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5. WELDING PRINCIPLES
IMPORTANT: These 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.
5.1.
MIG/MAG WELDING
5.1.1.
Welding wire is automatically fed through an insulated liner to the tip
of the torch. The torch consists of a switch, liner, and control cable.
The switch activates the wire feed roller. Releasing the switch stops
wire feed. The weld current is transferred to the electrode (the wire)
from the contact tip at the torch end. The current to the electrode is
set using the rocker switch on the front of the control panel.
Wire speed must be adjusted according to current output using the
rotary control positioned to the left of the control panel. The higher the
current the faster the wire speed.
5.2.
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. ENSURE THAT YOU READ, UNDERSTAND AND
APPLY THE SAFETY INSTRUCTIONS IN SECTION 1.
5.2.1.
To ensure a complete circuit, the negative lead must be securely attached to the workpiece close to the weld area. Best connection is
obtained by grinding the point of contact on the workpiece before connecting the clamp.
5.2.2.
The weld area must be free of paint, rust, grease, etc.
5.3.
THERMAL PROTECTION
5.3.1.
Should the welder become overheated due to prolonged use beyond the stated duty cycle the thermal protection will cause the welder
to cut out and the orange light on the front panel will illuminate. Wait for fifteen minutes for the welder to cool down at which time it will
reconnect automatically.
6. RATINGS PLATE
On the front panel of the welder is the ratings plate,
giving the following data:
1 - The BS/EU standard relating to the safety and
construction of arc welding and associated equipment.
2 - Single phase transformer.
3 - Symbol indicates welding with a continuous flow of
welding wire.
4 - Symbol for Single-phase AC supply.
5 - Rating of internal protection provided by casing.
6 - Output U0 Rated minimum and maximum no load
voltage.
I2, U2 Current and corresponding voltage.
X Welding ratio based on a 10 minute cycle.
20% indicates 2 minutes welding and 8
minutes rest,
100% would indicate continuous welding.
7 - Mains Supply U1 Rated supply voltage and frequency.
I1max Maximum current.
I1eff Maximum effective current.
8 - Welding current range.
9 - Serial Number. Specifically identifies each welder.
7. MAINTENANCE
▲
DANGER! Unplug the welder from the mains power supply before performing maintenance or service.
7.1.
WIRE FEED UNIT
7.1.1.
Check the wire feed unit at regular intervals. The feed roller wire guide plays an important part in obtaining consistent results. Poor wire
feed affects the weld. Clean the rollers weekly, especially the feed roller groove, removing all dust deposits.
7.2.
TORCH
7.2.1.
Protect the torch cable assembly from mechanical wear. Clean the liner from the machine forwards by using compressed air. If the liner is
blocked it must be replaced.
7.3.
TURNING FEED ROLLER IMPORTANT: TURN THE FEED ROLLER TO SUIT THE WIRE SIZE.
7.3.1.
There are two grooves on the feed roller, 0.8mm and 1mm. Always have the groove that is being used on the outside of the roller
(nearest to you). To turn the feed roller first loosen the wire tension knob and move it into its up position (see fig.8-1) then move
the tensioning roller assembly to its down position (see fig.8-2). Take hold of the triangular knob on the roller retainer and rotate
it 90°anticlockwise to release it as shown in fig.8.3. Now pull the roller retainer off the drive spindle to reveal the roller as shown in fig.9.
© Jack Sealey Limited
3
4
5
Original Language Version
fig.6
WIRE
SPEED
2
SUPERMIG100
POWER
THERMAL
OVERLOAD
1
8
6
7
9
fig.7
Issue 2 (4,F) 03/05/23
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