Firepower FP-235 User Manual

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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 . . .

PLEASE READ

CAREFULLY!

Table of Contents3
Introduction5
Safety Profile5
Safety Information5
Safety Symbols5
General Welding Safety Instructions7
- Location7
- Personal Protection7
- Safety Instructions7
- Fire Prevention7
- Ventilation8
- Electromagnetic Compatibility8
- Health Hazards8
- Electric Shock8
Welder Specifications9
Welder Operating Characteristics9
Internal Thermal Overload Protection (FP-100 ONLY)9
- Specifications for FP-100 Arc(SMAW) Welding System (1443-0402)10
- Specifications for FP-235 Arc(SMAW) Welding System (1443-0404)10
- Specifications for FP-235 AC/DC Arc(SMAW) Welding System (1443-0406)10
Welder Installation11
- Power Source Connection11
Welder Assembly11
Figure 1: Wheel and Handle Installation12
ARC Welding12
Machine Operation13
- AC Output Connections (FP-235 and FP-235 AC/DC)13
- DC Output Operations (FP-235 AC/DC)13
Selecting AC or DC Welding Output13
AC Current Welding13
Direct Current Welding14
Adjusting Amperage/Increasing Amperage14
- Lowering the Amperage14
Preparations for Welding14
Figure 2:Welding Positions15
Figure 3: Workpiece Preparation15
Welding Positions15
Preparing the Joint15
Ground Clamp Connection16
Selecting the Electrode16
- High Vs. Low Voltage Electrodes16
- Figure 4: Shielded Metal Arc Welding16
Selecting the Proper Amperage17
Welding Parameters17
- AC Welding17
- Figure 5: Bead Heat Requirement Samples17
- DC Straight Polarity Welding18
- DC Reverse Polarity Welding18
Learning to Weld19
Arc Welding Techniques19
Figure 6: Weld Angles19
Figure 7: Weld Appearance19
Striking the Arc19
Types of Commonly Used Weld Beads20
- Stringer Bead20
- Weave Bead20
Finishing the Bead20
Figure 8: Stringer Bead20
Figure 9: Weave Bead20
Special Applications21
- Burning Holes21
- Cutting21
- Recognizing Metals21
- Magnetic Test21
- Figure 10: Triple Pass Cutaway21
- Figure 11: Triple Pass Welds21
- Color Test22
- Spark Test22
Additional Safety Information22
Troubleshooting Information24
Figure 12: FP-100 Parts Breakdown25
Figure 13: FP-235 Parts Breakdown27
Figure 14: FP-235 AC/DC Parts Breakdown29
Figure 15: FP-100 Wiring Diagram30
Figure 16: FP-235 Wiring Diagram30
Figure 17: FP-235 AC/DC Wiring Diagram31
Firepower Limited Warranty33

Brand	Firepower
Model	FP-235
Category	Welding System
Language	English

Firepower FP-235 User Manual

Table of Contents

Firepower FP-235 Specifications

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