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Insert  the  welding  torch  into  the  “ ”  output  socket  on  the 
front panel of the wire feeder, and tighten it. Manually thread 
the welding wire into the torch body.

Insert the quick plug of the interconnection cable set into the 
“+”  output  terminal  of  the  welding  machine,  and  tighten  it 
clockwise. Connect the other end of the interconnection on 
the rear of the wire feed unit

Insert the multi pin plug of the interconnection cable set into 
the control cable socket of the welding machine and connect 
the  other  end  of  the  control  cable  into  the  rear  of  the  wire 
feed unit

Installation of the wire spool

 

Install  the  wire  spool  on  the  spindle  adapter  on  the  wire 
feeder, locating the hole on the wire spool to the fixing pin on 
the spindle adapter.

Select the correct size feed drive roll according to the size of 
welding wire.

Release  the  pressure  arm  of  the  wire  feeder  to  thread  the 
wire  through  the  guide  tube,  and  into  the  drive  roll  groove. 
Adjust the pressure arm, ensuring no sliding of the wire. Too 
high  pressure  will  lead  to  wire  distortion,  which  will  a

ect 

wire feeding.

Press the inch wire feeding button to thread the wire out of 
the torch head.

Installation of the cylinder 

Connect  the  cylinder  equipped  with  a  regulator  to  the  gas 
inlet  on  the  wire  feeder  with  a  hose,  and  tighten  it  with  a 
hose clamp.

Please note: 

Avoid  excessive  exposure  of  the  cylinder  to  high 
temperature or sunlight. 

Always keep the cylinder in an upright position

Always fix the cylinder securely

Before  the  installation  of  gas  regulator,  open  and  close  the 
valve  for  several  times  in  order  to  remove  the  dust  on  the 
joint.

Keep your head and face away from the cylinder valve outlet 
when opening the cylinder valve.

Leakage  of  shield  gas  a

ects  welding  performance,  so 

tighten  the  cylinder  valve  joint  with  a  spanner.  Check  for 
leaks

10

Machine rear

Cable of the heater

Gas regulator

Input cable

Cylinder

Wire feeder

Gas hose

Welding torch

Workpiece

Summary of Contents for JM-250S MIG Series

Page 1: ...wilkinsonstar com MIG Series MIG MAG MMA Separate wire feed welding machine Order code JM 250S MIG 250S OPERATOR MANUAL ...

Page 2: ...upplier of equipment in the UK and our products are supported by our extensive service network Call your distributor in the unlikely event of a problem occurring Please record below the details from your product as these will be required for warranty purposes and to ensure you get the correct information should you require assistance or spare parts Date purchased __________________________________...

Page 3: ...ye protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work ground Never touch the electrode if you are in contact with the work ground or another electrode from a different machine Do not wrap cables over your body Ensure that you take additional safety precautions when you are welding in electrically hazardous c...

Page 4: ... fan may cut fingers and hands and snag garments Protections and coverings may be removed for maintenance and controls only by qualified personnel after first disconnecting the power supply cable Replace the coverings and protections and close all doors when the intervention is finished and before starting the equipment Take care to avoid getting fingers trapped when loading and feeding wire durin...

Page 5: ...network at the public network connection point must be applied to these systems In this case the installer or the user is responsible for ensuring the equipment can be connected consulting the electricity provider if necessary Materials and their disposal The equipment is manufactured with materials which do not contain any toxic or poisonous materials dangerous to the operator When the equipment ...

Page 6: ...t welding characteristics A unique welding dynamic characteristic control circuit provides a stable arc low spatter high welding efficiency and excellent weld appearance Removing wire tip ball after welding high no load voltage and soft start wire feeding results in a excellent arc ignition Welds a wide range of wires from 0 6 1 6mm diameter Improved functional design With the wire feeder separate f...

Page 7: ...t A 12 1 Rated power supply capacity KVA 8 4 Output current range MMA 10 220A Welding current range A 35 250 Welding voltage range V 14 32 No load voltage V 52 Wire feed speed range m min 1 5 16 Wire diameter applicable mm 0 8 1 0 Rated duty cycle 400 C 250A 60 Efficiency 85 Power factor 0 93 Protection class IP21S Overall size mm 510 196 385 Weight kg 15 ...

Page 8: ...ng switch 2 MMA MIG switch 3 Voltmeter 4 Over current LED 5 Power LED 6 Overheating LED 7 Ammeter 8 Current control knob in MMA 9 Inductance control knob 10 output terminal 11 Connector for the wire feeder 12 output terminalConnector for the wire feeder 7 ...

Page 9: ...ower switch 14 Socket for the heater 15 Input power cord gland 16 Ground terminal Wire feed control 1 Welding current control knob 2 Manual wire feeding switch 3 Welding voltage control knob 4 2T 4T Selector switch 8 ...

Page 10: ...lding electrodes the electrode holder is connected the the positive terminal and the work return to the negative terminal Always consult the electrode manufacturer s data sheet if you have any doubts MMA welding Insert the cable plug with electrode holder into the socket on the front panel of the welding machine and tighten it clockwise Insert the cable plug of the work return lead into the socket...

Page 11: ...to thread the wire through the guide tube and into the drive roll groove Adjust the pressure arm ensuring no sliding of the wire Too high pressure will lead to wire distortion which will affect wire feeding Press the inch wire feeding button to thread the wire out of the torch head Installation of the cylinder Connect the cylinder equipped with a regulator to the gas inlet on the wire feeder with a...

Page 12: ...n pushing the torch trigger again the machine enters into crater welding and at this time Crater parameters should be set by adjusting the crater welding current control knob and crater voltage control knob on the front panel of the machine The actual current and voltage values are displayed on the front panel of the machine When the torch trigger is released welding ends 2 seconds after welding e...

Page 13: ...ng Generally the stick out should be 10 times as the welding wire diameter 4 Shield gas flow selection The protection effect is the primary consideration Besides the protection effect of inner angle welding is better than that of external angle welding so the gas flow in inner angle welding should be lower Less or no shield gas is needed in FCAW Refer to the table below for the recommended gas flow ...

Page 14: ...tion LED warnings 13 Period Maintenance item Daily examination Carry out a full visual inspection Check for any damage to the machine leads cables and connections Replace where necessary Switch on the machine and check for any warning Led s and general operation Monthly examination Using the dry compressed air to clean the inside of arc welding machine Especially check for build up of dust debris ...

Page 15: ...1 Check if the control cable of the wire feeder is broken 2 Check if the wire feeder is blocked 3 Check if the wire feed PCB of the welding machine fails 4 Check if the wire feeder is damaged Welding can be carried out when pushing the torch trigger but the current is too high the voltage can not be adjusted and the no load voltage is too high 1 Check if the control cable of the wire feeder is bro...

Page 16: ...Electrical schematic 7 15 ...

Page 17: ...Parts list 8 16 ...

Page 18: ...075 Main transformer 6 10001867 Fan 20 10014690 Front Panel 7 10013342 Back panel 21 10001577 Indicator Light 8 10021881 Square sockets 22 10006795 Digital Meter 9 10004955 Power switch 23 10004944 Transform switch 10 10021912 Line button 24 10006507 MMA Current Potentiometer 11 10001146 Silicon bridge 25 10006507 Inductance Potentiometer 12 10044596 Power adapter plate 26 10021855 Quick socket 13...

Page 19: ...3 10015217 Control Panel 4 10021855 Output Terminal 14 10044630 10044640 Potentiometer 5 10044600 Wire Feeding PCB Board 15 10015526 CS501B Remote Plastic Box 6 10045742 Bottom panel 16 10012376 Wire Feeder Cover 7 10003814 Wire Feeder 17 10016524 Door Catch 8 10003831 Central socket 18 10015767 Platen 9 10015216 Front Panel 19 10016681 Spool for wire feede 10 10044633 Inching button ...

Page 20: ...JM MIG Series MIG MAG MMA WELDING MACHINE Order code JM 250S MIG 250S Wilkinson Star Limited Issue 1 January 2014 Product is subject to change without notice xix ...

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