Forney 220 MP User manual

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

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Forney Promise
We are committed to your success regardless of location, size or
needs. We understand it is your goal to get the job done right,
and we are ready to help you do just that.
President's Message
We market the highest quality tools, equipment and accessories
for the do-it-yourselfer and professional. Our passion and
dedication in bringing new products to the industrial and retail
market, combined with our personal service, is unmatched in our
industry. Our ability to listen to our customers’ needs enables us to
create solutions to their problems.
Our dedication to the highest quality customer service within our
corporate headquarters and the service provided in the field is
unequaled. We are committed to creating the best 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 the welding & metalworking industry.
80 years of unmatched product quality and an unwavering
commitment to our customers.
When our customers succeed we succeed.
STEVEN G. ANDERSON, President & CEO
Copyright©2019 Forney Industries,
Inc. All rights reserved. Unauthorized
reproduction and/or distribution is
subject to US copyright laws.
U.S. Facilities:
- Fort Collins, CO
- Tipp City, OH
FIVE WAYS TO ORDER
Web: www.forneyind.com
Phone: [phone]
Fax: [phone]
Mail: Forney Industries
2057 Vermont Drive
Fort Collins, CO 80525
Email: [e-mail]
Steven G. Anderson

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TECHNICAL ISSUES?
FORNEY CAN HELP!
WE MAKE IT EASY!
Please contact Forney Industries Technical
Service at 800-521-6038 x2 or
customerserv[email protected] for inquires,
technical and general questions.
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. 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.
Speaking to a Forney Technician directly helps us gather better data,
and i mprove our p roducts. I t is our h ighest priority t o ensure our
customers are cared for.

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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
INSTALLATION ....................................................................................................................................................................10
WELDER SPECIFICATIONS ............................................................................................................................................10
SITE SELECTION...........................................................................................................................................................10
POWER SOURCE CONNECTION..................................................................................................................................10
USING THE 230 VOLTS – 120 VOLTS PLUG ADAPTER ..................................................................................................11
GENERATORS..............................................................................................................................................................11
EXTENSION CORDS.....................................................................................................................................................11
VENTILATION ..............................................................................................................................................................11
ADDITIONAL WARNINGS ............................................................................................................................................11
GETTING TO KNOW YOUR WELDER....................................................................................................................................12
DESCRIPTION ..............................................................................................................................................................12
WELDER LAYOUT AND CONTROLS ..............................................................................................................................12
INSTALLING 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 WELDING (GTAW) WITH LIFT ARC ........................................................................................................20
MAINTENANCE & SERVICING .............................................................................................................................................19
GENERAL MAINTENANCE..................................................................................................................................................22
CONSUMABLE MAINTENANCE..........................................................................................................................................22
TROUBLESHOOTING...........................................................................................................................................................21
MACHINE PARTS DIAGRAM & CONSUMABLES LIST..............................................................................................................23
TIG TORCH & TIG CONSUMABLES LIST (SOLD SEPARATELY) ..................................................................................................20
TROUBLESHOOTING...........................................................................................................................................................23
MACHINE PARTS DIAGRAM & REPLACEMENT PARTS LIST .....................................................................................................26
MIG GUN CONSUMABLES LIST............................................................................................................................................27
TIG TORCH & TIG CONSUMABLES LIST (SOLD SEPARATELY) ..................................................................................................27
USER NOTES ......................................................................................................................................................................28
Table of Contents

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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.
The data within this safety summary are highlights of various safety standards. It is recommended
that you familiarize yourself with the standards listed below before beginning welding.
• ANSI Z49.1: SAFETY IN WELDING AND CUTTING - Obtainable from the American Welding Society, 550 NW Le Jeune
Road, Miami, FL 33126 Telephone [phone], Fax [phone] - www.aws.org.
• OSHA 29 CFR, Part 1910, Subpart Q.: WELDING, CUTTING AND BRAZING - Obtainable from your state OSHA office
or U.S. Dept. of Labor OSHA, Office of Public Affairs, Room N3647, 200 Constitution Ave., Washington, DC 20210 -
www.osha.gov.
• AWS F4.1: SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING
FOR WELDING AND CUTTING. - Obtainable from the American Welding Society, 550 NW Le Jeune Road, Miami, FL
33126 Telephone [phone], Fax [phone] - 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 [phone], Fax [phone]
- 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 [phone] Fax [phone] - www.nfpa.org.
• CGA Publication P-1: SAFE HANDLING OF COMPRESSED GASES IN CONTAINERS - Obtainable from Compressed
Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 Telephone [phone] Fax (703)
961-1831 - www.cganet.com.
• CSA W117.2 - Code for SAFETY IN WELDING AND CUTTING. - Obtainable from Canadian Standards Association,
178 Rexdale Blvd., Etobicoke, Ontario M9W 1R3 - www.csa.ca.
Symbols Legend
Safety Summary
Principal Safety Standards
SYMBOL MEANING SYMBOL MEANING SYMBOL MEANING
ARC RAYS HAZARD
FIRE HAZARD NOISE HAZARD
POISON HAZARD
ELECTRICAL HAZARD WARNING/CAUTION
MIG (GMAW) INPUT VOLTAGE LINE CONNECTION
STICK (SMAW) TEMPERATURE SINGLE PHASE ALTERNATING
CURRENT (AC)
TIG (GTAW) VOLTAGE DIRECT CURRENT (DC)
POSITIVE DINSE AMPERAGE SUITABLE FOR WELDING IN AN
ENVIRONMENT WITH INCREASED
RISK OF ELECTRIC SHOCK
NEGATIVE DINSE WIRE FEED
ION O
OFF SINGLE PHASE STATIC FREQUENCY
CONVERTER TRANSFORMER RECTIFIER

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• 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 [phone], Fax
[phone] - 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
[phone] Fax [phone] - www.nfpa.org.
California Proposition 65 Warning
WARNING: This product can expose you to chemicals, including lead, which are known to the State of California to
cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov. P65
details at forneyind.com. Wash hands after use.
EMF Information
Welding current, as it flows through the welding cables, will cause electromagnetic fields. There has been and still is some
concern about such fields. However, after examination, the committee of the National Research Council concluded that:
“The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-frequency electric and
a magnetic field is a human health hazard.” However, studies are still going forth and evidence continues to be examined.
Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields
when welding.
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep electrode and ground cables close together by twisting or taping them when possible.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect ground clamp to workpiece as close to the cut or weld as possible.
ABOUT PACEMAKERS & HEARING AIDS:
Pacemaker and hearing aid wearers consult your doctor first. If cleared by your doctor, then following the above
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 of injury from arc rays, read, understand, and follow the safety
instructions. In addition, make certain that anyone else that uses this welding equipment, or is a bystander in the
welding area understands and follows these safety instructions as well. Helmets and filter should conform to ANSI Z87.1
standards.
• Do not look at an electric arc without proper protection. A welding arc is extremely bright and intense and, with
inadequate or no eye protection, the retina can be burned, leaving a permanent dark spot in the field of vision. A
shield or helmet with a #10 shade filter lens (minimum) must be used.
• Provide bystanders with shields or helmets fitted with an appropriate shade filter lens.
• Do not strike a welding arc until all bystanders and you (the welder) have welding shields and/or helmets in place.
• Do not wear a cracked or broken helmet and replace any cracked or broken filter lenses immediately.
• Do not allow the uninsulated portion of the MIG gun to touch the ground clamp or grounded workpiece to prevent an
arc flash from being created on contact.
• Wear protective clothing. The intense light of the welding arc can burn the skin in much the same way as the sun,
even through lightweight clothing. Wear dark clothing of heavy material. The shirt worn should be long sleeved and
the collar kept buttoned to protect chest and neck.
• Protect against reflected arc rays. Arc rays can be reflected off shiny surfaces such as a glossy painted surface,
aluminum, stainless steel, and glass. It is possible for your eyes to be injured by reflected arc rays even when wearing
a protective helmet or shield. If welding with a reflective surface behind you, arc rays can bounce
• off the surface and off the filter lens. It can get inside your helmet or shield and into your eyes. If a reflective

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• 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. Keep flammables away and prevent fire from flying
sparks.
FUMES, GASSES, AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS, AND DEATH!
To reduce the risk, read, understand, and follow the safety instructions. In addition, make certain that anyone else that
uses this welding equipment or is a bystander in the welding area, understands and follows these safety instructions as
well.
• Read and understand manufacturers Safety Data Sheets (SDS) and Material Safety Data Sheets (MSDS).
• Do not weld in an area until it is checked for adequate ventilation as described in ANSI standard Z49.1. If
ventilation is not adequate to exchange all fumes and gasses generated during the welding process with fresh air, do
not weld unless you (the welder) and all bystanders are wearing air-supplied respirators.
• Do not heat metals coated with, or that contain, materials that produce toxic fumes (such as galvanized steel), unless
the coating is removed. Make certain the area is well ventilated, and the operator and all bystanders are wearing
air-supplied respirators.
• Do not weld, cut or heat lead, zinc, cadmium, mercury, beryllium, antimony, cobalt, manganese, selenium, arsenic,
copper, silver, barium, chromium, vanadium, nickel, or similar metals without seeking professional advice and
inspection of the ventilation of the welding area. These metals produce extremely toxic fumes which can cause
discomfort, illness and death.
• Do not weld or cut in areas that are near chlorinated solvents. Vapors from chlorinated hydrocarbons, such as
trichloroethylene and perchloroethylene, can be decomposed by the heat of an electric arc or its ultraviolet radiation.
These actions can cause phosgene, a highly toxic gas to form, along with other lung and eye- irritating gasses. Do
not weld or cut where these solvent vapors can be drawn into the work area or where the ultraviolet radiation can
penetrate to areas containing even very small amounts of these vapors.
• Do not weld in 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 EXPLOSION CAN CAUSE DEATH, INJURY, AND PROPERTY DAMAGE! To reduce these
risks, read, understand and follow the safety instructions. In addition, make certain that anyone else that uses this welding
equipment, or is a bystander in the welding area, understands and follows these safety instructions as well. Remember:
arc welding by nature produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can start fires,
burn skin and damage eyes.
• Do not wear gloves or other clothing that contains oil, grease, or other flammable substances.
• Do not wear flammable hair preparations.
• Do not touch the hot weld bead or weld puddle until fully cooled.
• Do not weld in an area until it is checked and cleared of combustible and/or flammable materials. Be aware that
sparks and slag can fly 35 feet and can pass through small cracks and openings. If work and combustibles cannot be
separated by a minimum of 35 feet, protect against ignition with suitable, snug-fitting, fire resistant, covers or shields.
• Do not weld on walls until checking for and removing combustibles touching the other side of the walls.
• Connect the ground cable to the workpiece as close as possible to the welding area. Do not connect ground cables
to building framing or other locations away from the welding area. This increases the possibility of welding current
passing through alternate circuits, creating fire hazards and other safety hazards.
• Do not weld, cut, or perform other such work on used barrels, drums, tanks, or other containers that had a flammable
or toxic substance. The techniques for removing flammable substance and vapors, to make a used container safe for
welding or cutting, are quite complex and require special education and training.
• Do not strike an arc on a compressed gas or air cylinder, and never allow any electrically “hot” parts to touch a
cylinder. Doing so will create a brittle area that can result in a violent rupture immediately or at a later time as a result
of rough handling.
• Ensure any compressed gas cylinders in the work area have properly operating regulators rated for the gas and

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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. Keep them
a safe distance from any source of flame, sparks, or heat.
• Do not weld or cut in an area where the air may contain flammable dust (such as grain dust), gas, or liquid vapors
(such as gasoline).
• Do not handle hot metal, such as the workpiece or electrode stubs, with bare hands.
• Wear leather gloves, heavy long sleeve shirt, cuffless pants, high-topped shoes, helmet, and cap. As necessary, use
additional fire-resistant protective clothing to cover and protect the upper and lower body. Hot sparks or metal can
lodge in rolled up sleeves, pant cuffs, or pockets. Sleeves and collars should be kept buttoned and pockets eliminated
from the shirt front.
• Have fire extinguisher equipment handy for immediate use. A portable chemical fire extinguisher, type ABC, is
recommended.
• Wear ear plugs when welding overhead to prevent spatter or slag from falling into ear.
• Make sure welding area has a good, solid, safe floor, preferably concrete or masonry, not tiled, carpeted, or made of
any other flammable material.
• Protect flammable walls, ceilings, and floors with heat resistant covers or shields.
• Check welding area to make sure it is free of sparks, glowing metal or slag, and flames before leaving the welding
area.
• Wear garments free of 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 navigation, safety services, computers and communication equipment.
• It is the user’s responsibility to have a qualified electrician promptly correct any interference problem resulting from the
installation. Electrician should regularly check and maintain installation.
• Stop using the equipment if notified by the FCC about interference.
• Keep H.F. source doors and panels tightly shut and keep spark gaps at correct setting.
Arc Welding
• Computers and computer driven equipment can be harmed with electromagnetic energy.
• Be sure all equipment is compatible with electromagnetic energy.
• Keep welding cables short to reduce interference.
• Follow manual to install and ground machine.
• If interference continues, shield the work area or move the welding machine.
WARNING: ELECTRIC SHOCK CAN KILL! To reduce the risk of death or serious injury from shock, read,
understand, and follow the safety instructions. In addition, make certain that anyone else who uses this welding
equipment, or who is a bystander in the welding area understands and follows these safety instructions as well.
IMPORTANT! TO REDUCE THE RISK OF DEATH, INJURY, OR PROPERTY DAMAGE, DO NOT
ATTEMPT OPERATION of this welding equipment until you have read and understand the following safety summary.
• Do not, in any manner, come into physical contact with any part of the welding current circuit. The welding current
circuit includes:
a. the workpiece or any conductive material in contact with it,
b. the ground clamp,
c. the electrode or welding wire,
Electric Shock

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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.
• Do not touch welder, attempt to turn welder ON or OFF if any part of the body or clothing is moist or if you are in
physical contact with water or moisture.
• Do not attempt to plug the welder into the power source if any part of body or clothing is moist, or if you are in
physical contact with water or moisture.
• Do not connect ground clamp to electrical conduit, and do not weld on electrical conduit.
• Do not alter INPUT POWER CABLE or plug in any way.
• Do not attempt to plug the welder into the power source if the ground prong on INPUT POWER CABLE plug is bent
over, broken off, or missing.
• Do not allow the welder to be connected to the power source or attempt to weld if the welder, welding cables,
welding site, or welder INPUT 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 from the welder and work area so that if spilled, the liquid cannot
possibly come in contact with any part of the welder or electrical welding circuit.
• Replace any cracked or damaged parts that are insulated or act as insulators such as welding cables, INPUT POWER
CABLE, or electrode holder immediately.
• When not welding, cut wire back to contact tip or remove electrode from electrode holder
Noise
Noise can cause permanent hearing loss. Welding processes can cause noise levels that exceed safe limits. You must
protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
Additional Safety Information
For additional information concerning welding safety, refer to the standards listed at the beginning of this safety summary
and comply with them as applicable.

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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.
120V- Minimum 5,000W continuous output with no low-idle
function (or low-idle off), 5% THD Max.
CSA Rated Output and Duty Cycle Refer to the data plate of your machine and the DUTY CYCLE
section of this manual, page 16.
Dimensions 22.5” (571.5mm) X 11” (279.40mm) X 15.5” (393.7mm)
Recommended Electrode Diameter Electrode Diameter: Up to 3/16”
Wire Diameter: Up to 0.035” (0.8mm)
BE SURE TO LOCATE THE WELDER ACCORDING TO THE FOLLOWING GUIDELINES:
• In areas free from moisture and dust;
• In areas with ambient temperature between 30° to 90°F;
• In areas free from oil, steam and corrosive gases;
• In areas not subjected to abnormal vibration or shock;
• In areas not exposed to direct sunlight or rain;
• Place at a distance of 12” or more from walls or similar obstructions that could restrict natural air flow for cooling.
Before you make any electrical connection, make sure that the ON/OFF SWITCH is OFF, power supply voltage and
frequency available at site are those 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 (electrically) in accordance with national and local regulations;
• Connected to an electric circuit that is rated for sufficient amperage per the ratings label of your welder.
If you are unsure of any of the above, have your outlet inspected by a qualified electrician before using the welder.
NOTE:
• Periodically inspect INPUT POWER CABLE for any cracks or exposed wires. If it is not in good condition, have it
repaired by a Service Center.
• Do not cut off the grounding prong or alter the plug in any way. Only use the included adapter between the welder’s
INPUT POWER CABLE and the power source receptacle.
• Do not violently pull the INPUT POWER CABLE to disconnect it from power outlet.
• Do not lay material or tools on the INPUT POWER CABLE. The INPUT POWER CABLE may be damaged and result in
electrical shock.
• Keep the INPUT POWER CABLE away from heat sources, oils, solvents or sharp edges.
• Do not use this welder on a circuit with a Ground Fault Circuit Interrupter (GFCI) on it. GFCIs are tripped by welding
arcs and your welding operations will be interrupted regularly.
Installation
Welder Specifications
Site Selection
Power Source Connection

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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.
Generators
This welder can be operated from an AC generator. As this is a dual voltage machine please ensure that when using on
230V, the generator must supply a minimum of 10,000 watts of continuous output. When using the 120V option, the
generator must supply a minimum of 5,000 watts of continuous output. The generator must not have an auto-idle fuel
saving feature or must have the option to turn auto-idle off. The generator must run at full speed at all times while your
welder is plugged into it or you risk damaging your welder. Any other power draws on the generator or anything that
reduces the generator RPM may damage your welder.
Extension Cords
For optimum welder performance, an extension cord should not be used unless absolutely necessary. If necessary, care
must be taken in selecting an extension 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
following wire size guidelines:
• #12 AWG or larger wire, or 120V.
• Do not use an extension cord over 25 ft. in length.
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated. See the
“Safety Summary” for more details (pages 5-9).
FOR YOUR SAFETY, BEFORE CONNECTING THE POWER SOURCE TO THE LINE CLOSELY
FOLLOW THESE INSTRUCTIONS:
• An adequate two-pole breaker must be inserted before the main outlet. This breaker must be equipped with
time-delay fuses.
• When working in a confined space, the welder must be kept outside the welding area and the ground cable
should be fixed to the workpiece. Never work in a damp or wet confined space.
• Do not use damaged INPUT POWER CABLE or welding cables.
• The welding gun/torch/electrode should never be pointed at the operator or other people.
• The welder must never be operated without its panels attached. This could cause serious injury to the operator
and could damage the equipment.
Ventilation
Additional Warnings
230V/50A120V/20A

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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. Welding current is adjusted using the LEFT KNOB.
TIG Welding, “GTAW”
In the TIG position, a TIG torch with a gas valve is not required. The internal gas valve automatically opens when foot
pedal or torch trigger is used.
Using the LEFT KNOB, maximum welding current can be adjusted and controlled with pedal or TIG torch.
Welder Layout and Controls
1. PROCESS SELECTOR BUTTON to select the welding process selection:
a. CV MIG (“GMAW”)- Constant Voltage.
b. DC TIG LIFT (“GTAW”) – Direct Current TIG automatic start when touch and lifted to create arc.
c. DC STICK (“SMAW”)- Direct Current Stick welding.
2. THERMAL FAULT LED thermal overload protection has been activated.
3. INPUT VOLTAGE LED will be illuminated when input voltage to the machine is present and the ON/
OFF SWITCH is in the ON position. LED will be green in 230V mode and white in 120V mode.
4. FAULT/THERMAL OVERLOAD 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 voltage is outside of the acceptable range. If this indicator remains illuminated for more
than 10 minutes, it is likely that there is an input voltage problem.
c. A fault condition exists. See troubleshooting guide.
5. RIGHT KNOB is used to adjust the following welding parameters:
a. In MIG (“GMAW”) Mode it adjusts wire feed speed at 230V from 90- 550 (IPM)/ 120V from 90-
220 (IPM).
b. In STICK (“SMAW”) Mode it is not active.
c. In TIG, (“GTAW”) Mode it is not active.
6. LEFT KNOB is used to adjust the following welding parameters:
a. In MIG (“GMAW”) Mode it adjusts arc voltage at 230V from 13.0-25.0 / 120V from 13.0-20.0.
b. In STICK (“SMAW”) Mode it adjusts welding current (amperage) at 230V from 10.0-200 / 120V
from 10.0-75.0.
c. In TIG, (“GTAW”) Mode it adjusts welding current (amperage) at 230V from 10.0-200.0 / 120V
from 10.0-110.0.
7. EURO CONNECT SOCKET FOR MIG TORCH
8. MIG ELECTRODE POLARITY JUMPER
9. ACCESSORY SOCKET plug for the pedal, amptrol or TIG torch (unit will recognize accessory)
10. NEGATIVE (-) DINSE SOCKET 35/50
11. TIG GAS OUTPUT
12. POSITIVE (+) DINSE SOCKET 35/50
13. POWER SWITCH
14. TIG GAS INPUT
Getting to Know Your Multi-Process Welder

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REAR VIEW 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

14 WWW.FORNEYIND.COM
• 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.
• Turn the regulator adjustment knob counter-clockwise to ensure the valve is fully closed.
• Screw the gas regulator down on the gas bottle valve and tighten.
• Connect the gas hose to the regulator, securing with the clip/nut provided.
• Connect the other end to the GAS INPUT (14 for TIG welding or 15 for MIG welding) on the 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 it over, expose it to excessive heat, flames or
sparks. Do not strike it against other cylinders or strike an arc on it.
Installing the Welding Wire
ENSURE GAS AND ELECTRICAL SUPPLIES ARE DISCONNECTED. Before proceeding, remove the nozzle
and the contact tip from the gun.
WARNING: ELECTRIC SHOCK CAN KILL! Always turn the ON/OFF SWITCH to the OFF position and unplug
the welder’s INPUT POWER CABLE from the AC power source before installing wire. When the gun trigger is depressed,
the drive rolls, spool of wire, wire being fed, and electrode are all electrically live (hot).
Installing the MIG Gun Assembly
4
8

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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. Remove the outer wrapping from the included spool of wire and then find the leading end of the wire (it
goes through a hole in the outer edge of the spool and is bent over the spool edge to prevent the wire from
unspooling) but do not unhook it yet.
6. Place the spool on the WIRE SPOOL SPINDLE in such a manner that when the wire comes off the spool, it will
look like the illustration above. The wire should unspool from the bottom, and the spool will rotate in a counter-
clockwise fashion.
7. Place the washer, wire spool locking bushing, spring, and nut back in place.
8. Proceed to “FEEDING WIRE THROUGH THE MIG GUN” instructions below.
INSTALLING 8-INCH SPOOL (SEE FIGURE FOR PART IDENTIFICATION):
1. Open the access panel.
2. Unscrew and remove the wire spool retention cap (A).
a. NOTE: If the wire spool retention cap and the spindle adapter for 8-inch spools (B) are not present (machine
was last used with a 4-inch spool) put the spindle adapter for 8-inch spools back in place.
3. Make sure all of the components used for a 4-inch spool are still in place. They are necessary for 8-inch spools
as well (nut (C), spring (D), and washers (E)).
4. Remove the outer wrapping from the spool of wire and then find the leading end of the wire (it goes through a
hole in the outer edge of the spool and is bent over the spool edge to prevent the wire from unspooling) but do
not unhook it yet.
5. Place the spool on the spindle adapter for 8-inch spools in such a manner that when the wire comes off the
spool, it will look like the illustration above. The wire should unspool from the bottom, and the spool will rotate in
a counter-clockwise fashion.
a. NOTE: Be sure the alignment pin near the base of the spindle adapter for 8-inch spools is inserted 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 too loose will allow the wire to uncoil freely from the spool,
leaving a mess of wire in the cabinet.
2. While holding the wire in place, use a wire cutter to cut the bent end of the wire so that only a straight end
remains.
3. Continue to hold the wire end in one hand and release the drive roll pressure arm (I) by pulling the pressure arm
adjustment knob (G) toward you. Hold the drive roll pressure arm up off of the drive roller and insert the leading
end of the wire into the inlet guide tube (H). Push the wire across the drive roller (J) and into the gun assembly
approximately six inches.
4. Line the wire up in the outside groove of the drive roller and allow the drive pressure arm to drop onto the
drive roller. Pull the pressure arm adjustment knob back over the pressure arm and tighten (turn clockwise) the
pressure adjusting knob until the pressure roller is applying enough force on the wire to prevent it from slipping
out of the drive assembly. NOTE: Too much pressure will cause wire to feeding problems and may burn out the
wire feed motor.
5. Let go of the wire.
6. Remove the nozzle (K) and contact tip (L) from the end of the gun assembly (M).
7. Plug the welder’s INPUT POWER CABLE into the AC power source. Adjust the settings on the front panel per the
setup chart on the inside panel door of the welding machine according to the size of the wire and workpiece.
8. Pull the trigger on the MIG gun to feed the wire through the gun assembly. Check if the drive roll is slipping on
the wire and increase pressure on the pressure arm adjustment knob if necessary.
9. When at least an inch of wire sticks out past the end of the gun, release the trigger.
10.Slide the contact tip (L) over the wire protruding from the end of the gun (M). Screw the contact tip into the end
of the gun and hand tighten securely.
11.Install the nozzle (K) on the gun assembly.

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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. When the drive pressure is set correctly, there should be no slippage between the wire and the drive roller. But if an
obstruction occurs along the wire feed path, the wire should then slip on the drive roller. This can be checked by
squeezing the wire between two fingers with moderate force as it comes out of the gun. If this stops the wire from
feeding, increase pressure until the wire feeds through your fingers without issue.
3. Double check your spool tension: After feeding the wire and releasing the trigger, the wire coming off the spool should
not remain under tension (in a straight line from the spool to the WIRE FEEDER). It should relax a little bit and take
on some of the curvature the coiled wire naturally reverts to. It should also not relax so much that the wire begins to
loosen on the spool.
CORRECT INCORRECT
KEEP THE GUN STRAIGHT. WHEN FEEDING A NEW WIRE THROUGH THE LINER, 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! THE ROLLS, WHEN MOVING, MAY CRUSH FINGERS. PERIODICALLY CHECK
THE ROLLS. REPLACE THEM WHEN THEY ARE WORN AND COMPROMISE THE REGULAR
FEEDING OF THE WIRE.
Performance Data Plate and Duty Cycle
On the machine, there is a plate that includes all the operating specifications for your new unit. The serial number of the
product is also found on this plate.
The duty cycle rating of a welder defines how long the operator can weld and how long the welder must rest and be
cooled. Duty cycle is expressed as a percentage of 10 minutes and represents the maximum welding time allowed. The
balance of the 10-minute cycle is required for cooling.
For example, a welder has a duty cycle rating of 30% at the rated output of 90A. This means with that machine, you
can weld at 90 A output for three (3) minutes out of 10 with the remaining seven (7) minutes required for cooling.
The duty cycle of your new welder can be found on the data plate affixed to the machine. It looks like the diagram
below. Referring to the sample below, the “X” row lists duty cycle percentages while the “I2” row lists the amp draw
corresponding to the duty cycle. Various duty cycles at other amperages are listed on your data plate.
Operation

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(Example Data Plate)
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. You must do this even if the thermal protector resets itself before the
ten minutes is up or you may experience less than specified duty cycle 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 specifically be free of all flammables with both a
fire extinguisher and a bucket of sand available.
To properly prepare for welding with your new welder, it is necessary to:
• Read the safety precautions at the front of this manual.
• Prepare an organized, well-lit work area.
• Provide protection for the eyes and skin of the operator and bystanders.
Internal Thermal Protection
Welding Preparation
IP21S

18 WWW.FORNEYIND.COM
• 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.
PROLONGED EXPOSURE TO A WELDING ARC CAN CAUSE BLINDNESS AND BURNS. NEVER
STRIKE AN ARC OR BEGIN WELDING UNLESS YOU ARE ADEQUATELY PROTECTED. WEAR
FIRE RESISTANT WELDING GLOVES, HEAVY LONG SLEEVED SHIRT, CUFFLESS PANTS; HIGH
TOPPED SHOES AND A WELDING HELMET.
Some experience is required to adjust and use a MIG welder. In MIG welding, two parameters are fundamental: the
welding voltage and the wire feed speed. The resulting welding current is a result of these two settings but is more directly
related to the wire feed speed.
• Set the voltage (LEFT KNOB) and wire feed speed (RIGHT KNOB) to positions suitable for the thickness of the material
to be welded (see “MIG Set-Up Chart”, page 19). Welding current varies in relationship to wire feed speed. For low
wire feed speed (RIGHT KNOB), welding current output will be low. Turning the wire feed speed control clockwise will
result in increased wire feed speed and welding current. Welding voltage should be adjusted to match the wire feed
speed/welding current. Progressively select higher voltage positions when increasing wire speed.
Increasing welding voltage leads 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 obtained. These are:
1. Feeding wire too fast (too high speed with regard to the welding voltage) results in pulsing within the gun. This is
because the wire electrode dips into the puddle and cannot be melted off fast enough.
2. Setting welding voltage too high (too high with regard to the wire feed speed), will result in excessive and unstable
arc. Increase the voltage even higher and the contact tip will burn.
3. Excessive wire speed can be corrected through the arc voltage increase. The limit of this adjustment depends on the
thickness of the material to be welded (a certain limit exceeded will result in burn through).
Place the gun on the joint you want to weld: the angle between the gun and the workpiece should be around 45°. The
distance between the gun and the workpiece should be about 1/2” - 5/8”. Lower your face shield and press the gun
trigger to start the arc. When the arc has struck, move the nozzle slowly from left to right along the joint. Adjust the wire
feed speed until the arc makes a “crisp” sound (experience will help you to recognize the right sound).
This welder can work with solid steel wire from 0.023” - 0.035” (0.6 - 0.9mm) diameter; stainless steel wire from 0.023”
- 0.035” (0.6 - 0.9mm) diameter (MIG welding, “GMAW”) and with 0.035” (0.9mm) diameter flux-cored wire (flux-
cored wire welding, “FCAW”).
Factors to Consider for Best MIG Welding Results
Welding Wire Selection

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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 NOTE
Copper, Nickel & Alloys Argon
Argon + Helium
Suitable for light gauges because of low flowability
of the weld pool.
Higher heat input suitable for heavy sections
Use Spool Gun for MIG
NOTE: THIS MACHINE IS NOT AN APPROPRIATE POWER SOURCE FOR WELDING
ALUMINUM.
• Press the PROCESS SELECTOR BUTTON on the front panel to the top position.
• Connect the MIG gun into the EURO CONNECT SOCKET.
• Connect the MIG ELECTRODE POLARITY JUMPER (8) to the appropriate DINSE SOCKET:
o Flux-cored wire welding (FCAW): Jumper to NEGATIVE (-) DINSE SOCKET.
o MIG Welding (GMAW): Jumper to POSITIVE (+) DINSE SOCKET.
• Connect the ground cable to the appropriate DINSE SOCKET:
o Flux-cored wire welding (FCAW): Ground cable to POSITIVE (+) DINSE SOCKET.
o MIG Welding (GMAW): Ground cable to NEGATIVE (-) DINSE SOCKET.
• Ensure the ground clamp has a good connection to 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 the LEFT KNOB.
• (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.
Gas Selection
Setup for MIG (GMAW) & Flux-Cored Wire (FCAW) Welding
220 MP MIG SET-UP CHART
MIG (GMAW) Material
Thickness
18GA (1.2mm) 16GA (1.6mm) 14GA (2.0mm) 1/8" (3.2mm) 3/16" (4.8mm) 1/4" (6.4mm) 5/16" (7.9mm) 3/8" (9.53mm)
Polarity Wire
Diameter
ER70S-6
Solid Wire
AR75%/CO25%
DCEP
.030" 16-17 150-175 17-18 220-250 17-18 250-340 17.5-19 300-350 18-19 330-400 - - - - - -
.035" 16-17 140-160 17-18 180-220 17-18 240-260 18-19 280-300 18-19 320-340 21-22 360-380 21-22 400-420 23-24 420-520
E71T-GS
Flux-Core
No Gas
DCEN
.030" - - - - 14-15 165-190 14-15 190-215 15-16 220-235 - - - - - -
.035" - - - - 14-15 145-155 14-15 175-185 15-16 205-215 15-16 220-230 16-17 235-245 16-17 245-255
ER4043
Aluminum
100% Argon
DCEP
.030" - - 14-16 320-340 15-17 360-380 22-24 450-480 24-26 490-520 - - - - - -
.035” - - - - 14-16 260-290 21-22 350-400 23-24 430-450 24-25 350-375 - - - -
CAN WELD ALUMINUM WITH SPOOL GUN

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• 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.
• 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.
Setting up the Equipment for TIG Welding (GTAW):
Lanthanated Tungsten recommended for use.
WARNING: TIG TORCH IS ALWAYS LIVE (ELECTRICALLY HOT). Use caution and ensure the TIG
torch is not in contact with or near conductive or grounded materials.
• Switch the PROCESS SELECTOR BUTTON on the front panel.
• Remove the MIG ELECTRODE POLARITY JUMPER from the POSITIVE (+) and NEGATIVE (-) DINSE SOCKETS.
• Connect the TIG torch cable to the NEGATIVE (-) DINSE SOCKET of the welder.
• Connect the ground cable connector to the POSITIVE (+) DINSE SOCKET of the welder.
• Ensure the ground clamp has a good connection 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 ¼ inch from the torch nozzle.
• Ensure the TIG torch is safely away from all conductive materials.
• Switch the unit ON with the ON/OFF SWITCH.
• Set the amperage with the LEFT KNOB.
• Initiate the weld arc with a lift arc technique.
REMEMBER TO CLOSE THE VALVE ON THE GAS CYLINDER IMMEDIATELY AFTER ALL
WELDING IS COMPLETED.
Setup for Stick Welding (SMAW)
Setup for TIG Welding (GTAW) with Lift Arc
220 MP STICK SET-UP CHART
STICK
(SMAW)
Electrode
Type E6010 E6011 E6013 E7014 E7018 E308L/E309L/E316L
Electrode
Diam Amperage Polarity Amperage Polarity Amperage Polarity Amperage Polarity Amperage Polarity Amperage Polarity
1/16"
(1.6mm) N/A DCEP N/A AC-DCEP 20-45 AC-DCEP-DCEN N/A AC-DCEP-DCEN N/A DCEP 20-40 DCEP
3/32"
(2.4mm) 30-75 DCEP 40-85 AC-DCEP 40-90 AC-DCEP-DCEN 70-90 AC-DCEP-DCEN 65-100 DCEP 40-70 DCEP
1/8"
(3.2mm) 75-125 DCEP 75-125 AC-DCEP 70-110 AC-DCEP-DCEN 90-140 AC-DCEP-DCEN 110-165 DCEP 75-115 DCEP
5/32"
(4.0mm) 110-165 DCEP 110-165 AC-DCEP 115-140 AC-DCEP-DCEN 140-190 AC-DCEP-DCEN 150-220 DCEP 105-160 DCEP