Cornwell Tools MIG 250MGS Owner'S Manual Download Page 4

Page      of 28 

-Connect ground lead as close to the area being welded as possible to ensure a good ground. 

-Do not allow any body part to come in contact with the welding wire if you are in contact with the 

material being welded, ground or electrode from another welder. 

-Do  not  weld  if  you  are  in  an  awkward  position.  Always  have  a  secure  stance  while  welding  to 

prevent accidents. Wear a safety harness if working above ground. 

-Do not drape cables over or around your body. 

-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety 

glasses while welding. 

-Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals, 

UV and IR rays. 

-Do not overuse or overheat your welder. Allow proper cooling time between duty cycles. 

-Keep hands and fingers away from moving parts and stay away from the drive rolls. 

-Do not point torch at any body part of yourself or anyone else.   

-Always use this welder in the rated duty cycle to prevent excessive heat and failure. 

 

1.4 Specific Areas of Danger, Caution or Warning 

  Electrical Shock 

 

Electric  arc  welders  can  produce  a  shock  that  can  cause  injury  or  death.  Touching 

electrically live parts can cause fatal shocks and severe burns. While welding, all metal 

components  connected  to  the  wire  are  electrically  hot.  Poor  ground  connections  are  a  hazard,  so 

secure the ground lead before welding.     

-Wear dry protective apparel: coat, shirt, gloves and insulated footwear. 

-Insulate yourself from the work piece. Avoid contacting the work piece or ground. 

- Do not attempt to repair or maintain the welder while the power is on. 

-Inspect all cables and cords for any exposed wire and replace immediately if found. 

-Use only recommended replacement cables and cords. 

-Always attach ground clamp to the work piece or work table as close to the weld area as possible. 

-Do not touch the welding wire and the ground or grounded work piece at the same time. 

-Do not use a welder to thaw frozen pipes.     

  Fumes and Gases 

 

-Fumes  emitted  from  the  welding  process  displace  clean  air  and  can  result  in  injury  or 

death. 

-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and 

safe. 

-Work only  in a  well-ventilated area  or  use  a  ventilation device  to  remove  welding  fumes  from  the 

environment where you will be working. 

-Do  not  weld  on  coated  materials  (galvanized,  cadmium  plated  or  containing  zinc,  mercury  or 

barium).    They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator, 

respirator with air supply or remove the coating from the material in the weld area.     

-The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety 
data sheet for the manufacturer’s instructions.   
-Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays 

and degreasers can be highly toxic when heated. 

 

 

Summary of Contents for MIG 250MGS

Page 1: ...MANUAL 2 2016 WARNING Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating Failure to follow the safety rules and other basic safety precautions may result in seriou...

Page 2: ...re considered consumable items and are not covered under warranty 1 year Parts and Labor on MIG gun parts except those listed under normal wear items cables regulator and plasma torch except those lis...

Page 3: ...this equipment Make sure the area is clean dry and ventilated Do not operate the welder in humid wet or poorly ventilated areas Always have your welder maintained by a qualified technician in accordan...

Page 4: ...a hazard so secure the ground lead before welding Wear dry protective apparel coat shirt gloves and insulated footwear Insulate yourself from the work piece Avoid contacting the work piece or ground D...

Page 5: ...ot operate any electric arc welder in areas where flammable or explosive materials are present Remove all flammable materials within 35 feet of the welding arc If removal is not possible tightly cover...

Page 6: ...ossible 1 5 Proper Care Maintenance and Repair Always have power disconnected when working on internal components Do not touch or handle PC board without being properly grounded with a wrist strap Put...

Page 7: ...G welding steel and stainless steel with the correct shielding gas Use the optional MMWEZFSG2 Spool Gun for best results when MIG welding aluminum The quick connect polarity connections make switching...

Page 8: ...n the shielding gas cylinder for MIG welding with solid wires The regulator controls the compressed gas and allows you to adjust the flow rate of the gas GAS HOSE The gas hose connects to the regulato...

Page 9: ...aining bolt 1 2 Make note of the retaining groove on the back end of the MIG torch 1 3 Insert the back end of the MIG torch into the MIG socket on the front of your machine Make certain to completely...

Page 10: ...witched into the MIG TORCH position 2 SPOOL GUN ASSEMBLY 2 1 This unit is set up to accept the MMWEZFSG2 gun only 2 2 The MMWEZFSG2 has three connection points at the back of the spool gun 1 The gas c...

Page 11: ...ock High voltage danger from power source Consult a qualified electrician for proper installation of receptacle This welder must be grounded while in use to protect the operator from electrical shock...

Page 12: ...o the wire spool by hand turning the spool clockwise Be careful not to all the wire to come out of the rear end of the inlet guide tube without holding onto it or the wire spool will unspool itself Pu...

Page 13: ...e power cord from the AC power source before installing wire NOTE Before installing make sure that you have removed any old wire from the torch assembly This will help to prevent the possibility of th...

Page 14: ...ool Hold on to it securely so as not to allow unspooling or tangling of the wire as it will result in tangled wire and feeding problems 4 2 8 Cut off any bent portion of the wire using a wire cutter 4...

Page 15: ...e welder ON 5 SETTING THE DRIVE ROLL TENSION Arc flash can injure eyes To reduce the risk of arc flash make certain that the wire coming out of the end of the torch does not come in contact with the w...

Page 16: ...nting toward you or any other person Turn the valve on the gas bottle clockwise and quickly close This quick thrust of gas will clear any debris in the connection Connect the regulator to the gas bott...

Page 17: ...he power switch is in the ON position the welding circuit is activated ALWAYS turn the power switch to the OFF position and unplug the welder before performing any maintenance 2 VOLTAGE SELECTOR The v...

Page 18: ...sleeved shirt trousers without cuffs high topped shoes and an ANSI approved welding helmet 7 1 Connect the Ground Clamp to a scrap piece of the same type of material which you will be welding It shou...

Page 19: ...ill prevent proper fusion or create a lumpy uneven bead Travel direction is the direction the torch is moved along the weld joint in relation to the weld puddle The torch is either PUSHED into the wel...

Page 20: ...ing positions and is most commonly used It is best if you can weld in the flat position if at all possible as good results are easier to achieve HORIZONTAL POSITION Is performed very much the same as...

Page 21: ...into the nozzle Angle B should be held at zero degrees so that the wire is aiming directly into the weld joint If you experience excessive dripping of the weld puddle select a lower heat setting Also...

Page 22: ...t fillet weld joints on metals of moderate to heavy thickness will require multiple pass welds to produce strong joint The following figure will show the sequence of laying multiple pass beads into a...

Page 23: ...allowed to fill up the hole leaving a spot weld that is smooth and flush with the surface of the top piece Select the wire diameter heat setting and tune in the wire speed as if you were welding the...

Page 24: ...r Too Little Drive Roll Tension See Setting Drive Roll Tension Section Drive Roll is Worn Replace Drive Roll Can Not Create An Arc Work Piece is Painted Or Rusty Remove All Paint And Rust Ground Clamp...

Page 25: ...Page of 28 25 DIAGRAM PARTS LIST...

Page 26: ...0080 DOOR LATCH 2 20 105200121 LOWER RIGHT PANEL 1 21 105200122 WHEEL 200 X 50 MM 2 22 105200123 FLAT WASHER 2 23 105200124 AXLE CAP 2 24 105200125 FLAT WASHER 2 25 105200126 DUAL CYLINDER TRAY 1 26 1...

Page 27: ...LOSURE 1 52 105200151 CONTROL TRANSFORMER 1 53 105200152 MAIN PC BOARD 1 54 105200153 AC CONTACTOR 1 105200154 MIG TORCH 1 105200155 MIG TORCH NOZZLE 1 105200156 MIG CONTACT TIP 023 1 105200157 MIG CO...

Page 28: ...Page of 28 28 Distributed by CORNWELL QUALITY TOOLS 667 SEVILLE RD WADSWORTH OH 44281 www conwelltools com Made in China...

Reviews: