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Victor Enterprise FP-160 manual

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Table of contents for the manual

  • Page 1

    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 . . . PLEASE READ CAREFULL Y![...]

  • Page 2

    T able of Contents page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Prof ile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 3

    page FP-120 P arts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FP-130 P arts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FP-160 P arts List . [...]

  • Page 4

    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. It gi ves instructions on set-up, installatio[...]

  • Page 5

    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 .[...]

  • Page 6

    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. Additionally , make certain that anyone else who uses this welding equipment, or wh[...]

  • Page 7

    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. NEVER perform welding operations in an area con- taining combustible vapors, flammable liquids or explosive d[...]

  • Page 8

    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. W ear a helmet, glov es and shoes with an insu- lating sole. 2. AL W A YS use a welding mask or helmet with the properly tinted protecti ve glass in the shade adequate to the we[...]

  • Page 9

    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. The use of larger diameter wire makes welding dif f icult. The r[...]

  • Page 10

    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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 11

    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 275 amps WELDER INST ALLA TION PO WER SOURCE CONNECTION Po wer Requir ements This welder is designed to operate on a properly grounded 120 volt, 60 H[...]

  • Page 12

    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. 7. Place the po wer source in a well v entilated area. DO NO T obstruct th[...]

  • Page 13

    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. Remove the contact tip and gun nozzle from the MIG gun before starting this p[...]

  • Page 14

    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. Feed rolls installed on the FP 120, FP 130, FP 160 are marked "[...]

  • Page 15

    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. The wire can be one of three types: 1. Solid wire - AL W [...]

  • Page 16

    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. Make sure that the contact is good. 4. Mak e sure that t[...]

  • Page 17

    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 roll has two groov es, one marked by 0.035[...]

  • Page 18

    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).[...]

  • Page 19

    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 . 6. Non-penetrating weld or[...]

  • Page 20

    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 . Regularly inspect the conductor tube, handle, cable hose, and other parts of the MIG gun for abrasio[...]

  • Page 21

    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. 3. Unscre w the wire liner stop from the rear connector plug. 4. Re[...]

  • Page 22

    Figure 8: FP 120 19[...]

  • Page 23

    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 1444-0476 FR ONT P ANEL FRAME 1 7 1444-0477 TORCH GR OMMET 1 8 1444-0478 SWITCH KNOB 1 9 1444-0479 FR ONT P ANEL ADHESIVE PLA TE 1 10 1444-0480 PO TENT[...]

  • Page 24

    Figure 9: FP 130 21[...]

  • Page 25

    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 ONT P ANEL FRAME 1 7 1444-0477 TORCH GR OMMET 1 8 1444-0478 SWITCH KNOB 1 9 1444-0479 FR ONT P ANEL ADHESIVE PLA TE 1 10 1444-0480 PO TENTIOMETER KNOB[...]

  • Page 26

    Figure 10: FP 160 23[...]

  • Page 27

    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 ANEL FRAME 1 7 1444-0477 TORCH GR OMMET 1 8 1444-0478 SWITCH KNOB 1 9 1444-0479 FR ONT P ANEL ADHESIVE PLA TE 1 10 1444-0480 PO TENTIOMETER KNOB 1 11 144[...]

  • Page 28

    25 Figure 11: FP 120 Wiring Diagram[...]

  • Page 29

    26 Figure 12: FP 130 Wiring Diagram[...]

  • Page 30

    27 Figure 13: FP 160 Wiring Diagram[...]

  • Page 31

    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. If an autho- rized distrib utor or the customer of an authorized distrib utor (hereinafter , collecti vely , "Purchase[...]

  • Page 32

    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. Santa Cruze Aloyac Denton TX 76202-1007 Oakville, Ontario L6L5[...]