210 MIG WELDER OWNER’S MANUAL CAT.
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. 2 WWW.FORNEYIND.
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: sales@forneyind.com U.S. Warehouses: - Fort Collins CO - Horseheads NY 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.
Forney 5/3/1 Limited 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.
TABLE OF CONTENTS WARRANTY................................................................................................................................... 4 TABLE OF CONTENTS..................................................................................................................... 5 SAFETY INFORMATION.................................................................................................................. 6 ASSEMBLY AND MAJOR COMPONENTS...................................................
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 Z49.
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.
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.
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. • Make sure the pressure regulator and the gauges function properly.
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 pull violently the input power cable to disconnect it from supply outlet. • Do not squash the supply cable with other machines. It could be damaged and cause electric shock. • Keep the supply cable away from heat sources, oils, solvents or sharp edges. • In case you are using an extension cord, try to keep it straight, and untangled to avoid overheating.
Assembly • Unpack the welder. • Assemble the plastic top handle using the screws provided. • Plug the torch hose into the socket on the front of the welder. • Attach the gas hose and the electrical connector. Torch Lead and Spool Gun Assembly Standard Gun or Torch Lead Spool Gun Gas Cylinder and Regulator Connection The bottle (not supplied) should be located at the rear of the welder, securely held in position by the chain provided.
Shielding Gas Guide Metal GAS NOTE Mild Steel CO2 Argon + CO2 Argon + CO2 + Oxygen Argon controls spatter Oxygen improves arc stability Aluminum Argon Stainless Steel Argon + Helium Arc stability, good fusion and minimum splatter. Higher heat input suitable for heavy sections. Minimum porosity. Argon + CO2 + Oxygen Argon + Oxygen Arc stability. Minimum splatter. Copper, Nickel & Alloys Argon Argon + Helium Suitable for light gauges because of low flowability of the weld pool.
• Loosen and lower the plastic knob (A) (Fig.5). Release the upper roll (B) of the feeder. Extract the wire from the torch liner. • When the wire is disconnected, grasp it with pliers so that it cannot exit from the spool. If necessary, straighten it before inserting it in the wire input guide (C). Insert the wire on the lower roll (D) and in the torch liner (E). WARNING: keep the torch straight when feeding a new wire through the liner.
How to Choose the Wire Liner for Direct and Euro Connection Torches • There are basically 2 types of wire liners: Steel wire liners and Teflon wire liners. • Steel wire liners can be coated or not coated. Coated wire liners are used for air cooled torches. The wire liners are used for water cooled torches. • Teflon wire liners are recommended for aluminum welding as they allow a smooth feeding of the wire.
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 on page 14.
Front Panel Operation Units may be used either with the standard torch (supplied with them) or with the Spool Gun. 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 counterclockwise. The same procedure decreases the values on the welding parameters. Turn knob slowly. 3. Overheating indicator (yellow) This LED blinks when unit is overheating.
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.
Technical Data Information Guide 1. 2. 3. 4. 5. 6. 7. 8. Serial number of the unit Welder model Type of characteristic Min. - Max rated No Load Voltage Type of welding Symbol for the main supply and no. of phases Rated value of the supply voltage Code letter for degree of insulation 9. 10. 11. 12. 13. 14. 15. 16.
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. Input cable or plug malfunction. Check for proper input cable connection. Check fuse and replace as necessary. Wrong size fuse. Fan operates normally, but Faulty trigger gun. when gun trigger pulled, there is no wire feed, weld Thermostat intervention. output or gas flow. Replace torch trigger.
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Wire burns back to contact tip. Contact tip clogged or damaged. Replace the 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 nozzle is shorted. Clean or replace nozzle. Workpiece clamp and/or cable gets hot. Wire feed speed too fast. Decrease wire feed speed.
Tools and Spare Parts List NO. PART NUMBER 21 ITEM DESCRIPTION QTY. 01 21690226K Door latch (1pc pack) 1 02 05000262 Left panel with silk screen and labels 1 03 04600421 Kit spool holder with ring for 5kg spool 1 04 33720285 9005 Dividing panel 1 05 44410076 Metallic wire feeder d.37 2Rolls 1 06 04600145 Motor d.37 + Pinion 1 07 22210012K Circuit breaker 32a 1 pc pack 1 08 21690179K Switch knob d.38 Black 1pc pack 1 09 04600337 Black knob d.38 For potentiom.
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Torch/Gun Installation 1 Front View 4 2 Torch/Gun Installation Spool & Torch Assembly Complete 3 5 Torch/Gun Consumable Assembly Gas Hose Connection Polarity Change Electrical Connector 24 WWW.FORNEYIND.
Spool Installation 1 Loosen tension knob & lift roller 2 Install wire Lock in roller and correctly set tension 3 25 WWW.FORNEYIND.
MIG Gun Torch Spare Parts List NO. PART NUMBER 26 ITEM DESCRIPTION QTY. NO. PART NUMBER ITEM DESCRIPTION QTY. 01 23005373K Tweco torch nozzle 21-50f 1 pc pack 1 06 23005376K Black handle for m15 torch 1 pc pack 02 23005018K 0,6Mm contact tip for t1.4-1.6 10 pc pack 10 07 23005362K Screws for m25 torch handle 12 pcs pack 12 02 23005019K 0,8Mm contact tip for t1.4-1.6 10 pc pack 10 08 23005377K Red torch trigger 1 pc pack 1 02 23005182K 0,9Mm contact tip for t1.4-1.
Spool Gun Torch Spare Parts List NO. PART NUMBER 27 ITEM DESCRIPTION QTY. 01 23005147K Torch gas nozzle tw1 mc-31 5 pcs pack 5 02 23005331K Contact tip d.0,8 Al t1.4 10 pc pack 10 03 23005278K Gas diffuser for spoolgun neck 1 pc pack 1 04 23005186K Insulator torch body for spoolg.1Pc pack 05 NO. PART NUMBER ITEM DESCRIPTION QTY. 21 22910001K Fast conn.For hose d.4 M6x0,75 2 pcs pack 2 22 04600143 Wire feeding motor d.
Forney Industries, Inc. 1830 LaPorte Avenue Fort Collins, CO 80526 800-521-6038 www.forneyind.com WWW.FORNEYIND.
