Instruction/ maintenance manual of the product FP-160 Victor Enterprise
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FP-120, FP-130 and FP-160 MIG W elding System Instruction Manual FORM NO. 0056-1842 EFFECTIVE July 2001 Safety and Operating Instructions F or Y our Safety .
T able of Contents page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Prof ile . . . . . . . . . . . . . . . . . . . . . . . .
page FP-120 P arts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FP-130 P arts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTR ODUCTION This User’ s Guide provides specif ic information about your Firepo wer W elding System. This guide provides pertinent information needed to safely and ef fectiv ely use your Firepower W elding System. The information in this manual applies to specif ic Firepo wer W elding System models.
Indicates that the helmet must be worn during the step(s) that follo w to protect against eye damage and b urns due to flash hazard. Indicates that the possibility of toxic gas hazard exists during operation of the step(s) that follo w . Indicates that the possibility of being burned by hot slag exists during operation of the step(s) that follo w .
IMPR OPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULA T ORS CAN RESUL T IN SERIOUS INJUR Y OR DEA TH! Reduce the risk of injury or death from compressed gasses and equipment hazards. Read, understand and follo w the following safety instructions.
5. Remo ve all combustible materials from the work site. If you can not remov e them, protect them with f ire- proof co vers. NEVER perform welding operations on a container that has held toxic, com- bustible or flammable liquids or vapors.
HEAL TH HAZARDS The welding process can be hazardous to your health. Therefore, follow these precautions: 1. AL W A YS wear protecti ve clothing without pockets and cuf fs.
This unit is also capable of welding with either 0.030 inch (0.8 mm) or 0.035 inch (0.9 mm) flux cored weld- ing wire (FCA W) process. The use of shielding gas is not required for this welding process. Please refer to the instructions pro vided in this manual for proper machine setup.
SPECIFICA TIONS FOR FP 130 WIRE(GMA W/FCA W) WELDING SYSTEM (1444-0306) T ype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 AMP M IG W elding System Input V oltage . . . . . . . . .
Duty Cycle MIG-GUN 10% DUTY 35% DUTY 60% DUTY 100% DUTY MODEL NO. CYCLE CYCLE CYCLE CYCLE 150 230 amps 205 amps 180 amps 140 amps 200 320 amps 290 amps 250 amps 195 amps 300 500 amps 450 amps 400 amps.
3. Assemble the plastic handle as shown in Figure 1. 4. T ools required: Allen Wrench. Be sure that the welder ’s electri- cal power supply cord is not connected while performing this procedure. 5. Install MIG gun per instructions. 6. Install welding wire per instructions.
INST ALLA TION OF THE WELDING WIRE The po wer source is supplied with a spool of .030 MIG W elding Wire. Install the wire into the feeding system by follo wing the instructions belo w and referring to Figure 3. MIG (GMA W) welding applications require argon shielding gas.
When changing the wire diameter being used, or replacing the wire feed roll, be sure that the correct groove for the wire diameter selected is inside, closest to the machine. The wire is driven by the inside groove. Feed rolls are marked on the side identifying the nearest groove.
ti ve pole. When the wire is fed and touches the workpiece, an electric arc is produced. The arc melts the wire that is deposited on the workpiece. MIG welding uses a steel coppered wire as an electrode and an inert gas (CO 2 , CO 2 /Argon mix or pure Ar gon) for protection of the weld pool.
2. Make sure that the polarity of torch and ground cable is correctly set. For gasless welding, the ground cable must be connected to the positiv e ter- minal (+), while the torch must be connected to the ne g- ati ve terminal (-) (see Figure 4). 3. Connect the ground cable to the w orkpiece.
REPLA CEMENT OF THE WIRE SPOOL The welding power source is supplied with a mini wire spool of about 0.5 Kg of 0.024” (0.6mm) diameter wire. When the wire spool is finished it can be replaced with a wire spool of 2 lbs. or 10 lbs. The wire is pushed by a roll which is mov ed by a series of mechanisms.
The torch switch must be pressed thoroughly to perform its three functions: gas flow , wire feed and welding current.) Start welding and decrease the wire speed gradually . Continue to decrease the wire speed and listen to the sound. The sound will change from a crackling noise to a regular and strong buzzing (similar to the sound of frying bacon).
P R OBLEM 1. Dirty , porous or brittle weld. 2. Arc works but is not feeding wire. 3. When trigger pulled, there is no wire feed, weld output or gas flo w . Fan does not operate. 4. W ire feeding, but there is no arc. 5. F an operates normally , but when gun trigger pulled, there is no wire feed, weld output or gas flow .
GENERAL OPERA TING TIPS Contact tips and nozzles should be cleaned frequently . Spatter b uildup may cause bridging between nozzle and tip.This could cause electrical shorting between the nozzle and work piece as well as poor or improper gas flo w .
FP-200 WIRE LINER REPLA CEMENT T o remov e the wire liner: 1. Lay the MIG gun out on a table or on the floor in a straight line. Make sure the gun is fully extended and all twists in the cable are removed. 2. Remo ve the nozzle, dif fuser , contact tip and the left gun handle case.
Figure 8: FP 120 19.
ITEM NO. P ART NO. DESCRIPTION QTY . 1 1444-0433 INPUT POWER CABLE 1 2 1444-0428 CABLE CLAMP 2 3 1444-0473 HANDLE 1 4 1444-0474 SIDE P ANEL MIG 100 FP 1 5 1444-0435 PLASTIC HINGE FOR SIDE P ANEL 2 6 1.
Figure 9: FP 130 21.
ITEM NO. DESCRIPTION QTY . 1 1444-0433 INPUT POWER CABLE 1 2 1444-0428 CABLE CLAMP FOR HOLE 2 3 1444-0473 HANDLE 1 4 1444-0474 SIDE P ANEL 1 5 1444-0435 PLASTIC HINGE FOR SIDE P ANEL 2 6 1444-0476 FR .
Figure 10: FP 160 23.
ITEM NO. DESCRIPTION QTY . 1 1444-0463 INPUT POWER CABLE 1 2 1444-0428 CABLE CLAMP 2 3 1444-0473 HANDLE 1 4 1444-0474 SIDE P ANEL 1 5 1444-0435 PLASTIC HINGE FOR SIDE P ANEL 2 6 1444-0478 FR ONT P ANE.
25 Figure 11: FP 120 Wiring Diagram.
26 Figure 12: FP 130 Wiring Diagram.
27 Figure 13: FP 160 Wiring Diagram.
28 FIREPO WER LIMITED W ARRANTY SCOPE OF LIMITED W ARRANTY : Firepower , a division of Thermadyne Industries, Inc. (here- inafter , "Seller") warrants that its products are free of defects in workmanship or material.
U.S.A. International Canada Europe Asia/Pacific PTE, Ltd. Mexico Customer Service Customer Service Customer Service Europa Building Hillview House Unites 401-403 Calle de Zaragoza #25 P . O. Box 1007 2070 Wyecroft Road 2070 Wyecroft Road Chorley North Industrial Park 1 Jalan Remaja Col.
An important point after buying a device Victor Enterprise FP-160 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Victor Enterprise FP-160 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Victor Enterprise FP-160 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Victor Enterprise FP-160 you will learn all the available features of the product, as well as information on its operation. The information that you get Victor Enterprise FP-160 will certainly help you make a decision on the purchase.
If you already are a holder of Victor Enterprise FP-160, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Victor Enterprise FP-160.
However, one of the most important roles played by the user manual is to help in solving problems with Victor Enterprise FP-160. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Victor Enterprise FP-160 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
