90 MP MIG/STICK/TIG WELDER OPERATING MANUAL ENGLISH ITEM# 323 REV 05.10.
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TECHNICAL ISSUES? FORNEY CAN HELP! Thank you for choosing Forney! Please note: The store you purchased this machine from DOES NOT handle product returns. Forney Industries will repair or replace defective products at no charge to you! When you call Forney’s Technical Service department, you will speak to a trained product and application expert. Forney’s primary goal is to get your machine up and running in as little time as possible.
Table of Contents WARRANTY...........................................................................................................................................................................3 TABLE OF CONTENTS.............................................................................................................................................................4 SYMBOLS LEGEND...........................................................................................................................
CAUTION! BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE ON THE MACHINE, 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.
• ANSI Z87.1 - SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION - Obtainable from the American National Standards Institute, 11 West 42nd St., New York, NY 10036 Telephone (212) 642-900, Fax (212) 398-0023 - www.ansi.org. • NFPA 51B: STANDARD FOR FIRE PREVENTION DURING WELDING, CUTTING, AND OTHER HOT WORK- Obtainable from the National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101 Telephone (617) 770-3000 Fax (617) 770-0700 - www.nfpa.org.
• Flying sparks can injure. Wear proper safety equipment to protect eyes and face. Shape tungsten electrode on grinder wearing proper protection and in a safe location. Keep flammables away and prevent fire from flying sparks. FUMES, GASSES, AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS, AND DEATH! To reduce the risk, read, understand, and follow the safety instructions.
• Keep cylinders upright and securely chain them to a fixed support to prevent tipping. • Keep cylinders away from areas where they may be subjected to physical damage or accidentally struck. Keep them a safe distance from any source of flame, sparks, or heat. • Do not weld or cut in an area where the air may contain flammable dust (such as grain dust), gas, or liquid vapors (such as gasoline). • Do not handle hot metal, such as the workpiece or electrode stubs, with bare hands.
• Do not allow the welding equipment to come in contact with water or moisture. • Do not drag welding cables, MIG gun, or welder INPUT POWER CABLE through or allow them to come into contact with water or moisture. • Do not touch welder, attempt to turn welder ON or OFF if any part of the body or clothing is moist or if you are in physical contact with water or moisture.
Installation Welder Specifications Primary (Input) Volts 120VAC/240VAC Maximum Output 120V - 120A (DC output only) 240V - 200A (DC output only) Phase Single Frequency 50/60Hz Recommended Circuit Breaker 120V - 30A time-delay (slow-blow) breaker for maximum performance (15A minimum breaker size) 240V - 50A time-delay (slow-blow) breaker for maximum performance (30A minimum breaker size) Refer to the ratings label and set the output amperage so that the listed input amperage is not exceeded.
Using the 240 volt – 120 volt Adapter Cord If a 240V (50A) circuit is not available, you can connect your Forney 190 MP welder to a 120V, 20A dedicated circuit (with a 30A breaker) using the adapter cord. When using the adapter cord for 120V, use lower power settings on the machine to avoid frequent circuit breaker trips. At maximum settings on 120V, the machine will draw more than 20 amps regularly. 120V/20A 240V/50A Generators This welder can be operated from an AC generator.
Getting to Know Your Multi-Process Welder Description Your new inverter multi-process welder offers three welding processes in the same power source. MIG welding can be performed manually or with TruSet™. TruSet™ automatically sets optimal welding parameters based on wire diameter, type, welding gas, and workpiece thickness. These processes / TruSet™ wire diameters can be selected with the PROCESS SELECTOR BUTTON (1) on the front panel of the unit.
11. EURO CONNECT SOCKET FOR MIG GUN 12. MIG ELECTRODE POLARITY JUMPER 13. ACCESSORY SOCKET for connecting a spool gun (unit will automatically recognize the accessory) 14. NEGATIVE (-) DINSE SOCKET 15. POSITIVE (+) DINSE SOCKET 16. POWER SWITCH 17. MIG GAS INPUT 18. INPUT POWER CABLE 19. WIRE SPOOL SPINDLE 20. STAMPED ALUMINUM TWO-ROLL WIRE-FEEDER 21.
Installing the MIG gun Assembly • Attach the MIG welding gun to the EURO CONNECT on the front of the welder. Gas Cylinder and Regulator Connection The gas cylinder (not supplied) should be located near the rear of the welder, in a well-ventilated area and securely fixed to the work bench or to the wall to ensure that it will 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.
Setup for use with 4-inch spools: NOTE: These steps assume the despooler is completely assembled for the 8-inch spool arrangement (default configuration from the factory). 1. Open the wire cabinet door. 2. Press in on the locking key (B) (this will compress the spring (F) slightly), then twist counterclockwise approximately 1/8th of a turn until it stops. The locking key (B) can now be removed by sliding it straight out. 3. Remove the spindle adapter for 8-inch spools (A) and store it someplace safe. 4.
Setup for use with 8-inch spools: 1. Open the wire cabinet door 2. Install the washers (E) and spring (F) on the main shaft (D), followed by the spindle adapter for 8-inch spools (A) as shown in the diagram above. 3. Install the locking key (B) by aligning the internal key pegs with the keyways of the shaft (D). Press the key (B) onto the shaft (D) until it stops. Rotate the locking key (B) clockwise by approximately 1/8th of a turn until it stops. This will compress the spring (F). 4. Release the key (B).
7. Install the spool retaining ring (C) on the end of the spindle adapter (A) by first aligning the internal pegs of the retaining ring (C) with the keyways on the end of the spindle adapter (A). Slide the retaining ring (C) onto the spindle adapter (A) until it stops. 8. With a sharp twist clockwise, lock the retaining ring (C) in place. *NOTE: You will hear a click if done correctly. 9. Proceed to “FEEDING WIRE THROUGH THE MIG GUN” instructions below.
Operation Performance Data Plate and Duty-Cycle On the machine, there is a plate that includes all the operating specifications for your new unit. The serial number of the product is also found on this plate. The duty-cycle rating of a welder defines how long the operator can weld and how long the welder must rest and be cooled. Duty-cycle is expressed as a percentage of 10 minutes and represents the maximum welding time allowed. The balance of the 10-minute cycle is required for cooling.
Internal Thermal Protection If you exceed the duty-cycle of the welder, the thermal protection system will engage, shutting off all welder output. After cooling, the thermal protector will automatically reset and the welding functions can resume. This is normal and automatic behavior of the machine, and does not require any user action. However, you should wait at least ten minutes after the thermal protector engages before resuming welding.
Welding Wire Selection This welder can work with solid steel wire (MIG welding, “GMAW”) from 0.023” - 0.035” (0.6 - 0.9mm) diameter; stainless steel wire from 0.023” - 0.035” (0.6 - 0.9mm) diameter and with flux-cored wire (flux-cored wire welding, “FCAW”) from 0.030” - . 0.035” (0.8 - 0.9mm) diameter. Gas Selection Select the appropriate shielding gas in accordance with material being welded and wire being used.
e. SS98/2 = Solid Wire (Stainless Steel) + 98% Argon/2% CO2 Gas f. Al4043 + 100Ar = 4043 Aluminum Wire + 100% Argon g. Al5356 + 100Ar = 5356 Aluminum Wire + 100% Argon (.035” TruSet™ MIG only with 240 VAC input power) Please note that some options are only available with certain setups. For example, Aluminum options are not available if no spool gun is detected and steel options are not available with a spool gun. 3. Push the RIGHT KNOB to light the PARAMETER LED. 4.
Setup for DC TIG Welding (GTAW) with Lift Arc This machine does not support a foot pedal or amperage-controlling torch for TIG welding. Amperage adjustments must be made on the machine and a lift arc technique is required. Setting up the equipment for TIG welding (GTAW): WARNING: TIG TORCH IS ALWAYS LIVE (ELECTRICALLY HOT). Use caution and ensure the TIG torch is not in contact with or near conductive or grounded materials.
Maintenance & Servicing General Maintenance This welder has been engineered to need minimal service providing that a few very simple steps are taken to properly maintain it. 1. Always keep the cabinet cover closed unless changing the wire or the drive pressure. 2. Keep all consumables (contact tips, nozzles, and liner) clean and replace when necessary. See “Consumable Maintenance” (below) and “Troubleshooting” (page 25) for detailed information. 3.
Replacing the Gun Liner 1. Remove the MIG gun from the machine by disconnecting the Euro connector. 2. Use a wrench to remove the cap nut that holds the liner in place. Set the nut aside somewhere safe. 3. Straighten the gun lead as much as possible. It is best to lay it across the ground or another flat surface. 4. Grab the brass end of the liner and begin pulling. 5. Once enough of the liner is exposed, grab it by hand and pull until the full liner comes out of the gun. 6.
Troubleshooting The following is a troubleshooting table provided to help you determine a possible remedy when you are having a problem with your welder. This table does not provide all possible solutions, only those possibilities considered likely to be common faults. PROBLEM All LEDs OFF, No output power, Fan not operating. POSSIBLE CAUSE POSSIBLE SOLUTION No input power. Connect machine to proper input power source. Verify that circuit breaker has not been tripped in your main power panel.
PROBLEM Poor quality welds. Wire-feeds but no arc. POSSIBLE CAUSE POSSIBLE SOLUTION Insufficient gas at weld area. Check that the gas is not being blown away by drafts and, if so, move to a more sheltered weld area. If not, check gas cylinder contents, gauge, regulator setting, and operation of gas valve. Rusty, painted, oily or greasy workpiece. Ensure workpiece is clean and dry. Rusty or dirty wire. Ensure wire is clean and dry. Poor ground connection or gun/electrode connection.
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Weld parameters too low. Adjust welding parameters. Too long or improper extension cord. Use a proper extension cord (#12 AWG wire or heavier, no longer than 25 ft.). See “Extension Cords”, page 20. Wrong type or size wire. Use 0.023” (0.6mm) - 0.035” (0.9mm) wire. See “Welding Wire Selection” (page 20). Poor ground connection or gun connection. Reposition clamp and check cable to clamp connection. Low output or non-penetrating weld.
PROBLEM Wire burns back to contact tip. Difficult arc start. Arc is wandering (TIG). 28 POSSIBLE CAUSE POSSIBLE SOLUTION Wire-feed speed is set too low for voltage setting being used. Increase wire-feed speed (turn RIGHT KNOB clockwise) or choose a thicker material if using TruSet™ MIG. Stick-out too short. Increase stick-out (the amount the wire extends past the contact tip). Wrong size contact tip. Use correct size contact tip. Contact tip is clogged or damaged. Replace contact tip.
Machine Parts Diagram & Replacement Parts List NO. PART NUMBER ITEM DESCRIPTION 1 84094 MIG Gun 2 85667 Ground (25 Dinse) 3 85669 Electrode Holder (25 Dinse) 4 78036 240V-120V Adapter Cord 5 5084 Expert-Tech Tool 1 2 4 3 WWW.FORNEYIND.
MIG Gun Consumables List NO. PART NUMBER 1 60170 (4pk) Tip (Tweco® 11-23) 60171 (4pk) Tip (Tweco® 11-30) 60172 (4pk) Tip (Tweco® 11-35) 4 100356 3 ITEM DESCRIPTION NO. PART NUMBER 2 85339 Diffuser (Tweco® 35-50) 85336 Nozzle (Tweco® 21-50) 85337 Nozzle (Tweco® 21-62) 3 Liner 1 2 4 TIG Torch & TIG Consumables List Recommended TIG Torch: Part number 85659 17 FV TIG Torch 30 WWW.FORNEYIND.
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Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 +1-800-521-6038 www.forneyind.
