Maintenance - Sealey SuperMig185 Instructions Manual

4. MIG/MAG WELDING PRINCIPLES
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 consist 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 torch is connected to the positive side of a DC rectifier, and the negative clamp is attached to the workpiece.
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
a PROSAF/12 Electronic Circuit Protector available from your Sealey dealer.
4. 1. 2. 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. 3. Welding mild steel
To weld mild steel you use CO2 gas for most tasks where spatter and the high build up of weld do not pose a problem.
To achieve a spatter free and flat weld, you must use an Argon/CO2 mixture.
4. 1. 4. Welding aluminium
To weld aluminium use: !Argon gas, !0.8mm Contact Tip (AK957), !0.8mm Aluminium Wire, (MIG/2/KAL08).
MEANINGS OF MARKINGS, AND SYMBOLS
Single-Phase transformer & rectifier
Flat Characteristic
MIG/MAG welding
...A/ ... V to ...A/ ... V
Range of output, rated min
& max welding current and
their corresponding conventional
load voltage.
5. WELDING
IMPORTANT.
Should you have no welding
experience, we recommend you seek
training from an expert source to
ensure your personal health & safety.
You must familiarise yourself with
welding applications and limitations,
and specific potential hazards peculiar to welding. Good Mig welding
may be achieved only with continued, supervised practice.
For example:
Correct torch angle and direction of travel in relation to the workpiece
is essential for the appearance and quality of the weld. Illustrations
demonstrate various positions and directions.
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.
We recommend expert training and supervised practice.

6. MAINTENANCE

6. 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 feeding affects welding. Clean the rollers weekly, especially the feed
roller groove, removing all dust deposits.
6. 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.
6. 3. Changing Feed Roller
IMPORTANT: Adjust the feed roller to the corresponding wire size.
There are two grooves on the feed roller, 0.6mm and 0.8mm.Always use the groove on the outside
of the roller, (the groove nearest to you). To remove the feed roller, undo the two screws and remove the
plastic cover (fig 6). Clean and turn, or if damaged change the feed roller and replace
the plastic cover accordingly.
Rated on-load voltage
a) Peak value in case of direct current;
b) Peak & r.m.s. value in case of alternating current.
X
1
2
U
2
(1)3
Rightward Welding
Leftward Welding
U V
in
o
P
max
Direct current
Duty cycle (Factor)
U
Rated weld current
1
Conventional load voltage
Mains supply and number of phases
(i.e. 1 or 3) with symbol for
alternating current.
Vertical Rightward
3. Butt Weld
1. Direction of
Welding 4. Fillet Weld
SETTING CHARTS
Spot Welding
Wire Speed Voltage Timer
10 6 10
Alternating current & the rated
frequency in hertz i.e.
... kW
Maximum power consumption in case
of a rotating welding power source. This
value will only be given when it is not
combined with a prime mover.
... V/...Hz
Rated values of the supply voltage
and the frequency.
/
Rated supply current.
1
IP Degree of protection, i.e. 21 or 23.
s
Welding power sources which are suitable
for supplying power to welding operations
carried out in an environment with increased
hazard of electric shock.
Down Rightward
Downhard leftward
Normal
Welding
Arc
fig 6
Plastic cover
Roller
Supermig185, 195/9, 0051 (2) 180900
0.6mm Argon
/CO2 Mix
Wire
5 6 7 8 9 10
Speed:
Voltage
1 2 3 4 5 6
Step:
50Hz
Long
Welding
Arc
Short
Welding
Arc