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7.1.1.
The wire drive unit is supplied with one roller which has drive grooves for Ø0.8mm and Ø1.0mm wire.
Note: It is essential to place the roller the correct way round on the drive mechanism.
7.1.2.
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 furthest away from you so that it will be in line with the wire feed path
7.1.3.
When changing from Ø0.8mm to Ø1.0mm wire it will be necessary to reverse the position of the roller on its carrier. Firstly unscrew and
remove the black knurled knob that holds the roller and its carrier in position (see fig.11).
7.1.4.
Now slide the roller and its carrier off the main drive shaft as shown below in fig.13. taking care to keep the parts together as an
assembly. Note that there is a keyway in the roller which must align with the keyway on the roller carrier and the two components are held
together with a close fitting square key (see fig.13).
7.1.5.
Once the carrier is free from the main drive, you can now slide the roller off the carrier as shown below in fig.13A. Take care not to unseat
the loose key that aligns the roller with the carrier. The roller can now be reversed or replaced as required. In either instance the required
drive groove must be furthest away from you at the back of the roller in order to align with the wire drive path.
7.1.6.
With the carrier, roller and key reassembled as shown in fig.13B, orientate the carrier so that the keyway in the carrier itself is aligned with
the key on the wire feed drive shaft as shown in fig.12. Slide the carrier fully onto the drive shaft and fix it in position by screwing into
place the black knurled knob previously removed.
Straighten about 50-100mm of spool wire (do not allow wire to uncoil). Ensure that the wire is undistorted and clean cut with no burrs or
7.2.
sharp points. (Note: burrs or sharp points at wire tip may damage the torch liner.) Gently push the wire through the flexible wire guide until
it emerges into the wire feed drive unit. Guide the wire over the roller and into the torch fitting wire guide by 50 to 100mm.
7.2.1.
Close and hold down the pressure roller housing then hinge the pressure knob upwards and onto the housing until it snaps into
position. Set an intermediate pressure between marks 2 and 3. Turning the knob clockwise increases the pressure. Turning the knob
anti-clockwise decreases the pressure. (See fig.9).
7.3.
FEEDING WIRE THROUGH TO THE TORCH.
7.3.1.
Before feeding the wire through to the torch, the gas cup and contact tip should be
removed as shown in fig.15.
7.3.2.
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.
7.3.3.
To feed the wire through to the torch it will be necessary to power up the welder.
7.3.4.
The wire is required to feed through the full length of the torch cable 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.
7.3.5.
Check that the welder POWER switch is in the 'OFF' position, and that the earth clamp
is isolated and away from the torch tip.
7.3.6.
Connect the welder to the mains power supply and set the voltage switch to "1".
7.3.7.
Using the wire feed speed control, set the knob to position 5 or 6, (the higher the
number the faster the speed). See fig.16. Keep the torch cable as straight as possible
and press the torch switch to feed the wire through to the torch.
7.3.8.
When the wire has fed through, switch welder off, unplug from mains.
7.3.9.
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.
7.4.
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.
7.4.1.
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.9.
7.5.
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 reel clutch adjuster (located in the centre of the reel holder (fig.8), and test the machine as above until the wire stops
overrunning.
‰
WARNING! DO NOT over tighten the clutch as this will cause wire feed problems.
7.6.
WIRE FEED CONTROL
The wire feed speed can be set using the 'Wire Feed Speed' control situated on the front panel of each welder. (See fig.16).
Use this rotary control to set the basic wire feed speed required by the welding parameters of the weld to be executed.
© Jack Sealey Limited
fig.12
Original Language Version
.
fig.13
SUPERMIG255.V2
fig.14
fig.15
Issue:1 - 11/07/22
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