Cornwell Tools MMWTIG241I User manual

MMWTIG241I
OWNER’S MANUAL
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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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.
Limited to the warranty periods below, Cornwell Quality Tools will repair or replace the item under warranty that fails due to defects
in material and workmanship. Cornwell Quality Tools must be notified within 30 days of the failure, so as to provide instructions on
how to proceed with the repair of your welder and warranty claim processing. Warranty period begins at the time the welder is
purchased from and Authorized Cornwell Distributor. Keep your receipt as proof of purchase.
Warranty Periods
Limited Warranty is divided into three categories. No Warranty, 1 year and 3 year.
No Warranty
Normal wear items such as TIG torch parts (tungsten, collet, collet body and nozzle), regulator and gas hose are considered
consumable items and are not covered under warranty.
1 year
This warranty covers the existence of manufacturing defects in the TIG torch and foot pedal control, and the parts and labor
associated with repairing those defects. This warranty does not cover damage, such as cuts in cabling, crushing, or any other
damage that is a result of incorrect use of the torch or foot pedal. This warranty also does not cover the normal wear items as
stated above in the No Warranty section. Any shipping related to warranty repair is the responsibility of the customer.
3 year
This warranty covers parts and labor on items such as: transformer, reactor, rectifier, solenoid valve, PC Board, switches, controls,
gas valve, and any other component that requires the removal of the sheet metal to access; except for the TIG torch itself as
outlined in the 1 year warranty above. Any shipping related to warranty repair is the responsibility of the customer.
Voiding Warranty
Warranty does not apply to: Shipping Damage, Misuse and abuse of the unit, alteration of the unit in any way.
Warranty Claim
This is a parts and labor warranty. Contact your Cornwell distributor you purchased it from. Retain your receipt in the case a
warranty claim is needed. No warranty will be provided without the original receipt from an authorized Cornwell Distributor. To make
a warranty claim, contact your Cornwell Distributor. That Cornwell Distributor will contact the customer service department for
warranty instructions.

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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.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors which cannot be built into
this product, but must be supplied by the operator.
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 to your welding environment.
-Always have a qualified person install and operate 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 accordance with local, state and
national codes.
-Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.
-Keep harmful arc rays shielded from the view of others.
-Mount the welder on a secure bench or cart that will keep the welder secure and prevent it from
tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and welding cable to be sure the insulation is not damaged.
Always replace or repair damaged components before using the welder.
-Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Welder
Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do
not immerse them in water. These components and the welder must be completely dry before
attempting to use them.
-Follow the instructions in this manual.
-Keep welder in the off position when not in use.

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-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. 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 TIG torch tungsten 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.

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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.
-Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output,
use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for
more information.
-Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant
cloth or leather shirts, coats, pants or coveralls are available for protection.
-Use screens or other barriers to protect other people from the arc rays emitted from your welding.
-Warn people in your welding area when you are going to strike an arc so they can protect
themselves.
Fire Hazards
Do not weld 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 fireproof covers.
-Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,
cracks or areas you cannot see.
-Keep a fire extinguisher close in the case of fire.
-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
-Do not have on your person any items that are combustible, such as lighters or matches.
-Keep work lead connected as close to the weld area as possible to prevent any unknown,
unintended paths of electrical current from causing electrical shock and fire hazards.
Hot Materials
Welded materials are hot and can cause severe burns if handled improperly.
-Do not touch welded materials with bare hands.
-Do not touch torch nozzle after welding until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying
debris.
-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear
plugs to keep sparks out of ears and hair.

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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.
-Keep torch and ground cables on the same side of your body.
Shielding Gas Cylinders Can Explode
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 touch cylinder with torch.
-Do not weld on the cylinder.
-Always secure cylinder upright to a cart or stationary object.
-Keep cylinders away from welding or electrical circuits.
-Use the proper regulators, gas hose and fittings for the specific application.
-Do not look into the valve when opening it.
-Use protective cylinder cap whenever 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 or fan.
H.F. RADIATION can cause interference.
- High-frequency (H.F.) can interfere with radio navigation, safety services, computers,
and communications equipment.
- Have only qualified persons familiar with electronic equipment perform this
installation.
- The user is responsible for having a qualified electrician promptly correct any interference problem
resulting from the installation.
- If notified by the FCC about interference, stop using the equipment at once.
- Have the installation regularly checked and maintained.
- Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and
use grounding and shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
- Electromagnetic energy can interfere with sensitive electronic equipment such as
computers and computer-driven equipment such as robots.
- Be sure all equipment in the welding area is electromagnetically compatible.
- To reduce possible interference, keep weld cables as short as possible, close
together, and down low, such as on the floor.
- Locate welding operation 100 meters from any sensitive electronic equipment.
- Be sure this welding machine is grounded.
- If interference still occurs, the user must take extra measures such as moving the welding machine,
using shielded cables, using line filters, or shielding the work area.

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MMWTIG241I USE AND CARE
• Do not modify this unit in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the equipment. There are specific applications for which this
unit was designed.
• Always check of damaged or worn out parts before using this unit. Broken parts will affect
the operation. Replace or repair damaged or worn parts immediately.
• Store idle. When this unit is not in use, store it in a secure place out of the reach of children.
Inspect it for good working condition prior to storage and before re-use.
TECHNICAL SPECIFICATIONS
Item Description
Power Supply 230V, 35A, 50/60 Hz, Single Phase
Output No Load Voltage 68V
Rated Duty Cycle 35% @ 200A
DC TIG Output Range 5 - 200 A
AC TIG Output Range 10 - 200 A
Stick Welding Output Range 5 - 170 A
Pulse Frequency 0.5 - 200 HZ
Pulse W idth Adjustment (DC) 15 - 85 %
Weight 43 lbs.
Dimension L×W×H 19.75 in. x 9.5 in. x 16.125 in.
DESCRIPTION
The MMWTIG241I is an inverter powered AC and DC TIG, Pulse TIG and Stick welder. It requires
230 VAC (220-240), 50/60 Hz input power and a 50 Amp time delayed fuse or circuit breaker. This
machine comes complete with a TIG Torch, a Foot Pedal, regulator/flowmeter with inert gas hose, a
ground cable and clamp, and an 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. In the AC TIG mode, you are able to TIG weld non-ferrous metals
such as Aluminum. The MMWTIG241I also includes an Advanced Settings section that allows you
to move into advanced TIG welding including Pulse TIG and TIG sequencer control.
The advanced inverter technology that powers the MMWTIG241I provides for better arc control,
lower power consumption, in a lighter more portable unit.

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KNOW YOUR WELDER
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. Required for TIG welding. The regulator controls the
compressed gas and allows you to adjust the flow rate of the gas.
INERT GAS HOSE
The gas hose connects to the regulator/flowgauge and delivers the shielding gas from the shielding
gas bottle to the welder.
GROUND CABLE AND CLAMP
The ground cable and clamp are attached to the work piece to complete the circuit allowing the flow
of current needed to weld.
STYLE 26 TIG TORCH
The TIG torch transfers welding power from the welding power source to the tungsten for the
purpose of TIG welding. It also delivers the shielding gas from the welding power source to the
welding zone. This style 26 torch uses the same common parts as other Style 26 TIG torches.
FOOT PEDAL
The foot pedal is used to start the arc and manually adjust the amperage while TIG welding. The
cord will attached to the 5-Pin connector on the front of the unit.
TIG TORCH ACCESSORIES
The TIG torch for this welder comes installed with a collet, collet body, shielding cup and short back
cap. The accessory kit includes the long back cap and additional collet, collet body and shielding
cups for various applications. These common parts can be used on other 26 style TIG torches.
Inert Gas
Hose
Ground Clamp
And Cable
Electrode Holder
And Cable
Front Panel
Controls
Foot
Pedal
Style 26
TIG Torch
Inert Gas
Regulator/Flowgauge
TIG
Accessories

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FRONT PANEL CONTROLS
MODE SELECTOR
Use this button to choose between AC or DC welding output. The indicator lights to the left of the
Mode Selector will then indicate which mode the welder is in. Note that this unit will only stick weld
in the DC Mode and will automatically switch to DC when switching to STICK mode.
DIGITAL AMPERAGE DISPLAY
This display will indicate the set amperage while not welding and the actual amperage while
welding.
DIGITAL FUNCTION CONTROL DISPLAY
When using the function control, this display will indicate the set value that relates to the Functional
Control Display Indicator that is illuminated.
FUNCTION CONTROL DISPLAY INDICATORS
Use the Functional Control Indexing Button to illuminate the Function Control Display Indicator light
that relates to the setting you wish to set. The value will then be displayed in the Digital Functional
Control Display.
POWER INDICATOR LIGHT
In the “OFF” position no power is being supplied to the unit. In the “ON” position power is supplied
to the main inverter and control circuit.
TEMPERATURE (TEMP) INDICATOR LIGHT
This Temperature Indicator Light will be illuminated when the welder’s internal temperature has
exceeded safe operating levels. Leave the unit on and allow 15 minutes for cool down before the
light will go off and the temperature to fall into an allowable operating range.
Mode
Selector
Process
Selector
Digital Amperage
Display
Digital Function
Control Display
Functional
Control
Function Control
Display Indicators
Operation
Indicator Lights
Gas Purge
Button
Functional Control
Indexing Increase Button
Contactor Control
Selector
Advanced Settings
(See Next Section)
Functional Control
Indexing Decrease Button

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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. Push the button to choose Sequencer when you are using the optional push
button control with the sequencer.
GAS PURGE BUTTON
Use the Gas Purge button to push the inert gas through the TIG welding torch without energizing the
torch. This function helps to charge your gas lines to prepare for TIG welding. This function is only
operational in either HF TIG or LIFT TIG processes.
FUNCTIONAL CONTROL INDEXING BUTTONS
Use the Functional Control Indexing Buttons to move from one control setting to another. An indicator
light will then illuminate showing which function you are setting when turning the Functional Control.
FUNCTIONAL CONTROL
Use the Functional Control dial to increase and decrease the value of the function you are setting. An
indicator light will then illuminate showing which function you are setting.
PROCESS SELECTOR
Use the Process Selector Button to choose the welding process. The indicator lights to the left of the
button will illuminate to show which process is selected.
ADVANCED SETTINGS
Refer to the next section for detailed explanations of the Advanced Settings.
ADVANCED SETTINGS
PULSE ON PUSH BUTTON
Use this button to turn the pulsing feature on or off. When the indicator light next to PULSE is on,
the pulser is on. This function is only operational in either HF TIG or LIFT TIG processes. Pulse TIG
welding can increase travel speed while minimizing excessive penetration.
PREFLOW INDICATOR LIGHT
In the TIG mode only, and when the SEQR indicator light is on, use one of the FUNCTIONAL
CONTROL INDEX BUTTONS to turn on the preflow indicator light. The FUNCTIONAL CONTROL
KNOB can then be used to increase or decrease the amount of gas preflow time during your
sequenced weld. The functional control display indicator light SEC will be on indicating the set value
in the Digital Functional Control Display. This feature provides gas to the welding zone prior to the
arc starting to ensure a good welding environment. This function is only operational in the HF TIG
processes.

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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.
INITIAL CURRENT INDICATOR LIGHT
In the TIG mode only, and when the SEQR indicator light is on, use one of the FUNCTIONAL
CONTROL INDEX BUTTONS to turn on the INITIAL CURRENT indicator light. The FUNCTIONAL
CONTROL KNOB can then be used to increase or decrease the starting amperage setting, as
indicated in the Digital Amperage Display, for your sequenced weld. This setting helps to establish
an arc. During a sequenced weld, this amperage setting will remain constant until you activate the
upslope with the remote control.
UPSLOPE INDICATOR LIGHT
In the TIG mode only, and when the SEQR indicator light is on, use one of the FUNCTIONAL
CONTROL INDEX BUTTONS to turn on the UP SLOPE indicator light. The FUNCTIONAL
CONTROL KNOB can then be used to increase or decrease the amount of time it takes to go from
initial current to welding current during your sequenced weld. The functional control display indicator
light SEC will be on indicating the set value in the Digital Functional Control Display. This setting
helps to establish a smooth transition between the initial current and the welding current.
WELDING CURRENT INDICATOR LIGHT
Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the WELDING CURRENT
indicator light is on. The FUNCTIONAL CONTROL KNOB can then be used to increase or decrease
the welding amperage setting, as indicated in the Digital Amperage Display. During a sequenced
weld, this amperage setting will remain constant until you activate the down slope with the remote
control. The Welding Current Setting is not used in Pulse TIG. Peak Current will be set in Pulse TIG.
PEAK CURRENT 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 PEAK CURRENT indicator light.
The functional control knob can then be used to increase or decrease the peak amperage setting,
as indicated in the Digital Amperage Display. Peak amperage can be used in the pulse mode using
the remote foot pedal or when performing a sequenced weld.
PULSE WIDTH 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 PULSE WIDTH indicator light. The functional control
knob can then be used to increase or decrease the pulse width setting. The functional control
display indicator light % will be on indicating the set value in the Digital Functional Control Display.
Pulse width can be used in the pulse mode using the remote foot pedal or when performing a
sequenced weld. In general, a higher Pulse Width % will result in a hotter weld, making the puddle
more fluid and increasing penetration. Reduce this setting if burn-though is occurring.

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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.
Pulse frequency can be used in the pulse mode using the remote foot pedal or when performing a
sequenced weld. In general, a higher Frequency setting will result in a narrower arc and increased
penetration.
BACKGROUND CURRENT 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 BACKGROUND CURRENT indicator light. The
functional control knob can then be used to increase or decrease the background amperage setting,
as indicated in the Digital Amperage Display. Peak amperage can be used in the pulse mode using
the remote foot pedal or when performing a sequenced weld.
DOWNSLOPE INDICATOR LIGHT
In the TIG mode only, and when the SEQR indicator light is on, use one of the FUNCTIONAL
CONTROL INDEX BUTTONS to turn on the DOWN SLOPE indicator light. The FUNCTIONAL
CONTROL KNOB can then be used to increase or decrease the amount of time it takes to go from
initial current to welding current during your sequenced weld. The functional control display indicator
light SEC will be on indicating the set value in the Digital Functional Control Display. This setting
helps to establish a smooth transition between the welding current and the crater current.
CRATER CURRENT INDICATOR LIGHT
In the TIG mode only, and when the SEQR indicator light is on, use one of the FUNCTIONAL
CONTROL INDEX BUTTONS to turn on the INITIAL CURRENT indicator light. The FUNCTIONAL
CONTROL KNOB can then be used to increase or decrease the crater amperage setting, as
indicated in the Digital Amperage Display, for your sequenced weld. This Crater Current setting
helps to establish an amperage setting that can be used in conjunction with Down Slope to eliminate
a crater hole at the end of your sequenced weld. During a sequenced weld, this amperage setting
will remain constant until you active the postflow with the remote control.
POSTFLOW INDICATOR LIGHT
In the TIG mode only, and when the SEQR indicator light is on, use one of the FUNCTIONAL
CONTROL INDEX BUTTONS to turn on the postflow indicator light. The FUNCTIONAL CONTROL
KNOB can then be used to increase or decrease the amount of gas postflow time during your
sequenced weld. The functional control display indicator light SEC will be on indicating the set value
in the Digital Functional Control Display. This feature provides gas to the welding zone after your
weld is complete, ensuring a good environment for the molten metal to solidify. Be certain to keep
your torch in place until the post flow is complete.
AC FREQUENCY INDICATOR LIGHT
In the AC TIG mode only, use one of the FUNCTIONAL CONTROL INDEX BUTTONS to turn on the
AC FREQUENCY indicator light. The functional control knob can then be used to increase or
decrease the AC frequency setting. The functional control display indicator light HZ will be on
indicating the set value in the Digital Functional Control Display. AC frequency can be used in the
pulse mode using the remote foot pedal or when performing a sequenced weld. Increase AC
frequency to create a narrower arc and penetration pattern. Decrease AC frequency to create a
wider arc with shallow penetration.

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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. AC
balance can be used in the pulse mode using the remote foot pedal or when performing a
sequenced weld. Increase AC balance when the material you are welding has a higher amount of
oxidation and more cleaning is needed during the weld. Be mindful that increasing the AC balance
will also create a wider arc with shallower penetration. Decrease AC balance when the material you
are welding has less oxidation and less cleaning is needed during the weld. Be mindful that
decreasing the AC balance will also create a narrower arc with deeper penetration.
ARC FORCE: In the stick 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 ARC FORCE setting. The functional control display indicator light % will
be on indicating the set value in the Digital Functional Control Display. Arc Force that is increased
will generally result in a more forceful arc, increasing penetration when in the STICK mode and
preventing arc outages due to the electrode shorting out to the workpiece. Arc Force that is
decreased will generally result in a less forceful arc, decreasing penetration when in the STICK
mode. This control may be useful with materials you are welding are not perfectly fit together or if
you are in awkward positions and maintaining the proper arc length is difficult.
INSTALLATION
1. POWER REQUIREMENT - AC single phase 230V, 60 HZ with a 50 amp circuit breaker is
required. DO NOT OPERATE THIS UNIT if the ACTUAL power source voltage is less than 220 volts
AC or greater than 240 volts AC.
• 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. Do not use any adapters
between the welder's power cord and the power source receptacle. Make sure the
POWER switch is OFF when connecting your welder's power cord to a properly
grounded 230 VAC, 60 HZ, Single Phase, 50 Amp input power supply.
2. EXTENSION CORD - We do not recommend an extension cord because of the voltage drop they
produce. This drop in voltage can affect the performance of the welder. If you need to use an
extension cord, we recommend you check with a qualified electrician and your local electrical codes
for your specific area. Do not use an extension cord over 25 ft. in length.
3. STICK WELDING CONNECTION – DC Stick welding is generally performed DC Electrode
Positive. That means that the electrode holder and cable would be attached to the Positive (+) weld
output connection and the ground cable and clamp would be attached to the Negative (-) weld
output connection.

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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. Use this same connection when AC TIG welding.
5. BACK PANEL CONNECTIONS

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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.
• Keep cylinders away from welding or electrical circuits.
• Use the proper regulators, gas hose and fittings for the specific application.
6.1. Connect one end of the gas hose to the gas hose connection on the back of the welder. Use a
wrench to snug up the connection.
6.2. Connect the other end of the gas hose to the gas hose connection on the supplied
regulator/flowgauge. Use a wrench to snug up the connection.
6.3. Before installing the regulator, it is good practice to make certain no debris is in the gas bottle
connection. Rotate the bottle so the gas connection is not pointing 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 bottle connection. Use a wrench to snug
up the connection.
(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
(7) Gas Cylinder
6.4. Open the Gas Bottle Valve on the cylinder of gas.
6.5. 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 scale on the gauge.
NOTE: Slowly open the cylinder valve by turning it counterclockwise until the cylinder pressure
gauge registers on the first gauge of the regulator. Turn the adjustment knob clockwise (right) slowly
to increase gas flow to 20 cfh. To reduce the gas flow turn the adjustment counterclockwise (left).
The gas valve is located on the back panel of the welder and activated by the foot pedal or gas
purge button.
6.6. Gas selection – Except for very specialized TIG welding applications, TIG welding can be done
with 100% Argon. Consult your gas supplier for more information.
7
3 2
1

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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 – Contactor Control – Use the optional push button control in the TIG mode to turn the arc
on only. When using the push button for this purpose, the amperage will be set on the front
panel and will not vary during the weld.
7.1.b – Sequencer Control – Use the optional push button control in the TIG mode when using
the sequencer. Push the optional push button to initiate the arc and then push it again to
advance to the next step in the sequencer.
7.2 Remote Contactor And Amperage Control – This unit comes standard with a remote foot pedal
control. The remote foot pedal is used to initiate the arc and then vary the amperage during your
weld. Connect the remote foot pedal control to the Foot Pedal Connection on the back of the unit.

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PRE OPERATION SET-UP
1. SET UP INSTRUCTIONS FOR DC STICK ELECTRODE WELDING
•Connect the stick electrode holder to the POSITIVE terminal on the front of the machine
(See item 3 of the INSTALLATION section).
•Connect the ground cable to the NEGATIVE terminal on the front of the machine (See
item 3 of the INSTALLATION section).
•Connect the primary power cable to 230 volt AC single phase electricity.
•Turn on the machine using switch on the back of the machine.
•Use the PROCESS SELECTOR BUTTON to Select STICK on front panel
•Use the MODE SELECTOR BUTTON on the front panel to Select DC.
•Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the WELDING
CURRENT indicator light is on. Use the FUNCTIONAL CONTROL KNOB to select
preferred welding current as displayed on the Digital Amperage Display. Example: Set
weld current at 150 or adjust current according to the size of electrode.
•To set ARC Force, use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the
AC BALANCE/ARC FORCE indicator light is on. Use the FUNCTIONAL CONTROL
KNOB to select the preferred arc force setting as displayed on the Digital Functional
Control Display.
•To set HOT START, use one of the FUNCTIONAL CONTROL INDEX BUTTONS until
the HOT START indicator light is on. Use the FUNCTIONAL CONTROL KNOB to select
the preferred Hot Start setting as displayed on the Digital Amperage Display.
The machine is now set up to STICK weld using DC output.
Mode
Selector
Process
Selector
Digital Amperage
Display
Digital Function
Control Display
Functional
Control
Function Control
Display Indicators
Operation
Indicator Lights
Gas Purge
Button
Functional Control
Indexing Increase Button
Contactor Control
Selector
Advanced Settings
(See Next Section)
Functional Control
Indexing Decrease Button

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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
of the INSTALLATION section).
•Connect the Argon regulator securely to the cylinder. Secure and tighten one end of hose to
regulator, and the other end to the gas fitting on the rear of the welding machine. Slowly
open valve on cylinder. (See items 6 and 7 of the INSTALLATION section).
•Connect foot control to 5-pin receptacle on the back of the machine. (See item 8 of the
INSTALLATION section).
•Connect the primary power cable to 230 volt AC single phase electricity.
•Turn on the machine using switch on the back of the machine (See item 6 of the
INSTALLATION section).
•Use the PROCESS SELECTOR BUTTON to Select HF TIG on front panel
•Use the MODE SELECTOR BUTTON on the front panel to Select DC.
•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
light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred seconds of pre
flow as displayed on the Digital Functional Control Display. Example: Set Pre Flow to 3 SEC.
The purpose of pre flow is to cover the welding zone with shielding gas prior to the arc start.
This generally is a short setting. Hold the TIG torch steady during pre flow.
•Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the POST FLOW indicator
light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred seconds of post
flow as displayed on the Digital Functional Control Display. Example: Set Post Flow to 10
SEC.
•NOTE: Adjust the gas flow rate using the adjustable knob on the regulator. (See item 7 of
the INSTALLATION section). Depress the foot pedal and set the flow rate at approximately
20 CFH. With foot pedal depressed Open and Adjust the flow control valve on the regulator
to approximately 20 CFH. Release foot pedal.
Machine is now set up to TIG weld using DC output.
3. SET UP INSTRUCTIONS FOR AC 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
of the INSTALLATION section).
•Connect the Argon regulator securely to the cylinder. Secure and tighten one end of hose to
regulator, and the other end to the gas fitting on the rear of the welding machine. Slowly
open valve on cylinder. (See items 6 and 7 of the INSTALLATION section).
•Connect foot control to 5-pin receptacle on the back of the machine. (See item 8 of the
INSTALLATION section).
•Connect the primary power cable to 230 volt AC single phase electricity.
•Turn on the machine using switch on the back of the machine (See item 6 of the
INSTALLATION section).

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•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
light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred seconds of pre
flow as displayed on the Digital Functional Control Display. Example: Set Pre Flow to 3 SEC.
The purpose of pre flow is to cover the welding zone with shielding gas prior to the arc start.
This generally is a short setting. Hold the TIG torch steady during pre flow.
•Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the AC FREQUENCY
indicator light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred AC
frequency as displayed on the Digital Functional Control Display. Example: Set AC
Frequency to 100 Hz.
•Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the AC BALANCE
indicator light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred
percentage as displayed on the Digital Functional Control Display. Example: Set AC Balance
to 65%.
•Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the POST FLOW indicator
light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred seconds of post
flow as displayed on the Digital Functional Control Display. Example: Set Post Flow to 10
SEC.
•NOTE: Adjust the gas flow rate using the adjustable knob on the regulator. (See item 7 of
the INSTALLATION section). Depress the foot pedal and set the flow rate at approximately
20 CFH. With foot pedal depressed Open and Adjust the flow control valve on the regulator
to approximately 20 CFH. Release foot pedal.
•Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the PEAK CURRENT
indicator light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred top end
amperage when your foot pedal is completely pressed to the maximum position.
Machine is now set up to TIG weld using AC output.

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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. Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the PRE FLOW indicator
light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred seconds of pre
flow as displayed on the Digital Functional Control Display. Example: Set Pre Flow to 3 SEC.
The purpose of pre flow is to cover the welding zone with shielding gas prior to the arc start.
This generally is a short setting. Hold the TIG torch steady during pre flow.
4. Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the PEAK CURRENT
indicator light is on. Use the FUNCTIONAL CONTROL KNOB to adjust the peak current that
is present when the foot pedal is completely depressed to the maximum position. Peak
current will then be a percentage of this setting, dependent on the percentage you are
depressing the foot pedal. Practice with Peak Current. Try a sample run on scrap metal.
Then try increasing or decreasing the Peak Current and see what it does to the weld puddle.
In general, a higher Peak Current will result in more penetration.
5. Use one of the FUNCTIONAL CONTROL INDEX BUTTONS until the PULSE WIDTH
indicator light is on. Use the FUNCTIONAL CONTROL KNOB to select the preferred Pulse
Width as displayed on the Digital Function Control Display. Example: Set Pulse Width to
50%. The Pulse Width is the percentage of time the machine stays on the Peak Current.
Practice with this setting. Try a sample run on scrap metal. Then try increasing or
decreasing the Pulse Width and see what it does to the weld puddle. In general, a higher
Pulse Width % will result in a hotter weld, making the puddle more fluid and increasing
penetration. Reduce this setting if burn-though is occurring.