Service; Cleaning Of The Unit; Cleaning Of The Feed Rolls; Basic Troubleshooting - Firepower FP 125 Operating Manual & Installation Manual

5.01 Cleaning of the Unit

Periodically remove the right side panel (after disconnecting the
supply cord from the receptacle) and blow out the interior with
clean, dry, compressed air of not more than 25 PSI air pressure.
Do not strike any components with the air hose nozzle.

5.02 Cleaning of the Feed Rolls

Clean the wire groove on the feed roll at frequent intervals. This
cleaning operation can be done by using a small wire brush. To
clean the wire groove, loosen the pressure device and lift the
feedroll pressure arm. Remove all wire from the feedhead. Wipe
off the bearing roll (the "top" roll in the feedhead).

5.03 Basic Troubleshooting

The basic level of troubleshooting is that which can be performed
without special equipment or knowledge, and without removing
the covers from the Power Source.
If major components are faulty, then the Power Source should be
returned to an Accredited Firepower Service Agent for repair.
5.04 Solving Problems Beyond the
Welding Terminals
NOTE!
The general approach to fix Gas Metal Arc
Welding (GMAW) problems is to start at the
wire spool then work through to the MIG
torch. There are two main areas where
problems occur with GMAW:
1. Porosity
When there is a gas problem the result is usually porosity within
the weld metal. Porosity always stems from some contaminant
within the molten weld pool which is in the process of escaping
during solidification of the molten metal.
Contaminants range from no gas around the welding arc to dirt
on the work piece surface. Porosity can be reduced by checking
the following points:
1. Gas cylinder contents and flow meter.
a. Ensure that the gas cylinder is not empty and the
flow meter is correctly adjusted to 20CFM (15 liters
per minute).
2. Gas leaks
a. Check for gas leaks between the regulator/cylinder
connection and in the gas hose to the Power Source.
3. Internal gas hose in the Power Source.
a. Ensure the hose from the solenoid valve to the MIG
torch adaptor has not fractured and that it is con-
nected to the MIG torch adaptor.
Manual 0-5123
ESAB FIREPOWER FP-125,135,165
SECTION 5:

SERVICE

4. Welding in a windy environment.
a. Shield the weld area from the wind or increase the
gas flow.
5. Welding dirty, oily, painted, oxidized or greasy plate.
a. Clean contaminates off the plate.
6. Distance between the MIG torch nozzle and the work
piece.
a. Keep the distance between the MIG torch nozzle and
the work piece to a minimum.
7. Maintain the MIG torch in good working order.
a. Ensure that the gas holes are not blocked and gas is
exiting out of the torch nozzle. Refer to WARNING
below.
b. Do not restrict gas flow by allowing spatter to build
up inside the MIG torch nozzle.
2. Inconsistent wire feed
Wire feeding problems can be reduced by checking the following
points:
1. Wire spool brake is too tight.
a. Feed roller driven by motor in the cabinet will slip.
2. Wire spool brake is too loose.
a. Wire spool can unwind and tangle.
3. Worn or incorrect feed roller size.
a. Use 'U' groove drive feed roller matched to the
aluminum wire size you are welding. Use 'V' groove
drive feed roller matched to the steel wire size you
are welding. Use 'knurled V' groove drive feed roller
matched to the flux cored wire size you are welding.
4. Misalignment of inlet/outlet guides.
a. Wire will rub against the misaligned guides and
reduces wire feedability.
5. Liner blocked with slag.
a. Slag is produced by the wire passing through the
feed roller, if excessive pressure is applied to the
pressure roller adjuster. Slag can also be produced
by the wire passing through an incorrect feed roller
groove shape or size. Slag is fed into the liner where
it accumulates, thus reducing wire feedability.
5-1
WARNING
Disengage the drive roll when testing for
gas flow by ear.
SERVICE