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Forney 220 TIG AC/DC, Operating Manual

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WWW.FORNEYIND.COM

220 TIG AC/DC WELDER 

OPERATING MANUAL

FEATURES:

• 

230V Input; 200A Output

• 

TIG functions - High Frequency, Pulse (PPS, 

% On, Base Current), AC Frequency, AC 

Balance, Pre-flow, Post-flow, Crater Fill, 

Ramp Up/Down, Foot Pedal or Panel 

Control, Lift Arc Capable, 20 Default 

Programs, 20 User Defined Programs

• 

Stick functions - Hot Start, Arc Force

 

IDEAL FOR:

Automotive, Motorcycles, Stainless and 
Aluminum Fabrication or Repair

INCLUDES: 

Machine only

CAT# 325

REV 04.14.2017

Summary of Contents for 220 TIG AC/DC

Page 1: ... Base Current AC Frequency AC Balance Pre flow Post flow Crater Fill Ramp Up Down Foot Pedal or Panel Control Lift Arc Capable 20 Default Programs 20 User Defined Programs Stick functions Hot Start Arc Force IDEAL FOR Automotive Motorcycles Stainless and Aluminum Fabrication or Repair INCLUDES Machine only CAT 325 REV 04 14 2017 ...

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Page 3: ...ing 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 in...

Page 4: ...se call customer service at 1 800 521 6038 Monday through Friday from 7 a m 5 p m MST or at www forneyind com about us contact us Please take time to register your product at www forneyind com support product registration Thank you and enjoy your new welder For the most up to date warranty information visit www forneyind com ...

Page 5: ...Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 California Proposition 65 Warning WARNING This product can expose you to chemicals including lead which are known to the State of California to cause cancer and birth defects or other reproductive harm For more information go to www P65Warnings ca gov P65 details at forneyind com Wash hands afte...

Page 6: ...e 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 bac...

Page 7: ... 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 oth...

Page 8: ... 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 saf...

Page 9: ... 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 ...

Page 10: ...ELDER SPECIFICATIONS 11 SITE SELECTION 11 POWER SOURCE CONNECTION 11 OPERATION 11 DESCRIPTION 11 THERMAL OVERLOAD PROTECTION 11 PARAMETER CONTROLS 12 FUNCTION BUTTON DESCRIPTIONS 13 PARAMETER SETUP 15 TUNGSTEN RECOMMENDATIONS 16 RECOMMENDED AMPERAGE SETTINGS FOR SMAW ARC ELECTRODES 16 RECOMMENDED AMPERAGE ELECTRODE TYPES FOR TIG WELDING 16 DEFAULT PROGRAMS 17 MAINTENANCE SERVICING 18 GENERAL MAINT...

Page 11: ...ed on inadequate or excessive power The 220 TIG AC DC single phase constant current inverter welder is designed for portable use on jobs involving maintenance fabrication and construction This versatile arc welding power source allows for a high degree of user adjustability in both Stick and TIG processes Some highlights of the 220 TIG AC DC include TIG functions High Frequency Pulse PPS On Base C...

Page 12: ...EFLOW 3 RAMP UP NOTE only available on Panel Control 4 PULSE BASE CURRENT 5 PULSE PPS ON NOTE requires 2 touches of MENU 6 RAMP DOWN NOTE only available on Panel Control 7 CRATER FILL NOTE only available on Panel Control 8 POSTFLOW Parameter Controls AC DC F1 F2 F3 F4 F5 F6 F7 TIG PEDAL PANEL REMOTE LOCAL TIG HF CONSTANT STICK HS HOT START RAMP UP LOCAL CRATER FILL LOCAL RAMP DOWN LOCAL PULSE BASE...

Page 13: ...t on the entire weld Start Only on for only the beginning of the weld or off To turn HF off hold F3 for 3 seconds HF is particularly useful for arc starts to reduce tungsten contamination since it is not required to touch the work piece while HF is on Default setting for DC is START ONLY Default setting for AC is CONTINUOUS STICK Hot Start increases amperage when initiating the weld to prevent sti...

Page 14: ...the polarity stays in DCEN A higher percentage of DCEN 60 80 creates a tighter arc less cleaning and reduces tungsten balling A lower percentage of DCEN 40 60 creates a less focused arc more cleaning and will likely create a ball on the top of the tungsten F4 F5 F6 F7 PEDAL PANEL REMOTE LOCAL CRATER FILL LOCAL RAMP DOWN LOCAL MAIN CURRENT POSTFLOW FREQUENCY HZ BALANCE EN TIG FUNCTIONS CONTROL PULS...

Page 15: ...NS TIG FUNCTIONS STICK SELECT CONTROL PULSE PULSE MENU PROGRAM HOLD STORE PROGRAM ON OFF SELECT ADJUST SELECT POWER TEMP FAULT PROGRAM CURRENT VALUE INPUT OK SELECT Vin SELECT MENU TO MODIFY CAT 325 PULSE PPS ON NO ACTION REQUIRED DEFAULT SETTING IS DC AC DC F1 F2 F3 F4 F5 F6 F7 TIG PEDAL PANEL REMOTE LOCAL TIG HF CONSTANT STICK HS HOT START RAMP UP LOCAL CRATER FILL LOCAL RAMP DOWN LOCAL PULSE BA...

Page 16: ... ball up and not allow concentrated arc SIZE OF WELDING ELECTRODE AMPERAGE SETTING 1 16 16 Gauge 30 40 5 64 14 Gauge 50 65 3 32 70 100 1 8 100 140 5 32 140 180 3 16 150 200 TUNGSTEN Ø DCEN Th La Ce AC La Ce AC Pure 040 10 50A 20 40A N A 1 16 40 120A 30 170A 30 90A 3 32 90 200A 60 180A 40 120A 1 8 150A 130A 100 200A Tungsten Recommendations Recommended Amperage Settings for SMAW Arc Electrodes Reco...

Page 17: ... Start only 5 3 Remote Foot Pedal S7 SS Thin Pulse Th La Ce 1 8 100 50 DC 250 50 Start only 5 5 Remote Foot Pedal S8 SS Thick Pulse Th La Ce 1 4 180 90 DC 250 50 Start only 5 7 Remote Foot Pedal S9 SS Lift Arc Thin Pulse Th La Ce 1 8 100 50 DC 250 50 Start only 5 5 Panel Lift Arc S10 SS Lift Arc Thick Pulse Th La Ce 1 4 180 90 DC 250 50 Start only 5 7 Panel Lift Arc A1 Aluminum Sheet La Ce P 1 16 ...

Page 18: ...es The adjustment knob on the front panel didn t work Potentiometer broken current regulation Replace the potentiometer Cooling Fan not working or turning very slowly Switch broken Fan broken Wire broken or falling off Replace the switch Replace or repair the fan Check the connection No no load voltage Over voltage under voltage or scarcity of phase Welder getting overheated Switch broken See Yell...

Page 19: ... REAR LOUVERS 710 1 21 84066 POWER CORD ST 3X12AWG 4 6M W 6 50P PLUG 1 22 22910096 PLASTIC GROMMET D 6 1 8 FEMALE 1 23 85542 SOLENOID VALVE 11VA 230V 60HZ 1 PC PACK 1 24 22910004K HOSE TAIL D 6 1 8 M 1 PC PACK 1 25 85712 FAN RAH1751B1 C 230V AC 172X150X51 1 26 05000291 BOTTOM PANEL 1 27 05000302 FRONT PANEL 1 28 84058 LABEL GAS CABLE CONNECTION 1 29 85713 CONTROL PCB FORNEY 220 TIG AC DC 1 30 8571...

Page 20: ...20 WWW FORNEYIND COM Parts Diagram ...

Page 21: ...21 WWW FORNEYIND COM Wiring Diagram ...

Page 22: ...__________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ _________________________________...

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Page 24: ...Forney Industries Inc 2057 Vermont Drive Fort Collins CO 80525 800 521 6038 www forneyind com ...

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