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Cornwell Tools MMWTIG241I Owner's Manual

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00:7,*,
2:1(5·6 0$18$/
1/2017
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.

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Summary of Contents for Cornwell Tools MMWTIG241I

  • Page 1 00:7,*, 2:1(5·6 0$18$/ 1/2017 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 Effective December 22, 2015 LIMITED WARRANTY FOR MMWTIG241I This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from the factory.

  • Page 3: General Safety Rules

    WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in serious injury. CAUTION: Do not allow persons to operate or assemble this MMWTIG241I until they have read this manual and have developed a thorough understanding of how the MMWTIG241I works.
  • Page 4 -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 torch 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.
  • Page 5 UV and IR Arc Rays The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to your eyes and skin. Do not look at the welding arc without proper eye protection. -Always use a helmet that covers your full face from the neck to top of head and to the back of each ear.
  • Page 6 Electromagnetic Field -Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers. -Consult your doctor before using any electric arc welder or cutting device -Keep people with pacemakers away from your welding area when welding. -Do not wrap cable around your body while welding. -Wrap torch and ground cable together whenever possible.

  • Page 7: Technical Specifications

    Electrode Holder with cable. The MMWTIG241I is the ideal Stick and TIG welder for every shop. The DC stick mode allows you to stick weld when your application requires it. In the DC TIG mode you are able to TIG weld metals such as steel and stainless steel.

  • Page 8: Know Your Welder

    KNOW YOUR WELDER Front Panel Controls Electrode Holder And Cable Style 26 Foot TIG Torch Pedal Inert Gas Hose Inert Gas Accessories Ground Clamp Regulator/Flowgauge And Cable FRONT PANEL CONTROLS See the next section for a complete description of the front panel controls. INERT GAS REGULATOR/FLOWGAUGE Installs directly on the shielding gas cylinder.

  • Page 9: Front Panel Controls

    FRONT PANEL CONTROLS Mode Digital Amperage Digital Function Function Control Selector Display Control Display Display Indicators Operation Indicator Lights Advanced Settings Contactor Control (See Next Section) Selector Gas Purge Button Process Selector Functional Control Functional Functional Control Indexing Decrease Button Indexing Increase Button Control MODE SELECTOR...

  • Page 10: Advanced Settings

    ALARM INDICATOR LIGHT The Alarm Indicator Light will be illuminated when the input voltage is either too high or too low. CONTACTOR CONTROL SELECTOR Push the Contactor Control Selector button to choose Remote Amp when you are using a foot pedal for remote amperage control.
  • Page 11 HOT START INDICATOR LIGHT In the stick mode only, use one of the FUNCTIONAL CONTROL INDEX BUTTONS to turn on the HOT START indicator light. The functional control knob can then be used to increase or decrease the hot start amperage setting as indicated on the Digital Amperage Display. Hot Start that is increased will generally result in better arc starting on hard to start electrodes.
  • Page 12 FREQUENCY INDICATOR LIGHT In the TIG mode only, when the PULSE indicator light is on, use one of the FUNCTIONAL CONTROL INDEX BUTTONS to turn on the FREQUENCY indicator light. The functional control knob can then be used to increase or decrease the pulse frequency setting. The functional control display indicator light HZ will be on indicating the set value in the Digital Functional Control Display.

  • Page 13: Installation

    AC BALANCE/ARC FORCE INDICATOR LIGHT AC BALANCE: In the AC TIG mode only, use one of the FUNCTIONAL CONTROL INDEX BUTTONS to turn on the AC BALANCE/ARC FORCE indicator light. The functional control knob can then be used to increase or decrease the AC BALANCE setting. The functional control display indicator light % will be on indicating the set value in the Digital Functional Control Display.

  • Page 14: Back Panel Connections

    4. TIG WELDING CONNECTION – DC TIG welding is generally performed DC Electrode negative. That means that the TIG torch and cable would be attached to the Negative (-) weld output connection and the ground cable and clamp would be attached to the Positive (+) weld output connection.

  • Page 15: Gas Installation

    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 the cylinder. • Always secure cylinder upright to a cart or stationary object. •...

  • Page 16: Remote Control Installation

    7. REMOTE CONTROL INSTALLATION NOTE: When stick welding, remove all remote controls. Failure to do this will result in minimal welding output only. 7.1 Remote Contactor Only – An optional push button control is available for this machine. The push button can be used in two applications 7.1.a –...

  • Page 17: Pre Operation Set-Up

    PRE OPERATION SET-UP Mode Digital Amperage Digital Function Function Control Selector Display Control Display Operation Display Indicators Indicator Lights Contactor Control Advanced Settings Selector (See Next Section) Gas Purge Button Process Selector Functional Control Functional Control Functional Indexing Increase Button Indexing Decrease Button Control 1.
  • Page 18 2. SET UP INSTRUCTIONS FOR DC TIG WELDING Connect TIG torch to the NEGATIVE terminal on the front of the machine (See item 4 of the • INSTALLATION section). Connect the ground cable to the POSTIVE terminal on the front of the machine (See item 4 •...
  • Page 19 Use the PROCESS SELECTOR BUTTON to Select HF TIG on front panel • Use the MODE SELECTOR BUTTON on the front panel to Select AC. • Use the CONTACTOR CONTROL BUTTON TO Select RMT AMP position on front panel. • Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the PRE FLOW indicator •...
  • Page 20 PULSE TIG SET-UP 1. Follow the TIG welding set-up in the previous section. 2. For Manual Pulse TIG, using a foot pedal, set the CONTACTOR CONTROL SELECTOR so that the RMT AMP light is on. See the next section for sequencer set-up. 3.
  • Page 21 6. Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the FREQUENCY indicator light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred Pulse Frequency as displayed on the Digital Function Control Display. Example: Set Pulse Frequency to 1. The Pulse Frequency is the number of times per second that the machine changes from Peak Current to Back Ground Current.
  • Page 22 1. Follow the TIG welding set-up in the previous sections. NOTE: Using a sequencer will be more successful for DC TIG applications. Amperage controls are limited to set values in the sequencer. AC TIG applications usually require more amperage flexibility. 2.

  • Page 23: Setting Up The Work Piece

    BASIC STICK WELDING OPERATION High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.

  • Page 24: Ground Clamp Connection

    2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3.

  • Page 25: Welding Techniques

    4.2. b. The arc will be difficult to maintain 4.3. When the rod is too large 4.3. a. The arc will burn through light metals 4.3. b. The bead will undercut the work 4.3. c. The bead will be flat and porous 4.3.
  • Page 26 It is important that the gap be maintained during the welding process and it should be neither too wide nor too narrow. If too narrow, the rod will stick to the work piece. If too wide, the arc will be extinguished.
  • Page 27 The horizontal position it is performed very much the same as the flat weld except that the angle is different such that the electrode, and therefore the arc force, is directed more toward the metal above the weld joint. This more direct angle helps prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve good penetration.
  • Page 28 BASIC TIG WELDING OPERATION High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.
  • Page 29 T ungs ten Electr ode C ur r ent R anges G uide f or Selec ting F iller W ir e D iam eter T ungs ten Electr ode Typ es Page of 36...
  • Page 30 Alum inum W elding Mater ia l W elding R ate T IG W elding is gener all y regar ded as a s pecialized pr oc ess that requires oper ator c om petenc y. W hile m any of the pr inciples outl ined in the previous Ar c W elding s ection are a pplic able a c om pr ehens ive outline of the T IG W elding pr oc ess is outs ide the s cope of this Oper ating Manua l.

  • Page 31: Troubleshooting

    TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Unit Does Not Power Up Unit Is Not Plugged In Plug In Unit Input Power Circuit Breaker Not On Reset Input Power Circuit Breaker The Main Power Switch Is Not Working Replace Main Power Switch Leave power on and let the fan cool the unit.

  • Page 32: Diagram & Parts List

    DIAGRAM & PARTS LIST REF # PART # DESCRIPTION 105500015 HANDLE 155500001 ENCLOSURE 105500087 TIG WELDING WARNING LABEL 155200006 CORNWELL WELDER HELP LABEL 105500017 CONTROL PC BOARD 105500018 INPUT POWER STRAIN RELIEF 105500091 BACK PLASTIC BEZEL 105500019 INPUT POWER CABLE HOLDER 105500020 INPUT POWER CABLE 105500023...
  • Page 33 5-PIN REMOTE CONTROL RECEPTACLE 105500092 FRONT PLASTIC PANEL 105500040 TIG TORCH 105500041 GROUND CABLE AND CLAMP 105500042 FUNCTIONAL CONTROL KNOB 155500005 CORNWELL MMWTIG241I FACEPLATE 105500043 FACEPLATE SUPPORT PC BOARD 105200136 QUICK CONNECT SOCKET 105500044 HALL DEVICE 105500045 RECTIFIER LOWER HEATSINK 105500046...
  • Page 34 Reference # Part# Description Qty. 105500012 NOZZLE #5 105500013 NOZZLE#6 105500014 NOZZLE#7 105500078 COLLET BODY 105500010 COLLET 105500079 TORCH HEAD 105500080 SHORT BACK CAP 105500081 LONG BACK CAP 105500082 CONNECTOR ASSEMBLY 105500083 TIG TORCH HANDLE 105500084 TIG TORCH GAS HOSE 105500085 TIG TORCH CONTROL CABLE 105500086...
  • Page 35 Page of 36...
  • Page 36 Distributed by CORNWELL QUALITY TOOLS 667 SEVILLE RD WADSWORTH OH 44281 www.conwelltools.com Made in China Page of 36...

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