Forney 235 Operating Manual

OPERATING MANUAL FEATURES: • Dinse style connectors allow for easy cable replacement and polarity change • Power cable, ground cable, and electrode holder are all 15’ providing a large working envelope • Welds up to 1/2” AC / 3/8” DC metal SPECIFICATIONS: • Power: 235 Amp AC @ 20% Duty Cycle • Weight: 116 Lbs. (52.63 Kg) • Max. OCV: 72 VAC / 63 VDC • Main Voltage: 230V (60Hz)/48.5A • Duty Cycle: 150A @ 50% AC / 13 ...

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. ...

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 ...

Effective August 1, 2009 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. ...

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, Suit ...

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 safet ...

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 gas ...

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 ...

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 t ...

PRINCIPAL SAFETY STANDARDS ........................................................................................................... ...

CONNECTED WHILE PERFORMING THIS PROCEDURE. AVOID CONTACTS WITH WIRES OR PARTS. Do not work with the panels partially opened or removed completely from the power source. 1. Tools required: Hammer, Flat Head Screwdriver, Allen Wrench (metric) 2. Slide the axle through the opening in the bottom of the welder cabinet. Insert axle into wheels. Use a hammer to attach nuts on ...

Type 235 Amp AC/DC ARC Welding System Input Voltage 220V ±10% (60Hz) Rated Output 235A @ 20% Duty Cycle Agency Listing CSA Rated 200A @ 20% Duty Cycle AC CSA Rated 135A @ 35% Duty Cycle DC Maximum Output 230A AC Peak / 185A DC Peak Output Power Settings Shunt (45-235A) The duty rating defines how long the welding system can be used before it must pause and cool down. Duty Cycle ratings are expressed as a ...

electric arc created between the electrode and the workpiece. There are two parts to electrodes used for SMAW welding: 1) The inner core is a metal rod or wire that should be similar in composition to the base metal. 2) The outer coat-ing is called flux. There are various types of flux and each coating is used for a particular welding situation. W ...

• Heavy Aluminum welding • Rivet welding • Sheet Metal welding • Low Hydrogen Electrode welding • Arc Bronze Electrode welding This welder has two AC outlet plugs that are clearly marked with the electrode and ground clamp symbols. Connect the electrode output cable to the electrode connections and the ground cable to the ground connection. These connections are Dinse type connections and require that th ...

free of all flammables with both a fire extinguisher and bucket of sand available for emergencies. To properly prepare for welding follow these simple instructions: 1. Prepare an organized well lighted work area. 2. Follow the instructions for personal protection for yourself as well as those around you. 3. Make sure you’ve studied all ...

may cause the pieces to shift from the beginning position. If possible, workpieces should be clamped into position required when the welding is completed. WHEN GRINDING, ALWAYS WEAR GOGGLES AND ENSURE MACHINE GUARDS ARE IN PLACE THE GRINDER MUST ALSO BE INSPECTED TO VERIFY IT IS IN GOOD CONDITION. Be certain you have a solid ground conne ...

The rod wire joins with the base metal of the workpiece to form the weld bead. Burning Flux forms a gas shield around the arc, helping to control the flow of the fusing metals that form the weld bead. Type and thickness of the metal and the position of the work piece determines the electrode type and the amount of heat needed to weld (see diagram be ...

to run a good bead. Probably the first attempts in practice will fall short of acceptable weld beads. Too long an arc will be held or the travel speed will vary from slow to fast. A solid weld bead requires that the electrode be moved slowly and steadily along the weld seam. Moving the electrode rapidly or erratically prevents proper fusion or creates a lump ...

simple steps are taken to properly maintain it. • Replace power cord, ground cable, ground clamp, or electrode assembly when damaged or worn. • Periodically clean dust, dirt, grease, etc. from your welder. • Every six months, or as necessary, remove the cover panel from the welder and air-blow any dust and dirt that may have accum ...

Holding the electrode too long in one place or moving it too slowly across the base metal Speed up; maintain a uniform rate of speed along the bead Ragged depressions at edge of weld Moving the electrode too rapidly or holding too short an arc Slow down; lengthen the arc slightly Overlapping beads Arc too long or rate of travel too fast Slow down Electrode sticks to work ...