Forney FLEX 30 PLASMA ST Operating Manual
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Forney FLEX 30 PLASMA ST Operating Manual

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FLEX
30 PLASMA ST
™
OPERATING MANUAL
ENGLISH
ITEM# 320
REV 05.12.2022

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Summary of Contents for Forney FLEX 30 PLASMA ST

  • Page 1 FLEX 30 PLASMA ST ™ OPERATING MANUAL ENGLISH ITEM# 320 REV 05.12.2022...
  • 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: Warranty

    In fact, the majority of issues can be fixed over the phone! Please be near your machine when you call, so the Forney technician can guide you.

  • Page 4: Table Of Contents

    Box 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 PLASMA ARC CUTTING HAZARDS ........................6 ELECTRIC SHOCK ..............................

  • 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

    • NFPA 70: NATIONAL ELECTRICAL CODE - Obtainable from the National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101 Telephone (617) 770-3000 Fax (617) 770-0700 - www.nfpa.org • CGA Publication P-1: SAFE HANDLING OF COMPRESSED GASSES IN CONTAINERS - Obtainable from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 Telephone (703) 7882700 Fax (703) 961-1831 - www.cganet.com •...

  • Page 7: Electric Shock

    • Do not weld, cut, or perform other such work on used barrels, drums, tanks, or other containers that had a flammable or toxic substance. The techniques for removing flammable substance and vapors, to make a used container safe for welding or cutting, are quite complex and require special education and training. •...
  • Page 8 SIGNIFICANT DC VOLTAGE EXISTS ON INTERNAL PARTS OF INVERTER-BASED MACHINES AFTER THE REMOVAL OF INPUT POWER. Before touching anything inside the cabinet or performing maintenance activities, turn unit OFF, disconnect INPUT POWER CABLE, and allow sufficient time for the capacitors to discharge (check with a voltmeter that there are zero volts (0V) across the capacitor terminals).
  • Page 9 • Keep away from the torch CUTTING TIP. • Do not grip material near the cutting path. • The pilot arc can cause burns - keep away from torch CUTTING TIP when trigger is pressed. • Wear proper flame-resistant clothing covering all exposed body areas. •...

  • Page 10: Personal Protection

    Personal Protection THE WELDING ARC PRODUCES VERY BRIGHT ULTRAVIOLET AND INFRARED LIGHT. THESE ARC RAYS WILL DAMAGE YOUR EYES AND BURN YOUR SKIN IF YOU ARE NOT PROPERLY PROTECTED. To reduce the risk of injury from arc rays, read, understand, and follow the safety instructions.

  • Page 11: High-Frequency Radiation

    this welding equipment, or is a bystander in the welding area, understands and follows these safety instructions as well. Remember: arc welding by nature produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can start fires, burn skin and damage eyes. •...

  • Page 12: Arc Welding

    Arc Welding • Computers and computer driven equipment can be harmed with electromagnetic energy. • Be sure all equipment is compatible with electromagnetic energy. • Keep welding cables short to reduce interference. • Follow manual to install and ground machine. •...

  • Page 13: Additional Safety Information

    Additional Safety Information For additional information concerning welding safety, refer to the standards listed at the beginning of this safety summary and comply with them as applicable. Box Contents DESCRIPTION ITEM ITEM DESCRIPTION ITEM DESCRIPTION 240V-120V Ground Cable Machine Adapter Cord and Clamp ITEM DESCRIPTION...

  • Page 14: Site Selection

    Single-phase service must be of the 3-wire type with a green or green/yellow wire for the protective earth ground. Do not use 2-wire service. Using the 240 – 120V Adapter Cord If a 240V (50A) circuit is not available, you can connect your Forney Flex 30 Plasma ST machine to 20A outlet (with a ™...

  • Page 15: Generators

    Generators This machine can be operated from an AC generator. Ensure that the generator can supply a minimum of 4,000 watts of continuous output (for 120V input) or a minimum of 10,000 watts of continuous output (for 240V input). The generator must not have an auto-idle fuel saving feature or must have the option to turn auto-idle off. The generator must run at full speed at all times while your machine is plugged into it or you risk damaging your machine.

  • Page 16: Machine Layout And Controls

    Machine Layout Controls 1. Process SELECTION button used to select the welding/cutting process. 2. Process Indicator LED’s illuminate according to the selected welding process. a. CUT DC TIG STICK b. DC TIG (“GTAW”) (“GTAW”) (“SMAW”) STICK (“SMAW”) 3. INPUT VOLTAGE INDICATOR LED will be illuminated when input voltage to the machine is present, and the ON/OFF SWITCH (11) is in the ON position.
  • Page 17 REAR VIEW OF FORNEY FLEX 30 WELDER FRONT VIEW OF FORNEY FLEX 30 WELDER ™ ™ WWW.FORNEYIND.COM...

  • Page 18: Compressed Air Supply

    Compressed Gas Supply • The plasma cutting machine does not include a built-in air compressor; therefore, a source of clean, dry air or nitrogen must be supplied to your plasma cutting unit. • The air supply pressure must be between 60 and 100 PSI. NOTE: The flow rate must be at least 4.0 cu.ft/min. •...
  • Page 19 (E) SHIELD CUP (WITH SIX HOLES) ø (D) CUTTING TIP ( 0.9mm HOLE) (C) AIR DIFFUSER RING (B) ELECTRODE (A) TORCH BODY PROPERLY ASSEMBLED PLASMA TORCH PROPER CONSUMABLE ASSEMBLY FOR PLASMA TORCH HEAD Your PLASMA TORCH consumable parts will come already assembled. Plasma torch consumables will wear through the course of normal use and need to be replaced periodically.

  • Page 20: Operation

    User settings on the machine may need to be reduced or limited to avoid exceeding the rated input amperage. Failure to do so could result in frequent breaker trips or electrical hazards. Forney Industries 2057 Vermont Drive, Fort Collins, CO 80525 Flex 30 Plasma ST ™...

  • Page 21: Internal Thermal Protection

    Internal Thermal Protection If you exceed the duty-cycle of the machine, the thermal protection system will engage, shutting off all machine output. After cooling, the thermal protector will automatically reset, and the welding functions can resume. This is normal and automatic behavior of the machine and does not require any user action. However, you should wait at least 10 minutes after the thermal protector engages before resuming welding.

  • Page 22: Setup For Tig Welding (Gtaw) With Lift Arc

    Forney Flex 30 STICK SET-UP CHART ® ™ ELECTRODE DIAMETER MATERIAL ELECTRODE 1/16” (1.6 mm) 5/64” (2 mm) 3/32” (2.4 mm) 1/8” (3 mm) (Wire) TYPE Regulation Knob E6010 – – 50-70A E6011, Mild Steel E6013, 30-40A 40-60A 50-70A 70-80A...

  • Page 23: Ground Clamp Attachment

    Welding Tips: • Always weld clean, dry and well-prepared material. • Move the torch smoothly and steadily as you weld. • Avoid welding in very drafty areas. A weak, pitted and porous weld will result due to drafts blowing away the protective welding gas.

  • Page 24: Setup Or Plasma Cutting

    Cutting Capacity STAINLESS STEEL ALUMINUM GALVANIZED BRASS COPPER STEEL 5/8” 3/8” 3/8” 1/8” 3/8” 3/8” 3/8” RECOMMENDED CAPACITY SEVERANCE CAPACITY • Top end of machine capabilities. • Intended for • Optimal system performance. occasional severance • Ideal operating range for excellent cut quality. requirements;...
  • Page 25 • Pause at the edge (end of your cut) until the arc has cut completely through the workpiece. • To shut off the PLASMA TORCH, simply release the control switch. When the switch is released a post-flow will occur. If the torch trigger is pressed during the post-flow, the pilot arc will restart. •...

  • Page 26: Maintenance & Servicing

    Maintenance & Servicing General Maintenance This machine has been engineered to need minimal service providing that a few very simple steps are taken to properly maintain it. 1. Replace INPUT POWER CABLE (12), ground cable, ground clamp, or torch/electrode cable when damaged or worn.

  • Page 27: Consumable Maintenance

    CAUTION! Do not operate PLASMA TORCH (9) without a CUTTING TIP or ELECTRODE in place. Be sure to use genuine Forney parts. NOTE: It is recommended that the ELECTRODE and CUTTING TIP should be replaced at the same time to ensure even wear and optimal performance.

  • Page 28: Troubleshooting

    If you are unable to fix the problem by following the basic troubleshooting guide or if you need further assistance call Forney Customer Service at 1-800-521-6038 or email at customerservice@forneyind.com. The following is a troubleshooting table provided to help you determine a possible remedy when you are having a problem with your machine.
  • Page 29 Electrical short is present Separate the electrode or tungsten from the workpiece. between the + and – terminals. Stick welding electrode is OUTPUT SHORT FAULT stuck to the workpiece. CODE: “F09” DISPLAYED ON AMPERAGE DISPLAY (6) AND TIG tungsten is shorted to the FAULT INDICATOR LED (3) IS workpiece.
  • Page 30 If used, eliminate or reduce length of extension cord. PLASMA TORCH parts are Examine the consumables for wear and replace worn parts worn out. with new Forney consumable parts. Non-genuine manufacturer’s Use only genuine Forney consumables for optimum parts. performance. WWW.FORNEYIND.COM...
  • Page 31 Examine the consumables for wear and replace worn parts again. worn out. with new Forney consumable parts. Non-genuine manufacturer’s Use only genuine Forney consumables for optimum parts. performance. GROUND CABLE (4) is Securely CLAMP the GROUND CABLE to the material being disconnected.

  • Page 32: Machine Parts Diagram & Replacement Parts List

    Machine Parts Diagram & Consumables List PART NUMBER ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION 85667 Ground (25 Dinse) 85755 Electrode (2-pack) 85669 Electrode Holder (25 Dinse) 85393 Air Diffuser Ring (Swirl Ring) 85684 Cutting Tip (2-pack) 85681 Shield Cup 85680 Plasma Torch WWW.FORNEYIND.COM...

  • Page 33: Tig Torch & Tig Consumables List (Sold Separately)

    TIG Torch (SOLD SEPARATELY) PART NUMBER ITEM DESCRIPTION ITEM PHOTO 85659 Tig Torch (17FV) WWW.FORNEYIND.COM...

  • Page 34: User Notes

    User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 35 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 36 Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 +1-800-521-6038 www.forneyind.com...

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