INSTRUCTIONS FOR:
MIGHTYMIG
WELDERS
MODELS:
MIGHTYMIG170
MIGHTYMIG190
MIGHTYMIG210
Original Language Version
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
INSTRUCTIONS FOR:
PROFESSIONAL GAS / NO GAS
MIG WELDERS
MODELS: MIGHTYMIG170 MIGHTYMIG190 MIGHTYMIG210
Thank you for purchasing a Sealey Welder. 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: BEF OR E USIN G THIS PR ODU CT, PLEA SE RE AD THE IN STR UC TIO NS CA REF UL LY. M AK E CARE FUL NO TE OF SA FET Y INST RUC TI ONS ,
WARNINGS AND CAUTIONS. THIS PRODUCT SHOULD ONLY BE USED FOR ITS INTENDED PURPOSE. FAILURE TO DO SO MAY CAUSE DAMAGE
OR PERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
1. SAFETY INSTRUCTIONS
1.1. ELECTRICAL SAFETY
WARNING! It is the responsibility of the owner and the operator to
read, understand and comply with the following:
You must check all electrical products, before use, to ensure that they
are safe. You must inspect power cables, plugs, sockets and any
other connectors for wear or damage. You must ensure that the risk of
electric shock is minimised by the installation of appropriate safety
devices. A Residual Current Circuit Breaker (RCCB) should be
incorporated in the main distribution board. We also recommend that a
Residual Current Device (RCD) is used. It is particularly important to
use an RCD with portable products that are plugged into a supply
which is not protected by an RCCB. If in any doubt consult a qualified
electrician. You may obtain a Residual Current Device by contacting
your Sealey dealer. You must also read and understand the following
instructions concerning electrical safety.
1.1.1. The Electricity at Work Act 1989 requires that all portable electrical
appliances, if used on business premises, are tested by a qualified
electrician, using a Portable Appliance Tester (PAT), at least once a
year.
1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical
appliances responsible for the safe condition of those appliances and
the safety of the appliance operators. If in any doubt about
electrical safety, contact a qualified electrician.
1.1.3. Ensure that the insulation on all cables and on the appliance is safe
before connecting it to the power supply. See 1.1.1. and 1.1.2. and
use a Portable Appliance Tester.
1.1.4. Ensure that cables are always protected against short circuit and
overload.
1.1.5. Regularly inspect power supply cables and plugs for wear or damage
and check all connections to ensure that none is loose.
1.1.6. Important: Ensure that the voltage marked on the appliance matches
the power supply to be used and that the supply is correctly fused.
1.1.7. DO NOT pull or carry the appliance by the power cable.
1.1.8. DO NOT pull the plug from the socket by the cable.
1.1.9. DO NOT use worn or damaged cables, plugs or connectors.
Immediately have any faulty item repaired or replaced by a qualified
electrician.
1.1.10. MIGHTYMIG170, MIGHTYMIG190, MIGHTYMIG210 are single phase
machines and must be run from a minimum 16amp supply.
To achieve maximum output these models will require a 30Amp
fused supply. We recommend you discuss the installation of an
industrial round pin plug and socket with your electrician.
Fit a plug according to the following instructions (UK only).
a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check that there are no bare wires, that all wires
have been correctly connected, that the cable outer insulation
extends beyond the cable restraint and that the restraint is tight.
1.1.11. When a cable extension reel is used it should be fully unwound before
connection. A cable reel with an RCD fitted is recommended since any
product which is plugged into the cable reel will be protected. The
cross-section of the cable on the cable reel must be suitable for the unit
and never lower than the cross-section of the mains cable supplied with
the unit.
1.2. GENERAL SAFETY
DANGER! Unplug the welder from the mains power supply before
performing maintenance or service.
Keep the welder and cables in good condition. Take immediate action
to repair or replace damaged parts.
Use genuine parts and accessories only. Unapproved parts may be
dangerous and will invalidate the warranty.
Use an air hose to regularly blow out any dirt from the liner and keep
the welder clean for best and safest performance.
Check and spray the gas cup and contact tip regularly with
anti-spatter spray which is available from your Sealey dealer.
Locate the welder in a suitable work area. Ensure that the area has
adequate ventilation as welding fumes are harmful.
Keep work area clean, tidy and free from unrelated materials. Also
ensure that the work area has adequate lighting and that a fire
extinguisher is at hand.
Original Language Version
WARNING! Use welding head shield to protect eyes and avoid
exposing skin to ultraviolet rays given off by electric arc. Wear
safety welding gauntlets.
Remove ill fitting clothing, remove ties, watches, rings and other loose
jewellery and contain long hair.
Ensure that the workpiece is correctly secured before operating the welder.
Avoid unintentional contact with workpiece. Accidental or uncontrolled
use of the torch may be dangerous and will wear the nozzle.
Keep unauthorised persons away from the work area. Any persons
working within the area must wear protective head shield and gloves.
Operators must receive adequate training before using the welder.
Stand correctly, keeping a good footing and balance, and ensure that
the floor is not slippery. Wear non-slip shoes.
Turn voltage switch to OFF when not in use.
DO NOT operate the welder if it or its cables are damaged and DO
NOT attempt to fit any unapproved torch or other parts to the welder unit.
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.
DO NOT stand welder on a metal workbench, car bodywork or similar
object.
DO NOT touch any live metal parts of the torch or electrode while the
machine is switched on.
DO NOT pull the welder by the cable or the torch and DO NOT bend
or strain cables. Protect cables from sharp or abrasive items and DO
NOT stand on them. Protect from heat. Long lengths of slack must be
gathered and neatly coiled. DO NOT place cables where they could
endanger other people.
DO NOT touch the torch or workpiece immediately after welding as
they will be very hot. Allow to cool.
DO NOT operate welder while under the influence of drugs, alcohol or
intoxicating medication, or if tired.
When not in use store the welder in a safe, dry, childproof area.
1.3. GAS SAFETY
Store gas cylinders in a vertical position only and ensure that the
storage area is correctly secured.
DO NOT store gas cylinders in areas where temperature exceeds
50°C. DO NOT use direct heat on a cylinder. Always keep gas
cylinders cool.
DO NOT attempt to repair or modify any part of a gas cylinder or valve
and DO NOT puncture or damage a cylinder.
DO NOT obscure or remove any official cylinder labels. Always check
the gas identity before use. Avoid getting gas cylinders oily or greasy.
DO NOT lift a cylinder by the cap, guard or valve. Always keep caps
and guards in place and close valve when not in use.
2. INTRODUCTION & SPECIFICATION
2.1 INTRODUCTION: Our professional range of MIGHTYMIG welders all
feature a heavy-duty high output transformer and forced air cooling to
maximise duty cycle performance. MIGHTYMIG170, 190 and 210 are
supplied with a high quality cool running BINZEL® Euro torch thus
ensuring a steadier weld bead, 2mtr earth cable, 1.4mtr of gas hose, twin
guaged gas regulator, 1kg spool of 0.6mm wire, 0.6 and 0.8 tips. All three
units are supplied set up in gas mode, but can also easily be switched to
gasless mode by a simple change of polarity. Use in gasless mode will
require the purchase of a spool of flux cored wire, a pack of 1.0mm tips
and a 1.0mm wire feed roller.
2.2 IMPORTANT: These instructions contain information you require to
prepare your machine for welding, together with a maintenance and
trouble shooting section. If you have no previous experience the instructions
are not intended to show you how to become a welder . Should you have no
experience, we recommend that you seek training from an expert
source. MIG welding is relatively easy to perform, but does require a
steady hand and time practising under supervision with scrap metal
as it is only with continued practice that you will achieve the desired
results.
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
SPECIFICATION, Model No: ......................................................MIGHTYMIG170
Maximum Current: ......................................................................................... 170A
Wire Capacity steel: ..........................................................................................5kg
Duty Cycle: .......................100% @ 55Amps, 60% @ 70Amps, 15% @ 140Amps
Cooling System: ..................................................................................... Forced Air
Gas Type: .................................................................CO
Torch: ................................................................ Euro Non Live - BINZEL ® MB15
Power Input ............................................................................................. 230V 1ph
Absorbed power ........................................................................................... 5.4kW
Case size ...................................................................................................... Large
Weight ..........................................................................................................41.5kg
SPECIFICATION, Model No: . . . . . . . . . . . . . . . . . . . . . . . . . . .MIGHTYMIG190
Maximum Current: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190A
Wire Capacity steel: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15kg
Duty Cycle: . . . . . . . . . . .100% @ 70Amps, 60% @ 90Amps, 15% @ 180Amps
Cooling System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced Air
Gas Type: .................................................................CO
Torch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Euro Non Live - BINZEL ® MB15
Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230V 1ph
Absorbed power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2kW
Case size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Large
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.5kg
SPECIFICATION, Model No: . . . . . . . . . . . . . . . . . . . . . . . . . . .MIGHTYMIG210
Maximum Current: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210A
Wire Capacity steel: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15kg
Duty Cycle: . . . . . . . . . .100% @ 80Amps, 60% @ 105Amps, 15% @ 210Amps
Cooling System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced Air
Gas Type: .................................................................CO
Torch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Euro Non Live - BINZEL ® MB15
Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230V 1ph
Absorbed power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0kW
Case size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Large
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.5kg
3. ASSEMBLY & PREPARATION
3.1 ASSEMBLING THE WHEELS: (Refer to fig.1) The wheels are more
easily assembled with the welder placed upside down on a smooth
non-abrasive surface. The welder should be turned over by two people
as it is very heavy.
3.1.1 Bolt the two castors (1) to the front end of the base (2) using the bolts
provided.
3.1.2 Take the solid axle (3) and slide a wheel (4) over one end followed by a
washer (5). Insert a split pin (6) through the hole in one end of the axle
as shown below and bend it over.
3.1.3 Take an axle retaining bracket (7) and insert it into the slots in the base
(2). Hold the bracket in place and slide the axle assembly through both
parts of the bracket. Insert the second axle retaining bracket (7) through
the base and continue to slide the axle across so that it passes through
the second bracket and holds the wheel (4) up against the side of the
base. Slide the second wheel (8) onto the free end of the axle followed by
a washer (9). Retain the entire axle assembly by passing a split pin (10)
through the free end of the axle and bend it over to retain the whole axle
assembly.
3.1.4 With the assistance of another person turn the welder the right way up
onto its wheels.
²,
Argon & CO²/Argon mix
²,
Argon & CO²/Argon mix
²,
Argon & CO²/Argon mix
fig.1
3.2.3 Slide the socket on the right hand handle mounting (3) over the free end
of the handle tube and rotate the mounting downwards until it is resting
on the front of the welder. Using two of the 25mm round headed bolts
provided to fix the right hand mounting in place.
3.2.4 Now fully tighten all four fixings.
fig.2
3.3 ASSEMBLING THE EARTH CLAMP: (Refer to fig.3) Feed the eyelet on the
end of the earth lead through the hole in the clamp arm as shown in fig.3A.
3.3.1 Drop the eyelet over the terminal and firmly fix with the bolt provided as
shown in fig.3B.
fig.3
3.4 INSTALLING THE GAS CYLINDER. The welder is designed to
accommodate small or medium sized gas cylinders up to a maximum
height of 1000mm. Contact your local Gas dealer for supply.
3.4.1 Place the gas cylinder onto the rear platform of the welder. Drop one
end of the fixing chain into one side of the retaining bracket. Draw
the chain around the cylinder and place it into the slot on the other
side of the bracket leaving as little slack in the chain as possible.
3.5 ATTACHING THE REGULATOR. Whichever gas you are using it is
advisable to 'crack' the cylinder valve before attaching the regulator.
This means opening and closing the valve very quickly in order to
blow away any dust and dirt that may have accumulated in the gas
outlet. Stand to one side whilst doing this.
3.5.1 CO² GAS. Ensure that the threads on the gas bottle are undamaged
and free of oil and grease before attaching the regulator. (Oil or
grease in the presence of high pressure gases can be explosive.)
Ensure that the regulator has an undamaged gasket fitted. The
regulator will screw directly to the threads on the gas bottle. Tighten
with a spanner.
3.5.2 ARGON GAS OR ARGON MIXTURES. Cylinders containing Argon
gas and Argon mixtures have a female thread and will require the use
of a Bull Nose Adaptor to attach the regulator to the cylinder as
indicated in fig.4. Ensure that the threads on the gas bottle are
undamaged and free of oil and grease before attaching the regulator.
(Oil or grease in the presence of high pressure gases is explosive.)
Fit the Bull Nose Adaptor to the cylinder first and tighten with a
spanner. Ensure that the regulator has an undamaged gasket before
fitting onto the Bull Nose Adaptor. Tighten with a spanner.
3.5.3 Slide a jubilee clip over each end of the gas hose supplied. Push
one end of the hose onto the regulator outlet and the other end over
the gas inlet spigot on the back of the welder. Tighten the clips to
ensure a good seal.
3.5.4 Close the regulator valve by turning it anticlockwise before opening
the cylinder valve. Stand to one side when opening the cylinder valve.
3.5.5 Set the regulator flow rate to 5-8 litres/min depending on the
material to be welded, and whether there are draughts which are
strong enough to disturb the gas flow.
3.2 ASSEMBLING THE HANDLE: (Refer to fig.2) On the front of the welder
there are two pairs of threaded inserts, one pair in the top left corner and
one pair in the top right hand corner..
3.2.1 Attach the left hand handle mounting (1) to the front of the welder using
two of the 25mm round headed bolts provided. Do not fully tighten yet.
3.2.2 Slide the handle tube (2) into the socket in the mounting and push fully
home.
Original Language Version
fig.4
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
fig.5
fig.6
3.6 CONNECT THE TORCH CABLE TO THE WELDER. Align the pins
on the Euro connector with the socket on the welder front panel as
shown in fig.5. Push the connector into the socket and rotate the
locking ring (A) clockwise so that it draws the plug into the socket as
shown in fig.6.
Note: damage to torches and cables is not covered by warranty.
fig.9
3.8 FITTING A 5KG REEL OF WIRE. MIGHTYMIG 170 will only accept
a 5kg reel of wire. Ensure that the wire diameter used, is matched by
the correct groove size in the drive wheel and the correct tip size on
the torch as well as the correct torch liner. Failure to do this could
cause the wire to slip and/or bind.
3.8.1. Remove the retaining knob (D) from the end of the spindle (A) by
turning the knob 90° anticlockwise and pulling it outwards (see fig.9) .
Remove the spring (C) and the retaining disc (B) from the end of the
spindle also. Slide the reel of wire over the spindle and hold it against
the back plate so that the hole in the reel rests on the flange (E).
Ensure that the wire is coming off the top of the reel in the direction
of the wire drive unit as shown in fig.10.
3.8.2 Retain hand pressure on the reel to keep it on the flange and slide
the retaining disc (B) over the end of the spindle and into the hole in
the reel. Note that the disc (B) has a hexagonal hole in it which fits
onto the hexagonal portion of the spindle. Keep the disc under hand
pressure to retain the reel. Place the spring (C) over the spigot of
the retaining knob (D). Match the indented end of the spigot to the
hole in the end of the spindle. Push the knob spigot into the end of
the spindle, against spring pressure and turn it through 90° to lock it
in place.
fig.7
3.7 FITTING A 15KG REEL OF WIRE. MIGHTYMIG models 190 & 210
will accept either a 5kg or a 15kg reel of wire. Mightymig 170 will
only accept a 5kg reel of wire. Ensure that the wire diameter
used, is matched by the correct groove size in the drive wheel and
the correct tip size on the torch as well as the correct torch liner.
Failure to do this could cause the wire to slip and/or bind.
3.7.1 Unscrew the locking knob from the end of the spool holder (see
fig.7) and remove the spacer. Slide the reel of wire onto the spool
holder and ensure that the clutch pin at the back of the spool holder
engages into the guide hole in the wire reel moulding. This will
prevent the wire reel from freewheeling on the spool holder. When
using a 5kg reel, slide the spacer onto the spool holder before
refixing the locking knob. Ensure that the wire is coming off the top
of the reel in the direction of the wire drive unit as shown in fig.8
which shows a 15kg reel of wire in place on the spool holder.
fig.8
Original Language Version
fig.10
3.9 FEED WIRE THROUGH TO TORCH. Open the wire feed
mechanism by pushing the locking/wire tension knob (1) down to the
right allowing the pressure roller carrier (2) to spring up revealing the
feed roller as shown in fig.11. Ensure that the required feed groove
(0.6 or 0.8) is in line with the wire path. See Section 3.12 on how to
reverse or change the roller.
3.9.1 Release the wire from the reel and cut off any bent portion ensuring
that there are no burrs left on the end of the wire. Keep the wire under
tension at all times to prevent it uncoiling.
3.9.2 Straighten about 40-50mm of wire and gently push it through the
flexible metal sheathed cable (3) and through the 6 or 8mm feed roller
groove and on into the torch cable liner.
3.9.3 Push down the pressure roller carrier onto the wire feed roller and hold
it down. Lift up the locking/wire tension knob so that it enters the slot
in the pressure roller carrier and snaps into the indent in its top surface.
See fig.13. Rotate the tension knob to a medium setting i.e. between 2
and 3.
3.9.4 Remove gas cup (fig.12-2) and contact tip (1) from end of torch as follows:
a) Take torch in left hand with the torch tip facing to the right.
b) Grasp gas cup firmly in your right hand.
c) Turn gas cup clockwise only and pull it off end of torch tip.
WARNING! do not turn gas cup anti-clockwise, as this will damage
the internal spring.
d) Unscrew copper contact tip (right hand thread) to remove.
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
fig.11
fig.12
3.9.5 Check welder is switched off “0”, and that the earth clamp is away
from the torch tip. Connect the welder to the mains power supply and
set the voltage switch to one.
3.9.6 Set the wire speed knob to position 5 or 6. Keep the torch cable as
straight as possible and press the torch switch. The wire will feed
through the torch.
3.9.7 When the wire has fed through, switch welder off, unplug from mains.
a) Take torch in left hand, slide the contact tip over the wire and screw
back into place.
b) Grasp gas cup in right hand, push onto torch head and turn
clockwise only. Do not turn gas cup anti-clockwise, as this will
damage the internal spring.
c) Cut wire so that it is just protruding from the cup.
3.12 TURNING/CHANGING THE DRIVE ROLLER. (See fig.14) Ensure
that the wire diameter used, is matched by the correct groove size in
the drive wheel and the correct tip size on the torch as well as the
correct torch liner. Failure to do this could cause the wire to slip and/
or bind.
3.12.1 Referring to fig.11, open the wire feed mechanism by pushing the
locking/wire tension knob (1) down to the right allowing the pressure
roller carrier (2) to spring up revealing the feed roller.
3.12.2 Referring to fig.14, loosen and unscrew the black feed roller retaining
knob (C) and put to one side.
3.12.3 The roller carrier (A) is keyed to the main drive shaft and the drive
roller (B) is keyed to the carrier, see below. Place a finger onto the
end of the drive shaft to prevent the carrier moving and slide the drive
roller off the carrier with your other hand.
3.12.4 The size of each wire feed groove is printed on the edge of the roller
on the same side as the groove.
3.12.5 Turn the roller over to use the other groove or use a roller with
different sized grooves as required. The groove to be used should be
positioned furthest away from you to be in line with the drive path.
3.12.6 Check that the key in the carrier (A) is properly seated in its slot.
Ensure that the slot on the inside face of the drive roller (B) is aligned
with the key and slide the roller back onto the carrier.
3.12.7 Screw the black roller retaining knob (C) back on to the end of the
drive shaft and tighten.
fig.14
fig.13
3.10 SETTING WIRE TENSION. Adjust the wire tension by rotating the
wire tension knob. Turn clockwise to increase the tension and
anticlockwise to decrease the tension. See (1) in fig13.
IMPORTANT: Too little or too much tension will cause problematic
wire feed and result in poor welding.
3.10.1 Tension between rollers is checked by slowing down the wire between
gloved fingers. If top feed roller skids the tension is correct. Use as
low a tension as possible, too high a tension will disfigure wire and
result in a blown fuse.
3.11 CLUTCH ADJUSTMENT. Note: It is essential that the clutch is adjusted
correctly.
3.11.1 Once the wire is fed through the torch, switch on the machine and set
the wire speed to maximum.
3.11.2 Depress torch switch and release quickly. If the spool overruns it
indicates that the clutch is too loose.
3.11.3 Tighten the clutch nut located in the centre of the wire spool holder
with a spanner (fig.8-C) and test the machine as above until the wire
stops over running.
Note: DO NOT over tighten the clutch as this will cause wire feed
problems and strain the motor.
(Mightytmig170 is preset and has no direct clutch adjustment.)
Original Language Version
3.13 CONVERTING TO GASLESS WELDING. When delivered, your
welder is set up for gas welding with the torch cable connected to
the positive (+) terminal and the earthing cable connected to the
negative (-) terminal.
3.13.1 To weld without gas (using flux cored wire) you must reverse
the polarity and connect the torch cable to the negative (-)
terminal and the earthing cable to the positive (+) terminal as
shown below in fig.15.
3.13.1 Ensure that the machine is switched off and unplugged from
the mains supply before carring our this task.
3.13.2 Safely disconnect the gas.
3.13.3 Fit a 1.0mm tip to the torch.
3.13.4 Change the drive roller to one having a 1.0mm groove.
3.13.5 Mount the flux cored wire reel and feed it through to the torch.
fig.15
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
4. MIG/MAG WELDING
A spool of welding wire is positioned on the welder ’s spool holder and
automatically fed through an insulated liner in the torch to the tip. The torch
assembly consists of a switch, liner, gas hose, and control cable. The switch
activates the wire feed roller and the gas flow. Conversely, releasing the switch
stops the wire feed and gas flow. The weld current is transferred to the
electrode (the wire) from the contact tip at the end of the torch. A gas cup fits
over the contact tip to direct the gas flow towards the weld ensuring that the
arc welding process is shielded from oxidising air contaminates. The shielding
gas also assists heating of the weld materials. (The welder can also be used in
gasless mode using flux cored wire). The torch is connected to the positive
side of a DC rectifier, and the negative clamp is attached to the workpiece.
IMPORTANT: Should you have no welding experience, we recommend
you seek training from an expert source to ensure your personal health &
safety. Good Mig welding may be achieved only with continued,
supervised practice.
4. 1 PREPARATION FOR WELDING
IMPORTANT: BEFORE YOU COMMENCE, MAKE SURE THE
MACHINE IS SWITCHED OFF AT THE MAINS. IF WELDING A CAR,
DISCONNECT THE BATTERY OR FIT AN ELECTRONIC CIRCUIT
PROTECTOR. WE STRONGLY RECOMMEND THE USE OF
SEALEY “PROSAF/12V OR 24V IN ORDER TO PROTECT
SOPHISTICATED ELECTRONICS. ENSURE YOU HAVE READ &
UNDERSTOOD THE ELECTRICAL SAFETY INSTRUCTIONS IN
CHAPTER 1.
4.1.1 Connecting the Earth Lead.
To ensure a complete circuit, the earth lead must be securely
attached to the work piece that is to be welded.
a) Best connection is obtained by grinding clean the point of contact
on the workpiece before connecting the earth clamp.
b) The weld area must also be free of paint, rust, grease, etc.
c) When welding a vehicle, be sure the vehicle battery is
disconnected or fit an Electronic Circuit Protector available from
your Sealey dealer.
4.1.2 Power Output switch Set the switch to position 1 or 2 for welding
up to 2mm thickness. Use settings 3,4,5,6. for thicker welds.
4.1.3 Setting the welder controls. In principle, the lower the amperage
required, the slower the wire speed. See setting chart for voltage
and corresponding wire speeds. Note: these settings are only a
guide and will vary according to the operators experience.
4.1.4 Welding mild steel
To weld mild steel you can use CO² gas for most tasks where spatter
and the high build up of weld do not pose a problem. Welding with a
long arc reduces penetration and widens the arc. This in turn results
in more spatter. A long welding arc can be appropriate for welding butt
joints in thin materials. Welding with a short arc, at the same weld
settings, results in greater penetration and a narrower weld and
reduces the amount of spatter. To achieve a consistent spatter free
and flat weld, you must use an Argon/CO² mixture.
4.1.5 To weld aluminium use:
Argon gas,
0.8mm Contact Tip (MIG927),
0.8mm Aluminium Wire, (MIG/2KAL08).
4.1.6 Overload Protection. Thermostatic overload protection is provided.
When an overload has occurred, leave the unit to cool. The
thermostat will automatically reset the unit when the temperature has
returned within limits
SETTINGS SHOWN
AS GUIDE ONLY
Wire 0.6mm Steel
Argon / CO2 Mix
Voltage
Step:
Wire
Speed:
1 2 3 4 5 6
5 6 7 8 9 10
5. RATINGS PLATE
On the front of the welder is the ratings plate, giving the
following data:
1 - The standard relating to the safety and construction
of arc welding and associated equipment.
2 - Single phase transformer - rectifier.
3 - Welding with a continuous flow of welding wire.
4 - Single-phase AC supply.
5 - Rating of internal protection provided by casing.
6 - Output
U0: Rated minimum & 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% indicates continuous welding.
7 - Mains Supply U1: Rated supply voltage and frequency. Imax: Maximum current. I1eff: Maximum effective current.
8 - Welding current range.
9 - Serial Number. Specifically identifies each welder.
Original Language Version
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
5. MAINTENANCE
5.1. WIRE FEED UNIT Check the wire feed unit at regular intervals. The feed roller wire guide plays an important part in obtaining consistent results. Poor
wire feed affects welding. Clean the rollers weekly, especially the feed roller groove, removing all dust deposits.
5.2. TORCH Protect the torch cable assembly from mechanical wear. Clean the liner from the machine forwards by using compressed air. If the liner is
clogged it must be replaced.
5.3. CHANGING FEED ROLLER (See Section 3.12)
5.4. 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. Refer to fig.12 and section 3.9 for removal and replacement.
5.5. GAS CUP The gas cup must also be kept clean and free from spatter. Build up of spatter inside the gas cup can cause a short circuit at the contact tip
which will result in either the fuse blowing on the printed circuit card, or expensive machine repairs. To keep the contact tip free from spatter, we
recommend the use of Sealey anti-spatter spray (MIG/722308) available from your Sealey Dealer. Refer to fig.12 and section 3.9 for removal and
replacement.
5.6. REPLACING THE LINER Wind the wire back on to the spool and secure it. Unscrew the torch from the machine and undo the brass nut. The liner should
now be visible. Pull it out and replace with a new one.
6 . TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE
1. Power source stops Overheating protection activated due to overload Protection automatically resets when transformer has cooled (about 15 min)
2. No weld current Rectifier blown Replace rectifier
3. No weld current
4. Feed motor not working, lamp is on
5. Wire does not feed, feed roller rotates Pressure roller improperly adjusted Adjust tension
6. Wire feeds unevenly Dirt, etc, in liner Clean the liner from the machine forward. Use compressed air
7. Unstable arc Incorrect settings Check settings. (Section 4)
8. Porous weld No gas Open gas cylinder, regulate gas flow
Bad connection between clamp & workpiece Clean or grind contact surface and weld area
Break in earth lead Repair or replace earth lead.
Break in torch lead Repair or replace torch
Gear damaged or worn Replace gears. (Contact service agent)
Motor defective Replace motor (Contact service agent)
Dirt, copper, dust, etc, has collected in torch liner Clean the liner from the machine forward. Use compressed air. If too much dirt,
Gas cup (Nozzle) or tip defective Replace gas cup (nozzle) and/or tip. (Section 3.9.4 to 3.9.7)
Deformed wire Check roller tension and adjust it if necessary (Section 3.10)
Gas cup (Nozzle) or Tip defective Replace gas cup (nozzle) and/or tip. (Section 3.9.4 to 3.9.7)
Gas cup (Nozzle) spattered Clean or replace gas cup (nozzle) (Section 3.9.4 to 3.9.7)
Feed roller groove clogged Clean feed roller. (Section 3.12).
Feed roller groove deformed Replace feed roller. (Section 3.12)
Pressure roller tension improper Adjust tension. (Section 3.10)
Impurities in weld area Clean and/or grind workpiece. (Section 4.1.1)
Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 3.9.4 to 3.9.7)
Gas cup clogged Clean or replace cup. (nozzle) (Section 3.9.4 to 3.9.7)
Draft blowing away shielding gas Screen off welding site or increase gas flow
Rusty or dirty joints Clean and/or grind workpiece. (Section 4.1.1)
Torch too far from or at wrong angle to work The distance from gas cup to workpiece should be 8 to 10mm
REMEDY
replace the liner.
Gas leak Check hoses, connections and torch assembly. (Section 3.5, 3.5). Press the gas
Faulty Electrovalve
9. Electrode sticking in gas cup (nozzle) Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 3.9.4 to 3.9.7)
Electrode deformed Check roller tension. (Section 3.10)
Wire speed too slow See recommendations for wire speed
10. Irregular weld head Torch incorrectly held Use correct torch angle
Wire weaving in weld pool Check roller tension and adjust as needed. (Section 3.10)
11. Weld bead too narrow and raised Weld current too low Increase power and wire speed. (Section 4)
Weld speed too high Move torch slower and weave a little more
12. Weld bead too wide Weld current too high
Weld speed too low Move torch faster and weave less
Arc too long Bring torch closer to workpiece
13. Poor penetration Weld current too low Increase power and wire speed. (
Arc too long Bring torch closer to workpiece
14. Excessive penetration Weld current too high Decrease power and wire speed. (
Weld speed too slow
incorrect distance of torch to workpiece
Original Language Version
cup in correction position
Clean out or replace
Decrease power and wire speed. (Section 4)
Section 4
Section 4
Move torch faster
Torch distance should be 8-10mm
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
)
)
MODEL NOS:
MIGHTYMIG170
MIGHTYMIG190
MIGHTYMIG210
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 will be required for any claim. INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525
and leave your full name and address, including postcode.
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
Original Language Version
01284 757500
01284 703534
MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10
www.sealey.co.uk
Web
sales@sealey.co.uk
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