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140 MP
OWNER’S MANUAL
CAT#00322 MULTI-PROCESSOR
FEATURES:
• A Multi-Process inverter machine capable of
MIG, Stick, or TIG Welding
• Power saving and versatile inverter technology allows for use with 115V (20A OR 15A input)
• Welding range up to 140 Amps
• Can be used for Steel, Stainless Steel, and
Aluminum
• Easy to change between welding processes
• 12’ Premium MIG torch with Euro disconnect and Tweco ® style consumables
RELIABLE TECHNOLOGY:
• Advanced synergic electronics allow for outstanding arc control for all processes
• Metallic heavy-duty wire drive system
• Optional spool gun increases flexibility
• Large cabinet with easy access to 4” and 8” spools
• Digital readouts
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IDEAL FOR:
General Fabrication, Auto Body, Farm & Ranch,
Maintenance, Sheet Metal, Contractor, and More...
INCLUDES:
MIG Torch with 12’ lead; Ground Cable and Clamp;
Stick Electrode Holder; 8’ Power Cable; Gas Hose and
Regulator
LR114649
STOP PLEASE!
DO NOT RETURN
TO THE STORE
If you have questions or problems with your new Welder, please call customer service at
1-800-521-6038
Monday through
Friday from 7am-5pm Mountain Time or at www.forneyind.com/customer_service.
Please take time to register your product at www.forneyind.com/customer_service/register_your_product/.
This qualifies you for our industry leading 5/3/1 warranty.
Thank you, enjoy your new Welder.
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FIVE WAYS TO ORDER
Web: www.forneyind.com
Phone: 800-521-6038
Fax: 970-498-9505
Mail: Forney Industries
1830 Laporte Avenue
Fort Collins, CO 80521
Email: [email protected]
Forney Promise
We are committed to your success regardless of location, size or needs. We understand it is your goal to get the job done right, and we are ready to help you do just that.
U.S. Warehouses:
- Fort Collins CO
- Tipp City OH
President's Message
We market the highest quality tools, equipment and accessories for the do-it-yourselfer and professional. Our passion and dedication in bringing new products to the industrial and retail market, combined with our personal service, is unmatched in our industry. Our ability to listen to our customers’ needs enables us to create solutions to their problems.
Our dedication to the highest quality customer service within our corporate headquarters and the service provided in the field is unequaled. We are committed to creating the best solutions to our customer’s needs. Above all, our employees will provide the same respect and caring attitude within the organization as they are expected to share with every Forney customer. Our goal will be to exceed our customers’ expectations through empowered people, guided by shared values and commitments.
We work hard so our customers trust us because of our integrity, teamwork and innovation of Forney products, and Forney’s
80 years of unmatched product quality and an unwavering commitment to our customers.
When our customers succeed we succeed.
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Copyright© 2014 Forney Industries,
Inc. All rights reserved. Unauthorized reproduction and/or distribution is subject to US copyright laws.
STEVEN G. ANDERSON, President & CEO
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Forney 5/3/1 Limited Warranty
Effective August 1st, 2009
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1) Limited Warranty: Subject to the terms and conditions below, Forney Industries, Inc., Fort Collins,
Colorado, warrants to its original retail purchaser that the new Forney equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Forney. This is in lieu of all other warranties, express or implied.
2) Notification: Please call 1-800-521-6038 with your warranty questions. You can also visit www.
forneyind.com for additional information about your new welder.
3) Length of Warranty: Within the warranty periods listed below, Forney will repair or replace any warranted parts or components that fail due to defects in material or workmanship. Warranty is effective from the date of original retail purchase. Warranty duration is as follows:
A) 5 years: Original main power rectifiers only to include SCRs, diodes and discrete rectifier modules, transformers, stabilizers and reactors.
B) 3 years: Drive Systems, PC Boards, Motors, Switches and Controls.
C) 1 year: MIG guns, relays, contractors and regulators, plasma cutting torches, and accessories.
D) 90 days: Replacement parts. Does not include labor.
4) Non-Applicable Parts: Forney’s limited warranty shall not apply to consumables such as contact tips, cutting nozzles, felt wire cleaner, drive rollers, gas diffusers, plasma torch tips and electrodes, weld cables, tips and parts that fail due to normal wear. In addition, this warranty does not extend to any damage caused by the untimely replacement or maintenance of any of the previously listed consumable parts.
5) Warrantor:
Forney Industries
1830 Laporte Avenue
Fort Collins, CO 80521
1-800-521-6038 www.forneyind.com.
6) Purchaser / Warranty: The original purchaser of the Forney Industries product. The warranty is not transferable. Forney Industries products are intended for purchase and use by persons trained and experienced in the use and maintenance of welding equipment.
7) What is not covered under the warranty:
A) Implied warranties, including those of merchantability and fitness for a particular purpose are limited in duration to this express warranty. After this period, all risks of loss, from whatever reason, shall be on the purchaser.
B) Any incidental, indirect, or consequential loss, damage, or expense that may result from any defect, failure or malfunction of the Forney product.
C) Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with instructions provided in the owner’s manual(s) supplied with the product.
D) Pre-delivery service, i.e. assembly and adjustment.
8) Claim: In the event of a warranty claim under this warranty, the exclusive remedies shall be, at Forney
Industries sole option:
A) Repair; or
B) Replacement; or
C) Where authorized in writing by Forney Industries, the cost of repair or replacement at an authorized
Forney Industries Service Center; or
D) Payment of or credit for the purchase price less reasonable depreciation based on actual use upon the return of the goods at the customer’s risk and expense.
9) Purchaser will:
A) Contact Forney’s Customer Service at 1-800-521-6038 within 30 days of the defect or failure.
B) Provide dated proof of purchase (typically a purchase receipt).
C) Provide the serial number. Registering your welder at registration.forneyind.com:442 will speed up this process.
D) Deliver or ship welder to a Forney authorized Service Center. Freight &/or packaging costs, if any, must be borne by the purchaser.
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TABLE OF CONTENTS
WARRANTY .................................................................................................................................. 4
TABLE OF CONTENTS .................................................................................................................... 5
SAFETY PRECAUTIONS .................................................................................................................. 6
INSTALLATION RECOMMENDATIONS ............................................................................................. 9
ASSEMBLY .................................................................................................................................. 11
FRONT PANEL OPERATION.......................................................................................................... 12
GENERAL OPERATION INSTRUCTIONS ......................................................................................... 16
TROUBLESHOOTING ................................................................................................................... 26
SPARE PARTS AND DIAGRAMS .................................................................................................... 27
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CAUTION!
BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE ON THE 270 WELDER,
READ THE CONTENTS OF THIS MANUAL CAREFULLY, PAYING PARTICULAR ATTENTION TO THE
SAFETY RULES AND HAZARDS.
In the event of these instructions not being clear, please contact your
Forney Authorized Dealer or Forney Customer Service 1-800-521-6038
Safety Information
READ BEFORE USING
Principal Safety Standards
• Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 8669 Doral
Boulevard, suite 130, Doral, FL 33166 Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.
• Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have
Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American
Welding Society, 8669 Doral Boulevard, suite 130, Doral, FL 33166
• National Electrical Code, NFPA Standard 70, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
• Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
• Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
• Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.
• Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
EMF Information
Considerations about Welding or Cutting and the Effects of Low Frequency Electric and Magnetic Fields
Welding or cutting current, as it flows through the welding or cutting cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-frequency electric and a magnetic field is a human health hazard.” However, studies are still going forth and evidence continues to be examined.
Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep cutting power source and cables as far away from operator as practical.
5. Connect work clamp to work piece as close to the cut as possible.
About Pacemakers & Hearing Aides:
Pacemaker & Hearing Aide wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.
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Personal Protection
Welding processes of any kind can be dangerous not only to the operator but to any person situated near the equipment, if safety and operating rules are not strictly observed.
Arc rays can injure your eyes and burn your skin. The welding arc produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
• Wear closed, non-flammable protective clothing, without pockets or turned up trousers, gloves and shoes with insulating sole and steel toe. Avoid oily greasy clothing.
• Wear a non-flammable welding helmet with appropriate filter lenses designed so as to shield the neck and the face, also on the sides. Keep protective lens clean and replace them when broken, cracked or spattered. Position a transparent glass between lens and welding area.
• Weld in a closed area that does not open into other working areas.
• Never look at the arc without correct lens.
Gases and fumes produced during the welding process can be dangerous and hazardous to your health.
• Adequate local exhaust ventilation must be used in the area. It should be provided through a mobile hood or through a built-in system on the workbench that provides exhaust ventilation from the sides, the front and below, but not from above the bench so as to avoid raising dust and fumes. Local exhaust ventilation must be provided together with adequate general ventilation and air circulation, particularly when work is done in a confined space.
• Welding process must be performed on metal surfaces thoroughly cleaned from rust or paint, to avoid production of harmful fumes. The parts degreased with a solvent must be dried before welding.
• Be very careful when welding any metals which may contain one or more of the following:
Antimony
Copper
Beryllium
Mercury
Cobalt
Silver
Manganese Selenium
Barium
Arsenic
Chromium Lead
Cadmium
Nickel
Vanadium
• Remove all chlorinated solvents from the welding area before welding. Certain chlorinated solvents decompose when exposed to ultraviolet radiation to form phosgene gas (nerve gas).
Fire Prevention
Fire and explosion can be caused by hot slag, sparks or the welding arc.
• Keep an approved fire extinguisher of the proper size and type in the working area. Inspect it regularly to ensure that it is in proper working order;
• Remove all combustible materials from the working area. If you can not remove them, protect them with fire-proof covers;
• Ventilate welding work areas adequately. Maintain sufficient air flow to prevent accumulation of explosive or toxic concentrations of gases;
• Do not weld on containers that may have held combustibles;
• Always check welding area to make sure it is free of sparks, slag or glowing metal and flames;
• The work area must have a fireproof floor;
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Electric Shock
WARNING: ELECTRIC SHOCK CAN KILL!
• A person qualified in First Aid techniques should always be present in the working area; If a person is found unconscious and electric shock is suspected, do not touch the person if she or he is in contact with cable or electric wires. Disconnect power from the machine, then use First
Aid. Use dry wood or other insulating materials to move cables, if necessary away from the person.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Make sure the main line is properly grounded.
• Do not coil the torch or the ground cables around your body.
• Never touch or come in physical contact with any part of the input current circuit and welding current circuit.
Noise
Electric warning:
• Repair or replace all worn or damaged parts.
• Extra care must be taken when working in moist or damp areas.
• Install and maintain equipment according to local regulations.
• Disconnect power supply before performing any service or repair.
• Should you feel the slightest electrical shock, stop any welding immediately and do not use the welder until the fault has been found and corrected.
Noise can cause permanent hearing loss. Welding processes can cause noise levels that exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
Electromagnetic Compatibility
Before installing your welder, carry out an inspection of the surrounding area, observing the following guidelines:
• Make sure that there are no other power supply cables, control lines, telephone leads or other equipment near the unit.
• Make sure that there are no radio receivers, television appliances, computers or other control systems near the unit.
• People with pace-maker or hearing-prosthesis should keep far from the power source.
! In particular cases special protection measures may be required.
Interference can be reduced by following these suggestions:
• If there is interference in the power source line, an E.M.T. filter can be mounted between the power supply and the power source.
• The output cables of the power source should not be too long, kept together or connected to ground;
• After the maintenance all the panels of the power source must be securely fastened in place.
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Protective Welding Gases
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Treat them carefully.
• These welders use only inert or non-flammable gases for welding arc protection. It is important to choose the appropriate gas for the type of welding being performed;
• Do not use gas from unidentified cylinders or damaged cylinders;
• Do not connect the cylinder directly to the welder, use a pressure regulator;
• Make sure the pressure regulator and the gauges function properly;
• Do not lubricate the regulator with oil or grease;
• Each regulator is designed for use with a specific gas. Make sure the regulator is designed for the protective gas being used;
• Make sure that the cylinder is safely secured tightly to the welder with the chain provided.
• Never expose cylinders to excessive heat, sparks, slag or flame;
• Make sure that the gas hose is in good condition;
• Keep the gas hose away from the working area.
Installation Recommendations
Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust;
• Ambient temperature between 30° to 90°F;
• In areas, free from oil, steam and corrosive gases;
• In areas, not subjected to abnormal vibration or shock;
• In areas, not exposed to direct sunlight or rain;
• Place at a distance of 12” or more from walls or similar that could restrict natural air flow for cooling.
Ventilation
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.
Main Supply Voltage Requirements
Before you make any electrical connection, check that supply voltage and frequency available at site are those stated in the ratings label of your generator.
The main supply voltage should be within ±10% of the rated main supply voltage. Too low a voltage may cause poor welding performance. Too high a supply voltage will cause components to overheat and possibly fail. The welder Power Source must be:
• Correctly installed, if necessary, by a qualified electrician;
• Correctly grounded (electrically) in accordance with local regulations;
• Connected to the correct size electric circuit.
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Notes:
• Periodically inspect supply cable for any cracks or exposed wires. If it is not in good conditions, have it repaired by a Service Centre.
• Do not pull violently the input power cable to disconnect it from supply.
• Do not lay material or tools on the power supply cable. The cable may be damaged and result in electrical shock.
• Keep the supply cable away from heat sources, oils, solvents or sharp edges.
• If you use an extension cord, keep it as straight as possible. For lengths up to 100 ft. use 12
AWG. For lengths up to 100 ft. use 10 AWG.
Safety Instructions
For your safety, before connecting the power source to the line, closely follow these instructions:
• An adequate two-pole switch must be inserted before the main outlet; this switch must be equipped with time-delay fuses;
• The connection with ground must be made with a two-pole plug compatible with the above mentioned socket;
• When working in a confined space, the power source must be kept outside the welding area and the ground cable should be fixed to the work piece. Never work in a damp or wet area, in these conditions.
• Do not use damaged input or welding cables
• The welding torch should never be pointed at the operator’s or at other persons’ body;
• The power source must never be operated without its panels; this could cause serious injury to the operator and could damage the equipment.
California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the
State of California to cause birth defects and, in some cases, cancer. (California Health & Safety
Code Section 25249.5 et seq.)
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Assembly
• Unpack the welder;
• Assemble the plastic handle on torch wrap using the screws provided.
Torch Lead and Spool Gun Assembly
• Attach the standard MIG welding torch to the threaded connection on the front of the welder.
• To connect the spool gun, connect the spool gun cable to the threaded fitting on the front of the welder and also connect the seven pin cannon type plug to the connector on the front of the welder.
Gas Cylinder and Regulator Connection
WARNING: Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or misuse of compresses gas cylinders. Do not drop the cylinder, knock it over, expose it to excessive heat, flames or sparks. Do not strike it against other cylinders.
The gas cylinder (not supplied) should be fixed firmly to the work bench or to the wall in a way that it can’t fall.
• INSTALLING THE GAS REGULATOR: Insure that the pressure regulator valve is fully closed by turning the valve handle counter clockwise. Connect the regulator to the gas cylinder by threading the large nut on the regulator onto the mating fitting on the gas cylinder, tighten firmly.
• Connect the gas hose to the regulator.
• Completely open the cylinder valve, then set the gas flow to approx. 20-30 CFH by turning the pressure regulator valve clockwise.
• Release the pressure on the wire feed roll by flipping down the pressure adjust knob (A) Fig.5, page 19. Then turn the welder on and press the torch trigger to insure that gas is flowing through the torch.
Shielding Gas Guide
Metal
Mild Steel
Aluminium
Stainless Steel
GAS
CO2
Argon + CO2
Argon + CO2 + Oxygen
Argon
Argon + Helium
Argon + CO2 + Oxygen
Argon + Oxygen
Copper, Nickel & Alloys Argon
Argon + Helium
NOTE
Argon controls spatter
Oxygen improves arc stability
Arc stability, good fusion and minimum splatter.
Higher heat input suitable for heavy sections.
Minimum porosity.
Arc stability.
Minimum splatter.
Suitable for light gauges because of low flowability of the weld pool.
Higher heat input suitable for heavy sections.
Contact the technical service of your gas supplier to know the percentages of the different gasses which are the most suitable to your application.
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Front Panel Operation
Quick Start
Your new single phase inverter multi-function welder offers THREE WELDING FUNCTIONS in the same power source. These functions can be selected with knob (6) on the front panel of the unit:
Fluxcore Wire Welding, “FCAW” and MIG Welding, “GMAW”
This welder offers the choice to weld in manual or synergic mode.
1. Manual Mode: The operator is required to set both the wire speed (Left Knob - 8- ) and the welding voltage (Right Knob - 7 -). A setting chart can be found on page (28) of this manual.
2. Synergic Mode: As in manual function, the operator is required to set both the wire speed
(Left Knob -8-) and the welding voltage (Right Knob -7-) referring to the setting chart on page (24). Once both parameters are set, the synergic function allows the operator to move to different thickness of material to be welded simply adjusting the Left Knob (8). The correct voltage will be automatically set by the machine’s software.
Stick Welding, “SMAW”
Both rutile and basic electrodes can be welded. Welding current is adjusted using the Left Knob (8).
TIG Welding, “GTAW”
In the TIG position, a TIG torch with a trigger control and a gas valve in the handle is required.
The gas valve must be opened manually before welding and closed manually when welding is completed. The arc is activated using the torch trigger. Using the Left Knob (-8-) welding current can adjusted.
Controls and Operational Features
4 1 2 3 5
CAT# 322
IC
K
TIG
MIG M
ODES
4T
MAN
4T
SY
PROCESS SELECTOR
STICK (A)
TIG (A)
MIG MAN
(WFS)
MIG SYN
(WFS)
STICK
(HOT START)
TIG (N/A)
MIG MAN (V)
MIG SYN
(THICKNESS)
6
7
8
MULTI-PROCESS WELDER
120 VOLT 20 AMP INPUT
Forney Industries, Fort Collins, CO USA
11
12
9
10
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2T / 4T EXPLANATION:
2T: Press the torch trigger to weld. Welding continues until the trigger is released.
4T: Press the torch trigger and immediately release the trigger, welding will start and continue until the torch trigger is pressed and released a second time. The 4T function is useful when doing long welds and in some automatic welding operations where the torch may be mounted in a fixture.
1. Power switch indicator: This green LED lights when the welding machine is ON and is ready to work. A steady green LED indicates the welder is connected to power supply. In the event of an overvoltage supply the green LED blinks and the red LED (3) is ON.
2. Thermal overload indicator: If the yellow LED is ON it indicates that the welder has overheated and the machine has automatically shut down. This may be a result of having exceeded the welders duty cycle or that normal cooling air flow has been interrupted. Check to confirm that the cooling fan is running and that air flow is not blocked. Do not turn off the welder as this will stop the cooling fan.
When the welder has cooled sufficiently the yellow
LED will go out and the welder is ready to weld.
3. Alarm indicator: This red LED lights when there is a working abnormality such as an over voltage supply.
4. Left Display: During welding it displays the actual value of the output current (AMP). When the machine is not welding, (no load), the display shows the value of the parameter selected with the Left Knob (8): a. In STICK, “SMAW”and TIG, “GTAW” Mode it shows the selected current value. If Remote is selected with switch (20) for TIG Welding, “GTAW” with a foot control, the display will alternate between “ReC” (to indicate remote control), and the selected current. In this case the current is adjusted using the foot control.
b. In MIG, “GMAW” Manual Mode (2T/4T), the display shows the selected wire speed from 1 (minimum wire feeder speed) to 80 (maximum speed). If Remote is selected with switch (20), the display will alternate between “SPE” (to indicate spool gun external) and the selected wire speed which is adjusted with a potentiometer located on the spool gun handle.
c. In MIG, “GMAW” Synergic Mode (2T/4T), the display shows the selected wire speed from 1 (minimum wire feeder speed) to 80 (maximum speed). If Remote is selected with switch (20), the display will alternate between “SPE” (to indicate spool gun external) and the selected wire speed which is adjusted with a potentiometer located on the spool gun handle.
5. Right Display: During welding it displays the actual arc voltage. When the machine is not welding (no load) it displays the value of the parameter adjusted with the Right Knob (7): a. In STICK, “SMAW”Mode it displays the Hot Start over-current value expressed as a percentage of the base welding current selected with the left knob (8). The over current value is variable from 0 to 50% of the base current. Maximum Hot start value of 50% can be adjusted up to 55 Amp of welding current. On the display the value of Hot Start is shown as “H” and the value of the over current in %.
b. In TIG, “GTAW” Mode the display is not active.
c. In MIG, “GMAW” Manual Mode (2T/4T) it displays the selected arc voltage from 10V to
24V.
d. In MIG, “GMAW” Synergic Mode (2T/4T) it displays the value of the selected voltage expressed as a percentage of the maximum available voltage.
6. Selector switch for the Welding Modes Selection: STICK, “SMAW” - TIG, “GTAW” - MIG,
“GMAW” manual 2T, manual 4T, Syn 2T, Syn 4T.
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7. Right Knob: It is used to adjust the following welding parameters: a. in STICK, “SMAW”Mode it adjusts the over-current value of the electric arc (Hot Start), variable from 0 to 50% on the current value adjusted with the Left Knob (8).
b. In TIG, “GTAW” Mode is not active.
c. In MIG, “GMAW” Manual Mode (2T/4T) it adjusts arc voltage value (no load) from 10V to 24V. d. In MIG, “GMAW” Synergic Mode (2T/4T) it adjusts the % of welding power available
(depending on the input voltage) variable from 0 to 80% (maximum power).
8. Left Knob, It is used to adjust the following welding parameters: a. In STICK, “SMAW”Mode it adjusts the current value from a minimum of 20Amp to a maximum of 80 Amp. If Remote is selected with switch (20) the left knob is not active.
b. In TIG, “GTAW” Mode, it adjusts the current value from a minimum of 5 Amp to a maximum of 100Amp. If Remote is selected with switch (20) the Left knob is not active.
c. In MIG, “GMAW” Manual Mode (2T/4T) it adjusts the wire speed from 1 (minimum wire feeder speed) to 80 (maximum speed). If Remote is selected with switch (20) the Left knob is not active.
d. In MIG, “GMAW” Synergic Mode (2T/4T) it adjusts the wire speed from 1 (minimum wire feeder speed) to 80 (maximum speed). If Remote is selected with switch (20) the Left knob is not active.
9. Negative Dinse socket: a. In STICK Welding, “SMAW” for the connection of the ground cable connector (check for correct polarity for the electrode you are going to use, refer to the information on its box); b. In TIG Welding, “GTAW” for the TIG torch cable connection (Torch trigger connection must be connected to the 7 pin connector – 12 -) c. In MIG Welding, “GMAW” (with gas) for the connection of the ground cable connector
10. Positive Dinse socket: a. In STICK Welding, “SMAW”, for the connection of the ground cable connector (check for correct polarity for the electrode you are going to use, refer to the information on its box); b. In FLUXCORE WIRE Welding, “FCAW”, for the connection of the ground cable connector.
11. Euro connect for attaching the MIG torch cable.
In FLUXCORE WIRE Welding, “FCAW”, change the polarity of the Euro socket using the terminals on the Polarity Change Board located inside the wire spool compartment above the wire feeder -19-). To attach the Spool
Gun, remove the standard MIG torch from the Euro Connect and connect the Spool Gun.
Also connect the Spool gun control lead to the seven pin connector (12) on the front of the cabinet and switch the Local / Remote switch (20) to the Remote position.
12. 7 pin connector it is used when: a. in STICK, “SMAW”Mode when Remote is selected with switch (20) for connecting the foot remote control; b. in TIG, “GTAW” Mode when Local is selected with switch (20), for connecting the TIG torch trigger control cable; c. in TIG, “GTAW” Mode when Remote is selected with switch (20) for connecting the foot pedal remote control; in this case the TIG torch trigger control cable has to be disconnected; d. In MIG Welding, “GMAW”, Manual and Synergic when Remote is selected with switch
(20), for connecting the Spool gun torch 7 pin male connector;
13. Input power cable
14. ON/OFF Switch
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FIGURE 3 20
17
18
19
16
16. 2 roll Aluminum wire feeder
17. Slope up Time regulation potentiometer
18. Burn Back Time Regulation potentiometer (B.B.T.)
19. Polarity Change Terminals for the Euro Socket: a. positive polarity for MIG Welding, “GMAW”; b. negative polarity for FLUXCORE WIRE Welding, “FCAW”
20. Local / Remote switch: a. Local: when selected all welding parameters have to be adjusted using knobs 7 and 8 on the front control panel b. Remote: when selected Left Knob (8) is not active. In STICK Welding, “SMAW” and TIG
Welding, “GTAW” Mode current is adjustable using the foot pedal. In MIG Welding,
GMAW” Mode the wire speed is adjustable using the potentiometer on the Spool Gun torch.
Welding Preparation
• Connect the ground cable to the correct Dinse socket (9 & 10) for the welding you plan to do.
Attach the ground clamp to the bare metal to be welded, making sure of good contact;
• Make sure that the wire-roller groove in the roller corresponds to the diameter of the wire being used. Refer to paragraph 6.
• Plug the machine into a suitable outlet.
• Open the gas valve on the gas cylinder all the way. Adjust the gas flow regulator valve to the desired flow. Clockwise to increase, Counter clockwise to decrease the flow.
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General Operating Instructions
This manual was edited to give some indications on the operation of the welder and was thought to offer information for its practical and safe use. Its purpose is not to teach welding techniques.
All suggestions are indicative and intended to be only guide lines.
To ensure that your welder is in good conditions, inspect it carefully when you remove it from its packing having care to ascertain that the cabinet or the stocked accessories are not damaged.
Your welder is capable of daily activity metal fabrication and maintenance. Its simplicity and versatility and its excellent welding characteristic are the product of the most up to date inverter technology. This welding inverter offers the welder the ability to create precise arc characteristics and at the same time reduce consumption of energy with respect to the welders based on a traditional transformer.
Respect the duty cycle of the welder making reference to the technical data label on the welder’s back. Duty cycle is given as percentage on a 10 minute time. During this period of time the unit can be used at the rated duty cycle. Exceeding the rated duty cycle may cause overheating or welder damage.
Welders Basic Specifications:
16
Welding Wire Selection:
This welder can work with Aluminum wire .030” (0.8mm) diameter, solid steel wire .023”-
.035” (0.6-0.9mm) diameter and stainless steel wire .030”-.035” (0.8-0.9mm) diameter
(MIG Welding, “GMAW”) and with flux core wires 0.9mm diameter (.035”) (FLUXCORE WIRE
Welding, “FCAW”).
Gas Selection:
According to the material to be welded and to the wire you are going to use, select the shielding gas. The table below can give you some useful indications:
MATERIAL TO WELD
Mild Steel
Stainless Steel
Aluminum
GAS CYLINDER
Argon + CO2
Cylinder or CO2 Cylinder
Argon Cylinder
Argon Cylinder
WIRE
Copper coated mild steel wire spool. For
FLUXCORE WIRE Welding, “FCAW” use flux-cored wire spool
Stainless Steel wire spool
Aluminum wire spool
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17
Protective Gases Guide
METAL
Mild Steel
Aluminum
Stainless Steel
Copper, Nickel &
Alloys
GAS
CO2
75% Argon + 25% CO2
Argon + CO2 + Oxygen
Argon
Argon + Helium
Argon + CO2 + Oxygen
Argon + Oxygen
Argon
Argon + Helium
NOTE
Argon controls spatters
Oxygen improves arc stability
Arc stability, good fusion and minimum spatter
Higher heat input suitable for heavy sections. Minimum porosity
Arc stability
Minimum spatter
Suitable for light gauges because of low flowability of the weld pool
Higher heat input suitable for heavy sections
Contact the technical service of your gas supplier to know the percentages of the different gases which are the most suitable to your application.
STICK Welding, “SMAW”
Getting Ready for Stick Welding, “SMAW”:
• Select the STICK, “SMAW”function with the Selector Switch (6) on the front panel.
• Check the electrode packaging to determine the recommended polarity and connect the
Electrode holder and ground clamp to the plus and minus Dinse sockets accordingly.
• Switch the unit ON thru the ON/OFF switch (14).
• If “Local (20)” is selected set the welding current with the Left Knob (8) on the front panel and the strike over-current value of the electric arc (Hot Start) with the Right Knob (7)
• If “Remote (20)” is selected set the welding current using the foot pedal which has to be connected to the 7-pin connector (12). The over-current value of the electric arc (Hot Start) with the Right Knob (7).
Adjustable Welding current:
120V input voltage: Min 20 Amp - Max 80 Amp
MATERIAL
(Wire)
ELECTRODE
TYPE
140 MP STICK SET-UP CHART
ELECTRODE DIAMETER
1/16” (1.6 mm) .0787” (2 mm) 3/32” (2.4 mm) 1/8” (3 mm)
Regulation Knob
Mild Steel
Stainless Steel
6013
7018
316
Left Knob
30-35
30-35
30-35
Left Knob
40-70
40-70
40-70
Left Knob
70-80
70-80
40-80
Left Knob
-
80
60-80
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18
TIG Welding, “GTAW” with Lift Start
Setting up the Equipment for TIG Welding, “GTAW” with NO Foot Control:
• Select the TIG function on the control panel with knob (6).
• Choose LOCAL with switch (20).
• Connect the TIG torch cable to the negative Dinse socket (9) of the welder.
• Connect the ground cable connector to the positive Dinse socket (10) of the welder.
• Connect the TIG torch control cable to the 7 pin connector (12).
• Connect the TIG torch gas line to the gas regulator, ARGON GAS ONLY
The gas flow is manually controlled with the knob on the TIG torch. Use inert gas
(argon ) only.
Setting up the Equipment for TIG Welding, “GTAW using a Foot Control:
• Switch the unit on thru the ON/OFF switch (14).
• Select the TIG function on the control panel with knob (6).
• Choose REMOTE with switch (20).
• Connect the TIG torch cable to the negative Dinse socket (9) of the welder.
• Connect the ground cable connector to the positive Dinse socket (10) of the welder.
• Connect the Foot Control cable to the 7 pin connector (12)
• Connect the TIG torch gas line to the gas regulator ARGON GAS ONLY.
Close the Gas Valve on the Torch Handle:
Turn on gas at the gas regulator, then open the valve on the torch handle and check for gas flow.
Starting the Arc with Lift Start:
• Fix the tungsten electrode so that it protrudes approximately ¼ inch from the torch nozzle.
• Position the torch so that the tungsten electrode is in contact with the work piece at a 45 degree angle.
• Press the torch trigger or the foot control and then lift the tungsten electrode away from the work piece.
REMEMBER to turn OFF the gas immediately after you finish welding.
MATERIAL
(Wire)
Mild Steel
GAS
Regulation Knob
Solid Wire
100% Argon
TUNGSTEN
ELECTRODE
ø
140 MP TIG SET-UP CHART
22 Gauge
.0315” (.8 mm)
MATERIAL THICKNESS
18 Gauge
.0236” (1.2 mm)
16 Gauge
1/16” (1.6 mm)
.040” (1.0 mm)
1/16” (1.6 mm)
35-50
Left Knob
Mild Steel
Stainless
Steel
20-35
-
45-60
Left Knob
Mild Steel
Stainless
Steel
30-55
-
-
Left Knob
Mild Steel
Stainless
Steel
-
60-90 40-70
1/8” (3 mm)
-
Left Knob
Mild Steel
Stainless
Steel
-
80-100 65-100
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19
MIG, “GMAW” - Fluxcore wire, “FCAW” Welding
Torch Connection
• Plug the torch hose into the socket on the front of the welder having care to not damage the contacts and secure by hand screwing in the threaded connection.
Wire Loading
Ensure the gas and electrical supplies are disconnected. Before proceeding, remove the nozzle and the contact tip from the torch.
• Open the side panel.
• Loosen the nut of the spool holder (brake drum) and remove the spring and the external ring. (Fig.4)
• Remove the plastic protection from the spool (4) and place the wire spool on the spool holder.
• Mount the external ring the spring and the plastic lock nut again. These parts form the braking system of the wire spool speed. NOTE: Do not tighten the nut too much, excessive pressure strains the wire feeding motor, while too little pressure does not allow the immediate stop of the wire spool at the end of the welding.
• Loosen and lower the plastic knob (A) (Fig.5). Open the pressure arm (B) of the feeder.
• Disconnect the wire from the edge of the wire spool being careful to keep tension on the end of the wire.
Cut off a short section of the end of the wire to insure a straight end. Insert the the straight end into the wire inlet guide (C) past the wire feed roll and into the wire liner. Lower pressure arm (B) and lift pressure adjustment knob (A) into place. Connect the input power cord and turn on the welder. Press the torch trigger and observe the wire feeding into the torch liner. Adjust the pressure on the wire with knob (A) to insure smooth feeding without slippage. Do not over tighten the pressure adjustment as it may damage the motor. Close the welder side panel. Remove the nozzle and contact tip from the welding torch. Straighten the torch cable to remove any coils or kinks. Squeeze and hold the torch trigger until the wire appears at the end of the torch neck. Turn off the welder and install the contact tip and nozzle.
WARNING: Keep the torch straight. When feeding a new wire through the liner, make sure
the wire is cut cleanly (no burrs or angles) and that at least 2 cm from the end is straight (no curves). Failure to follow these instructions could cause damage to the liner.
WARNING: 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 groove nearest that side.
When loading wire and watching for it to come through the torch neck, to avoid injury, do not hold the torch close to your face, instead, direct the wire toward the floor. To avoid injury, do not place fingers near the wire feed rolls when the wire feeder is operating.
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20
Replacing the Wire Liner
Ensure the gas and electrical supplies are disconnected.
• Disconnect the torch from the machine.
• Place it on a flat surface and carefully remove the brass nut (1).
• Pull the liner out of the hose.
• Install the new liner and mount the brass nut (1) again. In case you are replacing a Teflon wire liner, follow these instructions:
• Install the new liner followed by the collet (3).
• Insert the O ring (4) on the wire liner collet (4)and replace the brass nut (1).
• Cut the wire liner close to the brass nut
WARNING: The length of the new wire liner must be the same as the liner you have just pulled out of the hose.
• Connect the torch to the machine and install the wire into the feeding system.
Gas Cylinder and Regulator Connection
WARNING: Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or misuse of compresses gas cylinders. Do not drop the cylinder, knock it over, expose it to excessive heat, flames or sparks. Do not strike it against other cylinders.
The gas cylinder (not supplied) should be located at the rear of the welder, in a well ventilated area and securely fixed to the work bench or to the wall to insure that it will not fall.
For safety, and economy, ensure that the regulator is fully closed, (turned counter-clockwise) when not welding and when installing or removing the gas cylinder.
• Turn the regulator adjustment knob counter-clock wise to ensure the valve is fully closed.
• Install the gas regulator on the gas cylinder, tighten the connecting nut firmly to insure against gas leakage.
• Connect the gas hose to the gas regulator.
• Open the cylinder valve, then set the gas flow to 20 - 35 CFH (cubic ft. per hour).
Fluxcore Wire Welding, “FCAW”
• Connect the ground cable to the positive terminal of the
Polarity Change Board inside the spool compartment.
• Connect the working cable to the negative terminal of
Polarity Change Board inside the spool compartment.
MIG Welding, “GMAW”
• Connect the ground cable to the negative terminal on the
Polarity Change Board inside the spool compartment
• Connect the working cable to the positive terminal of the
Polarity Change Board inside the spool compartment.
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21
MIG, “GMAW”, Fluxcore Wire, “FCAW” Manual Welding
Before connecting the unit to the mains, verify that all the accessories are correctly installed and mounted for electric welding (torch, wire spool etc ...).
• Select Manual MIG (2T or 4T) Welding function with the Selector Switch (6) on the front panel.
Select either the 2-Step or 4-Step function of the torch trigger. 2-Step trigger turns welding arc ON and OFF each time the trigger is pressed and released. Welding current is ON when the torch trigger is pressed. 4-Step mode permits the operator to weld with the torch trigger released. To start welding press the torch trigger and release. To stop welding press and release the torch trigger. 4-Step mode helps the operator make long welds with less fatigue.
• Switch the unit ON thru the ON/OFF switch (14) on the back side of the unit.
• Press the torch trigger to load the wire.
• Set the welding parameters: REFER TO SET UP CHARTS ON PAGE 24.
1. Wire feed speed: Welding Current (AMPS) If “Local (20)” is selected use Left Knob (8) to adjust the wire speed from 1 to 80 (maximum speed). If “Remote (20)” is selected use the potentiometer of the Spool Gun torch to adjust wire speed.
2. Arc voltage: use the Right Knob to adjust arc voltage value (no load) from 10V to 24V.
• Bring the torch close to the work piece and press the trigger
1. Wire feeder Slope-Up Time (Min. to Max. speed transition time), adjustable with the potentiometer located inside the access panel (17).
2. At the end of the Slope-Up Time, the wire feed speed reaches the value adjusted with the
Left knob (8).
• To stop welding, release the trigger. The arc stays ON accordingly to the set B.B.T. (Burn back time). B.B.T. is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the following arc start.
MIG, “GMAW”, Fluxcore Wire, “FCAW” Synergic Welding
• Select MIG Synergy (2T or 4T) Welding function thru the Selector Switch (6) on the front panel.
The 2-Step / 4-Step change the function of the gun’s trigger. 2-Step trigger turns welding arc
ON and OFF each time the trigger is pressed. Welding current is ON when the torch trigger is pressed. 4-Step mode permits the operator to weld with the torch trigger released. To stop welding press and release the torch trigger. 4-Step mode helps the operator make long welds.
• MIG Synergy functions permits the operator to move to different materials thickness to be welded simply adjusting the Left Knob (8). The correct voltage will be set automatically by the machine’s software. In order to permit the software to set the correct voltage the operator is asked to set the “starting welding parameter” as suggested on the setting chart (Page 24). In fact a wire speed value and voltage value have to be set in order to activate the synergy mode.
• Switch the unit ON thru the ON/OFF switch (14) on the back side of the unit.
• Press the torch trigger to load the wire and check that the gas is flowing from the welding torch.
• Set the “starting welding parameters”:
1. Wire feed speed: A) If “Local (20)” is selected use Left Knob (8) to adjust the wire speed from 1 to 80 (maximum speed). If “Remote (20)” is selected use the potentiometer of the
Spool Gun torch to adjust wire speed.
2. Arc length: use the Right Knob to adjust arc length value from 0 to 80.
3. Once both parameters are set the Synergic Mode allows the operator to weld different thickness of the same material simply adjusting the Left Knob (8).
• Bring the torch close to the work piece and press the trigger.
1. Wire feeder Slope-Up Time (Min. to Max. speed transition time), adjustable with the
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potentiometer located inside the access panel (17).
2. At the end of the the Slope-Up Time, the wire feed speed reaches the value adjusted with the
Left knob (8).
• To stop welding, release the trigger. The arc stays ON accordingly to the set B.B.T. (Burn back time). B.B.T. is the amount of time that the weld output continues after the wire stops feeding. It prevents the wire from sticking in the puddle and prepares the end of the wire for the following arc start.
Aluminum Welding
The machine needs to be set up as follows:
• 100% ARGON as welding protective gas.
• Ensure that your torch is set up for aluminum welding:
1. The length of the torch should not exceed 12” (it is advisable not to use longer torches).
2. Install a teflon wire liner (follow the instructions for the replacing of the wire liner).
3. Use contact tips that are suitable for aluminum wire and make sure that the diameter of the contact tip hole corresponds to the wire diameter that is going to be used.
• Ensure that drive rolls are suitable for aluminum wire.
22
Arrangement for Welding with Spool Gun
WARNING: Electric shock can kill! Always turn the POWER switch OFF and unplug the power cord from the ac power source before installing wire.
Before installing any welding wire into the unit, the proper sized groove must be placed into position on the wire drive mechanism. Adjust the drive roller according to the following steps:
1. Open the Wire Drive cover on the Spool Gun.
2. Remove the drive tension by loosening the tension adjusting screw and lifting the Drive
Tension Adjustor up, away from the Drive Tension
Arm. Pull the drive tension arm away from the drive roller.
3. Rotate the Drive Roller Cap counterclockwise and remove it from the Drive Wire Drive Cover
Drive Roller Cap FIG. 7 tension adjusting screw drive tension arm Roller. Pull the Drive Roller off of the Drive Roller Shaft . Note: The drive roller has two wire size (.030” – .035”) grooves built into it.
4. Find the side of the drive roller that is stamped with the same wire diameter as that of the wire being installed. Push the drive roller onto the drive roller shaft, with the side stamped with the desired wire diameter facing you.
5. Reinstall the Drive Roller Cap and lock in place by turning it clockwise.
6. Remove the nozzle and contact tip from the end of the gun assembly.
7. Open the Wire Spool Casing, located at the rear of the Spool Gun, by turning the retaining knob counterclockwise.
8. Unwrap the spool of wire and then find the end of the wire.
9. After checking to make sure that your welder is disconnected from the ac power source, free the leading end of the wire from the spool, but do not let go of it until told to do so, or the wire will unspool itself.
10. Using a pair of pliers, cut off the bent portion at the end of the wire so that you are left with a straight section of wire.
11. Unroll about 6” of welding wire from the wire spool.
12. Insert the leading end of the wire into the inlet guide tube (located in the Wire Spool Casing).
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23
Then push it across the drive roller and into the gun assembly about 6”.
13. Line the wire up in the top groove of the drive roller, then push the drive tension arm against the drive roller.
14. Flip the quick release drive tensioner back into position on the drive tensioner arm.
15. Tighten (turn clockwise) the drive tension adjusting knob until the tension roller is applying enough force on the wire to prevent it from slipping out of the drive assembly.
16. Let go of the wire.
17. Place the spool on the spindle in such a manner that when the wire comes off the spool, it will look like the top illustration in Figure 10. The welding wire should always come off the top of the spool into the drive mechanism. Technical Note: The purpose of the drive brake is to cause the spool of wire to stop turning at nearly the same moment that wire feeding stops.
18. Set the Drive Brake tension. Note: It is necessary to release the Drive Tensioner Arm while you are setting the Drive Brake Tension. Make sure you return the Drive Tension Arm to its locked position after adjusting the Drive Brake Tension.
a) With one hand, turn the wire spool counterclockwise - this will cause the wire to feed through the gun assembly (and continue turning it while adjusting the tension on the spool).
b) With your free hand, tighten (turn clock-wise) the drive brake adjustment knob.
c) Stop tightening when drag is felt on the wire spool that you are turning, then stop handturning the wire spool. Note: If TOO MUCH tension is applied to the wire spool, the wire will slip on the drive roller or will not be able to feed at all. If TOO LITTLE tension is applied, the spool of wire will want to unspool itself. Readjust the drive brake tension as necessary to correct for either problem.
19. Trim the wire which is sticking out the end of the spool gun to about 1/2” in length.
20. Select a contact tip stamped with the same diameter as the wire being used.
21. Slide the contact tip over the wire(protruding from the end of the gun).Thread the contact tip into the end of the gun and hand-tighten securely.
22. Install the nozzle on the gun assembly. For best results, coat the inside of the nozzle with antistick spray or gel.
23. Cut off the excess wire that extends past the end of the nozzle.
24. Replace the Wire Spool Casing cover and tighten adjustment knob by turning it clockwise.
25. Connect the welder power cord to the ac power source. Turn the welder ON. Set the
VOLTAGE switch.
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24
Set the Wire Drive Tension
WARNING: Arc flash can injure eyes! To reduce the risk of arc flash, make certain that the wire coming out of the end of the gun does not come in contact with work piece, ground clamp or any grounded material during the drive tension setting process or arcing will occur.
1. Open the Wire Drive Cover on the Spool Gun
2. Pull the trigger on the gun.
3. Turn the drive tension adjustment knob clockwise, increasing the drive tension until the wire seems to feed smoothly without slipping.
4. Close the Wire Drive Cover on the Spool Gun.
5. When set correctly, there should be no slippage between the wire and the drive roller under normal conditions.
Adjusting the Spool Position
Before you begin welding, you may want to adjust the position of the spool so it is most comfortable for you. There are three positions to choose from. To change the position of the spool:
1. With a flat tipped screwdriver, loosen the screw which connects the spool casing to the gun.
2. Pull the casing far enough away from the gun to allow for rotation of the casing.
3. Rotate the casing to one of the three available positions, making sure that the grooves on the gun are aligned with the grooves on the casing.
4. Push the casing and the gun back together.
5. With a flat tipped screwdriver, tighten the screw which connects the spool casing to t
MATERIAL
(Wire)
GAS
WIRE
ø
140 MP MIG SET-UP CHART
MATERIAL THICKNESS
22 Gauge
.0315” (.8 mm)
18 Gauge
.0236” (1.2 mm)
16 Gauge
1/16” (1.6 mm)
12 Gauge
.0984” (2.5 mm)
1/8” (3 mm)
Mild Steel
Aluminum
Regulation Knob
Solid Wire
75% Ar + 25%
CO
2
(ER70S-6)
Solid Wire
100% CO
2
(ER70S-6)
Flux Core Wire
(No Gas)
(E71T-GS)
Solid Wire
100% Argon
.023” (0.6 mm)
.030” (0.8 mm)
.035” (0.9 mm)
.023” (0.6 mm)
.030” (0.8 mm)
.035” (0.9 mm)
25
22
22
37
24
-
Left
Knob
Right
Knob
MIG
Man
17.8
15.1
15.5
19.3
15.8
-
Right
Knob
MIG
Syn
82
65
68
80
69
-
Left
Knob
42
33
28
48
33
19
Right
Knob
MIG
Man
18.5
16.7
16.4
19.9
17.5
18.2
Right
Knob
MIG
Syn
69
65
68
73
69
92
Left
Knob
51
44
33
59
44
30
Right
Knob
MIG
Man
19.5
18
17.1
21.2
18.9
19.7
Right
Knob
MIG
Syn
66
65
68
70
69
90
Left
Knob
71
55
44
85
60
38
Right
Knob
MIG
Man
20.6
19.7
18.7
23.7
21.9
21.1
Right
Knob
MIG
Syn
52
65
68
59
69
93
Left
Knob
-
74
-
-
78
60
Right
Knob
MIG
Man
22
20.7
-
24.6
-
-
Right
Knob
MIG
Syn
52
65
-
55
-
-
.035” (0.9 mm)
.030” (0.8 mm) -
-
-
-
-
-
44
-
14.3
-
34
18
55
14.7
14.4
66
26
30
76
16.5
15.8
66
15
37
86
17.2
17.1
66
17
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25
Troubleshooting
This chart will assist you in resolving common problems you may encounter. These are not all the possible solutions.
PROBLEM
No “power” from welder.
Fan operates normally, but when gun trigger pulled, there is no wire feed, weld output or gas flow.
Feed motor operates but wire will not feed.
Lack of penetration.
POSSIBLE CAUSE
Input cable or plug malfunction.
Wrong size fuse.
Faulty trigger gun.
Thermostat intervention.
POSSIBLE SOLUTION
Check for proper input cable connection.
Check fuse and replace as necessary.
Replace torch trigger.
Allow welder to cool. The extinguishing of the pilot lamp/ switch on the front panel indicates the thermostat has closed.
Replace wire feeding motor.
Faulty wire feeding motor (rare).
Insufficient feed roller pressure.
Burr on end of wire.
Increase roller pressure.
Re-cut wire square with no burr.
Liner blocked or damaged.
Voltage or wire feed speed too low.
Clear with compressed air or replace liner.
Re-adjust the welding parameters.
Loose connection inside the machine (rare).
Worn or wrong size contact tip.
Clear with compressed air and tighten all connections.
Replace the contact tip.
Wire is birdnesting at the drive roller.
Loose gun connection or faulty gun assembly.
Tighten or replace torch.
Wrong size wire.
Torch moved too fast.
Excessive pressure on drive roller.
Gun liner worn or damaged.
Use correct size welding wire.
Move the gun smoothly and not too fast.
Adjust pressure on drive roller.
Replace wire liner.
Contact tip clogged or damaged.
Liner stretched or too long.
Replace contact tip.
Cut wire liner at the right length.
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26
PROBLEM
Wire burns back to contact tip.
POSSIBLE CAUSE
Contact tip clogged or damaged.
Wire feed speed to slow.
Wrong size contact tip.
POSSIBLE SOLUTION
Replace the contact tip.
Increase wire speed.
Use correct size contact tip.
Bad connection from cable to clamp.
Slag buildup inside nozzle or nozzle is shorted.
Wire feed speed too fast.
Tighten connection or replace cable.
Clean or replace nozzle.
Workpiece clamp and/or cable gets hot.
Gun nozzle arcs to work surface.
Wire pushes torch back from the workpiece.
Poor quality welds.
Nozzle clogged.
Torch held too far from the workpiece.
Insufficient gas at weld area.
Rusty, painted, clamp, oil or greasy workpiece.
Decrease wire feed speed.
Clean or replace nozzle
Hold the torch at the right distance.
Check that the gas is not being blown away by drafts and if so move to more sheltered weld area.
If not check gas cylinder contents gauge, regulator setting and operation of gas valve.
Ensure workpiece is clean and dry.
Rusty or dirty wire.
Poor gound contact.
Incorrect gas/wire combination
Weld deposit “stringy” and incomplete.
Torch moved over workpiece too quickly.
Weld deposit too thick.
Gas mixture incorrect.
Torch moved over workpiece too slowly.
Welding voltage too low.
Ensure wire is clean and dry.
Check ground clamp/workpiece connection.
Check on the manual for the correct combination.
Move the torch slower.
See shielding gas table.
Move the torch faster.
Increase welding voltage.
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Tools and Spare Parts List
07 05000280
08 44410068
09 23005381K
10 23005520
11 04600145
12 21690556
13 04600433
14 21690797
15 21690796
16 21690713
17 22735516
18 21800067
19 04600412
20 21690733
21 22735375
22 22225333
23 22910004K
24 22900013
NO. PART NUMBER
01 21690226K
02 05000273
03 04600437
04 22200020
05 21690737
25 05000277
26 22910110
27 22200047
28 20220118
29 21605040K
30 22735523
Kit spool holder with ring for 5kg spool
Switch 3a
Knob
ITEM DESCRIPTION
Door latch (1pc pack)
Left panel with silk screen and labels
Metal box for front panel pcb protection
Dividing panel with labels
Wire feeder plast/all d.37 Rul.06-09
Wire guide tube d.2X5 l=71 1pc pack
Mig gun euro connection l=17
Motor d.37 + Pinion
Torch connection cover
Assembly frame + caps
Knob with cap and index
Knob with cap and index
Spacer for plastic frame
Front panel pcb 140mp forney
Knob with threaded bushing
Kit gas/no gas change board
Foot h=144
Slope external regulation pcb
Relay 40a 110vac
Hose tail d.6 1/8"M 1 pc pack
Gas solenoide valve 4w 110v 60hz
1/8"ff
1
Rear panel 1
Female gas connector 1/8"gas - 5/8"unf 1
1
1
1
1
1
Bipolar black switch w/protection 1
Input cable sjt3xawg14 usa plug 110v 20 1
Prensaestopa 2 piezas d.20
2
Power board mig 140a/mma90a 110v 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
QTY.
1
1
1
NO. PART NUMBER ITEM DESCRIPTION
Bottom panel
32 40211429
33 77650399
34 05000269
35 22100002K
36 26075013
37 33640336
38 21690225K
39 05000261
7 Pin connector cable assembly
Front panel label 140mp
QTY.
1
Front panel 140mp forney w/silk screen 1
Fem.Dinse plug 25sqmm cx30 (1 pc pack)
Hall probe ync-200a
Support bracket
Plastic hinge for door 20x30 2pcs pack
Right cover panel with silk screen
Torch wrapper
1
1
1
1
1
2
1
1
41 21600067
42 21060152K
43 33805071K
44 33810136
45 23000448
46 43210188
47 22100001K
48 22110033K
49 43205028K
50 22110010K
51 22905101
52 30900035
53 20220157
Handle for torch wrapper
Flat-key 3x3 l=20 1pc pack
Feed roll d.30 0,6-0,9Mm mot2r 1 pc pack
Feed roll secure knob
1
1
Mig torch 14mm2 3mt tweco 1 euro connect
Ground cable 16 mm2 mt.3 300Amp dn25
Black gas hose 3 meter
5-20R/5-15p stw awg12/3c 325mm adapter
1
1
Dinse plug 25mm2 cx20 1 pc pack 1
Earth clamp 300a zinc-coated 1 pc pack 1
Weld.Cable 16 sqmm m 3 w/c.202/
Dn25 1pc
Electrode holder art.202 1 Pc pack
Gas reducer 2 man. Cga580-5/8" unf-2b
1
1
1
1
1
1
1
27 WWW.FORNEYIND.COM
28 WWW.FORNEYIND.COM
MIG Gun Torch Spare Parts List
NO.
PART
NUMBER
01 23005373K
ITEM DESCRIPTION
Tweco torch nozzle 21-50f 1 pc pack
QTY.
1
02 23005018K 0,6Mm contact tip for t1.4-1.6 10 Ppc pack 10
02 23005019K 0,8Mm contact tip for t1.4-1.6 10 pc pack 10
02 23005182K 0,9Mm contact tip for t1.4-1.6 10 pc pack 10
03 23005374K Tweco gas diffuser 35-50 1 pc pack 1
04 23005375K Tw1 m15 torch neck 1 pc pack
05 23005360K Torch head plastic housing 1 pc pack
06 23005376K Black handle for m15 torch 1 pc pack
07 23005377K Red torch trigger 1 pc pack
1
1
1
1
NO.
PART
NUMBER
ITEM DESCRIPTION
08 23005362K Screws for m25 torch handle 12 pc pack
09 23005535
10 23005482
11 23005483
Coax cable 14mm2 3m 1 pc pack
Plastic cable support
Rear box kit
12 23005539
13 23005484
14 23005536
15 23005537
16 23005538
Black screw m4x6
Plastic grommet
Male euro connection
Torch liner block nut
Blue steel wire liner 0,8-1,0
QTY.
1
1
1
1
1
12
1
1
1
29 WWW.FORNEYIND.COM
30 WWW.FORNEYIND.COM
31 WWW.FORNEYIND.COM
Forney Industries, Inc.
1830 LaPorte Avenue
Fort Collins, CO 80526
800-521-6038 www.forneyind.com
WWW.FORNEYIND.COM
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