Forney 125 FC Operating Manual
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Forney 125 FC Operating Manual

Flux cored wire welder
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125 FC FLUX CORED
WIRE WELDER
OPERATING MANUAL
FEATURES:
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SPECIFICATIONS:
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IDEAL FOR:
Do-It-Yourself, Maintenance &
Repair, Metal Fabrication,
Hobbyist
WWW.FORNEYIND.COM
125A Output
120V Input
Easy to use
No gas required
Portable
Torch wrap
Recommended Wire Diameter: Up to .030"
Plate thickness range: 24 ga - 1/4"
Weight: 32.6 Lbs. (14.8 Kg)
Dimensions: 24.6" (411.48mm) X 12.6"
(205.74mm) X 18.5" (314.96mm)
6 month warranty
ENGLISH
REV 10.13.15

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Summary of Contents for Forney 125 FC

  • Page 1 125 FC FLUX CORED WIRE WELDER OPERATING MANUAL FEATURES: • 125A Output • 120V Input • Easy to use • No gas required • Portable • Torch wrap SPECIFICATIONS: • Recommended Wire Diameter: Up to .030” • Plate thickness range: 24 ga - 1/4”...
  • Page 2 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.
  • Page 3 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.

  • Page 4: Warranty

    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.

  • Page 5: Safety Summary

    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 Summary Principal Safety Standards •...

  • Page 6: Personal Protection

    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.

  • Page 7: Fire Prevention

    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.

  • Page 8: Electric Shock

    • 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.

  • Page 9: Noise

    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.

  • Page 10: Table Of Contents

    Table of Contents WARRANTY ..............................4 SAFETY SUMMARY .............................5 PRINCIPAL SAFETY STANDARDS ......................5 CALIFORNIA PROPOSITION 65 WARNING ....................5 EMF INFORMATION..........................5 PERSONAL PROTECTION ........................6 FIRE PREVENTION ..........................7 ELECTRIC SHOCK ..........................8 NOISE ..............................9 ADDITIONAL SAFETY INFORMATION ....................9 TABLE OF CONTENTS ..........................10 INSTALLATION ............................11 WELDER SPECIFICATIONS ........................11 SITE SELECTION ..........................11 POWER SOURCE CONNECTION ......................11...

  • Page 11: Installation

    Installation Welder Specifications Table 1. Welder Specifications Primary (input) volts 120 V Maximum Output 125 A Welding Range 65-80 Amps Phase Single Frequency 60Hz CSA Rated Output Amps Duty Cycle Rating Site Selection Select a clean, dry location with adequate working space around all components. Provide at least two feet of space in front of and behind the unit to allow for free flow of air.

  • Page 12: Preparation For Welding

    Preparation for Welding With the On/Off switch in the Off position, connect the ground clamp as follows: Clasp the ground clamp to the workpiece. NOTE: For good contact, the ground clamp must be attached to clean, bare metal (not painted). Assembling the Welder The following procedures describe the process required to assemble, install, maintain, and prepare to weld with your new wire feed welder.

  • Page 13: Operation

    tension roller is applying enough force on the wire to prevent it from slipping out of the drive assembly. 8. Let go of the wire. 9. Plug the welder’s power cord into the AC power source. Adjust the settings on the front panel per the setup chart on the inside panel door of the welding machine.

  • Page 14: Duty Cycle

    Welding THICKNESS OF STEEL Wire 18 gage 16 gage 14 gage 12 gage 1/8” 3/16” (.030”) Thickness SHEET METAL SHEET METAL SHEET METAL THIN PLATE THIN PLATE THIN PLATE Setting (Voltage) Wire Feed VOLTAGE SETTING/WIRE SPEED Speed WARNING: After installing new wire spool, make sure welding wire is inserted into torch hose liner and wire tension knob is correctly adjusted before pulling welding torch trigger.

  • Page 15: Controls And Indicators

    1. Handle - Rugged, top mounted handle allows for easy transport of your welder and a place to wrap your cables. 2. Wire Speed Control - Use this dial to adjust the speed at which the welder feeds wire to the gun (1 is the slowest and 10 is the highest).

  • Page 16: Setting Up The Work Piece

    • Select the electrode. • Adjust the heat control. EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN. PROLONGED EXPOSURE TO A WELDING ARC CAN CAUSE BLINDNESS AND BURNS. NEVER STRIKE AN ARC OR BEGIN WELDING UNLESS YOU ARE ADEQUATELY PROTECTED.

  • Page 17: Learning To Weld

    Learning to Weld Flux core wire welding (FCAW) is the process of uniting metal parts by heating and allowing the metals to flow together through the use of an electrical arc. The electric arc is created between a continuous consumable wire electrode (the welding wire) and the work piece. An atmosphere created by the flux protects the weld puddle from contamination and enhances the welding capabilities of the electrical arc.

  • Page 18: Welding Techniques

    2. Angle B can be varied for two reasons: to improve the ability to see the arc in relation to the weld paddle and to direct the force of the arc. The force of the welding arc follows a straight line out of the end of the nozzle. If Angle B is changed, so will the direction of arc force and the point at which penetration will be concentrated.
  • Page 19 2. TRAVEL SPEED is the rate at which the gun is being pushed or pulled along the weld joint. For a fixed heat setting, the faster the travel speed, the lower the penetration and the lower and narrower the finished weld bead. Likewise, the slower the travel speed, the deeper the penetration and the higher and wider the finished weld bead.
  • Page 20 is such that the wire and therefore the arc force, is directed more toward the metal above the weld joint. This is to help prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve good penetration. A good starting point for Angle B is about 30 degrees down from being perpendicular to the workpiece.
  • Page 21 SPECIAL WELDING METHODS Spot Welding The purpose of a spot weld is to join pieces of metal together with a spot of weld instead of a continuous weld bead. There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap.

  • Page 22: Maintenance

    Maintenance General Maintenance This welder has been engineered to need minimal service providing that a few very simple steps are taken to properly maintain it. 1. Keep the wire drive compartment lid closed at all times unless the wire needs to be changed or the drive tension needs adjusting.
  • Page 23 A shorted nozzle results when spatter buildup bridges the insulation in the nozzle allowing welding current to flow through it as well as the contact tip. When shorted, a nozzle will steal welding current from the wire whenever it contacts the grounded work piece. This causes erratic welds and reduced penetration.

  • Page 24: Troubleshooting

    Troubleshooting The following is a troubleshooting table provided to help you determine a possible remedy when you are having a problem with your welder. This table does not provide all possible solutions, only those possibilities considered to likely be common faults.

  • Page 25: Wiring Diagram

    Wiring Diagram WWW.FORNEYIND.COM...

  • Page 26: User Notes

    User Notes _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________...
  • Page 27 WWW.FORNEYIND.COM...
  • Page 28 Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 800-521-6038 www.forneyind.com WWW.FORNEYIND.COM...

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