Sealey POWERMIG6025S - Manual (Page 7)

6.7 FEEDING WIRE ThROUGh TO ThE TORCh.
6.7.1 Before feeding the wire through to the torch the gas cup and contact tip
should be removed as shown in fig.16.
6.7.2 The gas cup is a friction fit onto the torch and can be pulled off with a
twisting action in either direction. Unscrew the copper contact tip using
the maintenance spanner provided across the 6mm flats of the contact
tip. It has a conventional right hand thread.
6.7.3 To feed the wire through to the torch it will be necessary to power up
the welder.
6.7.4 The wire is required to feed through the full length of the umbilical
cable extension and if possible it should be laid out straight. If this is not
possible the cable should not be coiled at a diameter of less than 1mtr.
6.7.5 Check welder is switched off “0”, and that the earth clamp is isolated
and away from the torch tip.
6.7.6 Connect the welder to the mains power supply and set the voltage
switch to “1”.
6.7.7 Using the wire feed control within the wire feed compartment (see
fig.21), set the knob to position 5 or 6, (the higher the number the faster
the speed). Keep the torch cable as straight as possible and press the
torch switch to feed the wire through to the torch.
6.7.8 When wire has fed through, switch welder off, unplug from mains.
6.7.9 Replace contact tip and gas cup. Cut wire so that it is protruding 1/4”
from the cup.
 wARNING! During these operations the wire is live and subject to
mechanical stress; therefore, if adequate precautions are not taken the
wire could cause hazardous electric shock, injury and striking of electric
arcs. Do not direct the torch tip towards parts of the body and keep the
torch away from the gas bottle.
6.8 SETTING WIRE TENSION.
IMPORTANT: You must set the correct tension, too little or too much
tension will cause problematic wire feed and result in poor welding.
6.8.1. Tension between rollers is checked by slowing down the wire between
your fingers. 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 speed and
voltage switch to maximum. Depress the torch switch and release
quickly. If spool overruns it indicates that the clutch is too loose. Tighten
the clutch (located in the centre of the wire spool holder (fig.9), and
test the machine as above until the wire stops over running.
 WARNING! DO NOT over tighten the clutch as this will cause
wire feed problems.
fig.16
Original Language Version © Jack Sealey Limited
7. POWERMIG CONTROLS
fig.17
7.1 CONTROLS - POWERMIG60253 & 6035S
7.1.1 Fig.17 illustrates the main panel controls for POWERMIG6025S. Note
that this model has a TWO position voltage range switch and one socket
on the lower half of the front panel for the connection of the welding
current return cable (Earthing Clamp).
7.2 Fig.18 illustrates the main panel controls for POWERMIG6035S. Note
that this models has a THREE position voltage range switch and two
sockets on the lower half of the front panel for the connection of the
welding current return cable (Earthing Clamp). Which of the two sockets
is used depends on the material to be welded. Refer to section 5.5 and
fig.6 for more information.
fig.18
7.3 SYSTEM PROTECTION
To provide a level of protection against faults such as short circuits or
overheating, various safety features are incorporated into the welder
unit. There are two control circuit fuses. A 3Amp fuse is located on the
left hand side of the rear panel. An 8Amp fuse is located on the right
hand side of the rear panel. A thermostat is built into the system to
protect against overheating. The indicator light comes on when
overheating occurs and cuts off the power supply; it will reset
automatically within a few minutes, after cooling down.
POWERMIG6025S, POWERMIG6035S Issue: 2(L) -06/03/14