MIGHTYMIG WELDERS
I
MPORTANT:
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.
mODEL NO’s:
MIGHTYMIG170.V2, MIGHTYMIG190.V2,
MIGHTYMIG210.V2
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.
Refer to
instruction
manual
Breathing
welding fumes
can be
hazardous to
your health
Wear a
welding
mask
Electromagnetic
fields can cause
pacemaker
malfunction
Wear protective
gloves
Welding sparks
can cause
explosions
or fire
Warning!
Electricity
Shock hazard
Warning!
Keep away
from rain
Caution
required
Arc rays can
burn eyes and
injure skin
Electric shock
from welding
electrodes can
kill
1. SAFETY
1.1. ELECTRICAL SAFETY
WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following:
9 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 stockist. 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 are loose.
Important: Ensure that the voltage marked on the appliance matches the power supply to be used and that the supply is correctly fused.
8 DO NOT pull or carry the appliance by the power cable.
8 DO NOT pull the plug from the socket by the cable.
8 DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty item repaired or replaced by a qualified
electrician.
1.1.6. mIGHTYmIG170.V2, mIGHTYmIG190.V2, mIGHTYmIG210V2 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.
1.1.7. 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.
9 Keep the welder and cables in good condition. Take immediate action to repair or replace damaged parts.
9 Use genuine parts and accessories only. Unapproved 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 which is available from your Sealey stockist.
9 Locate the welder in a suitable work area. Ensure that the area has adequate ventilation as welding fumes are harmful.
© Jack Sealey Limited
Original Language Version
mIGHTYmIG170.V2, 190.V2, 210.V2 | Issue:2 (1,2) 14/02/19
9 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.
WARNING! Use welding head shield to protect eyes and avoid exposing skin to ultraviolet rays given off by electric arc. Wear
safety welding gauntlets.
9 Remove ill fitting clothing, remove ties, watches, rings and other loose jewellery and contain long hair.
9 Ensure that 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 unauthorised persons away from the work area. Any persons working within the area must wear protective head shield and gloves.
9 Operators must receive adequate training before using the welder.
9 Stand correctly, keeping a good footing and balance, and ensure that the floor is not slippery. Wear non-slip shoes.
9 Turn voltage switch to 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 unapproved torch or other 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 stand welder on a metal workbench, car bodywork or similar object.
8 DO NOT touch any live metal parts of the torch or electrode while the machine is switched on.
8 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.
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 tired.
9 When not in use store the welder in a safe, dry, childproof area.
1.3. GAS SAFETY
9 Store gas cylinders in a vertical position only and ensure that 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. Always 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 cylinder labels. Always check the gas identity before use. Avoid getting gas cylinders oily or
greasy.
8 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
mIGHTYmIG170, 190 and 210 are supplied with high quality cool running Ergo 15.2 torch thus ensuring a steadier weld bead, 2m earth cable,
1.4m of gas hose, twin gauged gas regulator, 0.6 and 0.8 tips. All three units are supplied set up in gas mode, but can easily be switched to
gasless mode by a simple change of polarity. Use in gasless mode will require the purchase of a spool of ux cored wire, a pack of 1mm tips and
a 1mm wire feed roller.
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.
3. SpECIFICATION
Model no. MIGHTYMIG170.V2 MIGHTYMIG190.V2 MIGHTYMIG210.V2
Welding current 40-170A 40-190A 45-210A
Wire capacity 5kg 5-15kg 5-15kg
Duty cycle 100% @ 55A, 60% @ 70A, 15%
@ 140A
Cooling system Forced air Forced air Forced air
Gas type CO2, Argon, CO2/Argon mix CO2, Argon, CO2/Argon mix CO2, Argon, CO2/Argon mix
Torch 3m Euro Non - Live - Ergo 15.2 3m Euro Non - Live - Ergo 15.2 3m Euro Non - Live - Ergo 15.2
Supply 230V - 16A (To achieve maximum
power a 32A supply may be
required).
Absorbed power 5.4kW 7.2kW 9kW
Case size Large Large Large
Weight 41.5kg 49.5kg 51.5kg
Gasless: Flux cored wire TG100/4 TG100/4 TG100/4
Consumables:
Replacement tips 1mm
(pack of 5):
TG100/2 TG100/2 TG100/4
100% @ 70A, 60% @90A, 15% @
180A
230V - 16A (To achieve maximum
power a 32A supply may be required).
100% @ 80A, 60% @ 105A, 15%
@ 210A
230V - 16A (To achieve maximum
power a 32A supply may be
required).
© Jack Sealey Limited
Original Language Version
mIGHTYmIG170.V2, 190.V2, 210.V2 | Issue:2 (1,2) 14/02/19
4. ASSEMBLY
4.1. 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.
4.1.1. Bolt the two castors (1) to the front end of the base (2) using the bolts
provided.
4.1.2. 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.
4.1.3. Take an axle retaining bracket (7) and insert it into the slots in the base (2).
4.1.4. 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.
4.1.5. With the assistance of another person turn the welder the right way up onto its wheels.
4.2. ASSEMBLING THE HANDLE: (Refer to fig.2)
4.2.1. 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.
4.2.2. 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.
4.2.3. Slide the handle tube (2) into the socket in the mounting and push fully home.
4.2.4. 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.
4.2.5. Now fully tighten all four fixing
s.
fig.4
fig.1
fig.3
fig.2
4.3. ASSEMBLING THE EARTH CLAMp (Refer to fig.3)
4.3.1. Feed the eyelet on the end of the earth lead through the hole in the clamp arm as shown in fig.3A.
4.3.2. Drop the eyelet over the terminal and firmly fix with the bolt provided as shown in fig.3B.
4.4. INSTALLING THE GAS CYLINDER
4.4.1. 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.
4.4.2. 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.
4.5. ATTACHING THE REGULATOR
4.5.1. 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.
4.6. CO² GAS
WARNING! 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.
4.7. ARGON GAS OR ARGON MIxTURES
4.7.1. 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.
4.7.2. 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.
4.7.3. Close the regulator valve by turning it anticlockwise before opening the cylinder valve. Stand to one side when opening the cylinder valve.
4.7.4. 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.
4.8. CONNECT THE TORCH CABLE TO THE WELDER
4.8.1. Align the pins on the Euro connector with the socket on the welder front panel as shown in g.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 g.6.
Note: Damage to torches and cables is not covered by warranty.
© Jack Sealey Limited
Original Language Version
mIGHTYmIG170.V2, 190.V2, 210.V2 | Issue:2 (1,2) 14/02/19
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