Thermal Arc Firepower FP-95 Operating Manual Download Page 1

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115

Art # A-09089

MINI MIG

Portable MIG Welder

FP-95

operating

Manual

Revision: AA

Issue Date: March 19, 2009

Manual No.: 0-5122

Operating Features:

Summary of Contents for Firepower FP-95

Page 1: ...95 115 1 Art A 09089 MINI MIG Portable mig Welder FP 95 Operating Manual Revision AA Issue Date March 19 2009 Manual No 0 5122 Operating Features...

Page 2: ...recautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide ThermalArci...

Page 3: ...603 298 5711 www thermalarc com Copyright 2009 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited...

Page 4: ...Duty Cycle 2 4 2 09 MIG Gun Maintenance 2 4 SECTION 3 INSTALLATION 3 1 3 01 Location 3 1 3 02 Safety 3 1 3 03 Grounding 3 1 3 04 Electrical Input Requirements 3 1 3 05 Requirements for Maximum Output...

Page 5: ...ed Rolls 5 1 5 03 Basic Troubleshooting 5 1 5 04 Welding Problems 5 2 5 05 Power Source Problems 5 3 APPENDIX 1 OPTIONS AND ACCESSORIES A 1 APPENDIX 2 power supply replacement parts A 2 APPENDIX 3 FIR...

Page 6: ...This Page Intentionally Blank...

Page 7: ...14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from...

Page 8: ...where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert that welding...

Page 9: ...harmful exhaust gases 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes WARNING ENGINE FUEL can cause...

Page 10: ...offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or...

Page 11: ...c Welding GMAW Increase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground...

Page 12: ...ment des galets d entrainement et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux 1 N...

Page 13: ...e d graissage de nettoy age ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants 7 Ne soudez des t les galvanis es ou...

Page 14: ...m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approu v es Des crans lat raux sont recommand s 2 Portez des v...

Page 15: ...nt de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT S...

Page 16: ...e Intensit de Courant Tension Hertz cycles sec Fr quence N gatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art...

Page 17: ...ed below and clicking on the Literature Library link http www thermalarc com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually...

Page 18: ...pe 5 15P Nominal Input Voltage 120V AC Rated Input Current 15A Rated kVA 100 Duty Cycle 1 2kVA Rated Input Current 15A 60A 20 Maximum Input Current 28A 85A 17 Generator Requirements 98145 4519 98145 4...

Page 19: ...any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improvements or replacement of such items...

Page 20: ...amps for1 7 minutes out of every 10 minute period During the other 8 3 minutes of the 10 minute period the FirePower FP 95 must idle and be allowed to cool The thermal cutout will operate if the duty...

Page 21: ...r circuit breaker mains receptacle capable of handling a minimum of 20 Amperes The Firepower FP 95 requires a 120VAC supply voltage SECTION 3 INSTALLATION The Firepower FP 95 s power cord is equipped...

Page 22: ...105 2 5mm in thickness The rated output with this installation is 85 amperes 18 25 Volt 17 duty cycle 1 minute 40 seconds out of every 10 minutes used for welding 3 06 Installing Wire Spool As delive...

Page 23: ...d from the power receptacle Do not plug machine in until told to do so in these instructions If Not Installed Load the Wire Spool per directions in sec tion 3 06 onto the hub so that the wire will fee...

Page 24: ...Arm Fig 3 5 7 Close the Pressure Adjust Device Tighten it to a snug condition Fig 3 6 8 Figure 3 6 shows the result with the wire installed NOTE If there is too much pressure on the drive roll the wir...

Page 25: ...piece the electrode wire is electrically hot when the gun switch is activated 5 Activate the gun switch until the wire feeds out past the gun nozzle and deactivate the gun switch Contact Tip Nozzle Gu...

Page 26: ...firepower FP 95 INSTALLATION Manual 0 5122 3 6 Installation This Page Intentionally Blank...

Page 27: ...s and Warnings chapter included in this manual Neglect of these precautions may result in personal injury WARNING Make all connections to the power source including electrode and work cables as well a...

Page 28: ...ved roller via screw adjustable spring pressure The adjustable spring screw should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage If slip ping occurs and i...

Page 29: ...nual 0 5122 FP 95 MIN MAX v RATED OUTPUT VOLTS 17 3 AMPS 90 DUTY CYCLE 16 MAX OCV 27 AMP RANGE 23 90 CSA 21 60 20 27 23 90 120V Wire Feed Welder Welds 22 gauge to 1 8 3 2mm Mild Steel 1 Art A 09064 3...

Page 30: ...ter releasing the gun switch the electrode wire will remain electrically hot for several seconds 4 05 Basic Welding Technique General Two different welding processes are covered in this section with t...

Page 31: ...the instructions in the Installation chapter Check List Before Starting Wire Feed Speed 1 to 10 Voltage Range Switch Setting MIN or MAX Electrode Wire Stick out approx 3 8 10mm 4 06 Welding Gun Posit...

Page 32: ...manual 4 09 Welding Procedure 1 Maintain the tip to work distance stickout at 5 16 to 3 8 8 to 9mm at all times 2 For transverse and longitudinal nozzle angles see section 4 06 Welding Gun Positions...

Page 33: ...iling Max 25 2 Decrease 4 Smaller Shallower Penetration 1 Decrease 3 Leading 2 Increase 4 Larger Larger Bead 1 Increase 2 Decrease 3 Increase Smaller Bead 2 Decrease 2 Increase 3 Decrease Higher Narro...

Page 34: ...Steel Flux Core E71T GS None Required 030 0 8mm 035 0 9mm Material Type Wire Type Shielding Gas and Flow Rate Wire Size Diameter 24 ga 0 6mm 22 ga 0 7mm 20 ga 0 9mm 18 ga 1 2mm 16 ga 3mm 1 8 3 2mm TH...

Page 35: ...torch nozzle and the work piece a Keep the distance between the MIG torch nozzle and the work piece to a minimum SECTION 5 SERVICE 2 Inconsistent wire feed Wire feeding problems can be reduced by chec...

Page 36: ...he voltage selection switch or reduce wirespeed control 5 Irregular weld shape A Incorrect voltage and current settings Convex voltage too low Concave voltage too high A Adjust voltage and current by...

Page 37: ...faulty component s B Faulty control PCB B Have an Accredited THERMAL ARC Service Agent in vestigate the fault 4 Wire feeds when the MIG Gun trigger switch is depressed but arc can not be established P...

Page 38: ...firepower FP 95 SERVICE Manual 0 5122 5 4 Service This Page Intentionally Blank...

Page 39: ...e Feed Rolls MIG Gun Consumables Part No Description 1444 0427 Wire Feed Roll Knurle 023 030 035 0 6 0 8mm 0 9mm Hard Cored 1444 0050 Nozzle 1444 0026 Contact Tip 030 0 8mm 1444 0027 Contact Tip 035 0...

Page 40: ...CABLE FP 95 1444 0724 11 EARTH CLAMP FP 95 1443 0025 12 FRONT FRAME FP 95 1444 0829 13 HANDLE FP 95 1444 0827 14 KIT SPOOL HOLDER FOR D 16 SPOOLS COMP 1444 0801 15 LEFT SIDE PANEL FP 95 W SILKS 1444 0...

Page 41: ...D OUTPUT VOLTS 17 3 AMPS 90 DUTY CYCLE 16 MAX OCV 27 AMP RANGE 23 90 CSA 21 60 20 27 23 90 120V Wire Feed Welder Welds 22 gauge to 1 8 3 2mm Mild Steel 22 5 3 15 13 25 8 19 6 21 17 16 10 11 18 23 9 20...

Page 42: ...firepower FP 95 APPENDIX Manual 0 5122 A 4 Appendix APPENDIX 3 FIREPOWER 95 SYSTEM SCHEMATIC Art A 09025 Figure A 3 FP 95 Simple System Schematic...

Page 43: ...Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE with respect to any contract or anything done in connection therewith s...

Page 44: ...400MSTP Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards Power Switch Semi Conductors 3 years 3 years All Other Original Circuits and Components Includi...

Page 45: ...strict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul E...

Page 46: ...World Headquarters Thermadyne Holdings Corporation Suite 300 16052 Swingley Ridge Road St Louis MO 63017 Telephone 636 728 3000 FAX 636 728 3010 Email sales thermalarc com www thermalarc com...

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