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Firepower FP 125 User Manual

Firepower FP 125
60 pages
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160
130
120
Art # A-09075
MINI MIG
PORTABLE MIG WELDER
FP-125
FP-135
FP-165
Operating Manual
Revision: AA Issue Date: March 19, 2009 Manual No.: 0-5123
Operating Features:

Table of Contents

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Firepower FP 125 Specifications

General IconGeneral
BrandFirepower
ModelFP 125
CategoryWelding System
LanguageEnglish

Summary

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS

1.01 Arc Welding Hazards

Details the risks and precautions associated with electric shock during arc welding operations.

1.02 Principal Safety Standards

Lists key industry standards and codes for safe welding and cutting practices.

1.03 Symbol Chart

Explains various symbols used on the welding machine for operational clarity.

1.04 Precautions De Securite En Soudage A L'arc

French safety precautions for arc welding, focusing on electrical hazards.

1.05 Dangers relatifs au soudage à l'arc

French section detailing hazards related to arc welding, including electrocution.

1.06 Principales Normes De Securite

French list of principal safety standards relevant to welding and cutting.

1.07 Graphique de Symbole

French guide to machine symbols for operational understanding.

SECTION 2: INTRODUCTION

2.01 How to Use This Manual

Guidance on interpreting manual conventions like WARNING, CAUTION, and NOTE for safe operation.

2.02 Equipment Identification

Instructions on locating and recording the machine's identification numbers for reference.

2.03 Receipt of Equipment

Procedures for inspecting received equipment for completeness and shipping damage.

2.04 General

Overview of the FirePower FP-125, 135, 165 machines and their included components.

2.05 Specifications

Detailed technical specifications for the FP-125, FP-135, and FP-165 models.

2.06 Volt - Amp Curves

Graphical representation of output voltage versus output current for different models.

2.07 Duty Cycle

Explanation of duty cycle and its specific percentages for each FirePower model.

2.08 MIG Gun Maintenance

Instructions for routine cleaning of the MIG gun conduit to prevent wire feeding issues.

2.09 Handle / Feet Assembly

Visual guide for assembling the handle and feet components of the machine.

SECTION 3: INSTALLATION

3.01 Location

Guidelines for selecting an optimal installation site for machine longevity and performance.

3.02 Safety

Directs users to refer to Section 1 for crucial installation safety instructions and warnings.

3.03 Grounding

Importance of proper grounding for personal safety and compliance with electrical codes.

3.04 Electrical Input Requirements

Details required input voltage, amperage, and plug types for each model.

3.05 Requirements for Maximum Output

Specifies branch circuit requirements for achieving maximum output for each model.

3.06 Installation of Shielding Gas (GMAW) Process

Step-by-step guide for installing the gas cylinder and regulator for GMAW.

3.07 Attaching the Gun and Cable Assembly to the Power Source

Instructions on how to connect the welding gun and cable to the main power source unit.

3.08 Polarity Changeover

Explains how to change polarity for different welding processes (GMAW, FCAW).

3.09 Installing Wire Spool

Guide for assembling the wire spool and its related parts onto the machine.

3.10 Feedrolls

Information about the feedroll sizes and how to identify them.

3.11 Install Wire into the Feedhead

Step-by-step instructions for routing the welding wire through the feedhead mechanism.

3.12 Install Wire into the Welding Gun

Detailed procedure for feeding the wire through the welding gun.

SECTION 4: OPERATION

4.01 General Safety Precautions

Emphasizes reading all safety instructions before operating the welding machine.

4.02 FirePower Controls

Identifies and describes the function of various controls and terminals on the FirePower unit.

4.03 Gas Metal Arc Welding (GMAW)

Outlines the steps and considerations for performing Gas Metal Arc Welding.

4.04 Flux Cored Arc Welding (FCAW)

Explains the procedure for Flux Cored Arc Welding, noting when shielding gas is not needed.

4.05 Shutdown Procedures

Provides the correct steps for safely shutting down the welding machine after operation.

4.06 Basic Welding Technique

Covers fundamental techniques for MIG and Flux Cored welding processes.

4.07 Welding Gun Positions

Illustrates correct gun angles for various welding joints like butt, horizontal, vertical, and overhead.

4.08 MIG Welding (GMAW) Variables

Details variables affecting MIG welding quality, including pre-selected and adjustable parameters.

4.09 Establishing the Arc and Making Weld Beads

Guidance on creating practice welds and achieving a proper arc.

4.10 Pre-Weld Procedure

Steps to follow before initiating the welding process, including safety checks.

4.11 Welding Procedure

Specific instructions for performing the welding operation, including stickout and arc initiation.

4.12 Reference Tables

Provides tables for gas selection and welding variables to optimize weld quality.

4.13 FirePower 125 Welding Setting Selection Guide

A guide to selecting appropriate settings for the FP-125 based on material and thickness.

4.14 FirePower 135 Welding Setting Selection Guide

A guide to selecting appropriate settings for the FP-135 based on material and thickness.

4.15 FirePower 165 Welding Setting Selection Guide

A guide to selecting appropriate settings for the FP-165 based on material and thickness.

4.16 Gas Selection for Gas Metal Arc Welding

Recommendations for choosing the correct shielding gas for various welding applications.

SECTION 5: SERVICE

5.01 Cleaning of the Unit

Instructions for periodically cleaning the internal components of the welding machine.

5.02 Cleaning of the Feed Rolls

Guidance on cleaning the feed rolls to ensure proper wire feeding.

5.03 Basic Troubleshooting

Basic troubleshooting steps that can be performed without specialized knowledge or disassembly.

5.04 Solving Problems Beyond the Welding Terminals

Focuses on troubleshooting common GMAW issues, particularly porosity.

5.05 Welding Problems

Details common welding faults, their causes, and recommended remedies.

APPENDIX 1: OPTIONS AND ACCESSORIES

Feed Roll Installation & Consumable Guide

Information on feed roll installation and a guide to consumable parts and weld wires.

Feed Roll Installation & Consumable Guide FP-135

Details consumables and feed roll installation for the FP-135 model.

Feed Roll Installation & Consumable Guide FP-165

Details consumables and feed roll installation for the FP-165 model.

APPENDIX 2: REPLACEMENT PARTS

FP-125 Replacement Parts List

A list of replacement parts for the FP-125 model with corresponding part numbers.

APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC

APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC

APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

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