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INSTRUCTIONS FOR

POWERMIG

WELDERS

POWERMIG6025S

POWERMIG6035S

MODEL No's:

POWERMIG6025S, POWERMIG6035S Issue: 1 - 18/09/12

© Jack Sealey Limited

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Summary of Contents for POWERMIG Series

Page 1: ...INSTRUCTIONS FOR POWERMIG WELDERS POWERMIG6025S POWERMIG6035S MODEL No s POWERMIG6025S POWERMIG6035S Issue 1 18 09 12 Jack Sealey Limited ...

Page 2: ...RSONAL INJURY AND WILL INVALIDATE THE WARRANTY RETAIN THESE INSTRUCTIONS FOR FUTURE USE 1 SAFETY INSTRUCTIONS INSTRUCTIONS FOR PROFESSIONAL MIG WELDERS 400V 250Amp and 400V 350Amp with Binzel EURO TORCH MODEL Nos POWERMIG6025S POWERMIG6035S 1 2 MODELS POWERMIG6025S 6035S ARE 3 PHASE MACHINES AND MUST HAVE AN APPROPRIATE PLUG FITTED WARNING Electrical installation of welder to a 3 phase 415Volt sup...

Page 3: ...ding machine If in doubt seek medical advice before entering a welding area Users of such devices should not operate the welding machine This welder complies with the requirements of the technical standard for the use of this type of product only and exclusively in industrial environments and for professional purposes It is not guaranteed to meet electronic compatibility requirements in the home 1...

Page 4: ...it If the unit is to be mounted on the welder do this before connecting the unit and before placing a reel of wire into it Lift up the wire feed unit and align the mounting collar on its underside with the pivot pillar on top of the main welder casing and lower it gently into position Do not let it suddenly drop onto the pillar 5 2 Connect umbilical cable extension 5 2 1 Whether the wire feed unit...

Page 5: ...ote The regulator supplied may differ from that illustrated 5 6 4 Close the regulator by turning the adjusting screw anti clockwise to relieve the pressure on the diaphragm before opening the cylinder valve If this is not done pressure from the cylinder can damage the diaphragm and render the regulator inoperative 5 6 5 Set the regulator flow rate to 4litres min depending on the material to be wel...

Page 6: ...he right way round on the drive mechanism 6 3 The roller groove size is stamped on the face of each roller adjacent to the appropriate groove Ensure that the groove size you require is positioned next to the drive gear so that it will be in line with the wire feed path To reverse the position of the rollers firstly unscrew and remove the knurled knobs that hold each roller in position see fig 13 N...

Page 7: ...If the top feed rollers skid the tension is correct Use as low a tension as possible too high a tension will deform wire and result in a blown fuse on the printed circuit board Adjust tension by turning the pressure knob as shown in fig 15 fig 15 6 9 Clutch adjustment It is essential that the clutch is adjusted correctly Once the wire is fed through the torch switch on the machine and set the wire...

Page 8: ... Feed Button can be used to check that the wire feed unit is powered and wire is being fed to the torch Hold down the button and listen for the action of the wire feed unit and or observe the wire issuing from the torch tip 8 3 BURN BACK POST GAS TIME 8 3 1 The burn back post gas time control allows a small amount of wire and gas to be fed to the weld even after the torch trigger has been released...

Page 9: ...hose using dry compressed air max 5 bar to make sure it is not damaged Before using the welding machine always check the torch terminal parts for wear and make sure they are assembled correctly nozzle contact pipe gas diffuser 10 6 Contact Tip to remove the tip refer to section 6 7 and fig 16 The contact tip is a consumable item and must be replaced when the hole becomes enlarged or oval The conta...

Page 10: ...Adjust wire feed rate control See section 8 2 10 Irregular weld bead Torch incorrectly held Wire weaving in weld pool Use correct torch angle Check roller tension and adjust as needed See section 6 6 11 Weld bead too narrow and raised Weld current too high Weld speed too low Increase power and wire speed Move torch slower and weave a little more 12 Weld bead too wide Weld current too high Weld spe...

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