220 MULTI-PROCESS WELDER OPERATING MANUAL ENGLISH ITEM# 410 REV 08.08.
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Table of Contents WARRANTY...........................................................................................................................................................................3 TABLE OF CONTENTS.............................................................................................................................................................4 SYMBOLS LEGEND...........................................................................................................................
CAUTION! 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.
• 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. Box 9101, Quincy, MA 02269-9101 Telephone (617) 770-3000 Fax (617) 770-0700 - www.nfpa.org.
• background exists in your welding area, either remove it or cover it with something non-flammable and nonreflective. 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. Keep flammables away and prevent fire from flying sparks.
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. • Keep cylinders upright and securely chain them to a fixed support to prevent tipping. • Keep cylinders away from areas where they may be subjected to physical damage or accidentally struck.
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. Do not allow the welding equipment to come in contact with water or moisture. Do not drag welding cables, MIG gun, or welder INPUT POWER CABLE through or allow them to come into contact with water or moisture.
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.
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. At maximum settings on 120V, the machine will draw more than 20 amps regularly. 120V/20A 230V/50A Generators This welder can be operated from an AC generator.
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” and MIG Welding, “GMAW” The operator is required to set both the wire speed (RIGHT KNOB) and the welding voltage (LEFT KNOB). Stick Welding, “SMAW” Both rutile and basic electrodes can be welded.
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 16 13 14 5 6 15 19 7 19 10 11 12 9 2 3 4 8 1 1a 1b 1c 17 18 WWW.FORNEYIND.
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. For safety and economy, ensure that the regulator is fully closed (turned counter-clockwise) when not welding and when fitting or removing the gas cylinder.
INSTALLING 4-INCH SPOOL (SEE FIGURE FOR PART IDENTIFICATION): 1. Open the access panel. 2. Unscrew and remove the wire spool retention cap used for 8-inch spools (A) and store it someplace safe. 3. Remove the spindle adapter for 8-inch spools (B) and store it someplace safe. 4. Remove the nut (C), spring (D), and washers (E). 5.
1. Cut off the excess wire that extends past the end of the nozzle. 2. 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. NOTE: If TOO MUCH pressure is applied you can crush the wire and create wire feeding problems. If TOO LITTLE pressure is applied, the wire will slip on the drive rolls and wire will not feed. b.
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. However, you should wait at least ten minutes after the thermal protector engages before resuming welding.
• 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. • Completely open the gas cylinder valve. Adjust the gas pressure regulator to the correct flow rate. (Not applicable to Stick “SMAW” process). EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN.
Gas Selection Select the appropriate shielding gas in accordance to material being welded and wire being used. The table below can give you some useful indications: METAL GAS NOTE Mild Steel CO2 Argon + CO2 Argon + CO2 + Oxygen Argon controls spatter Oxygen improves arc stability Stainless Steel Argon + CO2 + Oxygen Argon + Oxygen Arc stability. Minimum splatter METAL GAS Copper, Nickel & Alloys NOTE Argon Suitable for light gauges because of low flowability of the weld pool.
Setup for Stick Welding (SMAW) • Press the PROCESS SELECTOR BUTTON on the front panel to the middle position. • Remove the MIG ELECTRODE POLARITY JUMPER from the POSITIVE (+) and NEGATIVE (-) DINSE SOCKETS. • Check the electrode packaging to determine the recommended polarity and connect the electrode holder and ground clamp to the POSITIVE (+) and NEGATIVE (-) DINSE SOCKETS accordingly.
220 MP TIG SET-UP CHART Polarity Material Thickness DCEN DCEN -Recommend 2% Certiated Tungsten TIG (GTAW) 100% Argon 1/16" (1.6mm) 3/32" (2.4mm) 1/8" (3.2mm) 3/16" (4.8mm) Filler Diameter Amperage Gas Cup Tungsten Diam Filler Diameter Amperage Gas Cup Tungsten Diam Filler Diameter Amperage Gas Cup Tungsten Diam Filler Diameter Amperage Gas Cup Tungsten Diam 1/16" (1.6mm) 50-80 3/8" (#6) 1/16" (1.6mm) 1/16" (1.6mm) 80-110 3/8" (#6) 1/16" (1.6mm) 3/32" (2.
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. 1. Keep the cabinet cover closed at all times unless the wire needs to be changed or the drive pressure needs adjusting. 2. Keep all consumables (contact tips, nozzles, and liner) clean and replace when necessary. See “Consumable Maintenance” (below) and “Troubleshooting” (page 23) for detailed information. 3.
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 No input power. Connect machine to proper input power source. All LEDs OFF, No output power, Fan not operating. Verify that circuit breaker has not been tripped in your main power panel.
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 on clean, bare (not painted or rusted) metal. Wire feeds but no arc. Arc works but not feeding wire. No arc or wire feed. Fan operates normally (can be heard). No arc or wire feed. Fan does NOT operate (cannot be heard).
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” (0.6mm) - 0.035” (0.9mm) wire. See “Welding Wire Selection” (page 18). Poor ground connection or gun connection. Reposition clamp and check cable to clamp connection.
PROBLEM Wire burns back to contact tip. Difficult arc start. Arc is wandering (TIG). 26 POSSIBLE CAUSE POSSIBLE SOLUTION Wire feed speed is set too low for voltage setting being used. Increase wire feed speed (turn RIGHT KNOB clockwise). Stick-out too short. Increase stick-out (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. Amperage is too low. Increase amperage setting.
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 WWW.FORNEYIND.
MIG Gun Consumables List NO. PART NUMBER ITEM DESCRIPTION Tip (Tweco® 14-24) 1 Tip (Tweco® 14-30) Tip (Tweco® 14-35) Tip (Tweco® 14-45) NO. PART NUMBER 2 3 4 TIG Torch & TIG Consumables List () 28 WWW.FORNEYIND.
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Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 +1-800-521-6038 www.forneyind.
