Sealey POWERMIG500I 500A Professional MIG MMA TIG Inverter User Manual

SEALEY, 500A PROFESSIONAL GAS/GASLESS

MIG/MMA/TIG INVERTER WELDER WITH

PORTABLE WIRE FEEDER 415V 3PH

MODEL NO: POWERMIG500i & POWERMIG500Wi

Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions,

and properly maintained, give you years of trouble free performance.

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE

THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR

PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.

1. SAFETY

1.1. WARNING! It is the user’s responsibility to check the following:

9 Check all electrical equipment and appliances to ensure that they are safe before using.

9 Inspect power supply leads, plugs and all electrical connections for wear and damage.

9 Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply.

8 DO NOT use worn or damaged cables, plugs or connectors.

9  EnsurethatanyfaultyitemisrepairedorreplacedimmediatelybyaSealeyqualiedtechnician.

9  Ifthecableorplugisdamagedduringuse,switcho󰀨theelectricitysupplyandremovefromuse.

9 SealeyrecommendthatanRCD(ResidualCurrentDevice)isusedwithallelectricalproducts.

Important:Ensurethatthevoltageratingontheappliancesuitsthepowersupplytobeusedandthattheplugisttedwiththe 

correct fuse.

8 DO NOT pull or carry the appliance by the power cable.

8 DO NOT pull the plug from the socket by the cable.

1.2. GENERAL SAFETY

9 Welding power sources are not suitable for use in rain or snow

9 The output is rated at an ambient temperature of 20°C and the welding time may be reduced at higher temperatures.

9 Risk of electric shock: Electric shock from welding electrode can kill.

8 DO NOT weld in the rain or snow.

8 DO NOToperateonaslopeorunevenground.

9  Weardryinsulatinggloves.

8 DO NOT touch electrode with bare hands.

8 DO NOTwearwetordamagedgloves.

9 Protect yourself from electric shock by insulating yourself from workpiece.

8 DO NOT open the equipment enclosure.

 WARNING! Welding fumes: Breathing welding fumes can be hazardous to your health. Keep your head out of the fumes.

9 Use equipment in an open area.

9  Useventilatingfantoremovefumes.

 WARNING!Riskinducedbyweldingsparks:Weldingsparkscancauseexplosionorre.Keepammablesawayfromwelding.

8 DO NOTweldnearammables.Weldingsparkscancauseres.Haveareextinguishernearbyandawatchpersonreadytouseit.

8 DO NOT weld on drums or any closed containers.

 WARNING! Risk induced by the arc: Arc rays can burn eyes and injure skin.

9  Useweldinghelmetwithcorrectshadeoflter.Wearcompletebodyprotection.

 WARNING!Riskinducedbyelectromagneticelds:Weldingcurrentproduceselectromagneticeld.

8 DO NOTusewithmedicalimplants.Nevercoilweldingcablesaroundyourbody.Routetheweldingcablestogether.

9 The operator should be properly trained to use the welder safely and should be informed about the risks relating to MIG and ARC welding

procedures, the associated protection measures and emergency procedures.

9 DANGER!Unplugthewelderfromthemainspowersupplybeforeperformingmaintenanceorservice.

9  Keepthewelderandcablesingoodworkingorderandcondition.(Takeimmediateactiontorepairorreplacedamagedparts).

9  Usegenuinepartsandaccessoriesonly.(Nonrecommendedpartsmaybedangerousandwillinvalidatethewarranty).

9 Use an air hose to regularly blow out any dirt from the liner and keep the welder clean for best and safest performance.

9  Checkandspraythegascupandcontacttipregularlywithanti-spattersprayavailablefromyourSealeystockist.

9  Locatewelderinadequateworkingareaforitsfunction.Ensureareahasadequateventilationasweldingfumesareharmful.

9 Keep working area clean, tidy and free from unrelated materials. Also ensure the working area has adequate lighting, and that a fire

extinguisher is at hand.

 WARNING!: Always use a welding helmet or mask to protect your eyes.

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

Original Language Version

Refer to

instructions

Welding sparks

can cause

explosionsorre.

Arc rays can burn eyes

And injure skin.

Breathing welding fumes

can be hazardous to your

health.

Electrical

shock hazard

Hotsurfaces Do not use in

thevicinityofa

pacemaker

Wear a

welding mask

Wear

protective

gloves

Wear safety

footwear

Wear

protective

clothing

Do not use in

rain

9  UsespecialfireresistantprotectiveclothingandDO NOTallowtheskintobeexposedtotheultravioletandinfraredraysproducedbythe

 arc.Otherpeopleinthevicinityofthearcshouldbeprotectedbyshieldsofnonreflectingweldingcurtains.

9  Theoperatorshouldbeadequatelyinsulatedfromtheelectrode,theworkpieceandanyaccessibleearthedmetalpartsinthevicinityby

the wearing of safety shoes and welding gauntlets plus the aforementioned safety clothing.

9  Wherenecessarytheoperatorshouldworkoninsulatingmattsoronaninsulatedsafetyplatforminelevatedpositions.

9  Removeillfittingclothing,removeties,watches,rings,andotherloosejewellery,andcontainlonghair.

9 Ensure the workpiece is correctly secured before operating the welder.

9  Avoidunintentionalcontactwithworkpiece.Accidentaloruncontrolleduseofthetorchmaybedangerousandwillwearthenozzle.

9  Keepnonessentialpersonsawayfromtheworkingarea.Anypersonsworkingwithintheareamustuseprotectiveheadshieldand 

 gloves.

9  Operatorsmustreceiveadequatetrainingbeforeusingthewelder.Theweldermustonlybeoperatedundersupervision.

9 Stand correctly keeping a good footing and balance, and ensure the floor is not slippery, and wear non-slip shoes.

9  Turnvoltageswitchto“0”oroffwhennotinuse.

8 DO NOT operate the welder if it or its cables are damaged and DO NOT attempt to fit any non genuine torches, components, or parts to

the welder unit.

8 DO NOT get welder wet or use in damp or wet locations or areas where there is condensation.

▲ DANGER! DO NOT weld near inflammable materials, solids, liquids, or gases, and DO NOTweldcontainersorpipeswhichhaveheld

 flammablematerialsorgases,liquidsorsolids.Avoidoperatingonmaterialscleanedwithchlorinatedsolventsornearsuchsolvents.

8 DO NOTtouchanylivemetalpartsofthetorchorelectrodewhilethemachineisswitchedon.

8 DO NOT weld on any containers which are under pressure.

8 DO NOT pull the welder by the mains cable or by the umbilical connection cable.

8 DO NOT pull the wire feed unit by the umbilical connection cable or by the torch cable, and DO NOT bend or strain cables, protect from

 sharporabrasiveitems,andDO NOT stand on cables or leads. Protect from heat. Lengths of slack must be gathered & neatly coiled.

8 DO NOT place cables where they endanger others.

8 DO NOTtouchthetorchorworkpieceimmediatelyafterweldingastheywillbeveryhot.Allowtocool.

8 DO NOT operate welder while under the influence of drugs, alcohol or intoxicating medication, or if fatigued.

9 When not in use store the welder in a safe, dry, childproof area.

8 DO NOT weld in the rain.

9  Provideadequateventilationorfacilitiesfortheremovalforofweldingfumesfromnearthearc.TheriskshouldbeassessedbyaHealth

and Safety professional in relation to the exposure limits for the welding fumes, which will depend on their composition, concentration and

the exposure time

 WARNING! Electromagnetic interference: The electromagnetic fields generated by the welding process may interfere with the operation

 ofelectricalandelectronicequipment.Usersofvitalelectronicandelectricaldevicessuchaspacemakersandrespiratorsareadvised

 nottoremainintheviscinityofanoperatingwelding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.

 WARNING! Gas safety: Storegascylindersinaverticalpositiononlyandensurethestorageareaiscorrectlysecured.

8 DO NOT store gas cylinders in areas where temperature exceeds 50°C. DO NOT use direct heat on a cylinder. Keep gas cylinders cool.

8 DO NOTattempttorepairormodifyanypartofagascylinderorvalve,andDO NOT puncture or damage a cylinder.

8 DO NOTobscureorremoveanyofficiallabelsfromacylinder.Alwayscheckthegasidentitybeforeuse.Avoidgettinggascylindersoily

or greasy.

8 DO NOT trytoliftorhandlecylinderbyitscap,guardorvalve.Alwayskeepcapsandguardsinplaceandclosevalvewhennotinuse.

9  Thegascylinderisheavy,usemechanicalliftingequipment.Ensurethecylinderiscorrectlysituatedonthewelderbasestandand 

secured with chain.

9 Riskassessment:Whereweldingisunavoidableinawkwardsituationssuchasinconfinedspaces,inenvironmentswithincreasedrisk

 ofelecticshock,andinthepresenceofinflamableorexplosivematerials,ariskassessmentmustbecarriedoutbyanexperiencedand

 qualifiedexpertprofessionalinconsultationwithprovidersofemergencyservicestoensurethatoperationsarecarriedoutinthesafest

possible way.

 WARNING!Risk induced by electomagnetic fields: Welding current produces a electomagnetic field. DO NOT use with medical implants..

 Nevercoilweldingcablesaroundyourbody.Routetheweldingcablestogether.

 WARNING! DO NOT placetheweldingpowersourceonatiltedplaneasthismayleadtotheunittopplingover.

8 DO NOT use welding power source for pipe thawing

2. INTRODUCTION

 MultiprocessIGBTinverterGas/GaslessMIG/TIG/MMAweldersuitableforprofessionalfabricatorsandworkshops,aswellas 

mechanics and technicians. Fitted with a portable wire feeder allowing access into high or tight spaces that otherwise would not be

 possible.Maximumoutputof500AmakingitidealforweldingalargevarietyofmetalsincludingSteel,StainlessSteelupto20mm.

 2T/4Ttorchtriggerfunctionallowinggreaterprecisionduringlongerwelds.Featuresshortcircuit,over-heatingandover-current 

protection. Supplied with 2m power cable, 2m earth clamp, 3m Euro Mig torch and 2m Electrode holder. Wire capacity of 5-15kg with a

diameter of 0.6mm to 1.6mm. Electrode capacity from 1.6mm to 5mm. Duty Cycle: MIG 60% @ 500A, MMA 60% @ 500A, TIG 60% @

 500A.POWERMIG500Wiisalsosuppliedwithawatercoolertoprolongdutycycleande󰀩ciency

Original Language Version

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

3. CONTENTS

4. SPECIFICATION

5. op OPERATION

5.1.  Beforeweldingorcutting,therststepistodeterminewhichtoolsareneededandhowtomakethecorrectconnections.Ifthepolarity

 isincorrectlyconnected,itcaneasilydamageweldingorcuttingtools(especiallyweldingtorches),anditmayalsoresultinpoor 

welding quality.

5.2. ESTABLISHING THE ELECTRICAL CONNECTIONS

Original Language Version

Model No POWERMIG500i

Welding Current 50-500A

Wire Capacity 5-15kg(0.6-1.6mm)

E󰀩ceincy 0.8

Electrode Capacity 1.6-5mm

Duty Cycle MIG 60% @500A 100% @ 388A

Duty Cycle MMA 60% @ 500A 100% @ 388A

Duty Cycle TIG 60% @ 500A 100% @ 388A

Gas Type CO2, Argon, CO2/Argon Mix

MigTorch(inc) 3mEuroNon-LiveBinzel

Absorbed Power 19.04kW

No Load Voltage 82V(MMA),82V(MIG)

Supply 415V~ 3ph

Power Supply Cable Length 2m

Weight POWERMIG500i 42.5kg

Weight POWERMIG500Wi 55.7kg

EMCClassication Class A.

Input Current 39A(MMA),38A(MIG)

Output Voltage 50A/22Vto500A/40V(MMA),

30A/15.5Vto500A/39V(MIG)

IP Rating IP21S

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

TIG

Fig. 1

Welding Rod

Fig. 2

MMA

Electrode

Mode Tools Workpeice

polarity

Torch polarity

MMA Grounding clamp

Welding torch

Negative Positive

TIG Grounding clamp

TIG Welding torch

Argon cylinder

Positive Negative

MIG/MAG Grounding clamp

MIG Welding torch

Cylinder

Negative Positive

FLUX CORED Grounding clamp

FLUX CORED Welding torch

Positive Negative

Grounding clamp

FLUX CORED Welding torch

Cylinder

Negative Positive

Description Part No.

1 Earthclampset2m(notshown) POWERMIG500Wi-99

1 Gashose3m(notshown) POWERMIG500Wi-100

1 Electrodeholderset2m(notshown) POWERMIG500Wi-101

1 Powercable2m(notshown) POWERMIG500Wi-102

1 3MigTorch3m(notshown) POWERMIG500Wi-103

1 Signalconnectioncable(notshown) POWERMIG500Wi-104

1 Powerconnectioncable(notshown) POWERMIG500Wi-105

1 EuromigTorch3m(notshown) POWERMIG500i-85

5.3. INSTALLATION STEPS

5.3.1.  Makesurethemachineisturnedo󰀨.

5.3.2.  Checkwhetherthepowercableisingoodconditionandtheinputvoltageiscorrect.

5.3.3. Connect to the input power source.

5.3.4. If necessary, select the appropriate gas and connect it.

5.3.5. For MIG/MAG/Flux-Cored welding, ensure the wire feeder is properly connected.

5.3.6.  Makesuretheworkpieceisrmlyconnectedaccordingtothecorrectpolarity.

5.3.7. Connect the welding torch according to the correct polarity.

5.3.8. Turn on the machine.

5.3.9. Select the correct welding mode on the screen and adjust the appropriate parameters.

5.3.10. Before starting, ensure there is no short circuit formed between the torch and the workpiece.

5.4. CHOOSE THE CORRECT GAS

5.4.1.  Beforewelding,it’snecessarytousegastoprotecttheworkpiece.Selectingthecorrectgasiscrucialforachievingqualitywelding

results.

5.4.2. WIRE FEEDER (Fig.5)

5.4.3.  Releaseidlerarmsbyunscrewingtheidlerarmclamps(Fig.5)

5.4.4.  Selecttheappropriatewirefeedwheelforinstallationandfittodriveshaftusingthesuppliedfittings.

5.4.5. Install a suitable diameter reel of suitable material by unscrewing the turn wheel and locating the reel onto the shaft.

5.4.6. Thread a suitable diameter of wire through the wire feed mechanism.

5.4.7.  Lockidlerarmsusingtheclamps(Fig.5).

5.4.8.  Adjustfeedtensioner(Fig.5)asnecessary.

5.4.9.  Thermalcontrolcanbeacheivedadjustingeithervoltage,currentorfeedspeed.

5.4.10. Thediameteroftheweldingwire,wirefeedwheelandandthetypeoftheconductivenozzleshouldbethesame.

5.5. SELECTING THE CORRECT WIRE FEED

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

Original Language Version

Mode Material Gas

MMA Steel Not required

TIG DC TIG:Steel, Stainless steel Pure argon

AC TIG: Aluminum

MIG/MAG Steel 20% CO2 +80% argon or

Pure CO2

25% CO2 +75% argon

10% CO2 +90% argon

Stainless steel 2% CO2+98% argon or tri-

mix gas

2% O2+98% argon

Aluminium Pure argon

FLUX CORED Steel Not required

Feed Wheel Type Welded materials

U-shaped wheel Aluminium only

Knurled wheel Flux cored welding wire

V-shaped wheel Steel, Stainless steel

Idler Arm Clamps

Idler Arms

Fig. 5

Fig. 3

FLUX

CORED

Fig. 4

MIG/MAG

Feed Tensioner

Original Language Version

Key to Fig. 6

ITEM Description Function

1 Mode Button Select mode

2 LED Power light

3 LED Overheatindication

4 Display 1 ShowthevalueofwirespeedinMIGmodeandcurrentinMMA&TIGmodes

5 Display 2 ShowthevalueofvoltageinMIGmodeandarcforceinMMAmode

6 Wire speed &current Knob AdjustthevalueofwirespeedinMIGmodeandcurrentinMMA&TIGmodes

7 Voltage & arc force Knob AdjustthevalueofvoltageinMIGmodeandarcforceinMMAmode

8 Inductance Knob Adjustthevalueofinductance

9 Inching button Inching

10 Gas button Gas check

11 2T/4T button Select 2T/4T function

12 Wire diameter button Select the diameter of wire in MIG mode

13 Material button Select the material in MIG mode

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

5.6. MAIN CONTROL PANEL

5.7. WIRE FEEDER CONTROL PANEL

5.8. SHORT CIRCUIT PROTECTION

5.8.1. Whenashortcircuitisdetected,themachinewillturno󰀨theoutputcurrenttoavoidbeinginahighcurrentoutputstateallthetime.

 Sometimestheoutputcurrentmaystillexist,andtheusershouldavoidshortcircuitbetweentheelectrodeandtheworkpieceasmuch

 aspossible,anddonotgettooclose,especiallythealkalineelectrode.Ifthereisashortcircuit,itshouldbequicklyremovedfromthe

 shortcircuitstate,andifnecessaryandconvenient,itcanbeshutdownrstandthenprocessed.

Fig. 6

No Name Adjustments

1 Control knob 1 Adjust the wire feeding speed in MIGSYN & MIG modes

2 Inching button Press for wire feeding before welding in MIGSYN & MIG mode

3 Control knob 2 AdjusttheoutputvoltageinMIGSYN&MIGmodes

5.9. 2T/4T TRIGGER CONTROLS

5.9.1.  2T/4Taretwowaysofon-o󰀨controlofwelders.

2T/4T is commonly used for TIG, MIG, and PLASMA CUTTING.

5.9.2.  2T/4TWORKINGMETHODS

5.10. PRE GAS AND POST GAS

5.10.1. Beforestartingtheweldingwork,closetheweldingtorch,andthemachinewillbegintodelivergas,whichisthepregas.Thefrontair

 supplyensuresthattheweldingisinaprotectivegasatmosphereandimprovestheweldingquality.

 Aftertheendofthewelding,donotimmediatelyremovethetorch,thetorchcontinuestotransportasectionofgas,whichhelpsto

 reducethetemperatureoftheweldmentsurface,butalsotoavoidthehigh-temperatureworkpieceandairchemicalreaction.

5.11. SYN—JUST FOR MIG/MAG

5.11.1. SYN means synergy. The essence of synergy is that after testing, we get suitable welding parameters, and write it into the software,

when you need to query welding parameters, you do not need to ask and query, only need to select certain parameters on the panel,

 andtheweldingmachinewillrecommendtheappropriateweldingcurrent(andweldingvoltage).

5.11.2. However,everyone’sfeelandthespeedoftheweldingmachinevary,soalthoughwerecommendthecurrent(andvoltage),youcan

 stilladjustonthisbasis,onlynetuningisrecommended.

5.12. MMA (ARC FORCE)

5.12.1. When the electrode is too close to the workpiece, the machine will increase the output current. The electrode will melt faster.

5.12.2. ARCFORCEhelpspreventshortcircuits.

5.13. MIG/MAG (INDUCTANCE)

5.13.1. Thehardnessofweldingarccanbechangedbyadjustingtheinductance.Thesmallertheinductancevalueis,theharderthewelding

 arcisandthebiggerthesplashis.Thehighertheinductancevalue,thesofterthearcandthesmallerthesplash.

5.14. WELDING PROCEDURE

5.14.1. Specify the material to be welded, the thickness, and the welding mode to be used.

5.14.2. Selectappropriatetoolingformodetobeused(Section5).

5.14.3. Connectthepowerline,gas,wireorelectrodeandwelding/cuttingtorch,andturnon(seeFig.1,Fig.2,Fig.3,Fig.4)

5.14.4. Select the appropriate mode on the screen.

5.14.5. Adjustthecurrent(orvoltage,wirefeedspeed)tobeusedinweldingorcutting.

5.14.6. Determine the process to be used when welding, such as 4T mode, pulse, etc.

5.14.7. Start welding or cutting.

5.14.8. Duringtheweldingprocess,thecurrentorvoltage,wirefeedspeedandprocessparameterscanbeadjustedaccordingtothe 

 weldinge󰀨ectuntilasatisfactoryweldinge󰀨ectisobtained.

5.14.9. Forthemachinewithpostgasfunction,whentheweldingworkisnished,theweldingtorchshouldnotleavetheworkpiece 

immediately, and the post gas should be completed.

8 DO NOT immediately touch the workpiece and welding torch.

5.14.10. Turno󰀨thepower,turno󰀨thegas,cleanuptheweldingmachine,andkeepitsafe.

5.15. MIG/MAG/FLUX CORED

5.15.1. Thediameteroftheweldingwire,thediameterwirefeedwheelandthediameteroftheconductivenozzleshouldbethesame.

5.15.2. Thenozzleattheheadofthetorchplaysaprotectiverolefortheconductivenozzle,andconfirmthatithasbeeninstalledbefore 

welding.

6. FAULT CODES

6.1. If the machine stops working, please refere to these fault codes.

Original Language Version

2T Press the welding torch and the machine starts to work;

Release the torch and the machine stops working.

4T Presstheweldingtorchforthersttime,andthemachineentersthe

initial current;

Loosen the welding torch, the machine enters the working current,;

Press the welding torch again, the machine enters the end up current;

Loosen again and the machine stops working.

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

Fault Description

E01/F01 Overheating

E02/F02 Theinputvoltageisoverorundervoltage

E05/F05 Torch switch closed before turning on

E08/F08 Overcurrent

E09/F09 Theoutputisshort-circuitedorthevoltagefeedbacklineisabnormal

E10/F10 Closed torch, no output

E11/F11 Communication exception

E12/F12 The wire feeder is abnormal

E13/F13 Abnormaloutputcurrent(outputcurrentlessthansetvalue)

6.2. COMMON TROUBLES AND SOLUTIONS

7. MAINTENANCE.

 WARNING! Disconnect from power supply before carrying out any maintenance procedures.

8 DO NOT take apart the machine without permission, it may damage the machine.

9  Whenmovingthemachine,makesurethepowerisoff.

8 DO NOTblockthefanoftherunningmachineortouchthefanposition.Checktheventilationbeforeeachuse.

9 Always start by reading the manual for your specific welding equipment.

9  Regularlycleanyourweldingequipmenttoremoveanydirt,debris,ormetalshavingsthatcouldclogupthemachinery.Useasoftbrush

 orcompressedairtocleananycoolingfans,vents,orfilters.

9 Inspect the welding cables regularly for any damage or wear and tear. Replace any cables that show signs of damage, such as fraying, s,

or cracks.

9 Check the consumables, such as tips, nozzles, and electrodes, regularly for wear and tear. Replace any consumables that are damaged

 orwornout.Usingdamagedconsumablescannegativelyaffectthequalityofyourwelds.

9 Check the gas cylinder regularly for pressure and leaks. Replace the gas cylinder if it is empty or damaged.

9  Whennotinuse,storeyourweldingequipmentinaclean,dry,andsafelocation.Keeptheequipmentcoveredtoprotectitfromdust,

 moisture,andotherenvironmentalfactors.

9 Check the welding machine output wiring specifications, firmness, and the cable connection screws for rust and oxidation.

8 DO NOTshort-circuittheconductivenozzleandtheworkpiece.Theshortcircuitwillburnouttheconductivenozzle.Onceburnedout,it

needs to be replaced, otherwise it will affect the welding quality.

 WARNING!Ensuretheunitisdisconnectedfromthemainspowersupplybeforeperforminganymaintenanceorservice.

9 Regularly check all welding cables and secondary terminals to ensure they are in good order and connected correctly, also check

during welding to ensuretheyarenotoverheating.

9 Check that the gas hose connections are tight and that there are no gas leaks.

7.1. WIRE FEED UNIT

7.1.1.  Checkthewirefeedunitatregularintervals.Thefeedrollerwireguideplaysanimportantpartinobtainingconsistentresults.Poorwire

 feedingaffectswelding.Cleantherollersweekly,especiallythefeedrollergroove,removingalldustdepositsfromthefeederarea.

7.1.2.  CHANGINGFEEDROLLER/ROLLERSIMPORTANT: Set up the feed rollers according to the wire size required for the job in hand.

7.2. TORCH

7.2.1. Protect torch cable assembly from mechanical wear. Also do not allow the torch or its cable to come into contact with hot surfaces,

especially a hot workpiece as this would cause the insulating materials to melt, making the torch unsafe and unusable.

7.2.2. Make regular checks on the gas pipe and connector seals.

7.2.3.  Everytimethewirereelischanged,blowoutthewire-guidehoseusingdrycompressedair(max.5bar)tomakesureitisnotdamaged;

7.2.4. 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.

Original Language Version

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

Mode Fault Solution

All modes

E01/F01overheating Wait for the welder to cool down to return temperature, and then the welder will

continue to work.

E02/F02

Inputvoltageistoohighortoolow

Checkthepowersupplyandreplacethepowerinareasonablevoltage

E09/F09

Short-circuited

Firmly separate the welding torch from the workpiece and shut down the welding

machine if necessary.

Machine cannot be turned on Check whether the input line is intact, whether the power is turned on, and whether the

inputvoltageisnormal

E10/F10

Closed torch has no output

Check whether the ground cable and control cable are properly connected

Gas leaks Gas leaks can occur in welding machines, which can lead to poor quality welds.

Checkthegaslinesandttingsforleaks,andtightenorreplaceanyfaultyconnections.

It’simportanttoregularlyinspectthegaslinesandttingsforwearandtear,and

replace them if necessary.

Arc instability Check the ground connection, adjust the settings according to the type of material

being welded, and replace the electrode if necessary.

The workpiece is welded

Through

Reduce current.

MMA

Arcingdi󰀩culty Increase the current;

IncreaseHOTSTART;

Dried electrode.

Welding rod adhesion Increase the current;

Increase ARC FORCE.

Welding arc break Shorten the distance between the electrode and the workpiece, do not pull too high.

TIG

The weld colour is dark Accelerate the speed of welding;

DO NOTremovethetorchimmediatelyafterwelding;

Turn up the pre gas and post gas.

The tungsten needle burns

Out quickly

Check wiring polarity.

Irregular weld Sharpen the tungsten needle.

Weld failure Increase current.

7.3. CONTACT TIP Thecontacttipisaconsumableitemandmustbereplacedwhentheholebecomesenlargedoroval.Thecontacttip

MUST be kept free from spatter to ensure an unimpeded flow of gas.

7.4. GAS CUP

7.4.1.  Tokeepthecontacttipfreefromspatter,werecommendtheuseofSealeyanti-spatterspray(MIG/722307)availablefromyourSealey

stockist.

7.5. INTERNAL MAINTENANCE / INSPECTION

 INTERNALINSPECTIONANDMAINTENANCEOPERATIONSSHOULDBECARRIEDOUTONLYANDEXCLUSIVELYBYSKILLED

 ORAUTHORISEDELECTRICAL/MECHANICALTECHNICIANS.

 WARNING:BEFOREREMOVINGTHEWELDINGMACHINEPANELSANDWORKINGINSIDETHEMACHINEMAKESURETHE 

 WELDINGMACHINEISSWITCHEDOFFANDDISCONNECTEDFROMTHEMAINPOWERSUPPLYOUTLET.

7.5.1.  Ifchecksaremadeinsidetheweldingmachinewhileitislive,thismaycauseseriouselectricshockduetodirectcontactwithliveparts

 and/orinjuryduetodirectcontactwithmovingparts.

7.5.2.  Inspecttheweldingmachineregularly,withafrequencydependingonuseandthedustinessoftheenvironment,andremovethedust

 depositedonthetransformer,reactanceandrectifierusingajetofdrycompressedair(max.10bar).

7.5.3. DO NOTdirectthejetofcompressedairontheelectronicboards;thesecanbecleanedwithaverysoftbrushorsuitablesolvents.

7.5.4. At the same time make sure the electrical connections are tight and check the wiring for damage to the insulation.

7.5.5. At the end of these operations re-assemble the panels of the welding machine and screw the fastening screws right down.

 WARNING: Never,evercarryoutweldingoperationswhiletheweldingmachineisopen.

8. END OF LIFE

8.1. DisposeofunitandaccessoriesinaccordancewithLocalandNationalregulations,WEEERegulationsandEnvironmentProtection

footers.

9. WATER COOLER POWERMIG500WI

1. Metal housing

2. Cooling liquid tank

3. On/Off button

4. Fixed key

10. WATER COOLER FUNCTIONS

10.1.1. Increasethestableoperatingtimeofweldinginverters.

10.1.2. Providehighvoltagewithinarangeof17meters.

10.1.2.1. The cooler casing is corrosion-resistant.

10.1.3. Low noise.

10.1.4. Easy to operate.

10.1.5. Improvetheperformanceanddurabilityofweldingmachines.

10.1. WATER COOLER SPECIFICATIONS

5. Signal connector

6. Cooling liquid outlet connector 1

7. Cooling liquid outlet connector 2

Original Language Version

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

Power 370W

Required current 0.3-0.6A

Maximum pressure 3kg/cm²

Feed rate 8L/min

Powersupplyvoltage 230(1phase)V

Operating conditions -20 -- 40

Tank capacity 6L

Coolant Distilledwater(atnegativetemperature-antifreeze)

Protectionlevel IP21

External dimensions 580 * 265 * 288mm

Weight 15kg

FRONT

REAR

11. DESIGN AND WORKING PRINCIPLES

11.1. Liquidcoolingissuitableforintensiveworkandhigh-temperatureenvironments.Forexample,iftheenvironmentis+30°Corhigher,the

 hotaircirculationisnotsufficienttocooltheequipment.Inadditiontothefan,aliquidcoolingsystem(coolanttank)isalsoinstalled.It

contains a liquid or distilled water with special chemical components. Due to the circulation of coolant through the machine and welding

burner, it ensures continuous operation and cooling. This cooling method also optimizes the cooling of the welding burner. It is important

to remember that this type of equipment uses liquid cooled welding burners!

11.2. The main requirements for liquid cooling systems are:

11.2.1. Thelevelofcoolantmustbemonitored.Iftheliquiddecreases,theequipmentandburnerwillnothavesufficientcooling.

11.2.2. ItisprohibitedtomixliquidsfromdifferentmanufacturerstogetherbecauseThedevicemayfailduetodifferentchemicalcompositions

11.2.3. Regularly check the quality of the liquid.

12. EQUIPMENT CONNECTION

12.1. Removethedevicefromthepackaging.

12.2. Check the integrity of the equipment and accessories before use.

12.3. Openthefillingcap(hole)toensurethatthewatertankisclean.Althoughthewatertankandliquiditselfarecompletelyisolatedfromthe

 environment,sometimesthesystemmaymalfunction

12.4. Thecoolingprocessisfilledwithdirt.Dirtmayenterliquidsforvariousreasons,suchaspouringliquidsfromdirtycontainers.Ifdirtenters

the liquid, it may interfere with the pump’s operation and needs to be cleaned.

12.5. Install the liquid cooling system on the welding machine trolley instead of the toolbox and connect it to the welding machine.

12.6. Connectthewatercirculationpipefromthecoolingdevicetothewiresupplydevice.Itisimportanttoconnectthepipesaccordingto

colour, from blue to blue and from red to red. The blue circuit is the output circuit of the cooling water after the radiator, and the red circuit

is the output circuit. The hot water is discharged from the power cable of the burner.

12.7. Protect it from direct water and sunlight.

12.8. Ensure that there is sufficient space for air circulation in front and behind the equipment.

12.9. Connectthewatercoolingdevicecabletothepowergrid.

12.10. If necessary, use accessories to connect the water supply hose to the connector.

12.11. Input, output. Connect the outlet of the liquid cooling unit to the inlet of the burner, and connect the outlet of the burner to the inlet of the

liquid cooling unit.

12.12. Fill the water tank with water. Another type of antifreeze can also be used. When using alcohol, the ratio of distilled water is 90% and

10%.

12.13. Controlthepouringlevelofthesemitransparentprotrudingpartofthefueltank.

12.14. Turn on the power.

12.15. Disconnecttheinletconnectoroftheliquidcoolingdevice,ensurethatthewatercircuitoftheburnerisfilledwithwater,andliquidflows

out from the outlet of the burner. Tighten the joint.

12.16. Thedeviceisready.

12.17. Checktheliquidlevelandrefillifnecessary.

12.18. Iftheliquidleveldropsorthehoseisblockedordamaged,weldingisnotallowed.

13. MAINTENANCE

13.1. DAILY MAINTENANCE

13.1.1. List of required conditions for daily execution:

13.1.2. Checkthewaterlevel(ifnecessary,topupwithliquid).

13.1.3. Check the cables and connections. Tighten them or replace damaged parts.

13.2. MAINTAIN EVERY SIX MONTHS

13.2.1. Theseconditionsmustbemeteverysixmonths

13.2.2. Clean the dust and dirt in the equipment. Replace the coolant and clean the pipes and water tank with clean water.

14. TROUBLE SHOOTING

FAULT SOLUTIONS

Pump running No liquid enters; Canal blockage;

-Blow or replace blocked channels with compressed air.

Pumpcavitation Checkthesealingandwaterlevelofthejointorreplacethepump

membrane.

Pump malfunction Checkthepowersupplyvoltageandfuses.

Original Language Version

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

15. RATING PLATE

Onthefrontpanelofthewelderistheratingsplate,givingthefollowingdata:

1 - The BS/EU standard relating to the safety and construction of arc welding and associated equipment.

2 - Three phase transformer.

3-Symbolindicatesweldingwithacontinuousowofweldingwire.

4 - Symbol for three-phase AC supply.

5-Ratingofinternalprotectionprovidedbycasing.

6-OutputU0Ratedminimumandmaximumnoloadvoltage.

I2,U2Currentandcorrespondingvoltage.

X Welding ratio based on a 10 minute cycle.

20% indicates 2 minutes welding and 8 minutes rest,100% would indicate continuous welding.

7 - Mains Supply

U1Ratedsupplyvoltageandfrequency.

I1max Maximum current.

I1e󰀨Maximume󰀨ectivecurrent.

Original Language Version

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR

01284 757500 sales@sealey.co.uk www.sealey.co.uk

ENVIRONMENT PROTECTION

Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to

arecyclingcentreanddisposedofinamannerwhichiscompatiblewiththeenvironment.Whentheproductbecomescompletely

unserviceableandrequiresdisposal,drainanyfluids(ifapplicable)intoapprovedcontainersanddisposeoftheproductandfluids

according to local regulations.

Note:Itisourpolicytocontinuallyimproveproductsandassuchwereservetherighttoalterdata,specificationsandcomponentparts

without prior notice.

Important: No Liability is accepted for incorrect use of this product.

Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.

WEEE REGULATIONS

DisposeofthisproductattheendofitsworkinglifeincompliancewiththeEUDirectiveonWasteElectricalandElectronicEquipment

(WEEE).Whentheproductisnolongerrequired,itmustbedisposedofinanenvironmentallyprotectiveway.Contactyourlocalsolid

waste authority for recycling information.

PURCHASE HERE

POWERMIG500i POWERMIG500Wi Issue:2 12/03/25

Sealey POWERMIG500I 500A Professional MIG MMA TIG Inverter Welder

Product's Documents

Instructions

Specifications

Sealey POWERMIG500I Questions and Answers