Forney 220 Multi-Process Welder Quick Start Guide

Posted by Rachel Bigum on Jan 20, 2020 2:00:00 PM

In Welding, Forney Industries, Stick welding, TIG welding, MIG welding, Developed, Tested, Trusted, Quick Start Guide

Forney 220 MP In action

Get started with the Forney 220 MP Welder! Below is a breakdown of the Quick Start Guide included with your new machine. 

MIG Welding with the Forney 220 Multi-Process Welder

FIRST STEPS

Read User Manual 

Forney 220 MP and accessories

1. Select process

Select MIG

2. Set polarity for MIG (solid wire) or Flux-Cored

Set Polarity
Solid wire
Set Polarity Flux-Cored
Flux-cored

3. Connect MIG gun and ground clamp
Connect MIG gun and ground clamp

4. Install wire spool
Install wire spool





5. Set drive roll
Set drive roll
6. Feed wire and set pressure
Feed wire and set pressure
7. Connect to input power
Connect to input power

Gas Tips

8. Remove consumables and
depress trigger until wire
comes out. Replace consumables

Remove Consumables

9. Adjust wire feed speed ()

and voltage ()

Adjust wire feed speed

10. With contact tip 3/8" from metal, depress trigger completely to initiate arc 

Depress trigger

MIG TROUBLESHOOTING TIPS

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. 
Workpiece Preparation 
To ensure maximum quality, always clean and prepare welding surfaces. 

Frequently tripping circuit breaker or exceeding duty cycle 

 Use wire with a diameter between 0.023" (0.6mm) and 0.035" (0.9mm). Larger diameters draw too much amperage.
 Trying to weld single pass on material larger than 3/8" (9.5mm) thick is not possible with this machine. Multi-pass   recommended for thicker materials. 
 Welder should be the only thing plugged into the circuit.


Low weld output or poor fusion 

110-120V
• 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 3 conductor #12 AWG or larger up to 25 feet.
• Generators must be a minimum 5,000W continuous output with no low-idle function (or low-idle off), 5% THD Max.

Low weld output or poor fusion

208-240V
• 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 3 conductor #12 AWG or larger up to 25 feet.
• Generators must be a minimum 5,000W continuous output with no low-idle function (or low-idle off), 5% THD Max.

Improper wire spool installation 
• Can cause feed issues and inconsistent weld quality.
• Verify all parts are in the proper place. Refer to manual.
Improper wire spool installation

Too much spool tension 
Wire from spool to drive should relax with a slight curve after feeding. 

Too much spool tension

Incorrect drive roll pressure 

Too little pressure = roll can slip and feed can be erratic.
Too much pressure= can crush wire, causing wire feeding problems and welder damage.
Incorrect drive roll pressure 

No arc start on contact
No arc start on contact
Trigger must be pulled to initiate the arc.
This will initiate the arc and begin feeding the wire.

DEPRESS THE TRIGGER COMPLETELY 

Mismatched drive roll, liner, or contact tip size

Can cause feed and weld issues and arc instability.
Each component must be sized for wire diameter used. 

Mismatched drive roll, liner, or contact tip size


TIG Welding with the Forney 220 Multi-Process Welder

FIRST STEPS

Forney 220 MP and Accessories

Read User Manual 

1. Select  process

Select TIG Process

2. Connect TIG torch and ground clamp
Connect TIG torch and ground clamp
3. Connect TIG torch lead to gas (100% Argon) 
Connect TIG torch lead to gas (100% Argon) 

4. Adjust amperage per material thickness 
Adjust amperage per material thickness 
5. Connect to input power
Connect to input power


6. Choose between High Frequency (HF) start or Lift start
Choose between High Frequency (HF) start or Lift start
*Electrode is always electrically hot while in TIG mode

TIG TROUBLESHOOTING TIPS

Workpiece Grounding 
Workpiece Grounding Connect ground clamp to clean, bare metal. No rust, paint or other coatings. Attach the ground clamp directly to workpiece if you are experiencing issues. 
Workpiece Preparation
Workpiece PreparationTo ensure maximum quality, always clean and prepare welding surfaces.
Frequently tripping circuit breaker or exceeding duty cycle
Welder should be the only thing plugged into the circuit.
Aluminum welding
Aluminum welding is not recommended for this machine.
Low weld output or poor fusion
110-120V
• 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 3 conductor #12 AWG or larger up to 25 feet
• Generators must be a minimum 5,000W continuous output with no low-idle function
(or low-idle off), 5% THD Max
Low weld output or poor fusion
208-240V
• 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 3 conductor #8 AWG
• Generators must be a minimum 10,000W continuous output with no low-idle
function (or low-idle off), 5% THD Max


Stick Welding with the Forney 220 Multi-Process Welder

FIRST STEPS

220 MP and Accessories

Read User Manual 

1. Select  process

Select STICK Process

2. Connect electrode holder and ground clamp according to desired polarity
Connect electrode holder and ground clamp according to desired polarity
3. Connect to input power
Connect to input power

4. Adjust amperage per chart on the inside of the welder
Adjust amperage per chart on the inside of the welder
5. Recommended electrodes
Recommended electrodes


STICK TROUBLESHOOTING TIPS

Workpiece Grounding 
Workpiece grounding Connect ground clamp to clean, bare metal. No rust, paint or other coatings. Attach the ground clamp directly to workpiece if you are experiencing issues. 
Workpiece Preparation
Workpiece PreparationTo ensure maximum quality, always clean and prepare welding surfaces.
Frequently tripping circuit breaker or exceeding duty cycle
Use 3/16" diameter electrodes or smaller. Some 3/16" will draw too much amperage.
Trying to weld single pass on material larger than 3/8" thick  is not possible with this machine. Multi-pass recommended for thicker materials.
Welder should be the only thing plugged into the circuit.
Low weld output or poor fusion
110-120V
• 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 3 conductor #12 AWG or larger up to 25 feet
• Generators must be a minimum 5,000W continuous output with no low-idle function
(or low-idle off), 5% THD Max
Low weld output or poor fusion
208-240V
• 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 3 conductor #8 AWG
• Generators must be a minimum 10,000W continuous output with no low-idle
function (or low-idle off), 5% THD Max

 


FIND MORE INFORMATION AT FORNEYIND.COM 


Developed. Tested. Trusted.

 

 

QUESTIONS OR TROUBLE? Contact Forney Industries at 1-800-521-6038 or customerservice@forneyind.com