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Forney 250 MP PRO Operating Manual

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250 MP PRO
WELDER OPERATING MANUAL
ENGLISH
ITEM# 415
REV 09.04.2024

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  • Page 1 250 MP PRO WELDER OPERATING MANUAL ENGLISH ITEM# 415 REV 09.04.2024...
  • Page 2 Fort Collins, CO 80525 Since 1932, Forney has been at the forefront of innovation and excellence in all facets of our business. J.D. Forney was an entrepreneur who invented the instant-heat soldering iron and the first 110-volt arc welder. For over 90 years, we have continued U.S.

  • Page 3: Warranty

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

  • 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 INSTALLATION ..................................10...

  • 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

    • Flying sparks can cause injuries. Wear proper safety equipment to protect your eyes and face. Shape any tungsten electrodes on a grinder while wearing proper protection and in a safe location. Keep all flammables away to prevent a fire starting from flying sparks. FUMES, GASSES AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS AND DEATH! To reduce the risk, read, understand and follow the safety instructions.

  • Page 8: High-Frequency Radiation

    • Keep cylinders upright and securely chain them to a fixed support to prevent tipping. • Keep cylinders away from areas where they may be subjected to physical damage or accidentally struck. Keep them a safe distance from any source of flame, sparks or heat. •...

  • Page 9: Noise

    • Do not allow the welding equipment to come in contact with water or moisture. • Do not drag welding cables, MIG gun or welder INPUT POWER CABLE through or allow them to come into contact with water or moisture. •...

  • Page 10: Installation

    Installation Welder Specifications Primary (Input) Volts 120VAC/240VAC Maximum Output 120V - 100A 240V - 250A Phase Single Frequency 50/60Hz Recommended Circuit Breaker 120V - 30A time-delay (slow-blow) breaker for maximum performance (15A minimum breaker size) 240V - 50A time-delay (slow-blow) breaker for maximum performance (30A minimum breaker size) Refer to the ratings label and set the output amperage so that the listed input amperage is not exceeded.

  • Page 11: Using The 240V - 120V Plug Adapter

    Using the 240V – 120V Adapter Cord If a 240V (50A) circuit is not available, you can connect your Forney 250 MP PRO welder to a 120V, 20A dedicated circuit (with a 30A breaker) using the adapter cord. When using the adapter cord for 120V, use lower power settings on the machine to avoid frequent circuit breaker trips.

  • Page 12: Getting To Know Your Welder

    Getting to Know Your Multi-Process Welder Description Your new inverter multi-process welder offers multiple welding processes in the same power source. DC TIG, Stick, and MIG welding that can be performed manually or with TruSet MIG. TruSet automatically sets optimal welding parameters based on wire diameter, ™...
  • Page 13 17. TIG GAS INPUT 5/8” FNPT 18. MIG GAS INPUT 5/8” FNPT 19. POWER SWITCH 20. INPUT POWER CABLE 21. FAN(S) REAR VIEW OF FORNEY 250 MP PRO WELDER FRONT VIEW OF FORNEY 250 MP PRO WELDER WWW.FORNEYIND.COM...
  • Page 14 WWW.FORNEYIND.COM...

  • Page 15: Installing The Mig Gun Assembly

    Installing the MIG Gun Assembly • Attach the MIG welding gun to the EURO CONNECT on the front of the welder. Gas Cylinder and Regulator Connection The gas cylinder (not supplied) should be located near the rear of the welder, in a well-ventilated area and securely fixed to the work bench or to the wall to ensure that it will not fall.
  • Page 16 Setup for Use with 4” Spools: NOTE: These steps assume the despooler is completely assembled for the 8-inch spool arrangement (default configuration from the factory). 1. Open the wire cabinet door. 2. Press in on the locking key (B) (this will compress the spring (F) slightly), then twist counterclockwise approximately 1/8th of a turn until it stops.
  • Page 17 Setup for Use with 8” Spools 1. Open the wire cabinet door 2. Install the washers (E) and spring (F) on the main shaft (D), followed by the spindle adapter for 8” spools (A) as shown in the diagram above. 3.
  • Page 18 7. Install the spool retaining ring (C) on the end of the spindle adapter (A) by first aligning the internal pegs of the retaining ring (C) with the keyways on the end of the spindle adapter (A). Slide the retaining ring (C) onto the spindle adapter (A) until it stops.
  • Page 19 FEEDING WIRE THROUGH THE MIG GUN: Unhook the wire from the spool and hold the wire end while preventing the spool from turning with one hand. While holding the wire in place, use a wire cutter to cut the bent end of the wire so that only a straight end remains. Continue to hold the wire end in one hand and release the drive roll pressure arms (I) by pulling the pressure arm adjustment knob (G) toward you.

  • 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 250 MP PRO #A/#V #A/#V ##.#V ##.#V ##.#V...

  • Page 21: Internal Thermal Protection

    Internal Thermal Protection If you exceed the duty-cycle of the welder, the thermal protection system will engage, shutting off all welder 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.

  • Page 22: Welding Wire Selection

    Welding Wire Selection This welder can use solid steel wire (MIG welding, “GMAW”) from 0.023” - 0.045” (0.6 – 1.15mm) diameter: stainless steel wire from 0.023” - 0.045” (0.6 – 1.15mm) diameter and with flux-cored wire (flux-cored wire welding, “FCAW”) from 0.030”...
  • Page 23 Manual MIG Crater Fill (Sec) Crater Fill AMP % Inductance Crater Fill Controls Adjusts the length of the arcs short circuit cycle. High Adjusts the time the arc will Determines the percent inductance increases the time each cycle takes improving gradually decrease the weld of user-set amperage the the puddles wetting, ideal for thicker materials.

  • Page 24: Setup For Stick Welding (Smaw)

    250 MP PRO MIG SET-UP CHART 1/2" 3/8" 5/16" (12.7mm) 3/16" (9.53mm) 1/4" (6.4mm) 1/8" 14GA (7.9mm) 18GA 16GA (4.8mm) (3.2mm) (2.0mm) Material (1.2mm) (1.6mm) MIG (GMAW) Thickness Wire Polarity Diameter 150- 220- 250- 300- 330- .030" 16-17 17-18 17-18 17.5-19...

  • Page 25: Setup For Tig Welding (Gtaw)

    250 MP PRO STICK SET-UP CHART Electrode E308L/E309L/ E6010 E6011 E6013 E7014 E7018 Type E316L Polarity Definitions: Electrode Amperage Polarity Amperage Polarity Amperage Polarity Amperage Polarity Amperage Polarity Amperage Polarity AC: Alternating Current Diam DCEP: Direct Current 1/16" AC-DCEP- AC-DCEP-...

  • Page 26: Welding Tips

    Expert-Tech Tip: At any point, hold INFO/EXPERT SET to set highlighted secondary parameter to Forney’s ™ recommended Expert Settings. • Initiate the weld arc. • Using pedal or thumb control torch, adjust output amperage while working as needed. REMEMBER TO CLOSE THE VALVE ON THE GAS CYLINDER IMMEDIATELY AFTER ALL WELDING IS COMPLETED.
  • Page 27 Tungsten Recommendations TUNGSTEN TYPE COMMENTS 1.5-2% Lanthanated (La) Most versatile tungsten 1.5-2% Ceriated (Ce) Solid performance for most applications 1-2% Thoriated (Th) Performance OK but hazardous Pure Will NOT work with the machine Recommended Amperage & Electrode Types for TIG Welding TUNGSTEN DCEN (Th,La,Ce) .040”...

  • Page 28: Maintenance & Servicing

    Maintenance & Servicing General Maintenance This welder has been engineered to need minimal service providing that a few very simple steps are taken to properly maintain it. Always keep the cabinet cover closed unless changing the wire or the drive pressure. Keep all consumables (contact tips, nozzles and liner) clean and replace when necessary.

  • Page 29: Replacing Gun Liner

    Replacing the Gun Liner Remove the MIG gun from the machine by disconnecting the Euro connector. Loosen the diffuser set screw. Located on the gas diffuser on the torch, remove nozzle and insulator to uncover. Loosen set screw to free the end of the liner. Straighten the gun lead as much as possible.

  • Page 30: 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 likely to be common faults. POSSIBLE CAUSE POSSIBLE SOLUTION PROBLEM...
  • Page 31 PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION MIG electrode polarity jumper is not Connect the MIG electrode polarity jumper connected to a Dinse sockets. to the appropriate Dinse socket for your required welding polarity. Bad ground or loose ground connection. Check connection of the ground cable to the ground clamp.
  • Page 32 PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Weld parameters too low. Adjust welding parameters. If in TruSet ™ turn Trim up. Too long or improper extension cord. Use a proper extension cord (#12 AWG wire or heavier, no longer than 25’). See “Extension Cords”, page 11.
  • Page 33 PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Wire-feed speed is set too low for voltage Increase wire-feed speed (turn RIGHT KNOB setting being used. clockwise) or choose a thicker material if using TruSet MIG. ™ Stick-out too short. Increase stick-out (the amount the wire extends Wire burns back to contact tip.

  • Page 34: Machine Parts Diagram & Consumables List

    Machine Parts Diagram & Replacement Parts List PART NUMBER ITEM DESCRIPTION 85096 MIG Gun 85668 Ground (50 Dinse) 85670 Electrode Holder (50 Dinse) 78036 240V-120V Adapter Cord 5084 Expert-Tech Tool ™ WWW.FORNEYIND.COM...

  • Page 35: Mig Gun Consumables List

    MIG Gun Consumables List PART NUMBER ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION 100356 Liner (Tweco 42-4045-15) 60175 Tip (Tweco 14-35) ® ® 85341 Diffuser (Tweco 52)* 60168 Tip (Tweco 14-45) ® ® 85343 Diffuser (Tweco 52-FN) 85334 Nozzle (Tweco 22-50)* ®...

  • Page 36: User Notes

    User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 37 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 38 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 39 Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 +1-800-521-6038 www.forneyind.com WWW.FORNEYIND.COM...

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