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
1. Select 
process
2. Set polarity for MIG (solid wire) or Flux-Cored
Solid Wire Flux-Cored
4. Connect MIG Gun and ground clamp
5. Install wire spool
6. Set drive roll
7. Feed wire and set pressure
8. Connect to input power
9. Remove consumables and depress trigger until wire comes out. Replace consumables
10. Adjust wire feed speed and voltage (see chart on welder for correct settings)
11. With contact tip 3/8″ from metal, depress trigger completely to initiate arc
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. |  |
Too much spool tension
Wire from spool to drive should relax with a slight curve after feeding. 
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.
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. 
TIG Welding with the Forney 220 Multi-Process Welder
FIRST STEPS
Read User Manual
1. Select 
process
2. Connect TIG torch and ground clamp | 3. Connect TIG torch lead to gas (100% Argon)  |
4. Adjust amperage per material thickness | 5. Connect to input power |
6. Choose between High Frequency (HF) start or Lift start
*Electrode is always electrically hot while in TIG mode
TIG TROUBLESHOOTING TIPS
| 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 To 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
Read User Manual
1. Select 
process
2. Connect electrode holder and ground clamp according to desired polarity | 3. Connect to input power |
| 4. Adjust amperage per chart on the inside of the welder | 5. Recommended electrodes |
STICK TROUBLESHOOTING TIPS
| 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 To ensure maximum quality, always clean and prepare welding surfaces. |
Frequently tripping circuit breaker or exceeding duty cycleUse 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
QUESTIONS OR TROUBLE? Contact Forney Industries at 1-800-521-6038 or customerservice@forneyind.com
