Forney 242 Operating Manual
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242 DUAL MIG WELDER
OPERATING MANUAL
FEATURES:
• 240A Output
• 230V Input
• Heavy-Duty torch
• Aluminum drive system
• Welds steel or aluminum with only the flip
of a switch
• 2 Euro connects; 1 dedicated to spool gun
• Easy to use, increases productivity
• Digital readout for true amps
• Three trigger modes with spot weld timer
• Optional spool gun increases versatility
• Burn back and slope controls
• Spray transfer capability
• 2 gas solenoids
IDEAL FOR:
Steel, Stainless Steel, and Aluminum welding;
General Fabrication, Auto Body, Farm &
Ranch, Sheet Metal, Contractor, and More...
INCLUDES:
Torch with lead; Ground Cable and Clamp;
Input Power Cable; Gas Hose and Regulator;
Wheel Assembly Kit; Consumables Box
CAT# 327
ENGLISH
REV 09/01/15
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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 7 a.m. - 5 p.m. (MST) or at
www.forneyind.com/customer_service.
Please take time to register your product at
www.forneyind.com/customer_service/register_your_product/
Thank you, enjoy your new welder.
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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.
STEVEN G. ANDERSON, President & CEO
Copyright© 2014 Forney Industries,
Inc. All rights reserved. Unauthorized
reproduction and/or distribution is
subject to US copyright laws.
U.S. Warehouses:
- Fort Collins, CO
- Tipp City, OH
FIVE WAYS TO ORDER
Web: www.forneyind.com
Phone: 80 0-521-6038
Fax: 970-498-9505
Mail: Forney Industries
2057 Vermont Drive
Fort Collins, CO 80525
Email: sales@forneyind.com
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Forney 5/3/1 Limited Warranty
Effective July 1, 2015
1) Limited Warranty - Subject to the terms and conditions below, Forney Industris, 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, expressed or implied.
2) Notifications: Please call 1-800-521-6038 with your warranty questions. You can also visit:
www.forneyind.com for additional information about your new welder or plasma system.
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, and Switches and Controls
C) 1 year: MIG guns, relays, contactors, and regulators, plasma cutting torches, and accessories.
D) 90 days: Replacement parts. Does not include labor.
4) 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
2057 Vermont Drive
Fort Collins, CO 80525
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 risk 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 station; 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 forneywelding.forneyind.com 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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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
• 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
California Proposition 65 Warning
This product may contain chemicals known to the State of California to cause cancer, birth defects and
other reproductive harm (CA. Prop 65). Wash hands after use.
EMF Information
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 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 welding or cutting power source and cables as far away from operator as practical.
5. Connect work clamp to work piece as close to the cut or weld as possible.
ABOUT PACEMAKERS & HEARING AIDS:
Pacemaker & Hearing Aid wearers consult your doctor first. If cleared by your doctor, then following
the above procedures is recommended.
Principal Safety Standards
Safety Information
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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.
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. To reduce the risk of injury from arc rays, read,
understand, and follow the safety instructions. In addition, make certain that anyone else that
uses this welding equipment, or is a bystander in the welding area understands and follows
these safety instructions as well. Helmets and filter should conform to ANZI 287.1 stan dards.
• Do not look at an electric arc without proper protection. A welding arc is extremely bright
and intense and, with inadequate or no eye protection, the retina can be burned, leav ing
a permanent dark spot in the field of vision. A shield or helmet with a #10 shade filter lens
(minimum) must be used.
• Do not strike a welding arc until all bystanders and you (the welder) have welding shields
and/or helmets in place.
• Do not wear a cracked or broken helmet and replace any cracked or bro ken filter lenses
immediately.
• Do not allow the uninsulated portion of the wire feed gun to touch the ground clamp or
grounded work to prevent an arc flash from being created on contact.
• Provide bystanders with shields or hel mets fitted with an appropriate shade filter lens.
• Wear protective clothing. The intense light of the welding arc can burn the skin in much
the same way as the sun, even through light-weight clothing. Wear dark clothing of heavy
material. The shirt worn should be long sleeved and the collar kept buttoned to protect chest
and neck.
• Protect against reflected arc rays. Arc rays can be reflected off shiny sur faces such as a glossy
painted surface, aluminum, stainless steel, and glass. It is possible for your eyes to be injured
by reflected arc rays even when wearing a protective helmet or shield. If welding with a
reflective surface behind you, arc rays can bounce off the surface and off the fil ter lens. It can
get inside your helmet or shield and into your eyes. If a reflective background exists in your
welding area, either remove it or cover it with something non-flammable and non-reflective.
Reflective arc rays can also cause skin burn in addition to eye injury.
• 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. In addition,
make certain that anyone else that uses this welding equipment or is a bystander in the welding
area, understands and follows these safety instructions as well.
• Read and understand manufacturers SDS and MSDS.
• Do not weld in an area until it is checked for adequate ventilation as described in ANSI
standard Z49.1. If ventilation is not adequate to exchange all fumes and gasses generated
during the welding process with fresh air, do not weld unless you (the welder) and all
bystanders are wearing air-supplied respirators.
• Do not heat metals coated with, or that contain, materials that produce toxic fumes (such as
galvanized steel), unless the coating is removed. Make certain the area is well ventilated, and
the operator and all bystanders are wearing air-sup plied respirators.
• Do not weld, cut or heat lead, zinc, cad mium, mercury, beryllium, antimony, cobalt,
manganese, selenium, arsenic, copper, silver, barium, chromium, vanadium, nickel, or similar
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met als without seeking professional advice and inspection of the ventilation of the welding
area. These metals produce extremely toxic fumes which can cause discomfort, illness and
death.
• Do not weld or cut in areas that are near chlorinated solvents. Vapors from chlori nated
hydrocarbons, such as trichloroeth ylene and perchloroethylene, can be decomposed by the
heat of an electric arc or its ultraviolet radiation. These actions can cause phosgene, a high ly
toxic gas, to form, along with other lung and eye-irritating gasses. Do not weld or cut where
these solvent vapors can be drawn into the work area or where the ultraviolet radiation can
pene trate to areas containing even very small amounts of these vapors.
• Do not weld in a confined area unless it is being ventilated or the operator (and anyone else
in the area) is wearing an air-supplied respirator.
• Stop welding if you develop momentary eye, nose, or throat irritation as this indi cates
inadequate ventilation. Stop work and take necessary steps to improve ventilation in the
welding area. Do not resume welding if physical discomfort persists.
Fire Prevention
FIRE OR EXPLOSION CAN CAUSE DEATH, INJURY, AND PROPERTY DAMAGE!
To reduce these risks, read, understand and follow the safety instructions. In addition, make
certain that anyone else that uses this welding equip ment, or is a bystander in the welding
area, understands and follows these safety instruc tions as well. Remember: arc welding by
nature produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can
start fires, burn skin and damage eyes.
• Do not wear gloves or other clothing that contains oil, grease, or other flammable
substances.
• Do not wear flammable hair preparations.
• Do not touch the hot weld bead or weld puddle until fully cooled.
• Do not weld in an area until it is checked and cleared of combustible and/or flam mable
materials. Be aware that sparks and slag can fly 35 feet and can pass through small cracks
and openings. If work and combustibles cannot be sepa rated by a minimum of 35 feet,
protect against ignition with suitable, snug-fitting, fire resistant, covers or shields.
• Do not weld on walls until checking for and removing combustibles touching the other side of
the walls.
• Do not weld, cut, or perform other such work on used barrels, drums, tanks, or other
containers that had a flammable or toxic substance. The tech niques for removing flammable
sub stance and vapors, to make a used con tainer safe for welding or cutting, are quite
complex and require special educa tion and training.
• Do not strike an arc on a compressed gas or air cylinder. Doing so will create a brittle
area that can result in a violent rupture immediately or at a later time as a result of rough
handling.
• 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 work piece or electrode stubs, with bare hands.
• Wear leather gloves, heavy long sleeve shirt, cuffless pants, high-topped shoes, helmet, and
cap. As necessary, use additional protective clothing such as leather jacket or sleeves, fire
resistant leggings, or apron. Hot sparks or metal can lodge in rolled up sleeves, pant cuffs,
or pockets. Sleeves and collars should be kept buttoned and pockets eliminated from the shirt
front.
• Have fire extinguisher equipment handy for immediate use. A portable chemical fire
extinguisher, type ABC, is recom mended.
• Wear ear plugs when welding overhead to prevent spatter or slag from falling into ear.
• Make sure welding area has a good, solid, safe floor, preferably concrete or masonry, not
tiled, carpeted, or made of any other flammable material.
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• Protect flammable walls, ceilings, and floors with heat resistant covers or shields.
• Check welding area to make sure it is free of sparks, glowing metal or slag, and flames
before leaving the welding area.
• Wear garments free of oil or other flammable substances such as leather gloves, thick cotton
shirts with no synthetic materials, cuffless trousers, closed toed shoes. Keep long hair pulled
back.
• Remove any combustibles such as lighters and matches before doing any welding.
• Follow requirements in OSHA and NFPA for hot work and have an extinguisher nearby.
• High Frequency (H.F) can interfere with radio navigation, safety services, computers and
communication equipment.
• It is the user’s responsibility to have a qualified electrician promptly correct any interference
problem resulting from the installation. Electrician should regularly check and maintain
installation.
• Stop using the equipment if notified by the FCC about interference.
• Keep H.F. source doors and panels tightly shut and keep spark gaps at correct setting.
• Computers and computer driven equipment can be harmed with electromagnetic energy.
• Be sure all equipment is compatible with electromagnetic energy.
• Keep welding cables short to reduce interference.
• Follow manual to install and ground machine.
• If interference continues, shield the work area or move the welding machine.
WARNING: ELECTRIC SHOCK CAN KILL! To reduce the risk of death or serious injury
from shock, read, understand, and follow the safety instructions. In addition, make certain
that anyone else who uses this welding equipment, or who is a bystander in the welding area
understands and follows these safety instructions as well.
IMPORTANT! TO REDUCE THE RISK OF DEATH, INJURY, OR PROPERTY
DAMAGE, DO NOT ATTEMPT OPERA TION of this welding equipment until you have read
and understand the following safety summary.
• Do not, in any manner, come into physi cal contact with any part of the welding current
circuit. The welding current circuit includes:
a. the work piece or any conductive material in contact with it,
b. the ground clamp,
c. the electrode or welding wire,
d. any metal parts on the electrode holder, or wire feed gun.
• Do not weld in a damp area or come in contact with a moist or wet surface.
• Do not attempt to weld if any part of clothing or body is wet.
• Do not allow the welding equipment to come in contact with water or moisture.
• Do not drag welding cables, wire feed gun, or welder power cord 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.
• Do not attempt to plug the welder into the power source if any part of body or cloth ing is
moist, or if you are in physical con tact with water or moisture.
• Do not connect welder work piece clamp to or weld on electrical conduit.
Electric Shock
Arc Welding
High Frequency Radiation
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• Do not alter power cord or power cord plug in any way.
• Do not attempt to plug the welder into the power source if the ground prong on power cord
plug is bent over, broken off, or missing.
• Do not allow the welder to be connected to the power source or attempt to weld if the
welder, welding cables, welding site, or welder power cord are exposed to any form of
atmospheric precipitation, or salt water spray.
• Do not carry coiled welding cables around shoulders, or any other part of the body, when
they are plugged into the welder.
• Do not modify any wiring, ground connections, switches, or fuses in this welding equipment.
• Wear welding gloves to help insulate hands from welding circuit.
• Keep all liquid containers far enough away from the welder and work area so that if spilled,
the liquid cannot possibly come in contact with any part of the welder or electrical welding
circuit.
• Replace any cracked or damaged parts that are insulated or act as insulators such as
welding cables, power cord, or electrode holder immediately.
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.
Additional Safety Information
For additional information concerning weld ing safety, refer to the following standards and comply with
them as applicable.
• ANSI Standard Z49.1 - SAFETY IN WELDING AND CUTTING - obtainable from the
American Welding Society, 550 NW Le Jeune Road, Miami, FL 33126 Telephone (800)
443-9353, Fax (305) 443-7559 - www.amweld.org or www.aws.org
• ANSI Standard Z87.1 - SAFE PRAC TICE FOR OCCUPATION AND EDUCA TIONAL EYE
AND FACE PROTECTION - obtainable from the American National Standards Institute, 11
West 42nd St., New York, NY 10036 Telephone (212) 642A900, Fax (212) 398-0023 www.ansi.org
• NFPA Standard 518 - CUTTING AND WELDING PROCESS - 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
• OSHA Standard 29 CFR, Part 1910, Subpart Q., WELDING, CUTTING AND BRAZING
- obtainable from your state OSHA office or U.S. Dept. of Labor OSHA, Office of Public
Affairs, Room N3647, 200 Constitution Ave., Washington, DC 20210 - www.osha.gov
• CSA Standard W117.2 - Code for SAFE TY IN WELDING AND CUTTING. - obtainable
from Canadian Standards Association, 178 Rexdale Blvd., Etobicoke, Ontario M9W 1R3 www.csa.ca
• American Welding Society Standard A6.0. WELDING AND CUTTING CON TAINERS
WHICH HAVE HELD COM BUSTIBLES. - obtainable from the American Welding Society, 550
NW Le Jeune Road, Miami, FL 33126 Telephone (800) 443-9353, Fax (305) 443-7559 www.amweld.org or www.aws.org
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WARRANTY ................................................................................................................................................ 4
SAFETY INFORMATION ...............................................................................................................................5
PRINCIPAL SAFETY STANDARDS ............................................................................................................5
CALIFORNIA PROPOSITION 65 WARNING ............................................................................................5
EMF INFORMATION..............................................................................................................................5
PERSONAL PROTECTION ......................................................................................................................6
FIRE PREVENTION .................................................................................................................................7
HIGH FREQUENCY RADIATION ............................................................................................................. 8
ARC WELDING .....................................................................................................................................8
ELECTRIC SHOCK ..................................................................................................................................8
NOISE ..................................................................................................................................................9
ADDITIONAL SAFETY INFORMATION ....................................................................................................9
TABLE OF CONTENTS ................................................................................................................................ 10
INSTALLATION .......................................................................................................................................... 11
LOCATION .........................................................................................................................................11
VENTILATION .....................................................................................................................................11
MAIN SUPPLY VOLTAGE REQUIREMENTS ............................................................................................11
SAFETY INSTRUCTIONS ......................................................................................................................11
ASSEMBLY ................................................................................................................................................12
HANDLE AND WHEELS ASSEMBLY (FIG. 1) ..........................................................................................12
TORCH LEAD AND SPOOL GUN ASSEMBLY (FIG. 2) ............................................................................12
GAS CYLINDER AND REGULATOR CONNECTION ...............................................................................12
SHIELDING GAS GUIDE ......................................................................................................................13
LOAD WIRE ........................................................................................................................................13
REPLACING THE WIRE LINER ...............................................................................................................14
HOW TO CHOOSE THE WIRE LINER FOR DIRECT AND EURO CONNECTION TORCHES .......................15
ARRANGEMENT FOR WELDING WITH SPOOL GUN ............................................................................15
SETTING THE WIRE DRIVE TENSION ....................................................................................................16
ADJUSTING THE SPOOL POSITION .....................................................................................................17
WELDER CONTROLS .................................................................................................................................17
FRONT PANEL OPERATION ................................................................................................................17
BACK PANEL OPERATION ..................................................................................................................18
TECHNICAL DATA INFORMATION GUIDE ............................................................................................19
WELDING PREPARATION ....................................................................................................................19
MIG (GMAW) WELDING USING SHIELDING GAS ................................................................................ 19
FACTORS TO CONSIDER FOR BEST WELDING RESULTS .......................................................................19
ALUMINUM WELDING SET UP .............................................................................................................19
PARTS LIST ................................................................................................................................................20
PARTS DIAGRAM ......................................................................................................................................22
MIG GUN TORCH SPARE PARTS LIST ..........................................................................................................23
WIRING DIAGRAM ...................................................................................................................................24
USER NOTES ............................................................................................................................................25
Table of Contents
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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.
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively
ventilated.
Before you make any electrical connection, make sure the supply voltage and frequency available 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.
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 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.
• Do not pull violently on the input power cable to disconnect it from supply outlet.
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.
• 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 people’s bodies.
• The welder must never be operated without its panels attached. This could cause serious
injury to the operator and could damage the equipment
Installation
Location
Ventilation
Main Supply Voltage Requirements
Safety Instructions
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• Unpack the welder.
• Insert the axle (B) through the holes at the rear of the welder and slide a wheel (A) on to
each end followed by the retaining washers (C).
• Assemble the plastic handle (F) inside the plastic support (D-E).
• Assemble the plastic support using the screw provided (G-H).
• Screw the MIG torch lead into the socket (1) on the front of the welder, be careful not to
damage the contacts. Secure by hand screwing in the threaded connection.
• Screw the Spool Gun lead into the socket (2) as well as the 7-pin connector (3).
The bottle (not supplied) should be located at the rear of the welder, securely held in position by the
chain provided. For safety, and economy, ensure 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 is 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.
Assembly
Handle and Wheels Assembly (Fig. 1)
Torch Lead and Spool Gun Assembly (Fig. 2)
Gas Cylinder and Regulator Connection
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METAL GAS NOTE
Mild Steel CO2
Argon + CO2
Argon + CO2 + Oxygen
Argon controls spatter
Oxygen improves arc stability
Aluminium Argon
Argon + Helium
Arc stability, good fusion and minimum spatter.
Higher heat input suitable for heavy sections.
Minimum porosity.
Stainless Steel Argon + CO2 + Oxygen
Argon + Oxygen
Arc stability.
Minimum spatter.
Copper, Nickel & Alloys Argon
Argon + Helium
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.
Your MIG welder is designed to accept either 4”, 8” or 12” wire spools of mild steel, stainless steel or
aluminum according to the type of metal you wish to weld. Wire spools are not supplied with the unit
and must be purchased separately.
BE SURE 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 (A) of the spool holder (position 1) (brake drum).
Remove the spacer (E). In the case you are replacing the wire spool, extract it by pushing the
snap tongue (D) (Fig.4).
• Remove the plastic protection from the spool. Place it on the spool holder. Mount the spacer
again (only for 8” spools) and tighten the lock nut (A).
Your MIG welder can also accept 4” wire spools. To mount 4” spools:
• Remove the wire spool (B) from the spool holder (C).
• Loosen the nut (A), remove the spring and the washer; remove the spool holder (C)
from the pivot.
• Insert on the pivot the 4” wire spool; Mount the washer, the spacer (G) and the spring.
• Tighten the lock nut.
Shielding Gas Guide
Load Wire
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TIGHTEN NUT TO APPROPRIATE TIGHTNESS. EXCESSIVE PRESSURE STRAINS
THE WIRE FEEDING MOTOR. TOO LITTLE PRESSURE DOES NOT ALLOW THE
WIRE SPOOL TO STOP IMMEDIATELY.
• 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,
make sure the wire is cut cleanly (no burrs or angles) and that at least 1/2” from the
end is straight (no curves). Failure to follow these instructions could cause damage
to the liner.
• Lower the upper roll (B) and place the knob (A). Tighten slightly. If tightened too much, the
wire gets locked and could cause motor damage. If not tightened enough, the rolls will not
feed the wire.
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 ROLL
IS DRIVEN BY THE INSIDE GROOVE. FEED ROLLS ARE MARKED ON THE SIDE
IDENTIFYING THE GROOVE NEAREST THAT SIDE.
• Close the side panel of the machine. Connect the power
supply cable to the outlet. Turn on the switch. Press the torch
switch. The wire fed by the wire feeding motor at variable
speed must slide through the liner. When it exits from the
torch neck, release the torch switch. Turn off the machine.
Mount the contact tip and the nozzle.
WHEN CHECKING THE CORRECT EXIT OF THE WIRE
FROM THE TORCH DO NOT BRING YOUR FACE NEAR
THE TORCH. YOU MAY RUN THE RISK OF BEING
WOUNDED BY THE OUTGOING WIRE. DO NOT
BRING YOUR FINGERS CLOSE
TO THE FEEDING
MECHANISM WHEN WORKING! THE ROLLS,
WHEN MOVING,
MAY CRUSH THE FINGERS
PERIODICALLY, CHECK THE ROLLS. REPLACE THEM
WHEN THEY ARE WORN AND COMPROMISE THE
REGULAR FEEDING OF THE WIRE.
BEFORE PERFORMING THIS PROCEDURE, BE SURE THE GAS SUPPLY LINE AND
INPUT POWER CABLE 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.
• I
nstall the new liner and mount the brass nut (1) again.
Replacing the Wire Liner
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In case you are replacing a Teflon or graphite wire liner, follow these instructions:
• Install the new liner and insert the wire liner collet (3) and the O ring (4).
• Mount 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.
• 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.
• Teflon wire liners are recommended for aluminum welding as they allow a smooth feeding of
the wire.
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 find the end of the wire.
9. After checking to make sure 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 wire cutter, 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).
Then push it across the drive roller and into the gun assembly about 6”.
How to Choose the Wire Liner for Direct and Euro Connection Torches
Arrangement for Welding with Spool Gun
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13. Line the wire up in the appropriate 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 on page 14. 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 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 continue turning it while adjusting the tension on the spool.
b) With your free hand, tighten (turn clockwise) the drive brake adjustment knob.
c) Stop tightening when drag is felt on the wire spool that you are turning. Then stop hand-
turning 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 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
anti-stick 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.
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 THE 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
Setting the Wire Drive Tension
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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.
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 connecting the spool casing to the gun.
2. Pull the casing far enough away from the gun to allow the casing to rotate.
3. Rotate the casing to one of the three available positions, making sure 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 the gun.
Welder Controls
With welders in the digital series, thanks to a special electronic card it is possible to externally adjust
the welding parameters. The main purpose of these units is to make adjustment of these parameters
very easy.
The microprocessor control handles the functions of the p.c.board that are viewed by means of LED’s
while a digital display shows the parameters set and welding current. Units may be used either with the
standard torch (supplied with them) or with the Spool Gun.
1. Main ON/OFF switch (green):
Lights up when you switch ON the welder on.
2. Welding voltage adjustment knob
3. Spool Gun connection
4. 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.
5. Spot welding time regulation knob
MIN. 0.4 seconds - MAX. 10 seconds
6. Welding “MODE” selector key
Use these keys to select the following types of
welding:
- 2T: 2 time welding = manual
- 4T: 4 time welding = automatic
- Automatic spot welding with timer
Adjusting the Spool Position
Front Panel Operation
1
2
3
12
4
5 6
11 10
9
13
14
78
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7. B.B.T. ( Burn Back Time)
After releasing the torch trigger, wire will continue to feed for a short time.
This function
avoids burning of wire and consequent wire sticking to the contact tip. By turning the B.B.T.
potentiometer clockwise with a screwdriver, the time during which wire will continue to feed after
the trigger is released can be adjusted.
8. SLOPE
Turning this screw with a screwdriver wil adjust the time for the wire feed motor to reach the
speed that you selected.
MIN. slope 0.25 seconds - MAX. slope 1.6 seconds
9. Overheating indicator (yellow)
This LED blinks when unit is overheating. It will light up when thermostatic protection shut
down the machine and will cease blinking only after the machine has cooled sufficiently to
continue welding.
10. Spool gun torch green LED
Lights up when the spool gun torch is connected.
11. Display
Allows operator to view the real time weld current. After welding the display will show the
final welding current value for a maximum of 3 seconds.
12. Torch connection
13. 7 pin connection for Spool Gun (optional)
14. Toggle switch for the torch selection
1. Input Power Cable
2. Gas hose connector for torch 1 (MIG torch)
3. Gas hose connector for torch 2 (Spool Gun)
Back Panel Operation
1
2
3
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Refer to the back of the welder for specifications.
• Connect the ground cable to the proper female outlet on the bottom right-hand corner of the
welder (on some models the ground cable is already connected). 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.
• Open the gas valve on the gas cylinder regulator, (turn knob clockwise) and adjust the gas
regulator to the proper setting position. Note: this varies with different metals, thicknesses
and currents.
In MIG welding, two parameters are fundamental: (1) the welding voltage and (2) the wire speed. The
welding current is determined by these two settings. Set the voltage and wire speed controls to positions
suitable for the thickness of the material to be welded. Adjust the wire speed to fine tune the welding
current.
1. Material to be welded. (Mild steel, Stainless Steel, Aluminum)
2. Thickness of material to be welded.
3. Diameter of the welding wire.
4. Type of shielding gas used.
Using the Mode button, select the tigger mode.
• 2T - The welding process starts when the torch trigger is pressed and stops when the trigger
is released.
• 4T - The welding process starts when the trigger is pressed and released. Welding continues
until the trigger is pressed and released a seocond time. This mode is best for very long
welds or for some automative welding.
• Spot welding with timer - Automatic spot welder with timer. This process permits repeated
spot welds each time the trigger is pressed. The duration of the spot weld is controlled by
Knob (5). A spot welding nozzle is recommended.
The welder should be set up as for mild steel except for the following: Use 100% Argon for the shielding
gas. Ensure the Spool Gun is set up for aluminum welding with a teflon liner and does not exceed 10’
in length. Ensure the contact tip and drive rolls are suitable for aluminum wire. For aluminum welding,
or for welding other material that requires the use of soft wire, and for applications where a longer
torch cable is required, a Spool Gun is recommended.
Technical Data Information Guide
Welding Preparation
MIG (GMAW) Welding Using Shielding Gas
Factors to Consider for Best Welding Results
Aluminum Welding Set Up
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Parts List
REF. # PART # ITEM DESCRIPTION QTY
01 85005 DOOR LATCH 1
02 05000287 LEFT SIDE PANEL 1
03 85513 PLASTIC HINGE FOR DOOR 1
04 33705777 376C SMALL LEFT PANEL 1
05 33720311 9005 DIVIDING PANEL 1
06 04600275 SPOOL HOLDER 1
07 85130 FUSE HOLDER 1
08 85129 FUSE 10
09 44410081 METALLIC WIRE FEEDER 1
10 23005542 EURO BINZEL CONNECTION 1
11 21690675 EURO CONN. PLASTIC PROTECTION 1
12 22810030 MOTOR 1
13 33705735 376C COVER 1
14 30905054 COVER MAT 1
15 22305004 RESISTANCE 1
16 85081 CAPACITOR 1
17 85042 AUXILIARY CONTACTS 1
18 85023 CONTACTOR 1
19 33640145 METAL SUPPORT FOR AUXILIRY TRANSFOR-
MER
1
20 21690398 PLASTIC PART TO FIX SPOOL GUN 1
21 21690822 PLASTIC BOX FOR SPOOL GUN CONNEC-
TION
1
22 23005555 MINI EURO CONNECTION FOR SPOOL GUN 1
23 21690828 PLASTIC COVER FOR SPOOL GUN CONNEC-
TION
1
24 85551 KNURLED HANDWHEEL 2
25 04600166 GAS-NO GAS CONVERSION BOARD 1
26 44140054 AUXILIARY TRANSFORMER 1
27 22200033 WELDING CURRENT SWITCH 1
28 77650447 PCB FRONT PANEL 1
29 05000285 FRONT PANEL 1
30 21690429 PC BOARD FRAME 1
31 85579 UPPER PLASTIC PROFILE 1
32 33725134 9005 TUBE FOR HANDLE 1
33 85578 LEFT HANDLE 1
34 21690771 SIDE PLASTIC PROFILE 1
35 21690768 LOWER PLASTIC FRAME 1
36 21690770 RIGHT SIDE PLASTIC PROFILE 1
37 85577 RIGHT HANDLE 1
38 22200051 BIPOLAR SWITCH 1
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REF. # PART # ITEM DESCRIPTION QTY
39 22100009K DINSE SOCKET 1
40 85555 KNOB WITH CAP AND INDEX 1
41 85574 BLACK KNOB FOR SWITCH 1
42 77601051 YELLOW LABEL FOR ON-OFF SWITCH 1
43 40211532 SPOOL GUN TORCH WIRING ASSEMBLY 1
44 85530 SWITCH 1
45 22710084 MOTOR CONTROL PCB 1
46 33700427 9005 LOWER PANEL 1
47 44135176 CHOKE 1
48 44120195 TRANSFORMER 1
49 30490172 PLEXIGLASS AIRFLOW 1
50 85560 FAN 1
51 33640628 METAL CONVEYOR 1
52 22910004K HOSE TAIL 1
53 85052 SOLENOID VALVE 1
54 05000286 BACK PANEL 1
55 20220173 POWER CORD 1
56 21605040K SWITCH D.20 2
57 22910110 FEMALE GAS CONNECTOR 1
58 85545 WHEEL 1
59 55200036 WHEELS AXLE 1
60 22600043 SHUNT FOR AMMETER 1
61 05000288 RIGHT PANEL 1
62 85203 COMPLETE THERMOSTAT 1
63 22400085 RECTIFIER 1
64 33640603 METAL SUPPORT FOR RECTIFIER 1
65 21625003 RUBBER PIVOTING WHEEL 1
66 33805007K WIRE BLOCK ROLL 1
67 85509 FEED ROLL 1
67 85511 FEED ROLL 1
68 85520 FLAT-KEY 10
69 85557 FEED ROLL SECURE KNOB 1
70 23000453 MIG GUN TORCH 1
71 43210220K GROUND CABLE 1
72 22110026K GROUND CLAMP 1
73 22100003K DINSE PLUG 1
74 22905101 S REDUCER 1
75 30900036 BLACK GAS HOSE 1
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Parts Diagram
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MIG Gun Torch Spare Parts List
NO. PART NUMBER ITEM DESCRIPTION QTY.
1 23005552 TWECO TORCH NOZZLE 22-62 1
02 23005525K INSULATOR 1PC PACK 1
03 23005526K
0,9MM CONTACT TIP FOR TW2 1435 10PC PACK
10
03 23005521K
0,8MM CONTACT TIP FOR TW2 1430 10PC PACK
10
03 23005522K
1,2MM CONTACT TIP FOR TW2 1445 10PC PACK
10
04 23005527K
TWECO GAS DIFFUSER TW2 1 PC
PACK
1
NO. PART NUMBER ITEM DESCRIPTION QTY.
05 23005528k
TW2 62A-45 TORCH NECK 1 PC
PACK
1
06 23005529K
BLACK HANDLE FOR TW200 TORCH
1 PC PACK
1
07 23005530K TORCH TRIGGER 1 PC PACK 1
08 23005553 COAX CABLE 25MM2 15” 1
09 23005554 STEEL WIRE LINER .030-.035 1
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Wiring Diagram
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