Forney SPOOL PRO HORNET SG 250 Operating Manual
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Forney SPOOL PRO HORNET SG 250 Operating Manual

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SPOOL PRO
HORNET SG 250
™
™
OPERATING MANUAL
ENGLISH
ITEM# 85620
REV 01.27.2022

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Summary of Contents for Forney SPOOL PRO HORNET SG 250

  • Page 1 SPOOL PRO HORNET SG 250 ™ ™ OPERATING MANUAL ENGLISH ITEM# 85620 REV 01.27.2022...
  • Page 2 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 3 TECHNICAL ISSUES? FORNEY CAN HELP! Thank you for choosing Forney! Please note: The store you purchased this m achine from DOES NOT handle product r eturns. F orney Industries will repair or replace defective products at no charge to you! When you call Forney's Technical Service department, you will speak to a trained product and application expert.

  • Page 4: Table Of Contents

    Table of Contents WARRANTY ..................................3 TABLE OF CONTENTS ................................4 SYMBOLS LEGEND ................................5 SAFETY SUMMARY ................................5 PRINCIPAL SAFETY STANDARDS .............................5 CALIFORNIA PROPOSITION 65 WARNING ........................6 EMF INFORMATION ...............................6 PERSONAL PROTECTION ...............................6 FIRE PREVENTION ................................7 HIGH FREQUENCY RADIATION ............................8 ARC WELDING ................................8 ELECTRIC SHOCK ................................8 NOISE ...................................9 ADDITIONAL SAFETY INFORMATION ..........................9...

  • Page 5: Symbols Legend

    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. Symbols Legend MEANING...

  • Page 6: California Proposition 65 Warning

    • ANSI Z87.1 - SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION - Obtainable from the American National Standards Institute, 11 West 42nd St., New York, NY 10036 Telephone (212) 642-900, Fax (212) 398-0023 - www.ansi.org. • NFPA 51B: STANDARD FOR FIRE PREVENTION DURING WELDING, CUTTING, AND OTHER HOT WORK- Obtainable from the National Fire Protection Association, 1 Batterymarch Park, P.O.

  • Page 7: Fire Prevention

    welding area, either remove it or cover it with something non-flammable and non- reflective. Reflective arc rays can also cause skin burn in addition to eye injury. • Flying sparks can injure. Wear proper safety equipment to protect eyes and face. Shape tungsten electrode on grinder wearing proper protection and in a safe location.

  • Page 8: High Frequency Radiation

    pressure used. All hoses, fittings, etc. should be in good condition. • Do not stand in front of or put your head or face in front of a cylinder valve outlet when opening the valve. • If a cylinder is not in use or connected for use, keep a valve protection cap in place to protect the valve. •...

  • Page 9: Noise

    d. any metal parts on the electrode holder, or MIG gun. • Do not weld in a damp area or come in contact with a moist or wet surface. • Do not attempt to weld if any part of clothing or body is wet. •...

  • Page 10: Installation

    Installation Spool Gun Specifications Primary (Input) Volts 0-12 VDC Maximum Output Amperage 300A (DC output only) Rated Output and Duty Cycle 220A @ 60% Supplied Drive Roll 0.035” and 0.047” Grooves Recommended Wire Size 0.035” (Compatible with 0.030 - 0.047”) Wire Speed 1000 IPM Max Recommended Material...

  • Page 11: Getting To Know Your Spool Gun

    25 foot power cable with either Euro-Connect, or other proprietary machine connections. 11. Liner Inlet Guide - The Teflon (PTFE) liner of your new Spool PRO Hornet SG 250 is a consumable part and will need to be replaced from time to time. It can be easily removed and replaced via the liner inlet guide.
  • Page 12 Model Selector Switch. If using the Forney 190 MP (#324), or Forney 220 MP, the Model Selector Switch needs to be in the “Off” position. If using a Forney 242 MIG or 270 MIG, the Model Selector Switch needs to be in the “On”...

  • Page 13: Gas Cylinder And Regulator Connection

    • Connect the other end to the GAS INPUT on the back of the machine. If multiple GAS INPUT ports are present on the back of your Forney welding machine, use the port that is designated for MIG welding. •...
  • Page 14 Step 2: Move the spool brake to the locked position: • Slide the spool brake lock (9) forward (away from the wire spool housing) until it reaches the front end of its stroke. • Rotate the spool brake lock (9) downward into the locking notch: Step 3: Install welding wire spool: WWW.FORNEYIND.COM...
  • Page 15 Step 4: Unlock spool brake: • Rotate the spool brake lock upward out of the locking notch. • Release spool brake lock. Spring force will automatically drive the brake backwards until contact is made with the wire spool. Step 5: Remove wire feed tension: •...
  • Page 16 Step 7: Route the wire through the drive mechanism. • Ensure that the wire leaves the liner outlet guide. • Using your fingertips, route the wire past the drive roller and into the torch neck inlet guide. Step 8: Close the tension arms and apply drive tension (reverse Step 5). •...

  • Page 17: Drive Roll Groove Selection

    Changing the Drive Roller To remove or install the drive roller onto your Forney spool gun, simply remove the thumb screw from the top of the drive axle. Once this thumb screw is removed, the roller is free to slide on and off of the axle:...

  • Page 18: Operation

    Operation Welding Preparation An important factor in making a satisfactory weld is preparation. This includes studying the process and equipment and practicing welding before attempting to weld finished product. An organized, safe, comfortable, and well-lit work area should be prepared for the operator. The work area should specifically be free of all flammables with both a fire extinguisher and a bucket of sand available.

  • Page 19: Adjusting Machine Settings

    Allow for fine control, giving the user ± 10% of the wire feed speed that is set using the knob on the front of the welding machine. When using your new spool gun on a power supply or welding machine that was not manufactured by Forney Industries: •...
  • Page 20 Basic MIG Settings for 4XXX Series Aluminum Wire Diameter Material Thickness Voltage (V) Wire Feed Speed (IPM) 22 GA 13.5 20 GA 13.5 18 GA 14.5 16 GA 15.5 14 GA 16.5 0.030” 12 GA 17.5 1/8” 3/16” 1/4” 28.5 3/8”...

  • Page 21: Push Vs. Pull

    Push Vs. Pull When MIG welding aluminum with a spool gun, it is very important that the user “push” rather than “pull” the weld. This ensures adequate shielding gas coverage for the weld zone and will dramatically improve weld appearance and quality: WWW.FORNEYIND.COM...

  • Page 22: Maintenance & Servicing

    Gently pull the old liner completely out of the gun. Spare liners can be purchased from Forney Industries directly, or large quantities of liner material can be purchased online at a discounted price. The liner is standard white Teflon (PTFE) with ID = 2mm, OD = 4mm.

  • Page 23: Troubleshooting

    CAUTION: KEEP THE NOZZLE CLEAN! During the welding process, spatter and slag will build up inside the nozzle and must be cleaned out periodically. Failure to clean and/or replace the nozzle in a timely fashion will cause damage to the front end of the gun assembly, which is not replaceable.
  • Page 24 Empty wire spool. Replace wire spool. Welder is in throttled back-feed mode. If the Forney welding machine does not detect an arc after a few seconds with the trigger Wire feed speed slows down. depressed, the wire feed speed is automatically throttled back.

  • Page 25: Spool Gun Consumables List

    POSSIBLE CAUSE POSSIBLE SOLUTION PROBLEM Using contact tip that is the same size as Always use a contact tip that is one size larger welding wire. that the welding wire. Welding wire fused to contact tip. Burn Back Time (BBT) set too high. Turn burn back time (BBT) down.

  • Page 26: User Notes

    User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 27 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 28 Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 +1-800-521-6038 www.forneyind.com...

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