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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 The User Manual Icon Read User Manual 

1. Select MIG Welding Icon process

Select Process

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

Solid Wire Plug In Flux-Core Plug In
Solid Wire Flux-Cored

4. Connect MIG Gun and ground clamp

Connect MIG Gun and Ground Clamp

5. Install wire spool

Install Wire Spool Diagram

6. Set drive roll

Drive Roll Diagram

7. Feed wire and set pressure

Feed Wire and Set Pressure

8. Connect to input power

Connect to Input Power

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

Depress Trigger

10. Adjust wire feed speed and voltage (see chart on welder for correct settings)

Adjust wire speed and voltage

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

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.
single pass 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.
Incorrect Spool Diagram

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

Too much spool tension diagram

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

Pull Trigger

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

TIG Welding with the Forney 220 Multi-Process Welder

FIRST STEPS

Read The User Manual Icon Read User Manual 

1. Select  TIG Welding Icon process

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

Connect 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 

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 The User Manual Icon Read User Manual 

1. Select  Stick Welding Icon process

Select 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

4. Adjust amperage per chart on the inside of the welder

Adjust amperage
5. Recommended electrodes

Recommended Electrodes Chart


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 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


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

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