Forney 220 MP Operating Manual
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Forney 220 MP Operating Manual

Multi-process welder
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220 MULTI-PROCESS WELDER
OPERATING MANUAL
ENGLISH
ITEM# 410
REV 08.08.2019

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Summary of Contents for Forney 220 MP

  • Page 1 220 MULTI-PROCESS WELDER OPERATING MANUAL ENGLISH ITEM# 410 REV 08.08.2019...
  • 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

    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

    • background exists in your 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 Welder Specifications Primary (Input) Volts 120VAC/230VAC Maximum Output 220A (DC output only) Phase Single Frequency 50/60Hz Recommended Circuit Breaker 50A for 230V or 30A for 120V Extension Cord Recommendations 230V-3 conductor #8AWG 120V-3 conductor #12AWG or larger up to 25 Feet Generator Requirements 230V -Minimum 10,000W continuous output with no low-idle function (or low-idle off), 5% THD Max.

  • Page 11: Using The 230 Volts - 120 Volts Plug Adapter

    Using the 230 volt – 120 volt Plug Adapter If a 230V (50A) circuit is not available, you can connect your Forney 220 MP welder to 20A outlet (with a 30A breaker) using the plug adapter. When using the plug adapter 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 single phase inverter multi-process welder offers three welding processes in the same power source. These processes can be selected with the PROCESS SELECTOR BUTTON on the front panel of the unit. Flux-Cored Wire Welding, “FCAW”...
  • Page 13 15. MIG GAS INPUT 16. INPUT POWER CABLE 17. WIRE SPOOL SPINDLE 18. STAMPED ALUMINUM TWO-ROLL WIRE FEEDER 19. FAN(S) REAR VIEW OF FORNEY 220 MP WELDER FRONT VIEW OF FORNEY 220 MP WELDER WWW.FORNEYIND.COM...

  • Page 14: Installing The Mig Gun Assembly

    Installing the MIG Gun Assembly • Attach the standard 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 15 INSTALLING 4-INCH SPOOL (SEE FIGURE FOR PART IDENTIFICATION): Open the access panel. Unscrew and remove the wire spool retention cap used for 8-inch spools (A) and store it someplace safe. Remove the spindle adapter for 8-inch spools (B) and store it someplace safe. Remove the nut (C), spring (D), and washers (E).

  • Page 16: Operation

    Cut off the excess wire that extends past the end of the nozzle. Fine tune the wire drive pressure with the pressure arm adjustment knob (G). a. Turn the wire drive pressure adjustment knob clockwise, increasing the drive pressure until the wire seems to feed smoothly without slipping.

  • Page 17: Internal Thermal Protection

    IP21S (Example Data Plate) 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 18: Factors To Consider For Best Mig Welding Results

    • Attach the ground clamp to the bare metal to be welded, making sure of good contact. • Make sure that the wire-roller groove in the roller corresponds to the diameter and type of wire being used. • Plug the machine into a suitable outlet. •...

  • Page 19: Gas Selection

    (GMAW only) Turn on the gas cylinder, pull the trigger to check for gas flow and adjust the flow rate. • Bring the gun close to the workpiece and press the trigger. 220 MP MIG SET-UP CHART 18GA (1.2mm) 16GA (1.6mm) 14GA (2.0mm)

  • Page 20: Setup For Stick Welding (Smaw)

    Ensure the ground clamp has a good connection to the workpiece and is connected on clean, bare metal (not rusty or painted). • Switch the unit ON with the ON/OFF SWITCH. • Set the amperage with the LEFT KNOB. 220 MP STICK SET-UP CHART Electrode E6010 E6011 E6013 E7014...
  • Page 21 220 MP TIG SET-UP CHART Material Polarity 1/16" (1.6mm) 3/32" (2.4mm) 1/8" (3.2mm) 3/16" (4.8mm) Thickness (GTAW) Filler Tungsten Filler Tungsten Filler Tungsten Filler Tungsten DCEN Amperage Amperage Amperage Amperage Diameter Diam Diameter Diam Diameter Diam Diameter Diam -Recommend DCEN...

  • Page 22: 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. Keep the cabinet cover closed at all times unless the wire needs to be changed or the drive pressure needs adjusting. Keep all consumables (contact tips, nozzles, and liner) clean and replace when necessary.

  • Page 23: 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. PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION...
  • Page 24 PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Bad ground or loose ground connection. Check connection of the ground cable to the ground clamp. Tighten cable connection to ground clamp if needed. Ensure that the connection between the ground clamp and workpiece is good and is Wire feeds but no arc.
  • Page 25 PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Weld parameters too low. Adjust welding parameters Too long or improper extension cord. Use a proper extension cord (#12 AWG wire or heavier, no longer than 25 ft.). See “Extension Cords”, page 11. Wrong type or size wire. Use 0.023”...
  • Page 26 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). Stick-out too short. Increase stick-out (the amount the wire extends Wire burns back to contact tip. past the contact tip).

  • Page 27: Machine Parts Diagram & Replacement Parts List

    Machine Parts Diagram & Replacement Parts List PART NUMBER ITEM DESCRIPTION MIG Gun 84095 85668 Ground (50 Dinse) 85670 Electrode Holder (50 Dinse) 85516 Plug Adapter (230V-120V) 5084 Expert-Tech Tool WWW.FORNEYIND.COM...
  • Page 28 MIG Gun Consumables List PART NUMBER ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION Tip (Tweco 14-24) Diffuser (Tweco 35-50) ® ® Tip (Tweco 14-30) Nozzle (Tweco 21-50) ® ® Tip (Tweco 14-35) Nozzle (Tweco 21-62) ® ® Tip (Tweco 14-45) Liner ®...

  • Page 29: User Notes

    User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 30 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 31 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 32 Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 +1-800-521-6038 www.forneyind.com...

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