Tweco FP-90 User Manual

FP-90

Gasless Welding System (FCAW)

Instruction Manual

FORM NO. 0056-1839 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

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

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

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

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

Internal Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Specifications for FP-90 Gasless Welding System (1444-0302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Assembling the Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Welder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Power Source Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Connection to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Installation of the Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Welding Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Gasless Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Advantages of Gasless Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Preparation for Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Replacement of the Wire Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Welding Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

General Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Adjustment of the Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Selecting Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Wire Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Wire Spool Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Selecting Welding Current Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Preparing the Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Setting up the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Preparing the Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Workpiece Clamp Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Tuning in the Wire Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

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

Holding the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Position the Gun to the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Distance from the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Laying a Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Moving the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

page

Types of Weld Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Welding Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Multiple Pass Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Special Welding Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Spot Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Additional Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Firepower FO-150 MIG-Gun Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

General Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Troubleshooting Guide for Firepower FP-150 MIG Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

FP-90 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Firepower Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Table of Illustrations

page

Figure 1: Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Figure 2: Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Figure 3: Polarity Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Figure 4: Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Figure 5: Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Figure 6: Workpiece Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 7: Types of Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 8: Gun Position, Angle A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 9: Gun Position, Angle B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 10: Gun Travel Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 11: Stringer Weld Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 12: Weave Weld Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 13: Flat Position Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 14: Horizontal Position Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 15: Vertical Position Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 16: Overhead Position Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 17: Triple Pass V Butt Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Figure 18: Triple Pass Lap and T Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Figure 19: Spot Weld Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Figure 20: FP-150 MIG Gun Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 21: FP-90 Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Figure 22: FP-90 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

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

Please 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 existed 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 the 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.

2

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.

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 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 yel­low/green wire is for the compulsory connection to the ground.

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.

6. 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.

3

5. Remove all combustible materials from the work site. If you can not remove them, protect them with fire­proof 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 welding 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 alogenous grease which develop toxic gases when exposed to
heat.

WELDER SPECIFICATIONS

Your new Firepower Flux Core (FCAW) Wire Welding System is designed for maintenance and sheet metal
fabrication. The unit consists of a single-phase power transformer power source, arc stabilizer, rectifier and
heavy-duty wire feed system.

This welding power source is also capable of welding with either 0.030 inch (0.8 mm) or 0.035 inch (0.9 mm)

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flux cored welding wire FCAW process. The use of shielding gas is not required for this welding process.
Please refer to the instructions provided in this manual for proper machine setup.

The use of larger diameter wire makes welding difficult. The results cannot be guaranteed. The manufacturer

DOES NOT recommend using larger diameter welding wire with this unit.

WELDER OPERATING CHARACTERISTICS

The duty rating defines how long the user can weld and how long the welder must rest 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 Welding Systems have duty cycle ratings based on 15 amp and 20 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.

INTERNAL THERMAL OVERLOAD PROTECTION

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. 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.

If you find that your welder does not weld for a 1-5 minute time period without stopping, reduce the wire
speed slightly. Welding with the wire speed set too high not only causes poor visible welds but also increases
amperage draw and shortens the duty cycle.

SPECIFICATIONS FOR FP-90 GASLESS WELDING SYSTEM (1444-0302)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amp DC Wire Feed Welder

Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Volt/60 Hz

Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Amps @ 15% Duty Cycle

Agency Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CSA Rated 60 Amps @ 20% Duty Cycle

Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps Peak

Output Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .High/Low Amperage Settings

Wire Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Infinite Speed Controlled by Potentiometer

Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 foot 15 Amp Power Plug

MIG Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 foot FIREPOWER

®

Wire Gun

Ground Cable and Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 foot Ground Cable/150 Amp Ground Clamp

MIG Gun Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Connection

Spool Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 lb

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzle

Contact Tip

1 lb. .035” Spool Flux MIG Wire

Instruction Manual

The FP-90’s MIG gun torch is a “live” contact torch and is ALWAYS
in the power on position. Wear eye protection at all times when handling this
torch.

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6

The MIG gun on this unit is a “live” torch which is in the constant “ON” position.
Touching the torch to a grounded surface will produce and arc which could cause injury.
Please USE CAUTION when handling this unit.

ASSEMBLING THE WELDER

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

Avoid contacts with wires or parts. DO NOT work with the side panels

partially opened or removed completely from the power source.

The FP-90’s MIG gun torch is a “live” contact gun and is ALWAYS IN
THE POWER-ON POSITION. Wear Eye protection at all times when handling this
MIG gun.

Be sure that the welder’s elec­trical power supply cord is not connected while performing this procedure.

Tools Required: Allen Wrench (metric)

1. Unpack the welder.

2. Assemble and install the plastic handle as shown in Figure 1.

3. Install MIG wire per instructions noted in section
“Installation of Welding Wire.”

4. Place the power source in a well ventilated area. DO NOT
obstruct the air intake and output vents. A reduced air flow
can cause a reduced duty cycle and damage internal compo­nents.

5. Insure at least 6 feet of open space on the each side of the welder.

Connect the power supply cable to the correct receptacle, single-phase 120V (protected by slow blow fuses).

This equipment MUST be connected to ground.

WELDER INSTALLATION

POWER SOURCE CONNECTION

Power Requirements

This welder is designed to operate on a properly grounded 120 volt, 60 HZ, single-phase alternating current (AC)
power source fused with a 20 amp time-delayed fuse or circuit breaker. A qualified electrician should verify the ACTU-
AL 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 THIS 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.

Figure 1: Handle Installation