Sealey SUPERMIG Series,SUPERMIG150.V3 Instructions Manual

INSTRUCTIONS FOR:

SUPERMIG
WELDER

MODEL No:

SUPERMIG150.V3

SUPERMIG150.V3 Issue No:1 15/05/09

INSTRUCTIONS FOR:

PROFESSIONAL MIG WELDER 150Amp

MODEL No: SUPERMIG150.V3

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.

IMPORTANT: BEF OR E USING TH IS PRODUC T, PLE ASE READ THE INS TRU CTI ON S CAREF UL LY. MA KE CARE FU L NO TE OF SAFE TY INST RUCTI ONS ,
WARNINGS AND CAUTIONS. THIS PRODUCT SHOULD ONLY BE USED FOR ITS INTENDED PURPOSE. FAILURE TO DO SO MAY CAUSE DAMAGE
AND/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 user ’s responsibility to read, understand and comply
with the following: You must check all electrical equipment and appliances to
ensure they are safe before using. You must inspect power supply leads, plugs
and all electrical connections for wear and damage. You must ensure the risk
of electric shock is minimised by the installation of appropriate safety devices.
An RCCB (Residual Current Circuit Breaker) should be incorporated in the
main distribution board. We also recommend that an RCD (Residual Current
Device) is used with all electrical products. It is particularly important to use an
RCD together with portable products that are plugged into an electrical supply
not protected by an RCCB. If in 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 all portable electrical
appliances, if used on business premises, to be 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 the appliance, and the
safety of the appliance operator. If in any doubt about electrical
safety, contact a qualified electrician.

1.1.3. Ensure the insulation on all cables and the product itself is safe before
connecting to the mains power supply. See 1.1.1. & 1.1.2. above and
use a Portable Appliance Tester (PAT).

1.1.4. Ensure that cables are always protected against short circuit and overload.

1.1.5. Regularly inspect power supply leads, plugs and all electrical
connections for wear and damage and especially power connections, to
ensure that none is loose.

1.1.6. Important: Ensure the voltage marked on the product is the same as
the electrical power supply to be used and check that plugs are fitted
with the correct capacity fuse.

1.1.7. DO NOT pull or carry the powered appliance by its power supply lead.

1.1.8. DO NOT pull power plugs from sockets by the power cable.

1.1.9. DO NOT use worn or damaged leads, plugs or connections.
Immediately replace or have repaired by a qualified electrician. A U.K. 3
pin plug must be fitted according to the following instructions. (UK only -
see diagram below).
Ensure the unit is correctly earthed via a three-pin plug.

a) Connect the green/yellow earth wire to the earth terminal ‘E’.
b) Connect the brown live wire to 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 external insulation
extends beyond the cable restraint and that the restraint is tight.

1.1.10. Cable extension reels. 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 section of the cable on the cable reel is important
and should be at least 1.5mm², but to be absolutely sure that the
capacity of the cable is suitable for this product and for others that may
be used in the other output sockets, we recommend the use of 2.5mm²
section cable.

 WARNING! Be very cautious if using a generator to power the
welder. The generator must be self-regulating and stable with
regard to voltage, wave form and frequency. The output must be
greater than the power consumption of the welder. If any of these
requirements is not met the electronics within the welder may be
affected. NOTE: The use of an unregulated generator may be
dangerous and will invalidate the warranty on the welder.
 WARNING! The welder may produce voltage surges in the mains
supply which can damage other sensitive
equipment e.g. computers. To prevent
this happening, it is recommended that
the welder is connected to a power
supply that does not feed any
sensitive equipment.

1.1.11 IMPORTANT! If using welder to full
capacity, we recommend a 16amp
supply. We recommend you discuss
the installation of a 16amp industrial
round pin plug and socket with your
electrician.

Blue
Neutral
Wire

Yellow & Green
Earth Wire

FUSE RATING

13 AMP

Brown
Live
Wire

Cable
Restraint

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 working order and 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, available from your Sealey dealer.
 Locate welder in a suitable work area. Ensure that the area has
adequate ventilation as welding fumes can be harmful.
 Keep work 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! 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 the workpiece is correctly secured before welding.
 Avoid unintentional contact with the 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 a protective head shield and gloves.

 Operators must receive adequate training before using the welder.
 Stand correctly keeping a good footing and balance, ensure the

floor is not slippery and wear non-slip shoes.

 DO NOT operate the welder if it or the cables are damaged.
 DO NOT attempt to fit any unapproved torches or other components

to the welder.
 DO NOT get welder wet or use in damp or wet locations or areas
where there is condensation.

 DANGER! DO NOT weld near flammable solids, liquids or
gases and DO NOT weld containers or pipes which have held
flammable materials. Avoid welding materials which have been
cleaned with chlorinated solvents or welding near such solvents.

 DO NOT stand welder on a metal workbench, car bodywork or similar.
 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. Protect cables
from sharp or abrasive items. DO NOT bend, strain or stand on
cables or leads. Protect from heat. Long lengths of slack must be
gathered and 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 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 the
storage area is correctly secured.
 DO NOT store gas cylinders in areas where the temperature may
exceed 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 on a cylinder. 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

IMPORTANT: These instructions contain the information you require to prepare

your machine for welding, together with a maintenance and a troubleshooting
section. The instructions are not intended to teach you how to weld. If you
have no experience, we recommend that you seek training from an expert
source. MIG welding is relatively easy, but does require a steady hand and
supervised practice on scrap metal, as it is only with continued practice that
you will achieve the desired results.

SUPERMIG150.V3 Issue No:1 15/05/09