Mig/Mag Welding; Rating Plate - Sealey SUPERMIG250 Instructions For Use Manual

4. MIG/MAG WELDING

A spool of welding wire is positioned on the spool holder and the wire is 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. Pressing the switch activates the wire feed roller
and the gas flow, 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 the air.
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 VEHICLE, DISCONNECT THE BATTERY OR FIT AN ELECTRONIC CIRCUIT PROTECTOR. WE STRONGLY
RECOMMEND THE USE OF SEALEY PROSAF/12 OR PROSAF/24 IN ORDER TO PROTECT THE VEHICLE
ELECTRONICS. ENSURE THAT YOU READ, UNDERSTAND AND APPLY THE ELECTRICAL SAFETY INSTRUCTIONS
IN SECTION 1.
4.1.1. Connecting the earth lead
To ensure a complete circuit, the earth lead must be securely attached to the workpiece.
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. Current Regulator switch (fig.8). Set the switch to position 1 or 2 for welding up to 2mm thickness. Use settings 3 to 8 for
thicker welds.
4.1.3. Setting the welder controls (fig.7) 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 operator's experience.
4.1.4. Welding mild steel
Hold the nozzle between 8mm and 10mm away from the workpiece at an angle of about 20° from the vertical with the
nozzle shroud angled forward.
4.1.5. Welding aluminium
To weld aluminium use:  Argon gas,  0.8mm Contact Tip (120/722556),  0.8mm Aluminium Wire, (MIG/2/KAL08).
4.1.6. Spot welding
Spot welding may be carried out as shown in fig.9.
It will be necessary to fit a spot welding gas cup (Sealey Part No.120/722687).
(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 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.
IMPORTANT:
If you have no welding experience,
we recommend you seek training
from an expert source to ensure your
personal health and safety. Good
welding will be achieved only with
continued practice.
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
when the temperature has returned
to within limits.

5. RATING PLATE

GUIDE TO RATING PLATE AND SYMBOLS
Made in European Community 
Welder model 
Transformer and rectifier 
MIG/MAG welding symbol 
Indicates a welding power source 
suitable for use in an environment with
increased hazard of electric shock
Indicates an alternating current 
power supply, phases and frequency
International standard relating 
to casing protection
For the actual ratings of your model refer to front panel.
Direct current symbol


Rated no-load voltage: (a) Peak value in case of direct current,
(b) Peak and r.m.s. values in case of alternating current
Rated supply voltage 
fig.9
 Serial number
 European Standard number
Power output range shown as minimum
and maximum welding current and the
 corresponding voltages
 Duty cycle (x)
 Rated weld current (I 2 )
 Conventional load voltage (U 2 )
 Rated maximum supply current
 Maximum effective supply current
SETTINGS SHOWN
AS GUIDE ONLY
Wire 0.6mm Steel
Argon/CO2 Mix
Voltage
1 2 3 4 5 6
Step:
Wire
Speed: 5 6 7 8 9 10
Spot Welding Timer
fig.7
fig.8
Supermig250 Issue No: 1 - 03/03/09
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