FP-90 Gasless Welding System (FCAW) Instruction Manual FORM NO. 0056-1839 EFFECTIVE: July 2001 Safety and Operating Instructions For Your Safety . . .
Table of Contents page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page Types of Weld Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Welding Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Multiple Pass Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Special Welding Methods . . . . . . . . . . . . . .
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 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).
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.
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.
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.
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.
Remove the contact tip and gun nozzle from the welding torch before starting this procedure. 1. Loosen the nut of the spool holder (brake drum). Remove the spring and the external ring. 2. Remove the plastic protection from the spool. Place it on the spool holder again. Mount the external ring, the spring and the plastic lock nut again. These parts form the braking system for the wire spool. Tighten nut until slightly snug. Excessive pressure strains the wire feeding motor.
3. Welding time is about 50% less compared to the normal electrode welding. 4. The learning time for the operator is very short. 5. Minimum waste of welding material. 6. Most important, this process allows to complete the welding more quickly and efficiently.. 7. Less heat, less distortion. 8. Possible to weld thin materials. PREPARATION FOR WELDING 1. Connect the welding machine to the 120V, 60 Hz line. 2. Connect the ground cable to the workpiece (see Figure 3). Make sure that the contact is good. 3.
The wire is pushed by a roll which is moved by a series of mechanisms. The roll has two grooves, one marked by 0.035” (0.9 mm) and the other marked by 0.030” (0.8 mm). It is very important to use the correct groove as explained in “Preparation for Welding” on page 9. Otherwise, the wire will not feed smoothly or it will be crushed. Make sure that the torch tip matches with the wire diameter.
start from a higher wire speed. This operation prevents damage to the contact tip during welding. During welding, keep the torch at a 45º angle from the workpiece. SELECTING WIRE WIRE DIAMETER SELECTION Using a wire that is too small in diameter causes excessive weld spatter and weld heat. Wire that is too large causes wire stubbing. Stubbing occurs when the molten metal bridge between the electrode and weld pool cannot be broken and the electrode stubs into the pool and the pool freezes.
SELECTING WELDING CURRENT POLARITY Using gas-shielded steel welding wire requires direct current (dc) reverse polarity. Self-shielding flux cored wires use direct current straight polarity. Depending on the type of wire you are using, the polarity may have to be converted. Some welders DO NOT have the capability of changing the polarity. Direct current reverse polarity is sometimes referred to as DCEP (Direct Current Electrode Positive).
2. Aluminum is often anodized to prevent oxidation. However, an anodized surface will NOT conduct electricity. Therefore, to weld anodized aluminum, you MUST sand or grind the anodized coating from the weld joint area and from the site where the workpiece clamp will be connected. Determine whether or not the aluminum you intend to weld is anodized. Touch the two probes of an electrical continuity tester or ohmmeter to the aluminum in question. Set the probes an inch or two apart.
WORKPIECE CLAMP CONNECTION Connect the workpiece clamp directly to the work piece as close to the weld as possible. If it is impractical to connect the workpiece clamp directly to the workpiece, connect it to the metal that is securely attached to the workpiece, but not electrically insulated from it. Also, make sure the attached metal piece is of about the same or greater thickness as the workpiece.
LEARNING TO WELD Whether you have welded before or not, it is important that you become familiar with your new welder, its controls and the results achieved at different settings. We strongly recommend that you practice with your new welder on scrap metal. Try different heat settings, base metal thicknesses and welding positions for each type and size of wire that you will use. By practicing, you will gain a feel for how changes in these welding variables affect the weld.
LAYING A BEAD EXPOSURE TO WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN! Prolonged exposure to the welding arc 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. ELECTRIC SHOCK CAN KILL! To prevent electric shock, DO NOT perform any welding while standing, kneeling or lying directly on the grounded work.
There are two basic types of weld beads: the stringer bead and the weave bead. 1. Form the stringer bead (see Figure 11) by traveling with the line while keeping the wire and nozzle centered over the weld joint. It is the easiest type of bead to make and is the type you have used up to this point. 2. Use the weave bead (see Figure 12) when you want to deposit much wider space than is possible with a stringer bead. It is made by moving the gun from side to side.
falling into the nozzle should it drip from the weld puddle. Hold angle B at 0º so that the wire is aiming directly into the weld joint. If the weld puddle drips excessively, select a lower heat setting. Also, the weave bead tends to work better than the stringer bead when welding overhead. MULTIPLE PASS WELDING 1. Butt weld joints - In "Preparing the Workpiece," we discussed the need for edge preparation on thicker materials by grinding a bevel on the edge of one or both pieces of metal being joined.
2. The punch and fill method produces a weld with the most finished appearance. In this method, a hole is punched or drilled into the top piece of metal. The arc is directed through this hole to penetrate into the bottom piece. The puddle fills up the hole leaving a spot weld that is smooth and flush with the surface of the top piece. Select the wire diameter, heat setting and wire speed as if you were welding the same thickness material with a continuous bead. 3.
ADDITIONAL SAFETY INFORMATION Make sure you read and understand all of the information and instructions contained in this manual BEFORE proceeding. The National Electrical Code, Occupational Safety and Health Act (OSHA) regulations, local industrial codes and local inspection requirements also provide a basis for equipment installation, use and service. For additional information concerning welding safety, refer to the following standards and comply with them as applicable. • ANSI Standard Z49.
TROUBLESHOOTING INFORMATION Use this chart to assist you in resolving common problems you may encounter. These are not all of the possible solutions. PROBLEM 1. Dirty, porous or brittle weld. POSSIBLE CAUSE Plugged welding nozzle. REMEDY Clean or replace welding nozzle. 2. Arc Works but is not feeding wire. Faulty wire speed control assembly. No tension on the drive roller. Faulty drive motor (very rare). Replace wire speed control assembly. Adjust the drive tension. Replace drive motor. 3.
Figure 20: FP-150 MIG Gun Assembly FIREPOWER FP-150 MIG-GUN PARTS LISTING Model No. FP150 FP21-50 FP11-30 FP35-50 Victor No. 1444-0600 1444-0601 1444-0602 1444-0603 Description Gun Assy Nozzle Contact Tip Trigger GENERAL OPERATING TIPS Contact tips and nozzles should be cleaned frequently. Spatter buildup may cause bridging between nozzle and tip.This could cause electrical shorting between the nozzle and work piece as well as poor or improper gas flow.
23 Figure 21: FP-90
24 PART NO. 1444-0425 1444-0426 1444-0434 1444-0435 1444-0436 1444-0437 1444-0438 1444-0439 1444-0440 1444-0441 1444-0442 1444-0432 1444-0443 1444-0433 1444-0444 1444-0445 1444-0427 1444-0428 1444-0446 1444-0447 1444-0448 1444-0449 1444-0450 1444-0451 1444-0429 1444-0430 1444-0431 1444-0452 1444-0724 1443-0025 1444-0404 ITEM NO.
Figure 22: FP-90 Wiring Diagram 25
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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.
LIMITATION OF LIABILITY: Seller shall not, under any circumstances, be liable for special, indirect, incidental or consequential damages (regardless of the form of action, whether in contract or in tort including negligence), including, but not limited to, damage or loss of other property or equipment, loss of profits or revenue, cost of capital, cost of purchased or replacement goods, or claims of Purchaser for service interruption.
