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WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,

operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s best judgement, the

Manufacturer assumes no liability for its use.

Operating Manual Number 0-5122 for:

FirePower 95 Mini MIG System MIG Welder

Part No. 1444-0322

Published by:

Thermadyne Industries Inc.

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermalarc.com

2009 by

Thermadyne Industries Inc.

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage

caused by any error or omission in this Manual, whether such error results from negligence, accident, or

any other cause.

Publication Date: March 19, 2009

Record the following information for Warranty purposes:

Where Purchased:

____________________________________

Purchase Date:

____________________________________

Equipment Serial #:

____________________________________

Содержание Firepower FP-95

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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