Forney 95FI Operating Manual
3
TABLE OF CONTENTS
Warranty ..............................................2
Safety Summary ..................................4
Safety Information ..............................4
Shock Hazards ..................................5
Flash Hazards ....................................5
Fire Hazards ......................................6
Fume Hazards....................................7
Additional Safety Information ............8
Welder Specifications ........................9
Description ........................................9
Duty Cycle ..........................................9
Internal Thermal Protection ................9
Know Your Welder ..............................10
Welder Installation ..............................11
Power Source Connection ................11
Extension Cords ..............................11
Assembling the Welder ......................11
Unpacking the Welder......................11
Packing List......................................11
Installing the Handle ........................11
Assemble the Face Shield ..............12
Selecting the Welding Wire..............12
Installing the Welding Wire ..............12
Operation ............................................14
Controls and Indicators ......................14
Power Switch ..................................14
Voltage Selector ..............................14
Preparations for Welding....................14
Setting Up the Workpiece ................14
Preparing the Joint ..........................14
Ground Clamp Connection ..............15
Learning to Weld ................................16
Holding the Gun ................................16
Welding Techniques ..........................17
Moving the Gun................................17
Types of Weld Beads ......................17
Welding Positions ............................18
Multiple Pass Welding......................19
Special Welding Methods ................19
Spot Welding..................................19
Maintenance ........................................20
General ..............................................20
Consumable Maintenance..................20
Maintaining the Contact Tip................20
Maintaining the Nozzle ......................21
Testing for a Shorted Nozzle..............21
Replace a Gun Liner ..........................21
Troubleshooting..................................23
Wiring Diagram....................................24
Parts List ..............................................25
Suggested Settings ............................29
4
TABLE OF CONTENTS
Every welder respects the tools with which
they work. They know that the tools represent years of constantly improved designs
and developments. The true craftsman also
knows that tools are dangerous if misused or
abused.
Reading this operator’s manual before using
the welder will enable you to do a better,
safer job. Learn the welder’s applications
and limitations as well as the specific potential hazards peculiar to welding.
IMPORTANT SAFETY INFORMATION
The following safety information is provided
as guidelines to help you operate your new
welder under the safest possible conditions.
Any equipment that uses electrical power
can be potentially dangerous to use when
safety or safe handling instructions are not
known or not followed. The following safety
information is provided to give the user the
information necessary for safe use and
operation.
A procedure step preceded by a WARNING
is an indication that the next step contains a
procedure that might be injurious to a person
if proper safety precautions are not heeded.
A procedure preceded by a CAUTION is an
indication that the next step contains a procedure that might damage the equipment
being used.
A NOTE may be used before or after a procedure step to highlight or explain something
in that step.
READ ALL SAFETY INSTRUCTIONS
CAREFULLY before attempting to install,
operate, or service this welder. Failure to
comply with these instructions could result in
personal injury and/or property damage.
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE.
Note:
• The following safety alert symbols identify
important safety messages in this manual.
• When you see one of the symbols shown
here, be alert to the possibility of personal
injury and carefully read the message that
follows.
This symbol indicates that the possibility of electric shock hazard
exists during the operation of the
step(s) that follow.
This symbol indicates that the possibility of fire hazard exists during
the operation of the step(s) that
follow.
This symbol indicates that the helmet must be worn during the
step(s) that follow to protect
against eye damage and burns
due to flash hazard.
This symbol indicates that the possibility of toxic gas hazard exists
during operation of the step(s) that
follow.
This symbol indicates that the possibility of being burned by hot slag
exists during operation of the
step(s) that follow.
This symbol indicates that the eye
protection should be worn to protect against flying debris in the following step(s).
• Published standards on safety are avail-
able. They are listed in ADDITIONAL
SAFETY INFORMATION at the end of this
SAFETY SUMMARY.
The National Electrical Code, Occupation
Safety and Health Act regulations, local
industrial codes and local inspection requirements also provide a basis for equipment
installation, use, and service.
SAFETY SUMMARY
5
SHOCK HAZARD
WARNING
ELECTRIC SHOCK CAN KILL! To reduce
the risk of death or serious injury from shock,
read, understand, and follow the following
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 OPERATION of this welding equipment until you
have read and understand the following
safety summary.
• Do not, in any manner, come into physical 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 clothing is moist, or if you are in physical contact with water or moisture.
• Do not connect welder work piece clamp
to or weld on electrical conduit.
• 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 can not 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.
FLASH HAZARDS
WARNING
ARC RAYS CAN INJURE EYES AND
BURN SKIN! To reduce the risk of injury
from arc rays, read, understand, and follow
the following 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. Headshields and
filter should conform to ANSI Z87.1 standards.
• 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, leaving a permanent dark spot in the field of
vision. A shield or helmet with a number 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
6
helmet and replace any cracked or broken 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 helmets fitted with a #10 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 surfaces 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, then off the filter lens on the inside of your helmet or
shield, then 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.
FIRE HAZARDS
WARNING
FIRE OR EXPLOSION CAN CAUSE
DEATH, INJURY, AND PROPERTY DAMAGE! To reduce the risk of death, injury, or
property damage from fire or explosion, read,
understand, and follow the following 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. 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 weld in an area until it is checked
and cleared of combustible and/or flammable 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 separated 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 contained a
flammable or toxic substance. The techniques for removing flammable substance and vapors, to make a used container safe for welding or cutting, are
quite complex and require special education and training.
• Do not strike an arc on a compressed
gas or air cylinder or other pressure vessel. 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 trousers, 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, trouser
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 recommended.
• 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
7
any other flammable material.
• 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.
FUME HAZARDS
WARNING
FUMES, GASSES, AND VAPORS CAN
CAUSE DISCOMFORT, ILLNESS, AND
DEATH! To reduce the risk of discomfort, ill-
ness, or death, read, understand, and follow
the following 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.
• 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-supplied respirators.
• Do not weld, cut, or heat lead, zinc, cadmium, mercury, beryllium, or similar metals 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 chlorinated hydrocarbons, such as trichloroethylene 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 penetrate 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 indicates inadequate ventilation. Stop work
and take necessary steps to improve
ventilation in the welding area. Do not
resume welding if physical discomfort
persists.
WARNING
This product contains chemicals, including
lead, or otherwise produces chemicals
known to the State of California to cause
cancer, birth defects and other reproductive
harm. Wash hands after Handling.
(California Health & Safety Code Sec.
25249.5 et seq.)
8
ADDITIONAL SAFETY INFORMATION
For additional information concerning welding 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 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)
642-4900,
Fax (212) 398-0023 – www.ansi.org
• NFPA Standard 51B – 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 SAFETY 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 CONTAINERS WHICH HAVE HELD COMBUSTIBLES. – 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
9
WELDER SPECIFICATIONS
DESCRIPTION
Your new flux core (FCAW) wire feed welder
is designed for maintenance and sheet metal
fabrication. The welder consists of a singlephase power transformer, and a unique builtin control/feeder. This welder is capable of
welding with 0.030 (0.8mm) and 0.035
(0.9mm) self-shielding flux-core wire. Now
you can weld sheet metal from 18 gauge up
to 3/16 inch thick with a single pass. You can
weld 1/4 inch steel with beveling and multiple
pass techniques. Table 1 lists your wire feed
welder specifications.
Table 1. Welder Specifications
Primary (input) volts 120 VAC
Welding Range 20-95Amps
Primary (input) Amps 13
Phase Single
Frequency 60Hz
Secondary (output) volts 21
CSA rated output amps 60
Open Circuit Volts (Max.) 27 VDC
Duty Cycle Rating 20%
DUTY CYCLE
The duty cycle rating of a welder defines
how long the operator can weld and how
long the welder must be rested and cooled.
Duty cycle is expressed as a percentage of
10 minutes and represents the maximum
welding time allowed. The balance of the 10minute cycle is required for cooling.
Your new welder has a duty cycle rating of
20% at the rated output. This means that you
can weld for two (2) minutes out of 10 with
the remaining eight (8) minutes required for
cooling. (See Table 2).
Table 2. Duty Cycle Ratings
Duty Maximum Required
Cycle Welding Resting
Rating Time Time
20% 2 minutes 8 minutes
40% 4 minutes 6 minutes
60% 6 minutes 4 minutes
80% 8 minutes 2 minutes
100% 10 minutes 0 minutes
INTERNAL THERMAL PROTECTION
CAUTION
Do not constantly exceed the duty cycle or
damage to the welder can result. If you
exceed the duty cycle of the welder, an internal thermal protector will open, shutting off
all welder functions. After cooling, the thermal protector will automatically reset and the
welder will function normally again. However
you should wait at least ten minutes after the
thermal protector opens before resuming
welding. You must do this even if the thermal
protector resets itself before the ten minutes
is up or you may experience less than specified duty cycle performance.
10
KNOW YOUR WELDER
Handle – Rugged, top mounted handle
allows for easy transport of your welder.
Wire Speed Control – Use this dial to adjust
the speed at which the welder feeds wire to
the gun. 1 is the slowest wire feed speed, 10
is the highest. You will need to adjust or
“tune-in” your wire speed for different welding
conditions (thickness of metals, metal type,
wire size, etc.). When the wire speed is properly “tuned-in” the welding wire will melt into
the material you are welding as quickly as it is
fed through the welding gun.
Voltage Selector – This two position switch
adjusts the voltage or “heat” of your welder.
Select MIN setting for lower voltage and
MAX setting for higher voltage. Different
materials and material thickness will require
different voltage settings. You will need to
adjust your voltage accordingly for different
welding conditions. By properly adjusting
your voltage settings and wire feed speed,
you will enable clean, precision welds. (Refer
to the Suggested Settings Chart on p.29 of
this manual.)
Power Switch – This switch turns the welder
ON and OFF. (Make sure the power switch is
in the OFF position before performing any
maintenance on the welder.)
Power Cord – This is a standard, grounded
120 volt power cord. (Make sure you are
using a properly grounded 120 Vac, 60Hz,
single phase, 20 amp power source.)
Ground Clamp – Attaching the ground
clamp to your work piece “completes” the
welding current circuit. You must attach the
ground clamp to the metal you are welding. If
the ground clamp is not connected to the
metal work piece you intend to weld, the
welder will not have a completed circuit and
you will be unable to weld. A poor connection
at the ground clamp will waste power and
heat. Scrape away dirt, rust, scale, oil or
paint before attaching the ground clamp.
Ground Cable – The ground cable connects
the ground clamp to the internal workings of
the welder.
Welding Gun and Cable – The welding gun
controls the delivery of the welding wire to
the material to be welded. The welding wire
is fed through the welding cable and welding
gun when the welding gun trigger is pulled.
You will need to install a contact tip and
welding nozzle to the end of the welding gun,
as described later in this manual, prior to
welding.
Welding Terms -Now that you are familiar
with the main parts of the welder, make note
of the following terms. You will see them
used throughout this manual.
weld puddle: The localized volume
of molten metal in a weld prior to its
solidification.
weld angle: The angle of the welding wire,
as it extends from the welding gun, in relation to the item being welded.
slag: The protective coating that forms on
the surface of molten metal.
arc: A sustained luminous discharge of electricity across a gap in a circuit.
welding bead: The extended build up of a
weld, made by pushing or pulling the weld
puddle.
Figure 1. Model Cat. 00304
Welding
Gun
Ground
Clamp
Power
Cable
Ground
Cable
Voltage
Selector
Power
Switch
Wire
Speed
Gun Cable
Handle
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