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ITEM# 410

REV 08.08.2019

220 MULTI-PROCESS WELDER

OPERATING MANUAL

ENGLISH

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Summary of Contents for 220 MP

Page 1: ...ITEM 410 REV 08 08 2019 220 MULTI PROCESS WELDER OPERATING MANUAL ENGLISH ...

Page 2: ... solutions to our customer s needs 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 We work hard so our customers trust us because of our integrity teamwork and innovation in ...

Page 3: ...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 Forney s primary goal is to get your machine up and running in as little time as possible In fact the majority of issues can be fixed over the phone Please be near your machine when you call so the Forney technician can guide you Sp...

Page 4: ...ALLING THE MIG GUN ASSEMBLY 14 GAS CYLINDER AND REGULATOR CONNECTION 14 INSTALLING THE WELDING WIRE 14 OPERATION 16 PERFORMANCE DATA PLATE DUTY CYCLE 16 INTERNAL THERMAL PROTECTION 17 WELDING PREPARATION 17 FACTORS TO CONSIDER FOR BEST MIG WELDING RESULTS 18 WELDING WIRE SELECTION 18 GAS SELECTION 19 SETUP FOR MIG GMAW FLUX CORED WIRE FCAW WELDING 19 SETUP FOR STICK WELDING SMAW 20 SETUP FOR TIG W...

Page 5: ...43 9353 Fax 305 443 7559 www aws org AWS A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES Obtainable from the American Welding Society 550 NW Le Jeune Road Miami FL 33126 Telephone 800 443 9353 Fax 305 443 7559 www aws org NFPA 70 NATIONAL ELECTRICAL CODE Obtainable from the National Fire Protection Association 1 Batterymarch Park P O Box 9101 Quincy MA 02269 9101 Telephone 617 770...

Page 6: ...ove procedures is recommended Personal Protection Welding processes of any kind can be dangerous not only to the operator but to any person situated near the equipment if safety and operating rules are not strictly observed THE WELDING ARC PRODUCES VERY BRIGHT ULTRAVIOLET AND INFRARED LIGHT THESE ARC RAYS WILL DAMAGE YOUR EYES AND BURN YOUR SKIN IF YOU ARE NOT PROPERLY PROTECTED To reduce the risk...

Page 7: ...n a confined area unless it is being ventilated or the operator and anyone else in the area is wearing an air supplied respirator Stop welding if you develop momentary eye nose or throat irritation as this indicates inadequate ventilation Stop work and take necessary steps to improve ventilation in the welding area Do not resume welding if physical discomfort persists Fire Prevention FIRE OR EXPLO...

Page 8: ...f oil or other flammable substances such as leather gloves thick cotton shirts with no synthetic materials cuffless trousers closed toed shoes Keep long hair pulled back Remove any combustibles such as lighters and matches before doing any welding Follow requirements in OSHA and NFPA for hot work and have an extinguisher nearby High Frequency Radiation High Frequency H F can interfere with radio n...

Page 9: ... POWER CABLE are exposed to any form of atmospheric precipitation or salt water spray Do not carry coiled welding cables around shoulders or any other part of the body when they are plugged into the welder Do not modify any wiring ground connections switches or fuses in this welding equipment Wear welding gloves to help insulate hands from welding circuit Keep all liquid containers far enough away...

Page 10: ...ose stated in the ratings label of your welder The main power supply voltage should be within 10 of the rated main power supply voltage Too low a power supply voltage may cause poor welding performance Too high a power supply voltage will cause components to overheat and possibly fail The welder outlet must be Correctly installed if necessary by a qualified electrician Correctly grounded electrica...

Page 11: ...ion cord appropriate for use with your specific welder Select a properly grounded extension cord that will mate directly with the AC power source receptacle and the welder INPUT POWER CABLE Only use the included adapter between the welder s INPUT POWER CABLE and the extension cord Make certain that the extension cord is properly wired and in good electrical condition Extension cords must fit the f...

Page 12: ... INDICATOR LED will be illuminated under the following conditions a The duty cycle of the machine has been exceeded or air flow is blocked The fan will continue to run until the machine has cooled but output power will be disabled Ensure that the cooling fan is running and that there are 12 inches of clearance around all vents When the LED turns off welding power will be enabled again b The input ...

Page 13: ...W OF FORNEY 220 MP WELDER FRONT VIEW OF FORNEY 220 MP WELDER 1 1a 1b 1c 2 3 4 5 6 7 9 8 10 11 12 15 MIG GAS INPUT 16 INPUT POWER CABLE 17 WIRE SPOOL SPINDLE 18 STAMPED ALUMINUM TWO ROLL WIRE FEEDER 19 FAN S 13 14 19 19 15 16 17 18 ...

Page 14: ...e back of the machine Open the cylinder valve then set the gas flow to approximately 20 35 CFH cubic ft per hour on the regulator For MIG welding Depress the gun trigger to ensure that the gas is flowing through the gun WARNING Cylinders are highly pressurized Handle with care Serious accidents can result from improper handling or misuse of compressed gas cylinders Do not drop the cylinder knock i...

Page 15: ...rted in the corresponding hole on the spool 6 Thread the wire spool retention cap back in place FEEDING WIRE THROUGH THE MIG GUN 1 Unhook the wire and hold the wire end and the spool in one hand With the other hand tighten the nut C just enough so that when the spool is released it does not spin freely and uncoil the wire Tightening the nut too much may cause inconsistent wire feeding Leaving it t...

Page 16: ...MAKE SURE THE WIRE IS CUT CLEANLY NO BURRS OR ANGLES AND THAT AT LEAST 1 FROM THE END IS STRAIGHT NO CURVES FAILURE TO FOLLOW THESE INSTRUCTIONS COULD CAUSE DAMAGE TO THE LINER WHEN CHECKING THE CORRECT EXIT OF THE WIRE FROM THE GUN DO NOT BRING YOUR FACE NEAR THE GUN YOU MAY RUN THE RISK OF BEING WOUNDED BY THE OUTGOING WIRE DO NOT BRING YOUR FINGERS CLOSE TO THE FEEDING MECHANISM WHEN WORKING TH...

Page 17: ...le performance CAUTION DO NOT REGULARLY EXCEED THE DUTY CYCLE OR DAMAGE TO THE WELDER CAN RESULT An important factor in making a satisfactory weld is preparation This includes studying the process and equipment and practicing welding before attempting to weld finished product An organized safe ergonomic comfortable and well lit work area should be prepared for the operator The work area should spe...

Page 18: ... to a longer arc without substantially affecting the current Conversely a decreased welding voltage results in a shorter arc the current again is not substantially changed A change in wire diameter results in changed parameters A larger diameter wire will draw a higher current than a smaller diameter wire at the same wire feed speed If certain limits are exceeded a satisfactory weld cannot be obta...

Page 19: ...o the workpiece and is connected on clean bare metal not rusty or painted Load the spool of wire inside the cabinet and feed it through the WIRE FEEDER into the gun see Installing the Welding Wire page 14 Switch the unit ON with the ON OFF SWITCH Press the gun trigger to load the wire through the gun Set the welding parameters 1 Adjust wire feed speed with the RIGHT KNOB 2 Adjust arc voltage with ...

Page 20: ...onnection to the workpiece and is connected on clean bare metal not rusty or painted Connect the TIG torch gas line to the gas regulator argon gas only USE INERT GAS ARGON ONLY TURN ON GAS AT THE GAS REGULATOR CHECK FOR GAS FLOW AND ADJUST FLOW RATE AS NEEDED Fix the tungsten electrode so that it protrudes approximately inch from the torch nozzle Ensure the TIG torch is safely away from all conduc...

Page 21: ... up or down by 10 as needed Foot Pedal adjusts amperage attach TIG torch to negative Dinse terminal and then plug in 7 pin foot pedal connector Double check the TIG process is selected Set desired maximum current on the machine Use pedal to fine control amperage Amperage controlled TIG torch attach TIG torch to negative Dinse terminal and then plug in 7 pin connector Double check the TIG process i...

Page 22: ...NTACT TIP The purpose of the CONTACT TIP is to transfer welding current to the welding wire while allowing the wire to pass through it smoothly Always use a contact tip stamped with the same diameter as the wire it will be used with 1 If the wire burns back into the tip remove the tip from the gun and clean the hole running through it with an oxygen acetylene torch tip cleaner or tip drill If the ...

Page 23: ...AULT CODE F05 DISPLAYED Torch triggered before machine is ready Torch triggered or turned on before machine is powered on will fault Release torch trigger and machine will reset within five seconds FAULT CODE F09 DISPLAYED Output short or abnormal voltage feedback Make sure the MIG wire is not touching the grounded work piece Make sure the TIG electrode is not touching the grounded work piece Stic...

Page 24: ...d or is not making contact Pull the trigger while in contact with the workpiece The machine does not arc unless the trigger is pulled Depress the trigger ALL THE WAY until the trigger stops moving into the gun Exceeded duty cycle thermal protector engaged Allow welder to cool at least 10 minutes with machine ON observe and maintain proper duty cycle Insufficient air flow causing machine to overhea...

Page 25: ...contact tip Ground clamp ground cable and or welding cable get hot Bad ground or loose ground connection Check the connection of the ground clamp and gun to the machine Check the connection of the MIG ELECTRODE POLARITY JUMPER Check connection of the ground cable to the ground clamp Tighten cable connection to ground clamp if needed Ensure the connection between the ground clamp and workpiece is g...

Page 26: ...t the amount the wire extends past the contact tip Wrong size contact tip Use correct size contact tip Contact tip is clogged or damaged Replace contact tip Difficult arc start Amperage is too low Increase amperage setting Make sure base metal is clean Properly clean base metal Make sure electrode is not damaged Replace electrode if needed Arc is wandering TIG Tungsten is too large Use a smaller t...

Page 27: ...YIND COM Machine Parts Diagram Replacement Parts List NO PART NUMBER ITEM DESCRIPTION 1 84095 MIG Gun 2 85668 Ground 50 Dinse 3 85670 Electrode Holder 50 Dinse 4 85516 Plug Adapter 230V 120V 5 5084 Expert Tech Tool ...

Page 28: ...es List NO PART NUMBER ITEM DESCRIPTION NO PART NUMBER ITEM DESCRIPTION 1 Tip Tweco 14 24 2 Diffuser Tweco 35 50 Tip Tweco 14 30 3 Nozzle Tweco 21 50 Tip Tweco 14 35 Nozzle Tweco 21 62 Tip Tweco 14 45 4 Liner TIG Torch TIG Consumables List ...

Page 29: ...__ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ _________________________________________________________________________...

Page 30: ...__ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ _________________________________________________________________________...

Page 31: ...__ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ _________________________________________________________________________...

Page 32: ...Forney Industries Inc 2057 Vermont Drive Fort Collins CO 80525 1 800 521 6038 www forneyind com ...

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