Position a transparent glass between the lens and the welding area. Weld in a closed, well ventilated area that does not open into other working areas.

3. NEVER look at the arc without proper protection to the eyes.

4. Thoroughly clean metal of rust or paint to avoid producing harmful fumes. Parts degreased with a solvent

must dry before welding.

5. NEVER weld on metals or coated metals containing zinc, mercury, chromium, graphite, lead, cadmium or

beryllium unless the operator and the people standing in the same area use an air-supplied respirator.

SAFETY INSTRUCTIONS

For your safety, BEFORE connecting the power source to the line, follow these instructions:

1. Insert an adequate two-pole switch, equipped with time-delay fuses, before the main outlet.

2. Make the single-phase connection with a two-pole plug compatible with the above mentioned socket.

3. The two wires of the two-pole input cable are used for the connection with the single-phase line. The yel-

low/green wire is for the compulsory connection to the ground in the welding area.

4. When working in a confined space, keep the power source outside the welding area and fix the ground cable

to the workpiece. NEVER work in a damp or wet area.

5. DO NOT use damaged input or welding cables.

NEVER operate the power source without its panels in place. This could cause

serious injury to the operator and could damage the equipment.

FIRE PREVENTION

Welding operations use fire or combustion as a basic tool.

1. The work area MUST have a fireproof floor.

2. Work benches or tables used during welding operations MUST have fireproof tops. DO NOT weld on

wooden work benches.

3. Use heat-resistant shields or other approved material to protect nearby walls or unprotected flooring from

sparks and hot metal.

4. Keep an approved fire extinguisher of the proper size and type in the work area. Inspect it regularly to

ensure that it is in proper working order. Know how to use the fire extinguisher.

5. Remove all combustible materials from the work site. If you can not remove them, protect them with fire-

proof covers.

NEVER perform welding operations on a container that has held toxic, combustible or flammable liquids or vapors. NEVER perform welding operations in an area containing combustible vapors, flammable liquids or explosive dust.

VENTILATION

Ventilate welding work areas adequately. Maintain sufficient air flow to prevent accumulation of explosive or toxic concentrations of gases. Welding operations using certain combinations of metals, coatings and gases generate toxic fumes. Use respiratory protection equipment in these circumstances. BEFORE welding, read and understand the Material Safety Data Sheet for the welding alloy.

ELECTROMAGNETIC COMPATIBILITY

BEFORE installing a MIG power source, inspect the surrounding area checking the following points:

1. Make sure there are no other power supply cables, control lines, telephone cables or other devices close to the power source.

2. Make sure that telephones, televisions, computers or other control systems are not in the working area.

3. People with pace-makers or hearing aides should keep far from the power source. In particular cases, special protection measures may be required.

Reduce interference by following these suggestions:

1. If there is interference in the power source line, mount an E.M.T. filter between the power supply and the power source.

2. Shorten the output cables of the power source, keep them together and connected to ground.

3. Securely fasten the panels of the power source in place after performing maintenance.

HEALTH HAZARDS

The welding process can be hazardous to your health. Therefore, follow these precautions:

1. ALWAYS wear protective clothing without pockets and cuffs. Wear a helmet, gloves and shoes with an insulating sole.

2. ALWAYS use a welding mask or helmet with the properly tinted protective glass in the shade adequate to the welding operation being performed and to the current intensity.

3. Make certain that bystanders in the welding area are also following these precautions.

4. ALWAYS keep the welding mask glass clean. Replace it if it is cracked or chipped.

5. NEVER weld in a damp area or come in contact with a moist or wet surface when welding.

6. If the welding area lacks proper ventilation, use fume extractors.

7. Clean the welding pieces from solvents or greases which develop toxic gases when exposed to heat.

ELECTRIC SHOCK

ELECTRIC SHOCK CAN KILL! Reduce the risk of death or serious injury from shock. Read, understand and follow ALL safety instructions. Be sure that everyone who uses this welding equipment or who is a bystander in the welding area understands and follows ALL safety instructions as well.

ELECTRIC SHOCK CAN BE FATAL. A person qualified in First Aid techniques should ALWAYS be present in the working area. If a person is unconscious and electric shock is suspected, DO NOT touch the person if he or she is in contact with cables. Disconnect power from the machine, then use First Aid. Use dry wood or other insulating materials to move cables, if necessary, away from the person.

1. Never touch or come in physical contact with any part of the input current circuit and welding current circuit.

2. Frequently, check that the input cable and plug are in good condition.

3. Make sure that the welder is disconnected from the main power supply BEFORE attempting any repairs, opening the side panels of the machine or repairing the input cable.

4. Fit the main line, BEFORE the distribution outlet, with a three-poles switch with adequate delayed fuses (check the characteristics plate for fuse values).

5. DO NOT weld with cables, torch or earth clamp in poor shape.

6. DO NOT coil the torch or the earth cables around your body.

7. DO NOT aim the welding torch against yourself or against bystanders.

8. Should you feel the slightest electrical shock, STOP welding IMMEDIATELY. DO NOT use the welder until the fault is found and resolved.

WELDER SPECIFICATIONS

Your new Firepower ARC (SMAW) Welding System is designed for maintenance and sheet metal fabrication. The unit consists of a single-phase power transformer power source and arc stabilizer. This welding power source is capable of welding with mild steel electrodes.

This unit is also capable of welding with high carbon steel, special alloy steel, cast iron, and nonferrous, such as aluminum. The electrode material should correspond with the workpiece metal.

Flux coatings are made for use with either AC (Alternating Current), DC (direct current) reverse polarity, or DC straight polarity, although some function well on both AC and DC current. Your welder is designed for using electrodes made for AC.

Please refer to the instructions provided in this manual for proper machine setup.

WELDER OPERATING CHARACTERISTICS

The duty rating defines how long the welding system can be used before it must pause and cool down. Duty Cycle ratings are expressed as a percentage of a ten-minute period. It represents the maximum welding time allowed at the specified amperage setting. The remaining balance of a ten-minute period is required for cooling off the unit.

Firepower 120 volt and 230 volt Welding Systems have duty cycle ratings based on 20 amp and 50 amp input currents. Please refer to the data plate located on the front of the unit for the specific rating that applies to your unit.

All Firepower 230 volt Welding Systems are rated at the required input amperage for proper operation. Please refer to the data plate located on the front of the unit for the specific rating that applies to your unit.

INTERNAL THERMAL OVERLOAD PROTECTION(FP-100 ONLY)

DO NOT constantly exceed the duty cycle or damage could result to your welder. If you do exceed the duty cycle of your welder, the internal thermal overload protection shuts off all welder functions except the cooling fan. If this happens, DO NOT SHUT OFF THE

WELDER. Leave the welder turned on and the fan running. After the welder is properly cooled, the thermal protector automatically resets and your welder will function properly.

SPECIFICATIONS FOR FP 100 ARC(SMAW) WELDING SYSTEM (1443-0402)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Amp ARC Welding System

Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Volt (60Hz)

Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Amps @ 20% Duty Cycle

Agency Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CSA Rated 65 Amps @ 15% Duty Cycle

Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Amps AC Peak

Output Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shunt Adjustment

Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Illuminated On/Off Switch

Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Ft 15 Amp Power Plug

Ground Cable & Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Ft Ground Cable with Clamp

Ground Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Connection

Welding Cable & Electrode Holder . . . . . . . . . . . . . . . . . . .6 Ft Welding Cable and 150 Amp Electrode Holder

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instruction Manual

SPECIFICATIONS FOR FP 235 ARC(SMAW) WELDING SYSTEM (1443-0404)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 Amp ARC Welding System

Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 Volt (60Hz)

Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 Amps @ 20% Duty Cycle

Agency Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CSA Rated 200 Amps @ 20% Duty Cycle

Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 Amps AC Peak

Output Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shunt (45-235 Amps)

Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Illuminated On/Off Switch

Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Ft Power Cord without Plug

Welding Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Ft Welding Cable and 300 Amp Electrode Holder

Ground Cable & Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Ft Ground Cable and 300 Amp Work Clamp

Ground Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Connection

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel Kit and Handle

Instruction Manual

SPECIFICATIONS FOR FP 235 AC/DC ARC(SMAW) WELDING SYSTEM (1443-0406)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 Amp AC/DC ARC Welding System

Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 Volt (60Hz)

Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 Amps @ 20% Duty Cycle

Agency Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CSA Rated 200 Amps @ 20% Duty Cycle AC

CSA Rated 135 Amps @ 35% Duty Cycle DC

Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 Amps AC Peak / 180 Amps DC Peak

Output Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shunt (45-235 Amps)

Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Illuminated On/Off Switch

Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Ft Power Cord without Plug

Welding Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Ft Welding Cable and 300 Amp Electrode Holder

Ground Cable & Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Ft Ground Cable and 300 Amp Work Clamp

Ground Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dinse Connection

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel Kit and Handle

Instruction Manual

WELDER INSTALLATION

POWER SOURCE CONNECTION

Power Requirements

This welder (FP-100) is designed to operate on a properly grounded 120 volt, 60 HZ, single-phase alternating current (AC) power source fused with a 20 amp time-delayed fuse or circuit breaker. (FP-235 and FP-235 AC/DC requires 230 Volt, 60 Hz, single phase AC with a 50 amp delayed fuse or circuit breaker. Please consult local codes for proper plug and receptacle applications.) A qualified electrician should verify the ACTUAL VOLTAGE at the receptacle into which the welder will be plugged and confirm that the receptacle is properly grounded. The use of the proper circuit size can eliminate the nuisance of circuit breaker tripping when welding.

DO NOT OPERATE THE FP-100 WELDER if the ACTUAL power source voltage is less than 110 Volts AC or greater than 132 Volts AC. Contact a qualified electrician if this problem exists. Improper performance and/or damage to the welder will result if operated on inadequate or excessive power.

DO NOT OPERATE THE FP-235 OR FP-235 AC/DC WELDER if the ACTUAL power source voltage is less than 220 Volts AC or greater than 240 Volts AC. Contact a qualified electrician if this problem exists. Improper performance and/or damage to the welder will result if operated on inadequate or excessive power.

Connection to Power Source

High voltage danger from power source! Consult a qualified electrician for

proper installation of receptacle at the power source.

This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician. DO NOT cut off the grounding prong or alter the plug in any way. DO NOT use any adapters between the welder’s power cord and the power source receptacle.

Make sure the POWER switch is OFF. Connect the welder's (FP-100) power cord to a properly grounded 120 VAC, 60 Hz, single-phase outlet. Connect the FP-235 / FP-235 AC/DC to a properly grounded 230 VAC, single-phase outlet. Contact a qualified electrician if a problem exists. Improper performance and/or damage to the welder results if operated on inadequate or excessive power.

Extension Cords (Applies to FP-100 ONLY)

For optimum welder performance, an extension cord should not be used unless absolutely necessary. If necessary, care must be taken in selecting an extension cord appropriate for use with your specific welder.

Select a properly grounded extension cord that will mate directly with the ac power source receptacle and the welder power cord without the use of adapters. Make certain that the extension cord is properly wired and in good electrical condition (minimum gauge size 10/3 AWG).

WELDER ASSEMBLY

The following steps describe the assembly, installation, maintenance and operations of your new welder.

Be sure that the welder’s electrical power supply cord is not connected

while performing this procedure.

Avoid contacts with wires or parts. DO NOT work with the panels partially opened or removed completely from the power source.

1. Tools required: Hammer, Flat Head Screwdriver, Allen Wrench (metric)

+ 23 hidden pages

Tweco FP-235DC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual