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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!

Summary of Contents for FP-100

Page 1: ...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...

Page 2: ......

Page 3: ...lding System 1443 0406 6 Welder Installation 7 Power Source Connection 7 Power Requirements 7 Connection to Power Source 7 Extension Cords applies to FP 100 ONLY 7 Welder Assembly 7 ARC Welding 8 Mach...

Page 4: ...ge Figure 1 Wheel and Handle Installation 8 Figure 2 Welding Positions 11 Figure 3 Workpiece Preparation 11 Figure 4 Shielded Metal Arc Welding 12 Figure 5 Bead Heat Requirement Samples 13 Figure 6 We...

Page 5: ...se and operation Items in this manual that significantly affect safety are identified with the following headings Please read and understand this manual Pay special attention to items identified with...

Page 6: ...PROPERTY DAMAGE Reduce the risk of death injury or property damage from fire or explosion Read understand and follow the following safety instructions Additionally make certain that anyone else who us...

Page 7: ...ntaining zinc mercury chromium graphite lead cadmium or beryllium unless the operator and the people standing in the same area use an air supplied respirator SAFETY INSTRUCTIONS For your safety BEFORE...

Page 8: ...ference by following these suggestions 1 If there is interference in the power source line mount an E M T filter between the power supply and the power source 2 Shorten the output cables of the power...

Page 9: ...of welding with mild steel electrodes This unit is also capable of welding with high carbon steel special alloy steel cast iron and nonferrous such as aluminum The electrode material should correspond...

Page 10: ...Duty Cycle Agency Listing CSA Rated 200 Amps 20 Duty Cycle Maximum Output 235 Amps AC Peak Output Power Settings Shunt 45 235 Amps Power Switch Illuminated On Off Switch Power Cord 6 Ft Power Cord wit...

Page 11: ...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 DO NOT cut o...

Page 12: ...c arc created between the electrode and the workpiece There are two parts to electrodes used for SMAW welding 1 The inner core is a metal rod or wire that should be similar in composition to the base...

Page 13: ...35 AC DC If you have purchased the FP 235 AC DC Model it has two DC outlet plugs marked DC and DC These plugs can be connected in either the DC direct current position or in the DC reverse polarity po...

Page 14: ...handle you will see the amperage indicator located in the sight glass on the amperage setting scale move upward increasing the amperage Stop cranking when you have reached the desired amperage range...

Page 15: ...es For best results position the workpiece so that the bead will run on a flat surface PREPARING THE JOINT For the most effective welding surfaces to be joined must be free of dirt rust scale oil or p...

Page 16: ...de manufacturers make most standard welding electrodes in two basic types 1 Designed to run on welders with High Open Circuit Voltage 2 Designed to run on welders with Low Open Circuit Voltage Most we...

Page 17: ...ill be flat and porous 4 Rod may freeze or stick to the workpiece The rate of travel over the workpiece affects the weld To ensure proper penetra tion and enough deposit of rod move the arc slowly and...

Page 18: ...ng 5 32 Maximum Dial Any Thickness Penetrating DC REVERSE POLARITY WELDING The electrode in DC reverse Polarity DCRP welding is positive and the work surface is negative The current flow is from the w...

Page 19: ...ed by a crisp cracking sound such as a frying egg To lay a weld bead only 2 positions are possible see Figure 6 1 Downward angle work angle 2 In the direction the weld is to be laid travel angle Alway...

Page 20: ...losely spaced ripple WEAVE BEAD The weave bead will deposit metal in a wider space than would normally be possible with the string bead see Figure 9 The weave bead is accomplished by a Weaving from on...

Page 21: ...metal can fall onto or into flammable materials When burning holes the electrode is held perpendicular to the base metal and the arc is rotated in a small cir cle until the base metal becomes soft Pus...

Page 22: ...l oxidize a different rates and the oxidization colors are different Relatively pure iron when heated by the grinding wheel does not oxidize quickly Therefore the sparks are long and fade out on cooli...

Page 23: ...NG AND BRAZING obtainable from your state OSHA office CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from Canadian Standards Association 178 Rexdale Blvd Rexdale Ontario Canada...

Page 24: ...Figure 12 FP 100 21...

Page 25: ...T 1 5 1443 0429 YELLOW PILOT LIGHT SWITCH 16A 250V 1 6 1443 0430 WELDING CABLE 1 7 1443 0431 UPPER PANEL 1 8 1443 0432 LOWER PANEL 1 9 1443 0433 CABLE CLAMP 1 10 1443 0434 SHUNT 1 11 1443 0435 TRANSFO...

Page 26: ...Figure 13 FP 235 23...

Page 27: ...LE 1 12 1443 0461 HAND CRANK KNOB 1 13 1443 0462 SWITCH 32 A 1 14 1443 0463 SHUNT 2 15 1443 0464 WHEELS AXLE 1 16 1443 0465 GREEN PILOT LAMP 220V 1 17 1443 0466 FRONT PANEL 1 18 1443 0467 DINSE PLUG 2...

Page 28: ...Figure 14 FP 235 AC DC 25...

Page 29: ...443 0462 SWITCH 32 A 1 14 1443 0479 TRANSFORMER 60HZ 230V 1 15 1443 0481 CHOKE 1 16 1443 0465 WHEELS AXLE 1 17 1443 0457 INPUT POWER CABLE 1 18 1443 0467 GREEN PILOT LAMP 220V 1 19 1443 0469 FRONT PAN...

Page 30: ...27 Figure 15 FP 100 Wiring Diagram Figure 16 FP 235 Wiring Diagram...

Page 31: ...28 Figure 17 FP 235 AC DC Wiring Diagram...

Page 32: ...lve months after an authorized distributor sells the product to its customer whichever is longer except that in no event will this warranty exceed eighteen months from the date the product is sold fro...

Page 33: ...f action whether in contract or in tort including negligence including but not limited to damage or loss of other property or equip ment loss of profits or revenue cost of capital cost of purchased or...

Page 34: ...426 1888 Canada Canada 44 1257 261755 65 763 4022 52 539 3708 FAX 800 535 0557 905 827 9777 905 827 1111 FAX 44 1257 261756 FAX 65 763 5812 FAX 525 539 1547 FAX 905 827 9797 FAX 905 827 3648 Telex 38...

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