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3.    DC STICK WELDING ASSEMBLY 

 

- Be aware that the ELECTRODE HOLDER will be electrically HOT when the Input Power Switch on the 

welder is turned ON. 

3.1  Install the ground cable quick connector to the negative (-) Weld Output Connector (Figure 8). 

3.2  Secure the ground clamp to the work piece. 

3.3  Install the electrode cable quick connector to the positive (+) Weld Output Connector. 

3.4  Follow the STICK WELDING SET-UP instructions in the Operating Instructions section. 

 

4. 

OPTIONAL TIG TORCH ASSEMBLY 

 

- Be aware that the TIG TORCH will be electrically HOT when the Input Power Switch on the welder is 

turned ON.

 

4.1  Remove  the  ground  cable  and  the  electrode  holder  from  the  weld  output  connections.  Install 

the ground cable to the positive (+) weld output connection (Figure 8). 

4.2  Secure the ground clamp to the work piece. 

4.3  Connect a regulator 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 approximately 20 

CFH. Open the shielding gas valve on the torch to start the flow of shielding gas.

 

OPERATING INSTRUCTIONS 

 

•

 

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. 

•

 

Do not remove grounding prong or alter the plug in any way. Use only the supplied 
adapter between the plasma cutter's power cord and the power source receptacle. Make 
sure the POWER switch is OFF when connecting your welder’s power cord directly to a 
properly grounded 230 VAC, 60 HZ, Single Phase, 50 Amp input power supply. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Содержание MMWMGS250

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

Страница 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...

Страница 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 ...

Страница 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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