VARIMAT Tech Tips

Changing the element on a VARIMAT

• See our article for more details. 

Correct the nozzle position on a VARIMAT

• See our article for more details. 

Working with generators

• The minimum generator capacity required when using only a VARIMAT is 6000W with at least 5000W of continuous output. However, if a 120V hand tool will be used simultaneously a 10,000W or higher rated generator is recommended. Do not run a generator above 85% of its rated power (not maximum power).
• To avoid electrical surges which may blow fuses or damage circuit boards:
  • Never turn the generator on or off with the tool connected and switched on.
  • Do not use dirty or water-contaminated fuel, or poorly maintained extension cords.

Symptom: The VARIMAT does not start driving when the ELECTRON is placed in the weld position, or it starts briefly and then stops driving.

• Be sure that the VARIMAT has reached the set temperature.
• When placing the blower in weld position be sure that the blower clicks into place and the trigger drops. If not, the blower may slip out of position while welding, stopping the drive.
• When the ELECTRON blower is put into weld position, it triggers either a proximity sensor or push-button switch to engage the drive.
  • VARIMAT models have a sensor with a green tip mounted through the centre of the pillow block
  • VARIMAT V and older VARIMAT V2 models have a sensor with a green tip mounted underneath the guide shaft
  • Newer VARIMAT V2 models have a push-button switch with a grey tip mounted underneath the guide shaft
  • Failing proximity sensors are replaced with push-button switches.
• To test a green proximity sensor:
  • Put the blower in the upper position and turn the heat on. When it reaches temperature and is ready to weld, press a piece of metal, such as the side of a screw driver, against the green tip of the sensor.
  • If the drive does not engage the VARIMAT needs to be sent to STANMECH for Service.
  • If the drive does engage, the sensor may be mounted too far back to sense the metal of the tool holder. See the Operator's manual for the proper installation procedure for the sensor. 
• To test a grey push-button switch:
  • Put the blower in the upper position and turn the heat on. When it reaches temperature and is ready to weld, push the switch in with your finger and see whether the drive turns on. If it does not, the VARIMAT needs to be sent in to STANMECH for service.

Symptom: The VARIMAT suddenly turns off and on, or does not turn on at all 

• The cord may be broken at the housing if the VARIMAT is often steered by pulling on the cord. The tracking should be corrected by the tracking adjustment screw, and steering should be done by the handle.
• Check the wires in the cord by bending it a short section at a time, from the housing end to the plug end, to see if the VARIMAT will turn on again. Look for cuts in the cord while doing this.
• Check the power source.
• In the VARIMAT cord and any extension cord, check that the plug is the same rating as the socket and is locked in properly.

Symptom: Temperature is not steady, it floats up and down 

• Check that the ground pin (the pin with the 90 degree bend) on the plugs of the VARIMAT and any extension cords used are connected to the ground wire. They may be either loose or pushed too far in so that the screw is clamping down on the insulation and not on the wire. If the ground is not connected the temperature can float up and down.

Symptom: The VARIMAT V displays the desired temperature but fails to reach the desired temperature

• The VARIMAT V can be put into "percent" mode to check how hard it is working to meet the desired temperature. If it is always working at 100%, the supply voltage is too low.
• Put the VARIMAT V into percent mode by cooling it down, shuting it off, and holding the "+" and "-" keys while turning it on. After 3 seconds the display values will appear. In the bottom right corner the normal Welded Length number will not be displayed, but instead the percentage that the blower motor is running. The VARIMAT V can be operated as normal in this mode. If after arriving at the desired temperature the display continually shows 100%, check the tool cord, extension cord, plugs and sockets. If using a generator, check the Tech Tip "Working With Generators" above.

Symptom: Bad tracking, membrane burns, folds

• Check if the nozzle is too far under the drive tire, contacting the green belt and lifting one of the rollers in the hold-down assembly. The nozzle should not touch the green belt or roller since this interferes with the placement of the membrane and the flow of air. In welding position the inside edge of the nozzle opening should be 1 - 2 mm. outside of the drive tire, with the rest underneath. The edge of the nozzle should be 4 to 5 cm. away from the bottom edge of the drive tire.

The lock pin may snap if shock or extreme pressure is put upon the ELECTRON blower while it is locked in the upper position.

• The most common reason that a lock pin breaks is if the VARIMAT is picked up with one hand on the blower handle when the nozzle is in the upper position. When lifting the VARIMAT, hold it by the T-Grip and frame only.

VARIMAT Wiring Instructions
Please consider the following when connecting a new plug to your VARIMAT:

• You must use 30 Amp or higher twist-lock plug
• The VARIMAT is single phase
• When using a generator make sure the plug is wired for A/C

Connecting a twist-lock plug:

• Connect the green wire to the pin with the bent tab
• Connect the white wire to one of the pins directly left or right of the bent tab
• Connect the black wire to the other pin directly left or right of the bent tab
• If using a 4 prong plug, leave the pin opposite the one with the bent tab disconnected

Please consider the following when making an extension cord for your VARIMAT:

• Use a 10 Gauge or thicker cable if you plan to make a 100 ft or longer extension cord

Generator Instructions: 

• Starting procedure:
  1. Switch on the generator
  2. Switch on the VARIMAT
• Shut-down procedure:
  1. Switch off the VARIMAT
  2. Switch off the generator