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10.1.4.
Turn on and adjust the protective gas using the pressure regulator. Adjust to a flow rate of 5-7 l/min.
NOTE:
At the end of the job, remember to turn off the protective gas.
10.1.5.
Switch the welder on and set the welding current by means of the rotary switches and by referring to the welding reference table below.
10.1.6.
Ensure that the earth clamp is in contact with the workpiece.
10.1.7.
Press the torch button, keeping the torch at a safe distance from the workpiece.
10.2.
ALUMINIUM WELDING.
Argon or an Argon-Helium mixture should be used for shielding. 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. A problem you may experience
when aluminium MIG welding is in pulling the wire for the whole length of the torch, as aluminium has poor mechanical characteristics.
The smaller the diameter of wire the more difficult the wire feed may be.
To overcome this problem do the following.
- Use contact tip suitable for aluminium.
- Replace the wire puller rollers with aluminium compatible rollers.
- Replace the steel guide hose for wire feed with a Teflon guide hose.
- For more information contact your local Sealey stockist.
10.3.
SPOT WELDING (fig.18)
10.3.1.
Ensure that the welding mode switch is set to the 'SPOT' welding position.
10.3.2.
This model has the capabilty to spot weld two overlapping metal sheets and is equipped with an adjustable
timer which allows ideal spot welding time to be set and therefore the creation of spot-welds which have the
same characteristics. In order to use the machine for spot welding, it should be set-up as follows:
10.3.3.
Replace the nozzle of the torch with the nozzle required for spot welding. The lugs on the cup keep it the
correct distance from the weld pool and allow the shielding gas to escape. The nozzle is also used to push the
two pieces being welded together.
10.3.4.
Set the rotary current adjustment switch / switches to the highest setting.
Set the wire feed speed at almost maximum speed.
Turn ON the Timer control and set the spot welding time according to the thickness of the metal sheets.
10.3.5.
To carry out the spot welding; rest the nozzle of the torch on the surface of the first metal sheet, then press the torch button to start
welding: the wire will melt the first sheet, pass through this sheet and into the second, making a molten wedge between the two metal
sheets.
10.3.6.
The torch button should be pressed until the timer interrupts the welding. This system allows spot-welding to be carried out which
would not normally be possible, since metal sheets can be joined which do not allow access to the rear side of the workpiece. This
system also makes the operator's work much easier thanks to the extremely light-weight torch in comparison to conventional spot welding
equipment. The application limits of this system depend on the thickness of the first metal sheet.
Material
Thickness
Diameter
(mm)
0.8 to 1.5
1.0 to 2.5
2.5 to 4.0
2.0 to 5.0
5.0 to 10
11. MAINTENANCE
‰
WARNING! Ensure the unit is disconnected from the mains power supply before performing any maintenance or service.
11.1.
Regularly check all welding cables and secondary terminals to ensure they are in good order and connected correctly, also
check during welding to ensure they are not overheating.
11.2.
Check that the gas hose connections are tight and that there are no gas leaks.
11.3.
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 from the feeder area.
11.4.
CHANGING FEED ROLLER / ROLLERS. IMPORTANT: Set up the feed rollers according to the wire size required for the job in hand.
Refer to section 7.
11.5.
TORCH
Protect torch cable assembly from mechanical wear. Also do not allow the torch or its cable to come into contact with hot surfaces,
especially a hot workpiece as this would cause the insulating materials to melt, making the torch unsafe and unusable.
- Make regular checks on the gas pipe and connector seals;
- Every time the wire reel is changed, blow out the wire-guide hose using dry compressed air (max. 5 bar) to make sure it is not damaged;
- Before using the welding machine, always check the torch terminal parts for wear and make sure they are assembled correctly: nozzle,
contact pipe, gas diffuser.
11.6.
Contact Tip (to remove the tip refer to section 7.3 and fig.15).
The contact tip is a consumable item and must be replaced when the hole becomes enlarged or oval. The contact tip MUST be kept free
from spatter to ensure an unimpeded flow of gas.
11.7.
GAS CUP (TO REMOVE THE TIP REFER TO SECTION 7.3 AND FIG.15).
The gas cup must also be kept clean and free from spatter. Build up of spatter inside the gas cup can cause a short circuit at the contact
tip which will result in either the fuse blowing on the printed circuit card, or expensive machine repairs. To keep the contact tip free from
spatter, we recommend the use of Sealey anti-spatter spray (MIG/722307) available from your Sealey stockist.
© Jack Sealey Limited
WELDING REFERENCE TABLE (for general guidance only)
Wire
Liner Inner
Diameter
(mm)
(mm)
Ø0.8
Ø1.4
Ø0.8
Ø1.4
Ø0.8
Ø1.4
Ø1.0
Ø1.6
Ø1.0
Ø1.6
Liner
Current
Specification
(mm)
1.2 x 1.6 (blue)
50 to 90
1.2 x 1.6 (blue)
60 to 100
1.2 x 1.6 (blue)
100 to 140
1.2 x 1.8 (black)
70 to 120
1.2 x 1.8 (black)
120 to 170
Original Language Version
Voltage
(Amps)
(Volts)
17 to 18
18 to 19
21 to 24
19 to 21
23 to 26
SUPERMIG255.V2
fig.18
Spot
Welding
Gas Flow
(l/min)
6
7
8
9
10
Issue:1 - 11/07/22
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