Advertisement
4. MIG/MaG WELDING
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 consists 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 an Electronic Circuit Protector available from
your Sealey dealer.
4.1.2. Power switch (fig B). Set the switch to position 1 or 2 for welding up to 2mm thickness.Use settings 3,4,5,6. for thicker welds.
4.1.3. Setting the welder controls. (fig a) In principle, the lower the amperage required, the slower the wire speed. See setting
chart for voltage and corresponding wire speeds.
Note: these settings a re only a guide and will vary according to the operators experience.
4.1.4. Welding mild steel
To weld mild steel you can use CO2 gas for most tasks where spatter and the high build up of weld do not pose a problem.
( 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.)
To achieve a consistent spatter free and flat weld, you must use an argon/CO2 mixture.
4.1.5. To weld aluminium use: Argon gas, 0.8mm Contact Tip (AK957), 0.8mm Aluminium Wire, (MIG/2/KAL08).
4.1.6. Spot Welding. Spot welding may be carried out as shown in fig.C below.
It will be necessary to fit a spot welding gas cup. ( Sealey part No. 120/722150 )
(a) Overlapping metal sheets with a maximum thickness of 0.8 mm may be welded as indicated.
(b) Alternatively they may be welded edge to surface as indicated.
(c) For thicker sheet pre drilled holes holes may be employed.
4.1.7. Use the wire feed control in conjunction with the spot weld timer below it. To activate the timer turn the knob clockwise. The
settings indicated in the black portion of the chart are for guidance only and may vary with operators experience.
4.1.8 OVERLOaD PROTECTION. Thermostatic overload protection is provided. When an overload has occurred, leave the unit
to cool. The thermostat will automatically reset the unit when the temperature has returned within limits
GUIDE TO RaTINGS PLaTE aND SYMBOLS
Made in European Community
Welder model type
Single Phase Transformer
and Rectifier (or 3 phase)
MIG/MAG welding symbol
Indicates a welding power source
suitable for supplying power to welding
operations carried out in an environment
with increased hazard of electric shock.
Indicates an alternating current
power supply and 1 or 3 phases as
required by specification.
International standard relating
to moisture ingress.
( For actual ratings of your model refer to front panel.
For further clarification refer to British Standard EN 60974-1 )
Direct current symbol
Rated no-load voltage: (a) Peak value in case of direct current
(b) Peak and r.m.s. value in case of alternating current
Rated Supply Voltage
Original Language Version
fig.C
IMPORTaNT.
Should you have no
welding experience, we
recommend you seek
training from an expert
source to ensure your
personal health & safety.
Good Mig welding may be
achieved only with
continued, supervised
practice.
Position for Serial Number
British Standard number
Power output range shown as minimum
and maximum welding current and the
corresponding conventional load voltages.
Duty Cycle (x)
Rated weld current (I 2 )
Conventional load voltage (U 2 )
Rated maximum supply current
Maximum effective supply current
SUPERMIG185.V2,195, 220.V5, 235.V4
SETTINGS SHOWN
aS GUIDE ONLY
Wire 0.6mm Steel
argon / CO2 Mix
Voltage
6
1 2 3 4 5 6
Step:
Wire
Speed: 5 6 7 8 9 10
10
Spot Welding Timer
6
fig. a
fig. B
Issue: 3 - 09/03/10
Advertisement
