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4.4. Setting Wire Tension.
IMPORTANT: You must set the correct tension, too little or too much tension will cause problems with wire feed and result in a
poor weld.
4.4.1. For mild steel 0.6mm wire the wire tension screw must be fully tightened and undone approximately two complete turns (fig.8).
4.4.2. Correct tension between the rollers is checked by slowing down the wire between the fingers. If the pressure roller skids the
tension is correct. Try to use the lowest tension possible as too high a tension will deform the wire and may result in blowing a fuse
on the printed circuit board.
Note: Damaged torches and cables are not covered under warranty.
fig.8
4.5
Turning the Feed Roller IMPORTANT: Always turn the feed roller to suit the wire size.
4.5.1. There are two grooves on the feed roller, 0.6mm and 0.8mm. Always have the groove that is to be used on the outside of the roller. To turn
the feed roller first loosen the wire tension knob and swing it into its down position then move the tensioning roller assembly to its up
position (see fig.5). Take hold of the triangular knob on the roller retainer and rotate it 90°anticlockwise to release it (fig.9). Now pull the
roller retainer off the drive spindle to reveal the roller.
4.5.2. Pull the roller off the drive spindle, flip it over and put it back on the drive spindle(fig.10). The groove size required should now be visible on
the face of the roller. Push the roller retainer back onto the drive spindle with the opening facing left. Ensure that the flanges at the base of
the retainer, seat fully into the circular recess in the main moulding and then rotate the retainer through 90° to lock it in place.
4.6.
Gasless Welding.
4.6.1. The machine is supplied configured for gas welding.
4.6.2. To use the machine for gasless welding, reverse the polarity of the connections in the side compartment (fig.3). For gasless welding, the
negative (black) lead should be secured to the positive (+) terminal and the positive (red) lead to the negative (-) terminal.
4.6.3. The feed roller should be turned to present the larger setting.
4.6.4. Restore the original settings before commencing gas welding.
5. OPERATION
5.1
Preparation for welding: IMPORTANT! BEFORE YOU COMMENCE, MAKE SURE THE MACHINE IS DISCONNECTED FROM THE
ELECTRICAL SUPPLY. IF WELDING A VEHICLE, DISCONNECT THE BATTERY OR FIT AN ELECTRONIC CIRCUIT PROTECTOR.
ENSURE THAT YOU READ, UNDERSTAND AND APPLY THE SAFETY INSTRUCTIONS IN SECTION 1.
5.1.1. To ensure a complete circuit, the negative lead must be securely attached to the workpiece close to the weld area. Best connection is
obtained by grinding the point of contact on the workpiece before connecting the clamp.
5.1.2. The weld area must be free of paint, rust, grease, etc.
5.3.
Gas types and their use
Welding mild steel with CO ² gas is appropriate for most welding tasks where spatter and high build-up of weld do not pose a problem. To
achieve a spatter free and flat weld however, requires an Argon/CO ² mixture.
5.3.1. To weld aluminium use: Argon Gas 0.8mm Contact Tip 0.8mm Aluminium Wire (MIG/2/KAL08).
5.4.
Thermal Protection
Should the welder become overheated due to prolonged use beyond the stated duty cycle the thermal protection will cause the welder to cut
out and the alarm light on the front panel will illuminate. Wait for fifteen minutes for the welder to cool down at which time it will restart.
automatically.
6. RATING PLATE
On the front panel of the welder is the rating plate, giving the following data:
1 - The BS/EU standard relating to the safety and construction of
2 - Inverter-transformer-rectifier symbols
3 - Symbol indicates welding with a continuous flow of welding wire.
4 - Symbol for Single-phase AC supply.
5 - Rating of internal protection provided by casing.
6 - Output
U
:
Maximum open-circuit voltage.
0
I
, U
: Current and corresponding voltage.
2
2
X:
Welding ratio based on a 10 minute cycle.
20% indicates 2 minutes welding and 8 minutes rest, 100% would indicates continuous welding.
7 - Mains Supply
U
: Rated supply voltage and frequency.
1
I
max: Maximum current.
1
8 - A/V - A/V: Welding current adjustment range and corresponding voltages.
9 - Serial Number. Specifically identifies each welder.
10- Symbol for welding power sources which are suitable for supplying power to welding operations carried out in an environment with
increased risk of electric shock (if applicable).
11- Insulation Class.
© Jack Sealey Limited
I
eff: Maximum effective current.
1
Original Language Version
fig.9
arc welding and associated equipment.
fig.10
IMIG160,IMIG180
Issue: 1 - 05/01/16
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