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 . . .
Table of Contents page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page Learning to Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Arc Welding Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Types of Commonly Used Weld Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Stringer Bead . . . . . . . . . . . . . . . . . . .
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.
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).
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.
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.
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Figure 1: Wheel and Handle Installation 2. Wheels and Pull Handle - Slide the axle through the opening in the bottom of the welder cabinet. Insert axle into wheels. Use a hammer to attach pal nuts on the axle by simply tapping them into position. 3. Assemble the plastic handle as shown in Figure 1. 4. Amperage Adjustment Handle - Thread handle onto shunt control shaft at the top of the machine until it contacts locking nut (Be sure to install lock washer first). Thread crank handle into shunt handle.
MACHINE OPERATION AC OUTPUT CONNECTIONS (FP-235 AND FP-235 AC/DC) This welder has two AC outlet plugs that are clearly marked with the electrode and ground clamp symbols. NEVER reverse cable connections as this could cause injury to the user as well as the equipment!) Connect the electrode output cable to the electrode connections and the ground cable to the ground connection. These connections are Dinse type connections and require that they be twisted into place in order to insure the best connection.
DIRECT CURRENT WELDING Direct current DC welding is performed when the welding cables are connected to the DC+ (Positive) and DC(Negative) output receptacles. The FP 235 AC/DC offers you two DC welding options, straight or reverse polarity. To weld with straight polarity place the electrode cable plugged into the receptacle market DC negative and the ground cable or work cable plugged into the receptacle marked DC positive.
5. Select the appropriate electrode. 6. Turn on the power switch of your welder. Arc rays can injure eyes and burn skin! Prolonged exposure to arc rays can cause blindness and burns. NEVER strike an arc or begin welding without adequate eye and skin protection. Follow our Health Hazard safety instructions on page 4 before welding. WELDING POSITIONS Arc welding can be performed from any of four basic positions 1. Flat - generally easier, faster, and allows for better penetration of the metal 2.
GROUND CLAMP CONNECTION Be certain you have a solid ground connection. The ground clamp connection is part of the current circuit. A poor connection at the ground clamp will result in wasted power and heat. Scrape away any dirt, rust, scale, oil or paint you may find on the workpiece. Make sure the ground clamp directly touches the metal surface. SELECTING THE ELECTRODE Welding electrode is a rod or wire of electrically conductive metal, coated with a layer of flux.
SELECTING THE PROPER AMPERAGE The electrode type and thickness of the metal work-piece determine the amount of heat needed in the welding process. See Figure 5 for bead examples of heat based on rod size. Heavier and thicker metals require more heat or amperage. Refer to a rod and amperage guide or experiment on scrap metal. When you weld with proper rod your results will be: 1. Bead will lay smoothly over the workpiece without ragged edges. 2.
DC STRAIGHT POLARITY WELDING The electrode in DC straight polarity (DCSP) welding is negative and the work surface is positive. The current flow is from the electrode to the work. Ideal Current for: • Hard Facing. • Build Up - Heavy Deposits. • Cutting Steel. ROD METAL AWS ROD NO.
E6013 General Purpose E7014 General Purpose Iron Powder Sheet Metal 1/16” 3/32” Min. - 60 amps 30 - 80 amps Min. - 1/16” 1/16” - 1/8” Sheet Metal 5/64” Min. - 100 amps Min. - 1/4” STRIKING THE ARC Exposure to a welding arc is extremely harmful to the eyes and skin. Prolonged exposure can cause blindness and burns. NEVER strike an arc or begin welding until you have adequate protection.
Exposure to a Welding arc is extremely harmful to the eyes and skin. Prolonged exposure can cause blindness and burns. NEVER strike an arc or begin welding until you are adequately protected. Wear flameproof welding gloves, a heavy long-sleeved shirt, cuffless trousers, high-topped shoes and a welding helmet. To prevent ELECTRIC SHOCK, DO NOT perform any welding while standing, kneeling or lying directly on the grounded work.
Figure 10: Triple Pass Cutaway Figure 11: Triple Pass Welds The intense heat produced at the arc sets up strains in the metal joined by welding. Peening the weld (striking the weld with a welding hammer) not only removes the scale left behind in the welding but relieves the internal strains developed by the heating and cooling process. A complete weld may require more metal than can be deposited in a single pass by either the stringer or weave method.
Generally, all ferrous metals are affected by magnetism while the nonferrous metals are not. However, some stainless steels are not magnetic. COLOR TEST The two main divisions of metal include the irons and steels which are indicated by their typical gray-white color and the nonferrous metals which come in two general color classifications of yellow and white. Copper may be easily identified due to its color (yellowish) as are brass and bronze.
• CGA Pamphlet P-I - SAFE HANDLING OF COMPRESSED GASSES IN CYLINDERS - obtainable from the Compressed Gas Association, 5005th Avenue, New York, NY 10038. • OSHA Standard 29 CFR, Part 1910, Subpart 0. - WELDING, CUTTING AND BRAZING - obtainable from your state OSHA office. • CSA Standard W117.2 - CODE FOR SAFETY IN WELDING AND CUTTING - obtainable from Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario Canada M9W 1R3. • American Welding Society Standard A6.
21 Figure 12: FP-100
22 PART NO. 1443-0425 1443-0426 1443-0427 1443-0428 1443-0429 1443-0430 1443-0431 1443-0432 1443-0433 1443-0434 1443-0435 1443-0015 1443-0437 1443-0025 1444-0724 ITEM NO.
23 Figure 13: FP-235
24 PART NO. 1443-0450 1443-0451 1443-0452 1443-0453 1443-0454 1443-0455 1443-0456 1443-0457 1443-0458 1443-0459 1443-0460 1443-0461 1443-0462 1443-0463 1443-0464 1443-0465 1443-0466 1443-0467 1443-0026 1443-0469 1444-0535 1443-0471 1443-0472 1443-0016 1443-0474 1443-0484 1443-0476 1443-0477 1443-0478 ITEM NO.
25 Figure 14: FP-235 AC/DC
26 PART NO. 1443-0450 1443-0451 1443-0452 1443-0480 1443-0454 1443-0455 1443-0456 1443-0457 1443-0458 1443-0459 1443-0460 1443-0461 1443-0462 1443-0479 1443-0481 1443-0465 1443-0457 1443-0467 1443-0469 1443-0471 1443-0026 1443-0469 1444-0535 1443-0467 1443-0482 1443-0016 1443-0474 1443-0484 1443-0476 1443-0477 1443-0478 ITEM NO.
Figure 15: FP 100 Wiring Diagram Figure 16: FP 235 Wiring Diagram 27
Figure 17: FP-235 AC/DC Wiring Diagram 28
FIREPOWER LIMITED WARRANTY SCOPE OF LIMITED WARRANTY: Firepower, a division of Thermadyne Industries, Inc. (hereinafter, "Seller") warrants that its products are free of defects in workmanship or material.
LIMITED WARRANTY CLAIM METHOD: To make a claim under this warranty, Purchaser must notify Seller of the details of such claim within thirty days of discovering a defect in material or workmanship. If the claim is covered by this warranty, Seller will direct Purchaser to return the product to an authorized warranty repair center. The Seller will not be responsible for transportation costs or risks of any kind under this warranty. The Purchaser will be responsible for all such transportation costs and risks.
The quality system of the Denton and Abilene, Texas locations of Victor Equipment Company, Victor de Mexico in Hermosillo, Mexico and Victor de Brazil in Rio de Janeiro, Brazil are registered by Det Norske Veritas (DNV) to meet the requirements of ISO-9001, 1994.
