Cornwell Tools MMWMGS250 Owner'S Manual Download Page 41

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REFERENCE #

PART #

DESCRIPTION

Qty

155200078

ENCLOSURE

105200110

SPOOL HOLDER BRACKET

105100144

DUAL CYLINDER BRACKET

105200310

POWER SWITCH

105200112

STRAIN RELIEF

155200059

BACK PANEL

155200060

CENTER PANEL

105500018

POWER CORD HOLDER

105200306

FAN

105200458

GAS VALVE

155200079

CYLINDER HOLDER

105200122

BACK WHEEL

155200061

LEFT LOWER COVER PLATE

155200080

CABLE HOOK

105200234

MAIN PCB BRACKET

105200459

MAIN PCB

105200317

OUTPUT REACTOR

105200128

FRONT CASTER WHEEL(S)

155200081

CASTER WHEEL BRACKET

155200082

BOTTOM PLATE

155200062

FRONT PANEL

105200301

POLARITY CONVERSION CABLE

105200137

PLASTIC FRONT BEZEL

105200300

POTENTIOMETER KNOB (SMALL)

165200047

POTENTIOMETER KNOB (LARGE)

155200063

LCD CONTROL PANEL/PCB

155200083

LEFT HANDLE SUPPORT

155200084

HANDLE

155200085

RIGHT HANDLE SUPPORT

105200136

QUICK CONNECTOR

105200052

GAS CONNECTOR

105200131

5-PIN CONTROL PLUG

105200452

FLANGE

105200460

SHIELDING BOX

155200064

RIGHT LOWER COVER PLATE

105200080

DOOR LATCH

105200292

CONTROL PCB

155200075

DOOR

155200076

BEAM

105800019

MIG BLOCK

155200077

WIRE FEEDER MOUNT

105200150

WIRE FEEDER ASSEMBLY

105200461

GAS VALVE TRANSFORMER BOARD

105200114

SPOOL HOLDER

105200120

HINGE

For replacement parts please call (800) 321-8356.

Summary of Contents for MMWMGS250

Page 1: ...S MANUAL 3 2019 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 serious personal injury ...

Page 2: ...are 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 listed under normal wear items Any shipping related to warranty repair is the responsibility of the customer 1 year 3 year Please see your product information to determine if your product has a 1 year o...

Page 3: ...ct can expose you to chemicals including Lead which is known to the State of California to cause cancer and birth defects or other reproductive harm For more information go to www P65warings ca gov SAVE THESE INSTRUCTIONS IMPORTANT SAFETY CONSIDERATIONS 1 1 Your Welding Environment Keep the environment you will be welding in free from flammable materials Always keep a fire extinguisher accessible ...

Page 4: ...is 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 ...

Page 5: ...d on containers or pipes that contain or have had flammable gaseous or liquid combustibles in them Welding creates sparks and heat that can ignite flammable and explosive materials Do not 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 them with fire...

Page 6: ...possible 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 PC board in static proof bag to move or ship Do not put hands or fingers near moving parts such as drive rolls of fan MMWMP251I USE AND CARE Do not modify this unit in any way Unauthorized modificat...

Page 7: ...s unit can also perform lift start DC TIG welding on steel and stainless steel materials with the optional TIG Torch MMWACTT2V Argon shielding gas and a TIG filler rod would also be required for TIG welding This unit is intended to be used on a 50 amp 230V AC circuit without the use of an extension cord If an extension cord is necessary for your application use the appropriate size and length of e...

Page 8: ...The ground cable and clamp are attached to the work piece to complete the circuit allowing the flow of current needed to weld ELECTRODE HOLDER AND CABLE The Electrode Holder holds the stick welding electrode The cable most often connects to the Positive weld output connection for stick welding INSTALLATION 1 POWER REQUIREMENT AC single phase 230V 200 240V 60 HZ fused with a 50 amp time delayed fus...

Page 9: ...e outside edge of the wire spool and bend it over to hold the wire in place Remove the spool of wire from the drive compartment of the welder 3 4 Remove the drive roller by turning the drive roll securement knob 4 counter clockwise Carefully slide the drive roll assembly off of the drive shaft This drive roll assembly consists of three pieces the outer drive roll inner drive roll and a key Be care...

Page 10: ...hen removing the welding nozzle The contact tip on this welder is live whenever the torch trigger is pulled Make certain POWER is turned OFF 4 2 1 Remove the nozzle and contact tip from the end of the torch assembly 4 2 2 Make sure the proper groove on the drive roller is in place for the wire installed If not change the drive roller as described in Section 3 4 2 3 Remove the packaging from the sp...

Page 11: ...pool 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 2 9 Loosen the tension adjusting knob holding the drive tension arm in place and lift the tension arm up off the drive roller 4 2 10 Insert the wire into the inlet guide tube feed it across the driv...

Page 12: ...ion setting process or arcing will occur 5 1 Press the trigger on the torch 5 2 Turn the drive tension adjustment knob clockwise until the wire seems to feed smoothly without slipping 6 GAS INSTALLATION Shielding gas cylinders and high pressure cylinders can explode if damaged so treat them carefully Never expose cylinders to high heat sparks open flames mechanical shocks or arcs Do not weld on th...

Page 13: ...se a wrench to snug up the connection Reference Subassembly 1 Gas Bottle Valve 2 Gas Flow Gauge Set at 20 CFH 3 Gas Pressure Gauge 4 Regulator 5 Gas Flow Adjuster 6 Gas Hose Connection 7 Gas Cylinder 6 5 Open the Gas Bottle Valve on the cylinder of gas 6 6 Turn the Gas Flow Adjuster on the regulator so that the gas flow rate is set at approximately 20 CFH Make certain you are reading the correct s...

Page 14: ...nt panel on the drive system Loosen the retaining 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 slide the torch all the way in Slightly twist to assist with pushing the torch to the back of the receptacle The retaining bolt can then be tightened making ...

Page 15: ...nap on connector 2 4 Carefully slide the weld power connection through the Spool Gun weld cable access opening in the front of the machine 2 5 Open the wire compartment door 2 6 Connect the weld power connection to the bolt on the side of the MIG connector 2 7 Connect the Spool Gun 5 Pin trigger connector to the Spool Gun 5 Pin receptacle on the front of the machine 2 8 Connect the Spool Gun Quick...

Page 16: ...or to a bottle of ARGON gas Then connect the gas connection from the TIG torch to the regulator 4 4 Connect the TIG torch weld cable to the negative weld output connection 4 5 Set the desired amperage on the amperage control knob on the front panel of the welder 4 6 Turn on the input power switch on the welder 4 7 Turn on the regulator on the bottle of shielding gas and adjust the regulator to app...

Page 17: ... selection 1 4 2 To change selection Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB 1 4 3 Turn the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to desired language 1 4 5 Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to confirm your selection 1 5 UNIT 1 5 1 Turn the MULTI FUNCTION ADJUSTMENT SELECTION KNOB until UNITS screen is displayed 1 5 2 Push in the MULTI FUNCTION ADJUSTMENT SELECTION KN...

Page 18: ...et or press the START BUTTON to exit 2 WIRE FEED WELDING SET UP 2 1 Press the START BUTTON 2 2 Turn the MULTI FUNCTION ADJUSTMENT SELECTION KNOB until the desired Wire Feed Welding screen is displayed 2 2 1 MIG Steel Choose this option if you are MIG welding steel with a shielding gas or flux core welding steel 2 2 1 1 Use the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to select your shielding gas P...

Page 19: ...NT SELECTION KNOB to confirm your selection 2 2 2 4 This machine is now set to weld 2 2 2 4 1 Use the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to fine tune wire feed speed 2 2 2 4 2 Use the VOLTAGE CONTROL KNOB to fine turn voltage 2 2 2 3 You can adjust other parameters 2 2 2 3 1 Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB Wire Speed will no longer be highlighted but will have a box around...

Page 20: ...e 2 2 3 1 1 5You can adjust other parameters 2 2 1 1 5 1 Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB Wire Speed will no longer be highlighted but will have a box around it Turn the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to go through other options Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to adjust the highlighted Option 2 2 3 1 2 With a spool gun 2 2 3 1 2 1Use the MULTI FUNCTIO...

Page 21: ...ENT SELECTION KNOB to adjust the highlighted Option 2 2 4 MIG CuSi Choose this option if you are welding Copper Silicon blend wires such as Silicon Bronze 2 2 4 1 Connect the Weld Power Cable See Figure 8 or follow the onscreen visual to the Positive Weld Output Connection Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to confirm your selection 2 2 4 2 Use the MULTI FUNCTION ADJUSTMENT SELECTI...

Page 22: ...N KNOB to go through other options Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to adjust the highlighted Option 2 2 6 Saving A MIG Program 2 2 6 1 Your MIG welding programs can be saved and called up at a later time 2 2 6 1 1 Test your welding parameters to make certain you wish to save this set up 2 2 6 1 2 Press the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to deselect the wire speed feed ...

Page 23: ...4 Follow the display set up 3 4 1 Connect the Electrode Holder to the Positive Weld Output Connection 3 4 2 Connect the Ground Cable to the Negative Weld Output Connection 3 5 This machine is now set to weld 3 6 AMPERAGE Adjustment Turn the MULTI FUNCTION ADJUSTMENT SELECTION KNOB 3 6 1 Counter Clockwise to decrease amperage 3 6 2 Clockwise to increase amperage 3 6 2 1 Note that you will only be a...

Page 24: ...election 3 9 3 2 The screen will automatically default back to your set up screen 4 DC LIFT START TIG WELDING SET UP 4 1 Press the START BUTTON 4 2 Turn the MULTI FUNCTION ADJUSTMENT SELECTION KNOB until the LIFT TIG screen is displayed 4 3 Push in the MULTI FUNCTION ADJUSTMENT SELECTION KNOB to confirm your selection 4 4 Follow the display set up 4 4 1 Connect the TIG torch to the Negative Weld O...

Page 25: ...ork best for you 3 POSITION OF THE TORCH TO THE WORK PIECE There are two angles of the torch nozzle in relation to the work piece that must be consider when welding a Angle a can be varied but in most cases the optimum angle will be 60 degrees the point at which the torch angle is parallel to the work piece If angle A is increased penetration will increase If angle A is decreased penetration will ...

Page 26: ... given voltage setting by increasing or decreasing the wire speed slightly Repeat this tune in procedure if you select a new voltage setting a different wire diameter or a different roll of wire 4 WELDING TECHNIQUES EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or begin welding until you a...

Page 27: ... try some different weld bead types The STRINGER BEAD is formed by traveling with the torch in a straight line while keeping the wire and nozzle centered over the weld joint See following figure The WEAVE BEAD is used when you want to deposit metal over a wider space than would be possible with a stringer bead It is made by weaving from side to side while moving with the torch It is best to hesita...

Page 28: ...G THE TORCH should be maintained at 60 degrees Maintaining this angle will reduce the chances of molten metal falling 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 the weave bead tends to work better than the stringer d Multiple Pass Welding Butt...

Page 29: ... weld bead before making another pass or the next pass will be of poor quality Fillet Weld Joints Most 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 T fillet joint and a lap fillet joint ...

Page 30: ...e of metal and the arc is directed through the hole to penetrate into the bottom piece The puddle is 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 same thickness material with a continuous bead iii The LAP SPOT METHOD directs the welding arc to pe...

Page 31: ...dapter to a properly grounded 120V 20 Amp input power supply 1 SETTING UP THE WORK PIECE a Welding positions There are two basic positions for welding Flat and Horizontal Flat welding is generally easier faster and allows for better penetration If possible the work piece should be positioned so that the bead will run on a flat surface b Preparing the Joint Before welding the surface of work piece ...

Page 32: ...red for every situation The type and thickness of metal and the position of the work piece determine the electrode type and the amount of heat needed in the welding process Heavier and thicker metals require more amperage It is best to practice your welds on scrap metals which match the metal you intend to work with to determine correct heat setting and electrode choice See the following helpful t...

Page 33: ...on scrap metal that can be discarded Do not attempt to make any repairs on valuable equipment until you have satisfied yourself that your practice welds are of good appearance and free of slag or gas inclusions a Holding the electrode The best way to grip the electrode holder is the way that feels most comfortable to you Position the electrode to the work piece when striking the initial arc it may...

Page 34: ...cking sound eggs frying To lay a weld bead only two movements are required downward as the electrode is consumed and in the direction the weld is to be laid as in the following figure c Types of weld bead The following paragraphs discuss the most commonly used arc welding beads The stringer bead is formed by traveling with the electrode in a straight line while keeping the electrode centered over ...

Page 35: ...ng an arc has been learned the next step is learning how to run a good bead The first attempts in practice will probably fall short of acceptable weld beads Too long of an arc will be held or the travel speed will vary from slow to fast see following A Weld speed is too fast B Weld speed is too slow C Arc is too long D Ideal weld A solid weld bead requires that the electrode be moved slowly and st...

Page 36: ...ly Or when using the supplied 120V adapter connect the 120V Adapter to a properly grounded 120V 20 Amp input power supply EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or begin welding until you are adequately protected Wear flame proof welding gloves a heavy long sleeved shirt trousers wi...

Page 37: ... installed tungsten electrode 8 3 Twist the torch to make contact between the work piece and the tungsten 8 4 Lift torch away from the work piece about 1 8 inch 8 5 Move down the joint to be welded by pushing the torch 8 6 Insert filler metal in the leading edge of the weld puddle as needed ...

Page 38: ... is too high Leave power on and let the fan cool the unit Output will continue when the unit has cooled Input power voltage is too high or too low Meter input power voltage This unit must be used with input voltage that ranges from 230V AC plus or minus 15 Cooling fan is damaged Replace the cooling fan Wire Drive Motor does not turn Wire feed speed control at zero Increase wire feed speed control ...

Page 39: ...STICK position Welding Arc is unstable excessive spatter The contact tip is too large Make certain the correct contact tip is installed Torch liner is plugged Clear or replace torch liner No shielding gas Connect shielding gas supply and turn shielding gas on MIG torch is not correctly installed and shielding gas is not transferring to the arc Remove and reconnect the MIG torch to make certain it ...

Page 40: ...Page of 43 40 DIAGRAM PARTS LIST ...

Page 41: ...E 1 21 155200062 FRONT PANEL 1 22 105200301 POLARITY CONVERSION CABLE 1 23 105200137 PLASTIC FRONT BEZEL 1 24 105200300 POTENTIOMETER KNOB SMALL 1 25 165200047 POTENTIOMETER KNOB LARGE 1 26 155200063 LCD CONTROL PANEL PCB 1 27 155200083 LEFT HANDLE SUPPORT 1 28 155200084 HANDLE 1 29 155200085 RIGHT HANDLE SUPPORT 1 30 105200136 QUICK CONNECTOR 2 31 105200052 GAS CONNECTOR 2 32 105200131 5 PIN CONT...

Page 42: ...ONTACT TIP 023 1 105200157 MIG CONTACT TIP 030 1 105200158 MIG CONTACT TIP 035 1 105200159 MIG CONTACT TIP 045 1 105200160 MIG CONTACT TIP ADAPTER 1 105200161 MIG TORCH LINER 1 105200081 INERT GAS HOSE 2 105200082 INTERT GAS REGULATOR 2 155200090 OPERATOR S MANUAL 1 For replacement parts please call 800 321 8356 ...

Page 43: ...Page of 43 43 Distributed by CORNWELL QUALITY TOOLS 667 SEVILLE RD WADSWORTH OH 44281 www cornwelltools com Made in China ...

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