Forney Flex 30 Plasma St Dual Voltage All In One Welding User Guide

Low weld output or poor fusion

• Usually due to low input power.
• Welder should be only thing plugged into circuit.
• Avoid using extension cords. If one must be used, it must be #12 AWG (120V) or #10 AWG (240V) or larger; 25’ (8m) or shorter.
• Generators must be 10,000 W (240 V) or 4,000 W (120 V) continuous output and not have a low-idle function (or have it disabled).

How to Use

1. Read user manual
2. Select STICK process
3. Connect electrode holder and ground clamp according to desired polarity
4. Connect to input power
   • Dedicated Circuit 240VAC – 50A breaker recommended or 120VAC – 20A outlet, 30A breaker
     • Generator OK with continuous output > 4,000 W (120V) or 10,000 W (240V)
     • Extension cord: #12 AWG (120V) or #10 AWG (240V) or larger. 25’ (8m) or shorter recommended
     • Always follow local electrical codes

Adjust amperage per settings chart on the welder

Recommended electrodes

• Performance may vary by brand

FIND STICK WELDING TIPS AT: WWW.ASKFORNEY.COM

STICK TROUBLESHOOTING TIPS

Fault codes

• Duty-cycle exceeded or insufficient air flow. Allow machine to cool. Ensure vents are clear of obstacles. See manual.
• Incorrect input power. Verify machine is plugged into an appropriate power source. Use proper extension cords. See manual.
• Electrode is shorted or stuck to workpiece. Separate the electrode or tungsten from the workpiece and fault will clear. See manual.

Aluminum welding

• Not recommended for this machine.
• Output is DC only which is not recommended for TIG welding aluminum.

Frequently tripping circuit breaker or exceeding duty-cycle

• Use 5/32” diameter electrodes or smaller. Some 5/32” will draw too much amperage (stick).
• Trying to weld single pass on material larger than 3/8” thick is not possible with this machine. Multi-pass recommended for thicker materials.
• Welding machine should be the only thing plugged into the circuit.

Workpiece grounding

• Connect ground clamp to clean, bare metal. No rust, paint or other coatings. Attach the ground clamp directly to the workpiece if you are experiencing issues.

Low weld output or poor fusion

• Usually due to low input power.
• Welder should be only thing plugged into circuit.
• Avoid using extension cords. If one must be used, it must be #12 AWG (120V) or #10 AWG (240V) or larger; 25’ (8m) or shorter.
• Generators must be 10,000 W (240 V) or 4,000 W (120 V) continuous output and not have a low-idle function (or have it disabled).

How to Use

1. Read user manual
2. Select CUT process

Connect to input air

• 60-100 PSI
• > 4.0 CFM
• Clean air
• No oil
• No moisture

Output air pressure is pre-set at the factory

Connect torch and ground clamp

• Connect plasma torch to machine
• Connect ground clamp to PLASMA GROUND dinse socket

Connect to input power

Dedicated Circuit 240VAC – 50A breaker recommended or 120VAC – 20A outlet, 30A breaker

• Generator OK with continuous output > 4,000 W (120V) or 10,000 W (240V)
• Extension cord: #12 AWG (120V) or #10 AWG (240V) or larger. 25’ (8m) or shorter recommended
• Always follow local electrical codes

Drag tip on workpiece

NOTE: Correct consumable assembly

• Torch body
• Electrode
• Air diffuser ring
• Cutting tip (0.9)
• Shield cup

OPERATING TIPS

Travel speed

Cutting capability

• Will cut clean up to 3/8” (9,5 mm)

Replace worn consumables

• Replacement electrodes – ITEM# 85755 (2-pack)
• Replacement cutting tips – ITEM# 85678 (2-pack)

FIND MORE PLASMA-CUTTING TIPS AT: WWW.ASKFORNEY.COM

TROUBLESHOOTING GUIDE

Fault Codes

• Duty-cycle exceeded or insufficient air flow. Allow machine to cool. Ensure vents are clear of obstacles. See manual.
• Incorrect input power. Verify power source is 120V or 240V +/- 10%. Use proper extension cords. See manual.
• Shield Cup loose or missing. Check consumable assembly. Tighten cup. See manual.
• Incorrect input air pressure. Ensure air input meets pressure and flow requirements. 80 PSI and 4.0 CFM recommended. See manual.
• Plasma torch is triggered when machine powered on. Release trigger. See manual.
• Check that ground clamp is connected to the proper Dinse socket. See manual.
• Wrong ground connection for plasma ground. Ensure the ground clamp is connected to the plasma ground Dinse socket. Cycle machine power. See manual.

Expert-Tech Tip: Use an electrically conductive cutting guide to cut expanded metal.

Contact

QUESTIONS OR TROUBLE

• Contact Forney Industries at 1-800-521-6038
• [email protected]
• askforney.com
• forneyind.com