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INTRODUCTION : The Spool Gun is specifically designed for use with the Sealey Electromig195
when welding aluminium and takes full advantage of the microprocessor controlled facilities of that
welder. Once the welding properties in relation to wire size, gas type and material have been
entered via the control panel, the wire feed rate is automatically adjusted by the built in microprocessor.
The Spool Gun has an integral wire feed drive and a minimum length wire feed path compared to
an ordinary torch, thus providing a consistently reliable way of welding aluminium. The gun is light in
weight, well balanced and has an on-gun wire feed control for fine adjustments during the welding
process. MIG/SGT15.V2 has a 6M cable. MIG/SGT15/12.V2 has a 12M cable.
3. SETTING UP THE SPOOL GUN
3.0.
THE SPOOL GUN SHOULD ONLY BE USED WITH THE SEALEY ELECTROMIG 195
WELDER FOR WHICH IT IS DESIGNED. AS WELL AS READING THESE INSTRUCTIONS
THE USER SHOULD RE-READ AND UNDERSTAND THE INSTRUCTIONS ORIGINALLY
SUPPLIED WITH THE WELDER.
3.1.
GAS SUPPLY. For welding aluminium use an Argon gas or Argo-Helium mixture. Set the
regulator flow rate to 5 - 7 litres/min taking into consideration any draughts which are strong
enough to disturb the gas flow. (For information on mounting the gas bottle, attaching the
regulator and making the gas connection, refer to the instructions supplied with Electromig195).
3.2.
SPOOL GUN CONNECTIONS. (See fig1) Your spool gun is fitted with a "Euro Connection" quick release connector (3). Line up the pins in the torch
connector (3) with appropriate holes on the front panel connector (4), push in and tighten the locking nut. The additional 'control' connector (5) should be
attached to the socket (6) on the front panel. The ring that encloses the pins has several ribs around its outer face. Identify the thickest rib and present this
to the socket in the '12 o'clock' position. Push the plug home and tighten the locking nut.
fig 2
3.3.
FITTING A REEL OF WIRE. (See fig.3) MAKE SURE THAT THE WIRE FEED ROLLERS, THE WIRE GUIDE HOSE AND THE CONTACT TIP OF THE
SPOOL GUN MATCH THE DIAMETER AND TYPE OF WIRE TO BE USED AND ENSURE THAT THESE PARTS ARE FITTED CORRECTLY. The wire
used must have the same characteristics as the material to be welded. Always use an alloy wire (i.e. aluminium/silicium); DO NOT use pure aluminium wire.
3.4.
First remove the circular tinted plastic cover from the spool holder by undoing the central knurled retainer nut.
3.5.
Remove the gas cup and torch tip as described below (fig.4).
a) Take gun/torch in left hand with the torch tip facing to the right.
b) Grasp gas cup 'a' firmly in your right hand.( Cup is a friction fit.)
c) Turn gas cup clockwise only and pull cup out to the right.
d) Unscrew the copper contact tip 'b' (right hand thread) to remove.
WARNING! do not turn gas cup anti-clockwise, as this will damage the internal spring.
3.6.
Open the hinged wire feed cover on the top of the gun body (see fig.5). Reduce the tension on the pressure
roller bracket (D) by partially unscrewing the tension knob (E) anticlockwise and slide the the retaining arm
out of the bracket and into the vertical position (see 1 in fig.2). Hinge the pressure roller bracket out
sideways (see 2 in fig.2) to reveal the grooved feed roller (A).
3.7.
Place the gun on its side on a flat clean surface with the wire reel spindle facing upwards (see fig.3).
3.8.
Release the end of the wire from the new reel and ensure that the end is cleanly cut and free from burrs.
Straighten the first 50/100 mm of the wire and place the wire reel on the surface next to the spool holder as
shown in fig.3. (It is easier to feed the wire through the gun first and then place the reel onto the spindle.)
3.9.
Feed the end of the wire into the flexible black plastic guide hose (see F in fig.3) and push it through until it
appears next to the feed roller (G). Guide the end of the wire into the red liner adjacent to the feed roller and
continue to push the wire through until it comes out of the gun/torch end.
3.10. Lift the wire reel and at the same time take up any slack by pulling the wire at the torch end and push the reel
over the spindle (H). Take care not to let the wire uncoil from the reel in loops.
3.11.
Replace the gas cup and tip as follows: Take torch in left hand and screw contact tip back into place.
3.12. Grasp gas cup in right hand, push onto torch head and turn clockwise only.
3.13. Check that the wire is properly seated in its groove in the feed roller and then swing the counter roller bracket inwards to make contact with the wire (see D in fig.5).
3.14. Swing the wire tension retaining arm downwards and back into the 'U' shaped slot in the counter roller bracket. Turn the wire tension knob clockwise by
about 4 turns to apply medium pressure/tension (see E in fig.5)
3.15. Close the wire feed cover.
3.16. Switch on welder to power level 1 and pull the gun trigger to test that the wire is feeding properly.
WARNING! When testing the wire feed do not allow the wire to come into contact with the workpiece or earthing connection as this would
inadvertently strike the arc causing potential injury. To avoid mechanical injury do not direct the wire at yourself or any other persons.
fig.1
fig 3
MIG/SGT15.V2 & MIG/SGT15/12.V2 - 1 - 21/12/07
fig 4
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