INSTRUCTIONS FOR
SUPERMIG
WELDER
MODEL No:
SUPERMIG180.V3
© Jack Sealey Limited
Original Language Version
SUPERMIG180.V3 Issue No:5(D) - 11/11/16
INSTRUCTIONS FOR:
SUpER MIG WELDER
MODEL NO: SUpERMIG 180.V3
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: BEFORE USING THIS pRODUCT, pLEASE READ THE INSTRUCTIONS CAREFULLY. MAKE CAREFUL NOTE OF SAFETY
iNSTRUCTIONS,
SO MAY CAUSE DAMAGE OR pERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY.
WARNINGS AND CAUTIONS. THIS pRODUCT SHOULD ONLY BE USED FOR ITS INTENDED pURpOSE. FAILURE TO DO
Refer to
instruction
manual
Wear a
welding
mask
Wear
protective
gloves
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:
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. SUpERMIG180.V3 is a single phase machine and must be run from a minimum 16Amp supply. To achieve maximum output this model 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.
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.
© Jack Sealey Limited
Original Language Version
SUPERMIG180.V3 Issue No:5(D) - 11/11/16
2. INTRODUCTION
2.1. All our Supermig® models are suitable for welding with CO², Argon or CO2/Argon mix. Each uses a Forced Air Cooling System to slow transformer heating in
order to increase duty cycle and a non-live torch to prevent the risk of accidentally striking an arc. All models are supplied with an industrial Argon/CO² regulator.
Welders are illustrated with gas bottles to give an indication of size only; gas is not included. A contract for the supply of gas should be arranged with your local
gas distributor.
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.
3. SpECIFICATION
Model No: ................................................................................SUpERMIG180.V3
Welding Current: .....................................................................................30 - 180A
Wire Capacity - steel: ................................................................................ 5 - 15kg
Duty Cycle: .............100%@56Amps, 75%@65Amps, 60%@73Amps, 15%@145Amps
Cooling System: .....................................................................................Forced Air
Spot Welding timer ............................................................................................Yes
Gas Type: .................................................................CO
Torch: ...........................................................................Euro Non Live - BINZEL ®
Power Input .............................................................................................230V 1ph
Absorbed power ........................................................................................... 5.7kW
Case size ......................................................................................................Large
Weight .............................................................................................................45kg
,
Argon & CO²/Argon mix
²
4. ASSEMBLY/pREpARATION
4.1. ASSEMBLING GAS pLATFORM: (Refer to 'P' in figs.1 & 2) Turn the welder 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 The gas platform is held in place with 7 M6 x 10mm bolts requiring a 10mm spanner. The casing has pre-prepared threaded inserts ready to take the fixings.
Place the platform onto the base of the welder with the axle uppermost and fix in place with 3 bolts. See (X) in fig.1 below.
4.1.2 Insert the remaining four bolts through the two fixing flanges laying on the back of the welder. See (X) in fig.2. Finally, tighten all 7 bolts.
4.2. ASSEMBLING THE WHEELS: (Refer to fig.1)
4.2.1 Slide a wheel (Y) over each end of the solid axle attached to the gas platform. Slide a washer over each end of the axle and insert a split pin (Z) through the
hole in each end of the axle and bend it over to retain the wheels.
4.2.2 Bolt the two castors (W) to the front end of the base using the 8 bolts provided. The casing has pre-prepared threaded inserts ready to take the fixings. See fig.1.
4.2.3 With the assistance of another person turn the welder the right way up onto its wheels.
4.2.4 The Gas Cylinder Bracket (Item 36) can be found stored inside the wire feed compartment, in the top corner above the wire feed assembly. Remove from this
location and fix to the rear of the machine.
4.3. 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.
4.3.1 Drop the eyelet over the terminal and firmly fix with the bolt provided as shown in fig.3B.
4.4. 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.
4.4.1 Place the gas cylinder onto the rear platform of the welder. See fig.2-P. Place 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. 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.
4.5.1 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.
4.5.2 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.
4.5.3 Slide a 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. See fig.2G. Tighten the clips to ensure a good seal.
4.5.4 Close the regulator valve by turning it anticlockwise before opening the cylinder valve. Stand to one side when opening the cylinder valve.
4.5.5 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.
© Jack Sealey Limited
fig.1
Original Language Version
fig.3fig.2
fig.4
SUPERMIG180.V3 Issue No:5(D) - 11/11/16
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