Related Manuals for Firepower FP-90
Summary of Contents for Firepower FP-90
- Page 1 FP-90 Gasless Welding System (FCAW) Instruction Manual FORM NO. 0056-1839 EFFECTIVE: July 2001 Safety and Operating Instructions For Your Safety . . . PLEASE READ CAREFULLY!
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Page 3: Table Of Contents
Specifications for FP-90 Gasless Welding System (1444-0302) ........ - Page 4 Troubleshooting Guide for Firepower FP-150 MIG Gun ........
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Page 5: Introduction
SAFETY INFORMATION The following safety information is provided to you as a guideline. Use it to operate your new Firepower Welding System under the safest possible conditions. Any equipment that uses electrical power is potentially dangerous to use when the safety or safe handling instructions are not known and/or are not followed. - Page 6 Indicates that the helmet must be worn during the step(s) that follow to protect against eye damage and burns due to flash hazard. Indicates that the possibility of toxic gas hazard existed during operation of the step(s) that follow. Indicates that the possibility of being burned by hot slag exists during operation of the step(s) that follow.
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Page 7: General Welding Safety Instructions
IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH! Reduce the risk of injury or death from compressed gasses and equipment hazards. Read, understand and follow the following safety instructions. Additionally, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area, understands and follows these safety instructions as well. -
Page 8: Ventilation
7. Clean the welding pieces from solvents or alogenous grease which develop toxic gases when exposed to heat. WELDER SPECIFICATIONS Your new Firepower Flux Core (FCAW) Wire Welding System is designed for maintenance and sheet metal fabrication. The unit consists of a single-phase power transformer power source, arc stabilizer, rectifier and heavy-duty wire feed system. -
Page 9: Welder Operating Characteristics
MIG Gun ........ -
Page 10: Assembling The Welder
Avoid contacts with wires or parts. DO NOT work with the side panels partially opened or removed completely from the power source. The FP-90’s MIG gun torch is a “live” contact gun and is ALWAYS IN THE POWER-ON POSITION. Wear Eye protection at all times when handling this MIG gun. -
Page 11: Extension Cords
Connection to Power Source High voltage danger from power source! Consult a qualified electri- cian for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician. -
Page 12: Welding Torch
Replace them when they are worn and compromise the regular feeding of the wire. The FP-90’s welding torch is a “live” contact torch and is ALWAYS in the power on position. Wear eye protection at all times when handling this torch. -
Page 13: Preparation For Welding
3. Welding time is about 50% less compared to the normal electrode welding. 4. The learning time for the operator is very short. 5. Minimum waste of welding material. 6. Most important, this process allows to complete the welding more quickly and efficiently.. 7. -
Page 14: Welding Tips
2. Adjust the wire speed. Start using a trial metal sheet thoroughly cleaned of layers of rust or paint. Connect the ground cable to the workpiece. Adjust the wire speed at the high setting. Press the torch switch. The FP-90’s welding torch is a “live” con- tact torch and is ALWAYS IN THE POWER ON POSITION. -
Page 15: Selecting Wire
start from a higher wire speed. This operation prevents damage to the contact tip during welding. During welding, keep the torch at a 45º angle from the workpiece. SELECTING WIRE WIRE DIAMETER SELECTION Using a wire that is too small in diameter causes excessive weld spatter and weld heat. Wire that is too large causes wire stubbing. -
Page 16: Selecting Welding Current Polarity
SELECTING WELDING CURRENT POLARITY Using gas-shielded steel welding wire requires direct current (dc) reverse polarity. Self-shielding flux cored wires use direct current straight polarity. Depending on the type of wire you are using, the polarity may have to be converted. Some welders DO NOT have the capability of changing the polarity. -
Page 17: Figure 6: Workpiece Preparation
2. Aluminum is often anodized to prevent oxidation. However, an anodized surface will NOT conduct electric- ity. Therefore, to weld anodized aluminum, you MUST sand or grind the anodized coating from the weld joint area and from the site where the workpiece clamp will be connected. Determine whether or not the aluminum you intend to weld is anodized. -
Page 18: Workpiece Clamp Connection
WORKPIECE CLAMP CONNECTION Connect the workpiece clamp directly to the work piece as close to the weld as possible. If it is impractical to connect the workpiece clamp directly to the workpiece, connect it to the metal that is securely attached to the workpiece, but not electrically insulated from it. -
Page 19: Learning To Weld
LEARNING TO WELD Whether you have welded before or not, it is important that you become familiar with your new welder, its controls and the results achieved at different settings. We strongly recommend that you practice with your new welder on scrap metal. Try different heat settings, base metal thicknesses and welding positions for each type and size of wire that you will use. -
Page 20: Laying A Bead
LAYING A BEAD EXPOSURE TO WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN! Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected. Wear flameproof welding gloves, a heavy long-sleeved shirt, cuffless trousers, high-topped shoes and a welding helmet. -
Page 21: Welding Positions
There are two basic types of weld beads: the stringer bead and the weave bead. 1. Form the stringer bead (see Figure 11) by travel- ing with the line while keeping the wire and nozzle centered over the weld joint. It is the eas- iest type of bead to make and is the type you have used up to this point. -
Page 22: Multiple Pass Welding
falling into the nozzle should it drip from the weld puddle. Hold angle B at 0º so that the wire is aiming directly into the weld joint. If the weld puddle drips excessively, select a lower heat setting. Also, the weave bead tends to work better than the stringer bead when welding overhead. -
Page 23: Spot Welding Instructions
2. The punch and fill method produces a weld with the most finished appearance. In this method, a hole is punched or drilled into the top piece of metal. The arc is directed through this hole to penetrate into the bot- tom piece. -
Page 24: Additional Safety Information
ADDITIONAL SAFETY INFORMATION Make sure you read and understand all of the information and instructions contained in this manual BEFORE proceeding. The National Electrical Code, Occupational Safety and Health Act (OSHA) regulations, local industrial codes and local inspection requirements also provide a basis for equipment installation, use and service. For additional information concerning welding safety, refer to the following standards and comply with them as applicable. -
Page 25: Troubleshooting Information
TROUBLESHOOTING INFORMATION Use this chart to assist you in resolving common problems you may encounter. These are not all of the possible solutions. ROBLEM OSSIBLE AUSE EMEDY 1. Dirty, porous or brittle weld. Plugged welding nozzle. Clean or replace welding nozzle. 2. -
Page 26: Firepower Fo-150 Mig-Gun Parts Listing
Regularly inspect the conductor tube, handle, cable hose, and other parts of the MIG-Gun for abrasion, cuts, or undue wear. Replace or repair any parts found deficient. TROUBLESHOOTING GUIDE FOR FIREPOWER FP-150 MIG GUN ROBLEM OSSIBLE... -
Page 29: Figure 22: Fp-90 Wiring Diagram
Figure 22: FP-90 Wiring Diagram... -
Page 31: Firepower Limited Warranty
• 2 years on the welding unit • 1 year on the MIG gun • Firepower engine-driven welding machines will be covered by a one-year (parts & labor) warranty. Engines will be covered by the manufacturer's warranty. • Firepower ADF (auto-darkening) welding helmets will be covered by a one-year warranty. Any ADF helmet claims must be made directly to Jackson / Morsafe products, Belmont, MI, 800-253-7281. - Page 32 LIMITATION OF LIABILITY: Seller shall not, under any circumstances, be liable for special, indirect, inci- dental or consequential damages (regardless of the form of action, whether in contract or in tort including neg- ligence), including, but not limited to, damage or loss of other property or equipment, loss of profits or rev- enue, cost of capital, cost of purchased or replacement goods, or claims of Purchaser for service interruption.