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Firepower FP-130 - User Manual

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FP-120, FP-130 and FP-160
MIG Welding System
Instruction Manual
FORM NO. 0056-1842 EFFECTIVE July 2001
Safety and Operating
Instructions
For Your Safety . . .
PLEASE READ
CAREFULLY!

Table of Contents

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Summary

Introduction

Safety Profile

Safety Information

Safety Warnings and Definitions

Explains 'WARNING', 'CAUTION', and 'NOTICE' terms used for safety.

Safety Instruction Compliance

Emphasizes reading and retaining safety instructions for future reference.

Safety Symbols

Electric Shock Hazard Symbol

Symbol indicating a possible electric shock hazard during operation.

Fire Hazard Symbol

Symbol indicating a possible fire hazard during operation.

Welding Hazard Symbols

Helmet Required Symbol

Symbol indicating a helmet must be worn for eye protection.

Toxic Gas Hazard Symbol

Symbol indicating a possible toxic gas hazard during operation.

Hot Slag Burn Symbol

Symbol indicating a possible burn hazard from hot slag.

Eye Protection Symbol

Symbol indicating eye protection should be worn for flying debris.

Compressed Gas Cylinder Hazard Symbol

Symbol indicating risk from improper gas cylinder handling.

Critical Safety Hazards

Electric Shock Danger

Warns that electric shock can be fatal; emphasizes safety instructions.

Fire and Explosion Danger

Warns that fire or explosion can cause death, injury, and property damage.

Arc Rays Danger

Warns that arc rays can injure eyes and burn skin; stresses safety.

Fumes and Gases Danger

Warns that fumes, gases, and vapors can cause discomfort, illness, or death.

General Welding Safety Instructions

Welding Area Safety

Emphasizes observing safety and operating rules for the welding area.

Personal Protection Equipment

Details required protective clothing, helmet, and eye protection for welding.

Power Source Connection Safety

Details safety steps before connecting the power source, including switches and grounding.

Fire Prevention Measures

Outlines essential fire prevention measures in the welding work area.

Combustible Material and Container Safety

Ventilation

Adequate Ventilation for Welding

Stresses the need for adequate ventilation to prevent hazardous gas concentrations.

Electromagnetic Compatibility

EMC Area Inspection and Interference Reduction

Advises area inspection and offers suggestions to reduce EMC interference.

Protective Welding Gases

Protective Gas Selection and Handling

Explains gas selection, regulator use, and cylinder safety for welding.

Gas Hose and Regulator Maintenance

Stresses maintaining gas hose condition and proper regulator lubrication.

Health Hazards

Health Hazard Precautions

Details necessary precautions for health hazards during welding.

Electric Shock Safety

Electric Shock Prevention and Response

Covers prevention, first aid, and immediate actions for electric shock.

Welder Specifications

Welder Operating Characteristics

Internal Thermal Overload Protection

Duty Cycle and Overload Protection

Explains duty cycle and the function of internal thermal overload protection.

Specifications for FP 120 Wire(GMAW;FCAW) Welding System (1444-0304)

Specifications for FP 130 Wire(GMAW;FCAW) Welding System (1444-0306)

Specifications for FP 160 Wire(GMAW;FCAW) Welding System (1444-0308)

MIG-Gun Specifications

MIG Gun Duty Cycle Chart

Welder Installation

Power Source Connection

Details requirements and safety for connecting the welder to the power source.

Welder Machine Assembly

Details the steps for assembling the welding machine.

Handle Assembly

Required Tools for Assembly

Power Cord Connection During Assembly

MIG Gun Installation

MIG Gun Liner Cover Removal

Details removing the MIG gun liner cover for installation.

Wire Feeder Screw Caution

Warns against removing screws at the front of the wire feeder.

MIG Gun Connector Nut and Washer Removal

Explains removing the nut and washer from the MIG gun connector.

Wire Liner Cutting

Instructs on cutting the wire liner to the correct length for proper fitment.

Gun Liner Cutting Caution

Warns against cutting the gun liner too short.

MIG Gun Connector Removal

Details using wire cutters to remove the MIG gun connector.

MIG Gun Connector Re-installation

Guides on re-installing the MIG gun connector correctly.

Arc Eye Protection Warning

Reiterates the warning against looking at an electric arc without eye protection.

Welding Wire Installation

Welder Placement and Ventilation

Welder Clearance Requirements

Panel and Wire Contact Safety

Installation of the Welding Wire

Wire Installation Preparation

Advises removing the contact tip and nozzle before installing the wire.

Spool Holder Nut Adjustment

Details loosening the spool holder nut for wire installation.

Spool Plastic Protection Removal

Instructs on removing the protective plastic from the wire spool.

Wire Feeder Knob Adjustment

Guides on loosening and lowering the wire feeder knob to access the wire.

Handling Disconnected Wire

Advises securing the wire with pliers when disconnected.

Torch Straightness Caution

Warns to keep the torch straight when feeding new wire to prevent liner damage.

Wire Feed Roll and Knob Adjustment

Explains lowering the upper roll and knob after inserting the wire.

Wire Feed Roll Diameter Selection

Connecting Power Supply Cable

Moving Roll Hazard Warning

Gas Cylinder and Regulator Connection

Gas Regulator to Cylinder Connection

Guides on assembling the pressure regulator to the gas cylinder.

Gas Hose to Regulator Connection

Explains connecting the gas hose to the regulator with a safety ring.

Gas Flow Check

Instructs on opening the cylinder valve and checking gas flow through the torch.

Pressurized Cylinder Handling

Warns about the high pressure of cylinders and the risks of improper handling.

Cylinder Condition Warning

Advises against using cylinders that are contaminated or damaged.

MIG Gun

MIG Welding

MIG Welding Process

MIG Wire Types

Experienced Personnel Requirement

Gasless Welding

Gasless Welding Polarity

Details the polarity connection for gasless welding.

Advantages of Gasless Welding

Preparation for Welding

Cylinder Handling Safety Precautions

Reiterates warnings regarding the safe handling of pressurized gas cylinders.

Cylinder Condition Check

Warns against using gas cylinders that are contaminated or damaged.

Machine Power Connection

Details connecting the welding machine to the appropriate power supply.

Polarity Setting Check

Ground Cable Connection

Wire Feed Roll Alignment

Gas Flow Regulator Setting

Welding Procedures

Welding Current Regulation

Explains the four current regulation positions and their use based on material thickness.

Welding Settings Table

Directs users to Table 1 for approximate settings for welding.

Replacement of the Wire Spool

Wire Spool Replacement Guide

Details the process of replacing the wire spool, including tip matching.

Welding Tips

Torch Angle and Distance

Advises on maintaining the correct torch angle and distance from the workpiece.

Torch Movement Technique

Recommends steady and controlled movement of the torch handle during welding.

Draft Prevention During Welding

Warns against welding in drafty areas that can affect shielding gas.

Wire Quality and Cleanliness

Stresses keeping wire clean and avoiding rusted wire for better welds.

MIG Gun Cable Care

Advises avoiding sharp bends or kinks in the MIG gun cable.

Wire Liner Cleaning

Suggests cleaning the wire liner with compressed air during spool replacement.

Welder Internal Cleaning

Recommends periodic cleaning of the welder's interior to ensure heat dissipation.

Spot Welding

Spot Welding Capability

States that spot welding is possible with a specific nozzle and provides settings.

Adjustment of the Power Source

Voltage and Stick Out Adjustment

Details setting voltage and achieving the correct wire 'stick out' for welding.

Voltage Setting Adjustment

Advises setting the voltage switch based on material thickness.

Wire Speed Adjustment

Guides on adjusting the wire speed using a trial metal sheet for optimal results.

Torch Switch Functionality

Wire Speed Adjustment Technique

Additional Safety Information

Manual Comprehension for Safety

Emphasizes reading and understanding the entire manual before proceeding.

Regulatory Compliance

Mentions adherence to electrical codes, OSHA, and local regulations.

Welding Safety Standards

Lists various standards for welding safety.

Troubleshooting Information

Troubleshooting Common Problems

Guides users on diagnosing and resolving common welding issues.

Weld Quality Issues

Addresses common weld defects like porosity or brittleness.

Wire Feed Problems

Helps diagnose and fix issues where wire feeding fails.

No Feed, Output, or Gas Flow

Troubleshoots scenarios where no wire feed, output, or gas flow occurs.

No Arc During Wire Feed

Diagnoses why there is no arc despite the wire feeding correctly.

System Power Failure During Operation

Addresses situations where the welder yields no output when the trigger is pulled.

Low Weld Penetration or Output

Helps resolve issues causing low weld penetration or output.

Wire Birdnesting

Provides solutions for wire birdnesting at the drive roller.

Wire Burn Back

Offers remedies for wire burning back to the contact tip.

Overheating Clamp or Cable

Troubleshoots issues causing the workpiece clamp or cable to overheat.

Nozzle Arcing to Work Surface

Provides solutions for the gun nozzle arcing to the work surface.

Wire Pushing Torch Back

Addresses the issue of wire pushing the torch back from the workpiece.

Wire Sticking to Contact Tip

Offers solutions for wire sticking to the contact tip.

General Operating Tips

Contact Tip and Nozzle Maintenance

Advises frequent cleaning of contact tips and nozzles to prevent issues.

MIG Gun Component Inspection

Recommends regular inspection of MIG gun parts for wear or damage.

FP-200 MIG Gun Troubleshooting

Inconsistent Wire Feed

Addresses issues with inconsistent or rough wire feeding.

MIG Gun Overheating

Provides troubleshooting steps for a MIG gun that is running hot.

Porous Weld Diagnosis

Helps diagnose and resolve causes of porous welds.

FP-200 Wire Liner Replacement

Wire Liner Removal Procedure

Outlines the steps to remove the wire liner from the MIG gun.

Wire Liner Installation Procedure

Provides step-by-step instructions for installing a new wire liner.

Firepower Limited Warranty

Warranty Scope

Defines what the warranty covers regarding defects in workmanship or material.

Warranty Exclusions

Lists warranties that are expressly excluded from the product warranty.

Warranty Period

Specifies the duration of the limited warranty for the welding equipment.

Specific Product Warranty Durations

Details specific warranty periods for different Firepower product categories.

Limited Warranty Claim Method

Limitation of Liability

Warranty Invalidity Conditions

Firepower FP-130 Specifications

General IconGeneral
BrandFirepower
ModelFP-130
CategoryWelding System
LanguageEnglish

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