Forney FLEX 30 PLASMA ST User manual

• 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
Dedicated Circuit
240VAC - 50A
breaker recommended
or 120VAC - 20A
outlet, 30A breaker
Connect to input power
* TIG Torch Sold Separately
4. 6.
Use lift arc technique to initiate a welding
arc.
7.
Adjust amperage per
material thickness
Connect TIG torch lead
to gas (100% Argon)
5.
Connect TIG torch and
ground clamp
3.
ELECTRODE IS ALWAYS ELECTRICALLY
HOT WHILE IN TIG MODE
QUESTIONS OR TROUBLE? Contact Forney Industries at 1-800-521-6038
[email protected] • askforney.com • forneyind.com
Read user manual
Select DC TIG process
2.
1.
EN_v1
TIG Torch Ground
Clamp
180 ST+
A
STICK
DC TIG
ITEM# 321
PULSE (Hz)
PULSE (% On)
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.
QUICK START GUIDE
FLEX™ 30 PLASMA ST (NOT RECOMMENDED FOR ALUMINUM)
ITEM# 320
• 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).
Low weld output or poor fusion
Welder should be the only thing plugged into the circuit.
Frequently tripping circuit breaker or exceeding
duty-cycle
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.
Workpiece grounding
• Not recommended for this machine.
• Output is DC only which is not recommended for TIG
welding aluminum.
Aluminum welding
DC
ONLY
TIG TROUBLESHOOTING TIPS
180 ST+
A
STICK
DC TIG
ITEM# 321
PULSE (Hz)
PULSE (% On)
2.

QUESTIONS OR TROUBLE? Contact Forney Industries at 1-800-521-6038
[email protected] • askforney.com • forneyind.com EN_v1
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.
QUICK START GUIDE
FLEX™ 30 PLASMA ST (NOT RECOMMENDED FOR ALUMINUM)
ITEM# 320
Read user manual
Select STICK process
2.
1. Ground
Clamp
180 ST+
A
STICK
DC TIG
ITEM# 321
PULSE (Hz)
PULSE (% On)
Electrode Holder
4. 6.
Adjust amperage per
settings chart on the
welder
5.
Connect electrode
holder and ground
clamp according to
desired polarity
3.
Usually
DCEP -
Electrode
Positive
• 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
Dedicated Circuit
240VAC - 50A
breaker recommended
or 120VAC - 20A
outlet, 30A breaker
Connect to input power
*Performance may vary by brand
Recommended electrodes
Electrode Diameter
Inches MM AMPS
E6010
&
E6011
E6013
E7014
E7018
Amperage
3/32
1/8
5/32
1/16
3/32
1/8
5/32
3/32
1/8
5/32
3/32
1/8
5/32
2,4
3,2
4,0
1,6
2,4
3,2
4,0
2,4
3,2
4,0
2,4
3,2
4,0
30-75
35-125
80-160
10-50
40-90
50-130
90-160
40-90
60-130
90-160
50-80
80-160
90-160
STICK TROUBLESHOOTING TIPS
FIND STICK WELDING TIPS AT WWW.ASKFORNEY.COM
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.
• 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).
Low weld output or poor fusion
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.
Workpiece grounding
• Not recommended for this machine.
• Output is DC only which is not recommended for TIG
welding aluminum.
Aluminum welding
DC
ONLY

QUESTIONS OR TROUBLE? Contact Forney Industries at 1-800-521-6038
[email protected] • askforney.com • forneyind.com EN_v1
Read user manual
Select CUT process
2.
1.
QUICK START GUIDE
FLEX™ 30 PLASMA ST
ITEM# 320
4. 6.
Connect torch and
ground clamp
5.
3.
Output air pressure is pre-set at the factory
Connect to input air
• 60-100 PSI
• >4.0 CFM
• Clean air
• No oil
• No moisture
• Connect plasma torch to machine
• Connect ground clamp to
PLASMA GROUND dinse socket
Drag tip on workpiece
Travel speed Cutting capability Replace worn consumables
FIND MORE PLASMA CUTTING TIPS AT WWW.ASKFORNEY.COM
OPERATING TIPS
Will cut clean up to
1/2” (12,7 mm)
NOTE: Correct consumable assembly
Torch body
Electrode
Air diffuser ring
Cutting tip (0.9)
Shield cup
Too fast.Watch
spark trail angle.
a.
b.
c.
d.
e.
Replacement electrodes - ITEM# 85755 (2-pack)
Replacement cutting tips - ITEM# 85678 (2-pack)
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.
Plasma Torch Ground
Clamp
• 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
Dedicated Circuit
240VAC - 50A
breaker recommended
or 120VAC - 20A
outlet, 30A breaker
Connect to input power
Expert-Tech Tip: Use an electrically conductive
cutting guide to cut expanded metal.