Sealey SUPERMIG255,SUPERMIG275 Instructions For

INSTRUCTIONS FOR

SUPERMIG

WELDERS

SUPERMIG255
SUPERMIG275

MODEL No's:

© Jack Sealey Limited 2013

SUPERMIG255, SUPERMIG275 Issue: 2 (SP)- 28/08/13

1.2 GENERAL SAFETY

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. (Refer also to the “IEC TECHNICAL SPECIFICATION or CLC/TS
62081: INSTALLATION AND USE OF EQUIPMENT FOR ARC WELDING”)

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

  Keep the welder and cables in good working order and condition. (Take immediate action to repair or replace damaged parts).
  Use genuine parts and accessories only. (Non recommended 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 available from your Sealey dealer.
  Locate welder in adequate working area for its function. Ensure area has adequate ventilation as welding fumes are harmful.
  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.
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 viscinity of the arc should be protected by shields of non reflecting welding curtains.
The operator should be adequately insulated from the electrode, the work piece and any accessible earthed metal parts in the viscinity by the
wearing of safety shoes and welding gauntlets plus the aforementioned safety clothing.
Where necessary the operator should work on insulating matts or on an insulated safety platform in elevated positions.

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

  Ensure 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 non essential persons away from the working area. Any persons working within the area must use protective head shield and gloves.
  Operators must receive adequate training before using the welder. The welder must only be operated under supervision.
  Stand correctly keeping a good footing and balance, and ensure the floor is not slippery, and wear non-slip shoes.
  Turn voltage switch to "0" or off when not in use.
  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.
  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 touch any live metal parts of the torch or electrode while the machine is switched on.
  DO NOT weld on any containers which are under pressure.

  DO NOT pull the welder by the mains cable or by the umbilical connection cable. 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. Long lengths of slack must be gathered & neatly coiled. DO NOT place cables where they endanger others.

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 fatigued.

  When not in use store the welder in a safe, dry, childproof area.
  DO NOT operate welder in damp or wet places and do not weld in the rain.

  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.

IMPORTANT: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. MAKE CAREFUL NOTE OF SAFETY INSTRUCTIONS,
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

INSTRUCTIONS FOR:

PROFESSIONAL MIG WELDERS 230V, 250Amp
and 230V, 270Amp, WITh BINzEL® EURO TORCh

MODEL Nos: SUPERMIG255, SUPERMIG275

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.

Original Language Version

© Jack Sealey Limited 2013

SUPERMIG255, SUPERMIG275 Issue: 2 (SP)- 28/08/13

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. SUPERMIG255 & SUPERMIG275 are single phase machines.

IMPORTANT: 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.

2. INTRODUCTION & SPECIFICATIONS

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. Model Nos. SUPERMIG255 / 275 are supplied with an industrial Argon/
CO² regulator. A contract for the supply of gas should be arranged with your local gas distributor.

1.3 VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES.

 Working with more than one welding machine on a single piece or on pieces that are connected electrically may generate a dangerous amount of no-load
voltage between the two electrode holders or torches, the value of which may reach double the allowed limit. Measuring instruments should be used to
determine the existence of a risk and suitable precautions taken as detailed in section 5.9 of the IEC TECHNICAL SPECIFICATION OF CLC/TS 62081.

1.4 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.

1.5 GAS SAFETY

 Store gas cylinders in a vertical position only and ensure 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 labels from a cylinder. Always check the gas identity before use. Avoid getting gas cylinders oily or greasy.
 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.

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

1.6 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
inflamnable 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.

Model: ...............................................SUPERMIG255 .................................................SUPERMIG275

Welding Current ............................................ 40-250A .......................................................40-270A

Wire Capacity: ................................................ 5-15kg ........................................................5-15kg

Duty Cycle: ......................100% @ 91A, 60% @ 118A, 20% @ 205A ..........................100% @ 112A, 60% @ 146A, 20% @ 255A

Cooling System: ............................................Forced Air ..................................................... Forced Air

Spot Welding Timer: ..............................................Yes ...........................................................Ye s

Gas Type: ....................................CO², Argon, CO²/Argon Mix .......................................CO², Argon, CO²/Argon Mix

Torch: .....................................Euro Non-Live - Binzel®MB24 .................................... Euro Non-Live - Binzel®MB24

Power Input: ..............................................230V - 1ph .....................................................230V - 1ph

Absorbed Power: ..............................................8.7kW ....................................................... 12.6kW

Case Size: .................................................... Large .........................................................Large

Net weight:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81kg ..........................................................92kg

3. RATINGS PLATE SYMBOLS

Detailed technical data relative to the performance of the machine is located on the back panel. Please note that the ratings plate shown below (fig.1) is an
example only intended to assist with the explanations of symbols. To determine the correct technical values of the machine in your possession, you must refer to
the data plate on that machine and the specifications shown above.

fig.1

Original Language Version

© Jack Sealey Limited 2013

SUPERMIG255, SUPERMIG275 Issue: 2 (SP)- 28/08/13