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Summary of Contents for BOC Firefly 130XP
- Page 1 OM-1316 186 229F March 2000 Processes MIG (GMAW) Flux Cored (FCAW) Description Wire Feeder Firefly 130XP...
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. -
Page 5: Section 1 - Safety Precautions - Read Before Using
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message. - Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. -
Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité... - Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité... -
Page 12: Principales Normes De Sécurité
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. -
Page 13: Section 2 - Specifications
SECTION 2 – SPECIFICATIONS 2-1. Specifications Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage Output Range W/ Gun Dimensions 115 V, 60 Hz, Single- Phase Length: 17 in (432 mm) 90 A @ 18 Volts DC, 69 lb Width: 10 in 30 –... -
Page 14: Welding Gun Duty Cycle And Overheating
2-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Definition .023 To .045 in (0.6 To 1.1 mm) -
Page 15: Section 3 - Installation
SECTION 3 – INSTALLATION 3-1. Selecting A Location Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-de- lay fuses or circuit breaker is re- quired. 18 in (460 mm) Plug From Unit Select extension cord of 12 AWG for up to 75 ft (23 m) or 10 AWG for up to 140 ft (46 m). -
Page 16: Installing Welding Gun And Changing Polarity
3-3. Installing Welding Gun And Changing Polarity Drive Assembly Gun Securing Nut Gun End Loosen securing nut. Insert gun Follow wire manufacturer’s recommendation. end through opening until it bottoms against drive assembly. Tighten Solid Steel Or nut. Aluminum Wires Flux Cored Wires Gun Trigger Plug (GMAW–With Gas) (FCAW–Without Gas) -
Page 17: Installing Gas Supply
3-4. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- Tools Needed: ary support so cylinder cannot fall and break off valve. 5/8, 1-1/8 in Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. -
Page 18: Installing Wire Spool And Adjusting Hub Tension
3-5. Installing Wire Spool And Adjusting Hub Tension 1 Lb Wire Spool Standard Wire Spool Standard Wire Reel Part No. 135 615 Part No. 183 312 When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in S-0499 OM-1316 Page 14... -
Page 19: Installing Drive Roll, Wire Guide And Threading Welding Wire
3-6. Installing Drive Roll, Wire Guide And Threading Welding Wire Tools Needed: Drive roll Choose correct drive roll for wire type, and align drive roll with flat spot on shaft. Slide drive roll onto shaft and secure with screw. Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of... -
Page 20: Weld Parameter
3-7. Weld Parameter Material Thickness Wire Type, Wire Operator Shielding Gas, Diameter 3/16 in 1/8 in Controls And Flow Rate (inch) (4.8 (3.2 14 ga 16 ga 18 ga 20 ga 22 ga 24 ga Voltage Tap* –– .023 Wire Speed ––... -
Page 21: Section 4 - Operation
SECTION 4 – OPERATION 4-1. Controls Wire Speed Control Use control to select a wire feed speed. As Voltage switch setting in- creases, wire speed range also in- creases (see weld setting label in welding power source). Voltage Switch (5 Position) Switch must “click”... -
Page 22: Section 5 - Maintenance &Troubleshooting
SECTION 5 – MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Repair or Clean unreadable replace tighten weld labels. cracked terminals. weld cable. 6 Months Remove drive roll Blow out or and apply light coat vacuum inside. -
Page 23: Cleaning Or Repairing Drive Assembly
5-4. Cleaning Or Repairing Drive Assembly Y Turn power before Tools Needed: cleaning or repairing drive assembly. 5/64 in Wire Spool Nozzle Cut welding wire off at nozzle. Re- tract wire onto spool and secure. Pressure Roll Arm Cotter Pin Screw Bearing Remove bearing. -
Page 24: Replacing Gun Contact Tip
5-5. Replacing Gun Contact Tip Y Turn power before replacing contact tip. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: Ref. 802 399-A OM-1316 Page 20... -
Page 25: Cleaning Or Replacing Gun Liner
5-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit. 3/8 in Head Tube Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. 1/2 in Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Insert new liner. -
Page 26: Replacing Switch And/Or Head Tube
5-7. Replacing Switch And/Or Head Tube Y Disconnect gun first. Remove handle locking nut. Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure. -
Page 27: Troubleshooting Table
5-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-1). does not run. Replace building line fuse or reset circuit breaker if open. Secure gun trigger plug in receptacle (see Section 3-3). Place Power switch in On position (see Section 4-1). -
Page 28: Section 6 - Electrical Diagram
SECTION 6 – ELECTRICAL DIAGRAM SB-186 204 Figure 6-1. Circuit Diagram OM-1314 Page 24... -
Page 29: Section 7 - Mig Welding (Gmaw) Guidelines
SECTION 7 – MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/... -
Page 30: Typical Mig Process Control Settings
7-2. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or Convert Material .125 in Thickness to... -
Page 31: Holding And Positioning Welding Gun
7-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece... -
Page 32: Conditions That Affect Weld Bead Shape
7-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long... -
Page 33: Gun Movement During Welding
7-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead – Steady Movement Along Seam Weave Bead –... -
Page 34: Troubleshooting - Excessive Spatter
7-8. Troubleshooting – Excessive Spatter Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. -
Page 35: 7-11.Troubleshooting - Lack Of Penetration
7-11. Troubleshooting – Lack Of Penetration Lack Of Penetration – shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. -
Page 36: 7-14.Troubleshooting - Waviness Of Bead
7-14. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. - Page 37 7-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
- Page 38 SECTION 8 – PARTS LIST Hardware is common and not available unless listed. ST-801 863-B Figure 8-1.Complete Assembly OM-1316 Page 34...
- Page 39 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly ....126 838 DRIVE ASSEMBLY, wire (consisting of) .......
- Page 40 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly ....026 843 INSULATOR, vinyl ..........
- Page 41 Item Part Description Quantity Figure 8-2. M-10 Gun ..169 715 NOZZLE, slip type .500 orf flush ......... . . ♦087 299 .
- Page 43 Warranty Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or warranties expressed or implied. Consumable components;...
- Page 44 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment...
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