FP-125 MINI MIG FP-135 Portable mig Welder FP-165 Art # A-09075 Operating Manual Revision: AA Issue Date: March 19, 2009 Operating Features: 120 130 160 Manual No.
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! 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 FirePower 135 Mini MIG System MIG Welder FirePower 165 Mini MIG System MIG Welder Part No. 1444-0324 Part No. 1444-0326 Part No.
TABLE OF CONTENTS SECTION 1:SAFETY INSTRUCTIONS AND WARNINGS................................................. 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 Arc Welding Hazards........................................................................................ 1-1 Principal Safety Standards............................................................................... 1-4 Symbol Chart...................................................................................................
TABLE OF CONTENTS 4.13 4.14 4.15 4.16 FirePower 125 Welding Setting Selection Guide............................................ 4-10 FirePower 135 Welding Setting Selection Guide............................................ 4-11 FirePower 165 Welding Setting Selection Guide............................................ 4-12 Gas Selection for Gas Metal Arc Welding....................................................... 4-13 SECTION 5:SERVICE......................................................................
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.
firepower FP-125, 135, 165 SAFETY INSTRUCTIONS WARNING WARNING FUMES AND GASES can be hazardous to your health. WELDING can cause fire or explosion. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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.
SAFETY INSTRUCTIONS firepower FP-125, 135, 165 WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. ENGINE FUEL can cause fire or explosion. Chipping and grinding cause flying metal. As welds cool, they can throw off slag. Engine fuel is highly flammable. 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.
firepower FP-125, 135, 165 SAFETY INSTRUCTIONS ! WARNING The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information. STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin. The coolant in the radiator can be very hot and under pressure. ABOUT PACEMAKERS: 1.02 Principal Safety Standards 1. Do not remove radiator cap when engine is hot. Allow engine to cool. Safety in Welding and Cutting, ANSI Standard Z49.
SAFETY INSTRUCTIONS firepower FP-125, 135, 165 1.03 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
firepower FP-125, 135, 165 1.04 SAFETY INSTRUCTIONS 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.
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. 1. Eloignez la tête des fumées pour éviter de les respirer. 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés. 3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.
firepower FP-125, 135, 165 SAFETY INSTRUCTIONS AVERTISSEMENT AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER 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.
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. AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX. 4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion. 5.
firepower FP-125, 135, 165 1.07 SAFETY INSTRUCTIONS Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle.
INTRODUCTION firepower FP-125,135,165 SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.03 Receipt of Equipment 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.
firepower FP-125,135,165 INTRODUCTION 2.05 Specifications Description Package System Part Number Power Source Weight Power Source Dimensions HxWxD Number of Phases Frequency Flexible Supply Cable Size Supply Lead Plug Type Nominal Input Voltage 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) 12 x 9.75 x 17.5" ( 304.8 x 247.7 x 444.5mm) 1Ø 60Hz 7 ft (2.2 m) 14AWG 7 ft (2.2 m) 14AWG 7.5 ft (2.
INTRODUCTION firepower FP-125,135,165 2.06 Volt - Amp Curves FP-125 FIREPOWER 35.0 Vin=115V 60Hz Art # A-09076 30.0 OUTPUT VOLTAGE 25.0 20.0 15.0 10.0 5.
firepower FP-125,135,165 INTRODUCTION FP-165 FIREPOWER Vin=230V 60Hz 35 Art # A-09078 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 Manual 0-5123 2-4 Introduction
INTRODUCTION 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 INTRODUCTION 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.
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.
firepower FP-125, 135, 165 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.
INSTALLATION 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! Installation 3-3 Manual 0-5123
firepower FP-125, 135, 165 INSTALLATION 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.
INSTALLATION 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 TWECO consumable parts. 1. Open the door to the machine. 2.
firepower FP-125, 135, 165 INSTALLATION 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 1.
INSTALLATION 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. A feedroll consists of two different sized grooves, .023” (0.6mm) and .030” / .035” (0.8mm / 0.9mm). Installation of Wire Spool The branding inside at the end of the feedroll refers to the size nearest to the mark Assemble parts in sequence (shown in Figure 3-6 from right to left). 1.
firepower FP-125, 135, 165 INSTALLATION Pressure Arm Pressure Adjust Device 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.
INSTALLATION firepower FP-125, 135, 165 3.12 Install Wire into the Welding Gun 3. Set the wire feed speed to half-way or "5". 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.
firepower FP-125, 135, 165 INSTALLATION 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. Contact Tip Nozzle Wire Gun Switch Art # A-09087 Figure 3-15: Feed Wire Through Gun 6.
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.
firepower FP-125, 135, 165 4.02 FirePower Controls OPERATION 10 The Gun Switch Connector is provided for connection of the Gun Switch Leads. Refer to Figure 4-1 and 4-2. 11. Negative (-) Welding Terminal. 1. Power ON / OFF switch turns the power on and off. It also lights when the power supply has gone into overtemp. 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).
OPERATION firepower FP-125, 135, 165 3 2 3 8 1 6 9 7 4 v 120V Wire Feed Welder Welds 24 gauge to 3/16" (4.8mm) Mild Steel RATED OUTPUT CSA VOLTS 15 21 AMP 110 60 DUTY CYCLE 13% 40% MAX OCV 30 30 AMP RANGE 40-110 40-110 FP-125 FINE COARSE 1 LOW 2 HIGH Art # A-09065 12 13 10 11 5 Figure 4-1: FirePower FP-125 Controls 2 3 8 1 6 9 7 4 120V Wire Feed Welder Welds 24 gauge to 1/4" (6.
firepower FP-125, 135, 165 OPERATION 4.03 Gas Metal Arc Welding (GMAW) NOTE To help you overcome any problems that might arise, you will find useful information in section 4.06 Basic Welding Techniques. 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.
OPERATION firepower FP-125, 135, 165 4.06 Basic Welding Technique GAS METAL ARC WELDING (GMAW) General 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.
firepower FP-125, 135, 165 ! OPERATION 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.
OPERATION firepower FP-125, 135, 165 4.08 MIG Welding (GMAW) Variables 2. Wire Feed Speed. Increase in wire feed speed increases weld current. Decrease in wire feed speed decreases weld current. 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. 3. Nozzle Angle.
firepower FP-125, 135, 165 4.09 Establishing the Arc and Making Weld Beads 4.11 Welding Procedure 1. Maintain the tip to work distance (stickout) at 5/16” to 3/8” (8 to 9mm) at all times. 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. 2. For transverse and longitudinal nozzle angles, see section 4.07 Welding Gun Positions.
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.
firepower FP-125, 135, 165 OPERATION 4.13 FirePower 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 FINE 1 COARSE LOW 2 Voltage Step Wire Speed THICKNESS HIGH 24 ga. (0.6mm) 22 ga. (0.7mm) 20 ga.
OPERATION firepower FP-125, 135, 165 4.14 FirePower 135 Welding Setting Selection Guide Material Type Wire Type Wire Size (Diameter) Shielding Gas and Flow Rate .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 OPERATION 4.15 FirePower 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.
OPERATION firepower FP-125, 135, 165 4.16 Gas Selection for Gas Metal Arc Welding Base Plate Metal Type Thickness Carbon Steel Filler Metal Transfer Suggested Welding Mode Shielding Gas Positions Greater than 22 gauge (.030”) ER70S-X Short Circuit 100% CO2 Greater than 22 gauge (.030”) ER70S-X Short Circuit 75% Argon All Position 25% CO2 Welding Greater than 22 gauge (.030”) ER70S-X Short Circuit 92% Argon All Position Higher deposition rates without melt-through.
SERVICE firepower FP-125, 135, 165 SECTION 5: SERVICE 5.01 Cleaning of the Unit 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). 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. 2. Gas leaks a.
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.
SERVICE firepower FP-125, 135, 165 5.05 Welding Problems FAULT 1 Undercut. CAUSE REMEDY A Welding arc voltage A Reduce voltage by reducing the voltage setoo high. lection switch position or increase the wire feed speed. B Incorrect torch angle B Adjust angle C Excessive heat input 2 Lack of penetration. C Increase the torch travel speed and/or reduce welding current by reducing the voltage selection switch position or reducing the wire feed speed.
firepower FP-125, 135, 165 SERVICE FAULT 6 Weld cracking CAUSE REMEDY A Weld beads too small A Decrease travel speed B Weld penetration nar- B Reduce current and voltage and increase MIG row and deep torch travel speed or select a lower penetration shielding gas. C Excessive weld stress- C Increase weld metal strength or revise dees sign D Excessive voltage D Decrease voltage by reducing the voltage selection switch.
APPENDIX firepower FP-125, 135, 165 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.
Manual 0-5123 Wire Feed Roll, Knurle, .023" - .030" /.035" (0.6-0.8mm/0.9mm), Hard/Cored Nozzle Contact Tip, .023" (0.6mm) Contact Tip, .030" (0.8mm) Contact Tip, .035" (0.9mm) 1444-0427 1444-0050 1444-0025 1444-0026 1444-0027 Figure A-2: FP-135 Feed Roll and Consumables Chart Art # A-09027 A-2 Wire Feed Roll, Knurle, .023" - .030" /.035" (0.6-0.8mm/0.9mm), Hard/Cored Nozzle Contact Tip, .023" (0.6mm) Contact Tip, .030" (0.8mm) Contact Tip, .035" (0.
APPENDIX firepower FP-125, 135, 165 This Page Intentionally Blank Appendix A-3 Manual 0-5123
firepower FP-125, 135, 165 APPENDIX APPENDIX 2: REPLACEMENT PARTS Model Part No.
APPENDIX firepower FP-125, 135, 165 Figure A-4: FP-125-135-165 Replacement Parts Callout Appendix A-5 Manual 0-5123
firepower FP-125, 135, 165 APPENDIX APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC Art # A-09022 Manual 0-5123 A-6 Appendix
APPENDIX firepower FP-125, 135, 165 APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC Art # A-09023 Appendix A-7 Manual 0-5123
firepower FP-125, 135, 165 APPENDIX APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC Art # A-09024 Manual 0-5123 A-8 Appendix
LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada. November 2007 LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company (“Thermal Arc”), warrants to customers of authorized distributors (“Purchaser”) that its products will be free of defects in workmanship or material.
WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. January 2009 SAFETY EQUIPMENT Auto-Darkening Welding Helmet (Electronic Lens) Harness Assembly ENGINE DRIVEN WELDERS Scout, Raider, Explorer Original Main Power Stators and Inductors Original Main Power Rectifiers, Control P.C.
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.
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.
