190 MIG WELDER OWNER`S MANUAL
Contents
1. j weost osos Pos 2 vase gt 2 2 fs e z t PIS T m m T n adus os ctas ees uis uounjnBoy pasy aum 4 anm peog anm f peog z e a 2 gt lu 2 5 9 6610 ww 9 Z0 150 9 9220 241M ww 79 g 1 8 1 eBnoo 9 81 eBnpo zz eBnpo yz 59 4 135 SIW O61 GMAW Welding Setting Chart Shielding Gas Guide NOTE Mild Steel CO2 Argon 2 Argon controls spatter Argon 2 Oxygen Oxygen improves arc stability Aluminum Argon Arc stability good fusion and minimum splatter Higher heat input suitable for heavy sections Argon Helium Minimum porosity Stainless Steel Argon CO2 Oxygen Arc stability Argon Oxygen Minimum splatter Copper Nickel amp Alloys Argon Suitable for light gauges because of low flowability of the weld pool Argon Helium 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 F2. Loose connection inside the machine rare Worn or wrong size contact tip Loose gun connection or faulty gun assembly Wrong size wire Torch moved too fast Eccessive pressure on drive roller Gun liner worn or damaged Contact tip clogged or damaged Liner stretched or too long WWW FORNEYIND COM Check for proper input cable connection Check fuse and replace as necessary Replace torch trigger Allow welder to cool When the pilot lamp switch on the front panel goes dark indicates the thermostat has closed Replace wire feeding motor Increase roller pressure Re cut wire square with no burr Clear with compressed air or replace liner Re adjust the welding parameters Clear with compressed air and tighten all connections Replace the contact tip Tighten or replace torch Use correct size welding wire Move the gun smoothly and not too fast Adjust pressure on drive roller Replace wire liner Replace contact tip Cut wire liner at the right length PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Wire burns back to Contact tip clogged or damaged Replace the contact tip contact tip Wire feed speed too slow Increase wire speed Wrong size contact tip Use correct size contact tip Bad connection from cable to clamp Tighten clamp connection or replace cable Slag buildup inside nozzle or Clean or replace nozzle nozzle is shorted Workpiece clamp and or Wire
3. 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 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 6 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 co
4. 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 examination the committee of the National Research Council concl
5. Welding voltage is adjusted to match the wire feed speed welding current Progressively select higher voltage positions while increasing wire speed Increasing welding voltage leads to a longer arc without substantially affecting the current Conversely a decreased welding voltage results in a shorter arc the current again is not substantially changed A change in wire diameter results in changed parameters A smaller diameter wire requires an increase in wire feed speed to reach the same current If certain limits are exceeded a satisfactory weld cannot be obtained Refer to welding set up chart on page 14 These are A Feeding wire too fast with regard to the welding voltage results in pulsing within the torch This is because the wire electrode dips into the puddle and cannot be melted off fast enough B Setting welding voltage to high with regard to the wire feed speed will result in excessive and unstable arc Increase the voltage even higher and the contact tip will burn C Excessive wire speed can be corrected through the arc voltage increase The limit of this adjustment depends on the thickness of the material to welded a certain limit exceeded will result in burnthrough Place the torch on the joint you want to weld the angle between the torch and the nozzle should be around 45 The distance between the torch and the work piece should be approximately 1 2 Lower the face shield and press the torch trigger to start
6. 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 A 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 Continually monitor check welding area to make sure it is free of lingering sparks slag or glowing metal and flames The work area must have a fireproof floor WWW FORNEYIND COM Electric Shock WARNING ELECTRIC SHOCK CAN KILL 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
7. 8 04600114 Kit gas no gas changeboard 09 04600270 __ Switch knob d 38 Black Female gas connector 1 8 gas 5 8 unf 21 20220173 Inp Power cable3x12awg 4 5M 50a6 50p plug 04600286 Fan amp fan motor assy 220V 60hz 21690261 Cable holder 22210014K Thermostat 1002 10a 1 pc pack PART NUMBER QTY Thermostat 1272 16a 1 pc pack EE 21690225K _ Plastic hinge for door 20x30 2pcspock 2 EE cE EE ITEM DESCRIPTION 33700414 Bott 9005 oltom pane 17A swilch csa 3 ER reri d pet 33740579 Torch 9005 orch wrapper 21600067 Handle for torch wrapper 21060152K 3x3 1 20 1pc pack 33805071K E d 30 0 6 0 9Mm mot2r 1 pc E 33810136 roll secure knob 23000448 Mig torch 14mm2 3mt tweco 1 euro connect 22905101 Gas reducer 2 man Cga580 5 8 unf 2b 1 30900035 Black gas hose 3 meter 25 26 27 28 30 31 2 WWW FORNEYIND COM MIG Gun Torch Spare Parts List PART PART NO NUMBER ITEM DESCRIPTION ITEM DESCRIPTION ary ot asse vermes 09 23005535 Coan cable pepck 1 Fas 05376 Block handle for m15 torch 1 WWW FORNEYIND COM rif 911504 o 2 pa z 2 2 ee Forney Industries Inc 1830 LaPorte Avenue Fort Collins CO 80526 800 521 6038 www forneyind com WWW FORNEYIND COM
8. EFF FEETEJ 190 MIG WELDER OWNER S MANUAL CAT 00318 WELDER FEATURES e Welding range up to 190 Amps 230V Input Can be used for Mild Steel Stainless Steel Aluminum and Cast Iron Large cabinet with easy access to 4 and 8 spools e heavy duty wire drive system Torch Cable wrap 12 Premium MIG torch with Euro disconnect and Tweco style consumables Extra long 15 power cable IDEAL FOR Do It Yourself Agriculture Maintenance amp Repair Contractor Automotive Metal Fabrication Hobbyist and More INCLUDES 12 Welding Torch Ground Clamp 15 Power Cable Gas Hose and Regulator 5 3 1 SINCE THE BEGINNING 18114649 WARRANTY 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 WWW FORNEYIND COM FIVE WAYS ORDER Web www forneyind com Phone 800 521 6038 Fax 970 498 9505 Mail Forney Industries 1830 Laporte Avenue Fort Collins CO 80521 Email sales forneyind com U S Warehouses Fort Collins CO Tipp City OH Copyright 2014 Forney Industries Inc Alll
9. afety Code Section 25249 5 et seq WWW FORNEYIND COM Unpack the welder Assemble the plastic top handle using the screws provided Attach the welding torch cable to the threaded connection on the front of the welder Attach the gas hose and the electrical connector Torch Lead Gun Assembly Standard Gun or Torch Lead Gas Cylinder and Regulator Connection The bottle not supplied should be located at the rear of the welder fix the cylinder securely to the work bench or to the wall to insure that it does not fall For safety and economy ensure that the regulator is fully closed turned counterclockwise when not welding and when fitting or removing the gas cylinder Turn the regulator adjustment knob counterclockwise to ensure the valve 15 fully closed Screw the gas regulator fully down on the gas bottle valve and fully tighten Connect the gas hose to the regulator securing with clip nut provided Open the cylinder valve then set the gas flow to approx 20 30 CFH on the regulator Operate the torch trigger to ensure that the gas is flowing through the torch WARNING Cylinders are highly pressurized Handle with care Serious accidents can result from improper handling or misuse of compressed 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 WWW FORNEYIND COM MIG GMAW Fluxcore wire FCAW We
10. d Warranty Effective August 1st 2009 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 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 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 contactors and regulators plasma cutting torches and accessories D 90 days parts Does not iilud labor 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 norma
11. feed speed too fast Decrease wire feed speed cable gets hot Gun nozzle arcs to work Nozzle clogged Clean or replace nozzle surface Wire pushes torch back Torch held too far from the Hold the torch at the right distance from the workpiece workpiece Poor quality welds Weld deposit stringy and incomplete Weld deposit too thick Insufficient gas at weld area Rusty painted oil or greasy workpiece Rusty or dirty wire Poor gound contact Incorrect gas wire combination Torch moved over workpiece too quickly Gas mixture incorrect Torch moved over workpiece too slowly Welding voltage too low WWW FORNEYIND COM 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 Ensure wire is clean and dry Check gound clamp workpiece connection Check the manual for the correct conbination Move the torch slower See shielding gas table Move the torch faster Increase welding voltage Tools and Spare Parts List NO PART NUMBER ITEM DESCRIPTION QTY 21690226K Door latch 1pc pack 05000272 Left panel with silk screen and labels 04600437 Kit spool holder with ring for 5kg spool 04 44410068 Wire feeder plast all 4 37 Rul 06 09 04600145 Motor d 37 Pinion 21800051 9 30 Hand wheel m8bush 2pcs 0
12. he working area Installation Recommendations Location A Be sure to locate the welder according to the following guidelines In areas free from moisture and dust In areas with 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 obstructions 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 make sure that supply voltage and frequency available at site are those stated in the ratings label of your welder 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 outlet 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 WWW FORNEYIND COM Notes Periodically inspect supply cable for any cracks or exposed wires If it is not in good condition have it repaired by a Service Center Do not pul
13. ing aids should keep far from the welder n particular cases special protection measures may be required Interference can be reduced by following these suggestions there is interference in the power source line an E M F filter can be mounted between the outlet and the welder The output cables of the welder should not be too long kept together or connected to ground After any maintenance all the panels of the welder must be securely fastened in place WWW FORNEYIND COM Protective Welding Gases Shielding Gas Cylinders contain gas under high pressure If damaged a cylinder can explode Treat them carefully Arc 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 connnect the cylinder directly to the welder Use a pressure regulator 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 sparks slag flame or excessive heat Make sure that the gas hose is in good condition Keep the gas hose away from t
14. l violently the input power cable to disconnect it from supply outlet 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 f you use an extension cord keep it as straight as possible For lengths up to 50 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 welder must be kept outside the welding area and the ground cable should be fixed to the workpiece Never work in a damp or wet confined space Do not use damaged input or welding cables The welding torch should never be pointed at the operator s or at other persons bodies The welder must never be operated without its panels attached This could cause serious injury to the operator and could damage the equipment California Proposition 65 Warnings Welding or cutting equipment and processes produce fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp S
15. l 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 Warrantor Forney Industries 1830 Laporte Avenue Fort Collins CO 80521 1 800 521 6038 www forneyind com Purchaser Warranty The original purchaser of the Forney Industries product The 15 not transferable Forney Industries products are intended for purchase and use by persons trained and experienced in the use and maintenance of welding equipment 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 supplied with the product D Pre delivery service i e assembly and adjustment Claim In the event of a warranty claim under this warranty the exclusive remedies shall be 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 auth
16. lding Torch Connection Connect the standard MIG torch to the threaded connector on the front of the welder tighten firmly by hand 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 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 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 Connell RES ut power cord and turn on the welder Press the torch trigger and observe the wire feedi
17. ng 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 WWW FORNEYIND COM 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 Replacing the Wire Liner Ensure the gas and electrical supplies are disconnected Disconnect the torch from the machine
18. nnecting 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 WWW FORNEYIND COM 4 epine aM ju joods Ulo Wal 002 s 01 uouisog gt of yoay Jo JONVHD Wdl 08 5 uouisog ssayBiy eui si 9 uouisog ALnIVIOd ONINNIO38 SHL ADNIS NI 9NIQ13M unB DJW eui ui ei epoape e y s Jo SJAA peeds S S siu BUY sjes 514 peeds Jo 4uo5 4SN 94055914 pe tes fe c ou Le 9 Te gt db oy
19. orized 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 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 amp or packaging costs if any must be borne by the purchaser WWW FORNEYIND COM TABLE OF CONTENTS WARRANTY TABLE OF CONTENTS SAFETY INFORMATION ASSEMBLY AND MAJOR COMPONENTS FRONT PANEL OPERATION GENERAL OPERATING INSTRUCTIONS TROUBLESHOOTING SPARE PARTS AND DIAGRAMS WWW FORNEYIND COM CAUTION BEFORE INSTALLING OPERATING OR CARRYING OUT MAINTENANCE ON THE 210 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 249 1 from American Welding Society 8669 Doral Boulevard Suite 130 Doral FL 33166 Safety and Health Standards OSHA 29 CFR
20. rights reserved Unauthorized reproduction and or distribution is subject to US copyright laws 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 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 Gr plin WWW FORNEYIND COM Forney 5 3 1 Limite
21. ront Panel Operation Units may be used with the standard torch Welder Controls 1 Main ON OFF switch and welding voltage adjustment 2 Wire feed adjustment knob To increase the wire speed turn the potentiometer clockwise to decrease the wire speed turn it counter clockwise The same procedure decreases the values on the welding parameters Turn knob slowly 3 Ground Clamp 4 MIG Torch Gun WWW FORNEYIND COM Welding Preparation 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 Plug the machine into a suitable outlet Completely open the gas cylinder valve Adjust the gas pressure regulator to the correct flow rate General Operating Instructions Some experience is required to adjust and use a MIG welder In MIG welding two parameters are fundamental the welding voltage and the wire speed The resulting welding current is a result of these two settings Set the voltage and wire feed controls to positions suitable for the thickness of the material to be welded Welding current varies in relationship to wire feed speed For low welding current output the wire feed speed potentiometer should be set at the low end of the wire feed speed scale Turning the wire feed speed control potentiometer clockwise Will result in increased wire feed speed and welding current
22. sed oir to periodically clean the hose liner especially when changing wire spools IMPORTANT Disconnect from power source when carrying out this operation Using low pressure air 3 5 20 30 PSI occasionally blow the dust from the inside of the welder This keeps the machine running cooler Note do not blow air over the printed circuit board and electronic components The wire feed roller will eventually wear during normal use With the correct tension the pressure roller must feed the wire without slipping If the pressure roller and the wire feed roller make contact when the wire is in place between them the wire feed roller must be replaced Check all cables periodically They must be in good condition and not cracked WWW FORNEYIND COM Troubleshooting This chart will assist you in resolving common problems you may encounter These are not all the possible solutions PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION No power from welder P 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 Wire is birdnesting at the drive roller Input cable or plug malfunction Wrong size fuse Faulty trigger gun Thermostat intervention Faulty wire feeding motor rare Insufficient feed roller pressure Burr on end of wire Liner blocked or damaged Voltage or wire feed speed too low
23. t 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 front and sides of the neck and face Keep protective lens clean and replace them when broken cracked or spattered Weld in a closed but well ventilated area that does not open into other working areas Never look at the arc without correct lens A 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 or zinc coatings to avoid production of harmful fumes Parts degreased with a solvent must be thoroughly dried before welding Be very careful when welding any metals which may contain one or more of the follwing Antimony Beryllium Cobalt Manganese Selenium Arsenic Cadmium Copper Mercury Silver Barium Chromium Lead Nickel Vanadium Zinc Remove all
24. the arc When the arc has struck move the nozzle slowly from left to right along the joint Adjust the wire feed speed until the arc makes a crisp sound experience will help you to recognize the right sound Aluminum Welding The machine should be set up as for mild steel except for the following changes 100 ARGON as weld shielding gas Ensure that your torch is set up for aluminum welding The length of the torch cable should not exceed 10 it is advisable not to use longer torches Install teflon wire liner Follow the instructions for changing the liner Ensure that drive rolls are suitable for aluminum wire 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 WWW FORNEYIND COM Welding Hints and Maintenance Always weld clean dry and well prepared material Hold gun at a 45 angle to the workpiece with nozzle about 1 2 from the surface Move the gun smoothly and steadily as you weld Avoid welding in very drafty areas A weak pitted and porous weld will result due to air blowing away the protective welding gas Keep wire and wire liner clean Do not use rusty wire Sharp bends or kinks in the welding cable should be avoided Always try to avoid getting particles of metal inside the machine since they could cause short circuits or other damage Use compres
25. uded 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 Keep cobles close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Keep welding or cutting power source and cables as far away from operator as practical Connect work clamp to work piece as close to the cut or weld as possible About Pacemakers amp Hearing Aids Pacemaker amp Hearing Aid wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended WWW FORNEYIND COM 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 ultraviolet and infrared light These arc rays will damage your eyes and burn your skin if you are not properly protected Wear closed non flammable protective clothing withou
26. 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 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 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 electrical appliances computers or other control systems near the unit People with pacemakers or hear
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