Firepower® FP 125, FP 135, FP165 PORTABLE MIG/FLUX CORED WELDER Operating Manual Révision : AC Issue Date: April 6, 2016 Manual No.: 0-5123 www.firepoweronline.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new Firepower product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on the web at www.firepoweronline.com. This Operating Manual has been designed to instruct you on the correct use and operation of your Firepower product.
! WARNING 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. Firepower FP 125, 135, 165 MIG/Flux Cored Welder Operating Manual Number 0-5123 Published by: ESAB 2800 Airport Rd. Denton, TX 76208 www.Firepoweronline.com Copyright 2015 by ESAB All rights reserved.
Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment.
TABLE OF CONTENTS SECTION 1: SAFETY......................................................................................... 1-1 1.0 2.0 Safety Precautions........................................................................................... 1-1 Précautions de sécurité................................................................................... 1-3 SECTION 2: INTRODUCTION....................................................................................... 2-1 2.01 2.02 2.03 2.04 2.05 2.06 2.
TABLE OF CONTENTS 4.15 4.16 Firepower FP 165 Welding Setting Selection Guide....................................... 4-11 Gas Selection for Gas Metal Arc Welding....................................................... 4-12 SECTION 5: SERVICE................................................................................................ 5-1 5.01 5.02 5.03 5.04 5.05 Cleaning of the Unit ........................................................................................ 5-1 Cleaning of the Feed Rolls ...
FIREPOWER FP 125,135,165 SECTION 1: SAFETY 1.0 Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
FIREPOWER FP 125,135,165 WARNING Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill. - Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards. - Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
FIREPOWER FP 125,135,165 2.0 Précautions de sécurité Les utilisateurs du matériel de soudage et de coupage plasma ESAB ont la responsabilité ultime d'assurer que toute personne qui opère ou qui se trouve dans l'aire de travail observe les précautions de sécurité pertinentes. Les précautions de sécurité doivent répondre aux exigences applicables à ce type de matériel de soudage ou de coupage plasma.
FIREPOWER FP 125,135,165 AVERTISSEMENT CHOC ÉLECTRIQUE - peut être mortel. LE SOUDAGE ET LE COUPAGE À L'ARC PEUVENT CAUSER DES BLESSURES À L'OPÉRATEUR OU LES AUTRES PERSONNES SE TROUVANT DANS L'AIRE DE TRAVAIL. ASSUREZ-VOUS DE PRENDRE TOUTES LES PRÉCAUTIONS NÉCESSAIRES LORS D'UNE OPÉRATION DE SOUDAGE OU DE COUPAGE. DEMANDEZ À VOTRE EMPLOYEUR UNE COPIE DES MESURES DE SÉCURITÉ QUI DOIVENT ÊTRE ÉLABORÉES À PARTIR DES DONNÉES DES RISQUE DU FABRICANT.
FIREPOWER FP 125,135,165 SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification This Owner’s Manual applies to just specification or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, DANGER, and NOTE may appear. Pay particular attention to the information provided under these headings.
FIREPOWER FP 125,135,165 2.05 Specifications Description Package System Part Number Power Source Weight FP 125 FP 135 FP 165 1444-0324 1444-0326 1444-0328 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 1Ø Frequency 60Hz Flexible Supply Cable Size 7 ft (2.2 m) 14AWG 7 ft (2.2 m) 14AWG 7.5 ft (2.
FIREPOWER FP 125,135,165 2.06 Volt - Amp Curves FP 125 FIREPOWER Vin=115V 60Hz 35.0 Art # A-09076_AB 30.0 OUTPUT VOLTAGE 25.0 20.0 15.0 10.0 5.
FIREPOWER FP 125,135,165 FP 165 FIREPOWER Vin=230V 60Hz 35 Art # A-09078_AB 30 OUTPUT VOLTAGE 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 OUTPUT CURRENT Figure 2-1: Volt/Amp curves of the Firepower 165 INTRODUCTION 2-4 Manual 0-5123
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 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.
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.
FIREPOWER FP 125,135,165 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. 2.
FIREPOWER FP 125,135,165 Cap 2 1 Shielding Gas “Cracking” /8” 3 4 Regulator and Flow Meter 11 Shielding Gas Shielding Gas 5 Shielding Gas Art # A-07965 Gas Hose Figure 3-1 Gas Cylinder Installation for Reference Only! Manual 0-5123 3-3 INSTALLATION
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 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 Firepower consumable parts. 1. Open the door to the machine. 2.
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 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 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. Assemble parts in sequence (shown in Figure 3-6 from right to left). 1.
FIREPOWER FP 125,135,165 Pressure Adjust Device Pressure Arm Pressure Adjust Device Pressure Arm Gun Cable End Gun Cable End Wire Wire Spool Inlet Wire Guide Feedroll Art # A-09083 Spool Wire Guide Feedroll Art # A-09085 Figure 3-10: Inserting Wire 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.
FIREPOWER FP 125,135,165 3.12 Install Wire into the Welding Gun Wire Feed Speed 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. .
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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.
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 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.
FIREPOWER FP 125,135,165 Direction of Gun Travel Art # A-05111 Leading or "Pushing" Angle (Forehand) 90º Trailing or "Pulling" Angle (Backhand) Figure 4-11: Nozzle Angle, Right-Handed Operator 4.09 Establishing the Arc and Making 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.
FIREPOWER FP 125,135,165 4.12 Reference Tables The following tables are provided as user aids when performing MIG or FLUX CORED welding.
FIREPOWER FP 125,135,165 4.13 Firepower FP 125 Welding Setting Selection Guide Material Type Wire Type Shielding Gas and Flow Rate Wire Size (Diameter) .023" (0.6mm) Solid (or hard) Steel ER70S-6 Flux Core E71T-GS Steel 100% CO2 25cfh .030" (0.8mm) .035" (0.9mm) .023" (0.6mm) 75% Ar 25% CO2 25cfh .030" (0.8mm) .035" (0.9mm) None Required .030" (0.8mm) .035" (0.9mm) Art # A-09030_AB COARSE LOW FINE 1 2 Voltage Step Wire Speed THICKNESS HIGH 24 ga. (0.6mm) 22 ga. (0.7mm) 20 ga. (0.
FIREPOWER FP 125,135,165 4.14 Firepower FP 135 Welding Setting Selection Guide Material Type Wire Type Shielding Gas and Flow Rate Wire Size (Diameter) .023" (0.6mm) 100% CO2 25cfh Solid (or hard) Steel .035" (0.9mm) ER70S-6 Steel Stainless Steel .030" (0.8mm) 75% Ar 25% CO2 25cfh Flux Core E71T-GS None Required Stainless Steel 98% Ar 2% CO2 35cfh ER 308L .023" (0.6mm) .030" (0.8mm) .035" (0.9mm) .030" (0.8mm) .035" (0.9mm) .023" (0.6mm) .030" (0.8mm) .035" (0.
FIREPOWER FP 125,135,165 4.15 Firepower FP 165 Welding Setting Selection Guide Material Type Wire Type Shielding Gas and Flow Rate Wire Size (Diameter) .023" (0.6mm) Steel Steel Stainless Steel Solid (or hard) ER70S-6 100% CO2 25cfh .035" (0.9mm) 75% Ar 25% CO2 25cfh Flux Core E71T-GS None Required Stainless Steel 98% Ar 2% CO2 35cfh ER 308L .030" (0.8mm) .023" (0.6mm) .030" (0.8mm) .035" (0.9mm) .030" (0.8mm) .035" (0.9mm) .023" (0.6mm) .030" (0.8mm) .035" (0.
FIREPOWER FP 125,135,165 4.16 Gas Selection for Gas Metal Arc Welding Base Plate Transfer Metal Type Thickness Filler Metal Mode Carbon Steel Suggested Welding Shielding Gas Positions Comments Greater than ER70S-X Short Circuit 22 gauge (.030”) 100% CO2 All Position High welding speeds. Good penetration and pool Welding control. Greater than ER70S-X Short Circuit 22 gauge (.030”) 75% Argon 25% CO2 All Position Suitable for high-current and high-speed welding.
ESAB FIREPOWER FP-125,135,165 SECTION 5: SERVICE 5.01 Cleaning of the Unit 4. Welding in a windy environment. a. Shield the weld area from the wind or increase the gas flow. 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. Welding dirty, oily, painted, oxidized or greasy plate. a.
ESAB FIREPOWER FP-125,135,165 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.
ESAB FIREPOWER FP-125,135,165 CAUSE FAULT 6 Weld cracking REMEDY A Weld beads too small A Decrease travel speed B Weld penetration narrow B Reduce current and voltage and increase MIG torch and deep travel speed or select a lower penetration shielding gas. 7 Cold weld puddle C Excessive weld stresses C Increase weld metal strength or revise design D Excessive voltage D Decrease voltage by reducing the voltage selection switch.
ESAB FIREPOWER FP-125,135,165 This Page Intentionally Blank SERVICE 5-4 Manual 0-5123
FIREPOWER FP 125,135,165 APPENDIX 1: OPTIONS AND ACCESSORIES • Contact your Firepower distributor to order options and accessories. For assistance in locating a Firepower distributor, contact the ESAB office listed in the inside rear cover that is nearest to you. • Note the model and specification number shown on the equipment nameplate.
FIREPOWER FP 125,135,165 APPENDIX 2: REPLACEMENT PARTS Model Part No. Item DESCRIPTION 1 TORCH GROMMET 2 FRONT PANEL FP 125 SILK-SCREEN PRINTED 3 PLASTIC HINGE FOR SIDE PANEL 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 8 FRONT FRAME, FP 125/135/165 1444-0833 1444-0833 1444-0833 9 CAP D.
FIREPOWER FP 125,135,165 3 4 5 40 3 5 2 2 7 1 7 1 8 8 1 6 6 9 9 13 21 20 22 23 31 30 19 32 33 34 & 34b 29 24 43 A-09100_AB 28 27 42 26 41 25 39 38 37 36 35 Figure A-4: FP 125-135-165 Replacement Parts Callout Manual 0-5123 A-3 APPENDIX
FIREPOWER FP 125,135,165 APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC Art # A-09022 APPENDIX A-4 Manual 0-5123
FIREPOWER FP 125,135,165 APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC Art # A-09023 Manual 0-5123 A-5 APPENDIX
FIREPOWER FP 125,135,165 APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC Art # A-09024 APPENDIX A-6 Manual 0-5123
FIREPOWER FP 125,135,165 This Page Intentiolnally Blank Manual 0-5123 A-7 APPENDIX
FIREPOWER FP 125,135,165 Revision History Date Rev Description 03/19/2009 AA Manual release 10/16/2015 AB Rebrand updates 04/06/2016 AC Updated Appx part numbers.
ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85 BELGIUM S.A. ESAB N.V. Heist-op-den-Berg Tel: +32 70 233 075 Fax: +32 15 257 944 BULGARIA ESAB Kft Representative Office Sofia Tel/Fax: +359 2 974 42 88 THE CZECH REPUBLIC ESAB VAMBERK s.r.o.
