Sealey Supermig200.v2 User manual

200A PROFESSIONAL MIG WELDER WITH

BINZEL® EURO TORCH

MODEL NO: SUPERMIG200.V2

Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these

instructions, and properly maintained, give you years of trouble free performance.

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE

THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGEAND/OR

PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.

1. SAFETY

1.1. ELECTRICAL SAFETY

WARNING! It is the owner’s responsibility to read, understand and comply with the following:

You must check all electrical equipment and appliances to ensure that they are safe before use. You must inspect power supply leads,

plugs and all electrical connections for wear and damage. You must ensure the risk of electric shock is minimised by the installation of

appropriate safety devices. An RCCB (Residual Current Circuit Breaker) should be incorporated in the main distribution board. We also

recommend that an RCD (Residual Current Device) is used with all electrical products. It is particularly important to use an RCD with

portable products that are plugged into an electrical supply not protected by an RCCB. If in doubt consult a qualified electrician. You

may obtain a Residual Current Device by contacting your Sealey dealer. You must also read and understand the following instructions

concerning electrical safety.

1.1.1. The Electricity At Work Act 1989 requires all portable electrical appliances, if used on business premises, to be tested by a qualified

electrician, using a Portable Appliance Tester (PAT), at least once a year.

1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of the appliance

and the safety of the appliance operator. If in any doubt about electrical safety, contact a qualified electrician.

1.1.3. Ensure the insulation on all cables and the product itself is safe before connecting to the mains power supply. See 1.1.1. & 1.1.2.

above and use a Portable Appliance Tester (PAT).

1.1.4. Ensure that cables are always protected against short circuit and overload.

1.1.5. Regularly inspect power supply, leads, plugs for wear and damage and all electrical connections

to ensure that none is loose.

1.1.6. Important: Ensure the voltage marked on the product is the same as the electrical power supply

to be used and check that supply is correctly fused, see fuse rating at right.

1.1.7. DO NOT pull or carry the powered appliance by its power supply lead.

1.1.8. DO NOT pull power plugs from sockets by the power cable.

1.1.9. DO NOT use worn or damaged leads, plugs or connections. Immediately replace or have

repaired by a qualified electrician.

1.1.10. This product comes without a plug. You must contact a qualified electrician to ensure an

adequate supply is available.

If fitting such a plug -

Ensure that the unit is correctly wired and earthed, as follows:

a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.

b) Connect the BROWN live wire to live terminal ‘L’.

c) Connect the BLUE neutral wire to the neutral terminal ‘N’.

d) After wiring, check there are no bare wires, that all wires have been correctly connected,

that the cable outer insulation is clamped by the cable grip and that the grip is tight.

1.1.11. Cable extension reels. When a cable extension reel is used it should be fully unwound before connection. A cable reel with an RCD

fitted is recommended since any product which is plugged into the cable reel will be protected. The section of the cores of the cable is

important. 2.5mm² section is a minimum, but to be absolutely sure that the capacity of the cable reel is suitable for this product and

for others that may be used in the other output sockets, we recommend the use of 2.5mm² section cable.

1.2. GENERAL SAFETY

▲DANGER! Unplug the welder from the mains power supply before performing maintenance or service.

9Keep the welder and cables in good condition. Take immediate action to repair or replace damaged parts.

9Use genuine parts and accessories only. Unapproved parts may be dangerous and will invalidate the warranty.

9Use an air hose to regularly blow out any dirt from the liner and keep the welder clean for best and safest performance.

9Check and spray the gas cup and contact tip regularly with anti-spatter spray which is available from your Sealey stockist.

9Locate the welder in a suitable work area. Ensure that the area has adequate ventilation as welding fumes are harmful.

THIS PRODUCT REQUIRES A

MINIMUM 16 AMP

SUPPLY

SUPERMIG200.V2 Issue 1 11/07/22

Original Language Version

Refer to

instructions Electric shock

from welding

electrodes can

kill.

Hot surfaces

Breathing

welding

fumes can be

hazardous to

your health.

Electromagnetic

elds can cause

pacemaker

malfunction.

Wear eye

protection Wear protective

gloves

Welding sparks

can cause

explosions or

re.

Arc rays can

burn eyes and

injure skin.

Wear safety

footwear Wear protective

clothing

9Keep work area clean, tidy and free from unrelated materials. Also ensure that the work area has adequate lighting and that a fire

extinguisher is at hand.

WARNING! Use welding head shield to protect eyes and avoid exposing skin to ultraviolet rays given off by electric arc. Wear

safety welding gauntlets.

9Remove ill fitting clothing, remove ties, watches, rings and other loose jewellery and contain long hair.

9Ensure that the workpiece is correctly secured before operating the welder.

9Avoid unintentional contact with workpiece.Accidental or uncontrolled use of the torch may be dangerous and will wear the nozzle.

9Keep unauthorised persons away from the work area. Any persons working within the area must wear protective head shield and

gloves.

9Operators must receive adequate training before using the welder.

9Stand correctly, keeping a good footing and balance, and ensure that the floor is not slippery. Wear non-slip shoes.

9Turn voltage switch to OFF when not in use.

8DO NOT operate the welder if it or its cables are damaged and DO NOT attempt to fit any unapproved torch or other parts to the

welder unit.

8DO NOT get welder wet or use in damp or wet locations or areas where there is condensation.

▲DANGER! DO NOT weld near inflammable materials, solids, liquids, or gases, and DO NOT weld containers or pipes which have held

flammable materials or gases, liquids or solids. Avoid operating on materials cleaned with chlorinated solvents or near such solvents.

8DO NOT stand welder on a metal workbench, car bodywork or similar object.

8DO NOT touch any live metal parts of the torch or electrode while the machine is switched on.

8DO NOT pull the welder by the cable or the torch and DO NOT bend or strain cables.

9Protect cables from sharp or abrasive items and DO NOT stand on them. Protect from heat. Long lengths of slack must be gathered

and neatly coiled. DO NOT place cables where they could endanger other people.

8DO NOT touch the torch or workpiece immediately after welding as they will be very hot. Allow to cool.

8DO NOT operate welder while under the influence of drugs, alcohol or intoxicating medication, or if tired.

9When not in use store the welder in a safe, dry, childproof area.

1.3. GAS SAFETY

9Store gas cylinders in a vertical position only and ensure that the storage area is correctly secured.

8DO NOT store gas cylinders in areas where temperature exceeds 50°C. DO NOT use direct heat on a cylinder. Always keep gas

cylinders cool.

8DO NOT attempt to repair or modify any part of a gas cylinder or valve and DO NOT puncture or damage a cylinder.

8DO NOT obscure or remove any official cylinder labels.Always check the gas identity before use. Avoid getting gas cylinders oily or

greasy.

8DO NOT lift a cylinder by the cap, guard or valve. Always keep caps and guards in place and close valve when not in use.

2. INTRODUCTION

2.1. Excellent continuous performance on car panel thickness material. Forced Air Cooling System allows high duty cycle. Binzel®

non-live Euro torch reduces accidental arcing and is comfortable in the hand thus ensuring a steadier weld bead. Welds stainless

and aluminium too. Includes industrial gas regulator, contact tips 0.6, 0.8mm and gas cup.

2.2. IMPORTANT: These instructions contain information you require to prepare your machine for welding, together with a maintenance

and trouble shooting section. If you have no previous experience the instructions are not intended to show you how to become a

welder. Should you have no experience, we recommend that you seek training from an expert source. MIG welding is relatively easy

to perform, but does require a steady hand and time practising under supervision with scrap metal as it is only with continued practice

that you will achieve the desired results.

3. SPECIFICATION

Welding Current:.......................................................30-200A

Wire Capacity:.............................................................5-15kg

Duty Cycle:............ 100% @ 62A, 60% @ 80A, 15% @ 160A

Cooling System:.....................................................Forced Air

Spot Welding Timer:.........................................................Yes

Gas Type:..................................CO2, Argon, CO2/Argon Mix

Torch:..........................3mtr Euro Non-Live - BINZEL® MB15

Supply:.................................................................230V-16A**

Absorbed Power:..........................................................7.4kW

Case Size:.....................................................................Large

** (To achieve max. power a 32A supply required)

Original Language Version

4. ASSEMBLY & PREPARATION

4.1. ASSEMBLING GAS PLATFORM: (Refer to ‘P’ in figs.1 & 2) Turn the welder upside down on a smooth non-abrasive surface. The

welder should be turned over by two people as it is very heavy.

4.1.1. The gas platform is held in place with 7 M6 x 10mm bolts requiring a 10mm spanner. The casing has pre-prepared threaded inserts

ready to take the fixings. Place the platform onto the base of the welder with the axle uppermost and fix in place with 3 bolts. See (X)

in fig.1 below.

4.1.2. Insert the remaining four bolts through the two fixing flanges laying on the back of the welder. See (X) in fig.2. Finally, tighten all 7

bolts.

4.2. ASSEMBLING THE WHEELS: (Refer to fig.1)

4.2.1. Slide a wheel (Y) over each end of the solid axle attached to the gas platform. Slide a washer over each end of the axle and insert a

split pin (Z) through the hole in each end of the axle and bend it over to retain the wheels.

4.2.2. Bolt the two castors (W) to the front end of the base using the 8 bolts provided. The casing has pre-prepared threaded inserts ready to

take the fixings. See fig.1.

4.2.3. With the assistance of another person turn the welder the right way up onto its wheels.

4.2.4. The Gas Cylinder Bracket (Item 36 see parts diagram) can be found stored inside the wire feed compartment, in the top corner above the

wire feed assembly. Remove from this location and fix to the rear of the machine.

4.3. ASSEMBLING THE EARTH CLAMP: (Refer to fig.3) Feed the eyelet on the end of the earth lead through the

hole in the clamp arm as shown in fig.3A.

4.3.1. Drop the eyelet over the terminal and firmly fix with the bolt provided as shown in fig.3B.

4.4. INSTALLING THE GAS CYLINDER. The welder is designed to accommodate small or medium sized

gas cylinders up to a maximum height of 1000mm. Contact your local Gas dealer for supply.

4.4.1. Place the gas cylinder onto the rear platform of the welder. See fig.2-P. Place one end of the fixing chain

into one side of the retaining bracket. Draw the chain around the cylinder and place it into the slot on

the other side of the bracket leaving as little slack in the chain as possible.

4.5. ATTACHING THE REGULATOR. Whichever gas you are using it is advisable to ‘crack’ the cylinder valve before attaching the regulator.

This means opening and closing the valve very quickly in order to blow away any dust and dirt that may have accumulated in the gas

outlet. Stand to one side whilst doing this.

4.5.1. CO²GAS. Ensure that the threads on the gas bottle are undamaged and free of oil and grease before attaching the regulator. (Oil or

grease in the presence of high pressure gases can be explosive).Ensure that the regulator has an undamaged gasket fitted.

The regulator will screw directly to the threads on the gas bottle. Tighten with a spanner.

g.1 g.2

g.3

g.4

Original Language Version

4.5.2. ARGON GAS OR ARGON MIXTURES.Cylinders containing Argon gas andArgon mixtures have a female thread and will require the use

of a Bull Nose Adaptor to attach the regulator to the cylinder as indicated in fig.4. Ensure that the threads on the gas bottle are undamaged

and free of oil and grease before attaching the regulator. (Oil or grease in the presence of high pressure gases is explosive).Fit the

Bull Nose Adaptor to the cylinder first and tighten with a spanner. Ensure that the regulator has an undamaged gasket before fitting

onto the Bull Nose Adaptor. Tighten with a spanner.

4.5.3. Slide a clip over each end of the gas hose supplied. Push one end of the hose onto the regulator outlet and the other end over the gas

inlet spigot on the back of the welder. See fig.2G. Tighten the clips to ensure a good seal.

4.5.4. Close the regulator valve by turning it anti-clockwise before opening the cylinder valve. Stand to one side when opening the cylinder valve.

4.5.5. Set the regulator flow rate to 5-8 litres/min depending on the material to be welded, and whether there are draughts which are strong

enough to disturb the gas flow.

4.6. CONNECT THE TORCH CABLE TO THE WELDER. Align the pins on the Euro connector with the socket on the welder front panel

as shown in g.5. Push the connector into the socket and rotate the locking ring (A) clockwise so that it draws the plug into the

socket as shown in g.6.

NOTE: damage to torches and cables is not covered by warranty.

4.7. FITTING A 15KG REEL OF WIRE. Ensure that the wire diameter used, is matched by the correct groove size in the drive wheel and

the correct tip size on the torch as well as the correct torch liner. Failure to do this could cause the wire to slip and/or bind.

4.7.1. Unscrew the locking knob from the end of the spool holder (see fig.7C) and remove the spacer (fig.7B). The spacer is not required for

15kg reels of wire. Slide the reel of wire onto the spool holder and ensure that the clutch pin at the back of the spool holder (fig.7E)

engages into the guide hole in the wire reel moulding. This will prevent the wire reel from freewheeling on the spool holder. Ensure

that the wire is coming off the bottom of the reel in the direction of the wire drive unit as shown in fig.8.

4.8. FITTING A 5KG REEL OF WIRE. Ensure that the wire diameter used, is matched by the correct groove size in the drive wheel and

the correct tip size on the torch as well as the correct torch liner. Failure to do this could cause the wire to slip and/or bind.

4.8.1. Unscrew the locking knob from the end of the spool holder (see fig.7C) and remove the spacer. Slide the reel of wire onto the spool

holder and ensure that the clutch pin at the back of the spool holder (fig.7E) engages into the guide hole in the wire reel moulding. This

will prevent the wire reel from freewheeling on the spool holder.

4.8.2. Slide the spacer onto the spool holder and retain it by screwing the knob into place as shown above in fig.9. Ensure that the wire is

coming off the bottom of the reel in the direction of the wire drive unit as shown in fig.10.

g.5 g.6

g.7 g.8

g.9 g.10

Original Language Version

4.9. FEED WIRE THROUGH TO TORCH. Referring to fig.12 open the wire feed mechanism by pushing the locking/wire tension knob

(fig.12.1) down to the right allowing the pressure roller carrier (Fig.12.2) to spring up revealing the feed roller. Ensure that the required

feed groove (0.6 or 0.8) is in line with the wire path. See Section 4.12 on how to reverse or change the roller.

4.9.1. Release the wire from the reel and cut off any bent portion ensuring that there are no burrs left on the end of the wire. Keep the wire under

tension at all times to prevent it uncoiling.

4.9.2. Straighten about 40-50mm of wire and gently push it through the flexible metal sheathed cable (fig.12.3) and through the 6 or 8mm feed

roller groove and on into the torch cable liner.

4.9.3. Push down the pressure roller carrier onto the wire feed roller and hold it down. Lift up the locking/wire tension knob so that it enters the slot

in the pressure roller carrier and snaps into the indent in its top surface. See fig.13. Rotate the tension knob to a medium setting i.e. between

2 and 3.

4.9.4.4.9.4. Remove gas cup (fig.11-2) and contact tip (1) from end of torch as follows:Remove gas cup (fig.11-2) and contact tip (1) from end of torch as follows: a) Take torch in left hand with the torch tip facing to the right.a) Take torch in left hand with the torch tip facing to the right.

b) Grasp gas cup firmly in your right hand.b) Grasp gas cup firmly in your right hand.

c) Turn gas cup clockwise only and pull it off end of torch tip.c) Turn gas cup clockwise only and pull it off end of torch tip.

WARNING! DO NOT turn gas cup anti-clockwise, as this will

damage the internal spring.

d) Unscrew copper contact tip (right hand thread) to remove.d) Unscrew copper contact tip (right hand thread) to remove.

4.9.5. Check welder is switched off “0”, and that the earth clamp is away

from the torch tip. Connect the welder to the mains power supply

and set the voltage switch to one.

4.9.6. Set the wire speed knob to position 5 or 6. Keep the torch cable as straight as possible and press the torch switch. The wire will feed

through the torch.

4.9.7. When the wire has fed through, switch welder off, unplug from mains.

a) Take torch in left hand, slide the contact tip over the wire and screw back into place.

b) Grasp gas cup in right hand, push onto torch head and turn clockwise only.b) Grasp gas cup in right hand, push onto torch head and turn clockwise only. DO NOTDO NOT turn gas cup anti-clockwise, as this will damageturn gas cup anti-clockwise, as this will damage

the internal spring.the internal spring.

c) Cut wire so that it is just protruding from the cup.c) Cut wire so that it is just protruding from the cup.

4.10. SETTING WIRE TENSION. Adjust the wire tension by rotating

the wire tension knob. Turn clockwise to increase the tension and

anticlockwise to decrease the tension. See (1) in fig13.

IMPORTANT:IMPORTANT: Too little or too much tension will cause problematicToo little or too much tension will cause problematic

wire feed and result in poor welding.wire feed and result in poor welding.

4.10.1. Tension between rollers is checked by slowing down the wire

between gloved fingers. If top feed roller skids the tension is

correct. Use as low a tension as possible, too high a tension will

disfigure wire and result in a blown fuse.

4.11. CLUTCH ADJUSTMENT. Note: It is essential that the clutch is

adjusted correctly.

4.11.1.4.11.1. OOnce the wire is fed through the torch, switch on the machine andnce the wire is fed through the torch, switch on the machine and

set the wire speed to maximum.set the wire speed to maximum.

4.11.2.4.11.2. DDepress torch switch and release quickly. If the spool overruns itepress torch switch and release quickly. If the spool overruns it

indicates that the clutch is too loose.indicates that the clutch is too loose.

4.11.3.4.11.3. TTighten the clutch nut located in the centre of the wire spool holderighten the clutch nut located in the centre of the wire spool holder

with a spanner (fig.7-D) and test the machine as above until thewith a spanner (fig.7-D) and test the machine as above until the

wirewire stops over running.

8DO NOT over tighten the clutch as this will cause wire feed

problems and strain the motor.

4.12.4.12. TTURNING/CHANGING THE DRIVE ROLLERURNING/CHANGING THE DRIVE ROLLER..(See fig.14)(See fig.14)

Ensure that the wire diameter used, is matched by the correct

groove size in the drive wheel and the correct tip size on the torch

as well as the correct torch liner. Failure to do this could cause the wire to slip and/or bind.

4.12.1. Referring to fig.12, open the wire feed mechanism by pushing the locking/wire tension knob (fig.12.1) down to the right allowing the

pressure roller carrier (fig.12.2) to spring up revealing the feed roller.

4.12.2.4.12.2. RReferring to fig.14, loosen and unscrew the black feed roller retaining knob (fig.14.C) and put to one side.eferring to fig.14, loosen and unscrew the black feed roller retaining knob (fig.14.C) and put to one side.

4.12.3.4.12.3. TThe roller carrier (fig.14.A) is keyed to the main drive shaft and the drive roller (fig.14.B) is keyed to the carrier, see below. Place a fingerhe roller carrier (fig.14.A) is keyed to the main drive shaft and the drive roller (fig.14.B) is keyed to the carrier, see below. Place a finger

onto the end of the drive shaft to prevent the carrier moving and slide the drive roller off the carrier with your other hand.onto the end of the drive shaft to prevent the carrier moving and slide the drive roller off the carrier with your other hand.

4.12.4. The size of each wire feed groove is printed on the edge of the roller on the same side as the groove.

g.11

g.12 g.13

Original Language Version

g.14

SUPERMIG200.V2 Issue 1 11/07/22

4.12.5.4.12.5. TTurn the roller over to use the other groove or use a roller with different sized grooves as required. The groove to be used should beurn the roller over to use the other groove or use a roller with different sized grooves as required. The groove to be used should be

positioned furthest away from you to be in line with the drive path.positioned furthest away from you to be in line with the drive path.

4.12.6.4.12.6. CCheck that the key in the carrier (fig.14.A) is properly seated in its slot. Ensure that the slot on the inside face of the drive roller (fig.14.B)heck that the key in the carrier (fig.14.A) is properly seated in its slot. Ensure that the slot on the inside face of the drive roller (fig.14.B)

is aligned with the key and slide the roller back onto the carrier.is aligned with the key and slide the roller back onto the carrier.

4.12.7.4.12.7. SScrew the black roller retaining knob (fig.14.C) back on to the end of the drive shaft and tighten.crew the black roller retaining knob (fig.14.C) back on to the end of the drive shaft and tighten.

5. 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.

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.

5.1. PREPARATION FOR WELDING

IMPORTANT: BEFORE YOU COMMENCE, MAKE SURE THE MACHINE IS SWITCHED OFFAT THE MAINS. IF WELDING A CAR,

DISCONNECT THE BATTERY OR FITAN ELECTRONIC CIRCUIT PROTECTOR. WE STRONGLY RECOMMEND THE USE OF

A Sealey “PROSAF/12V OR 24V IN ORDER TO PROTECT SOPHISTICATED ELECTRONICS. ENSURE YOU HAVE READ &

UNDERSTOOD THE ELECTRICAL SAFETY INSTRUCTIONS IN CHAPTER 1.

NOTE! When welding on a tilted plane ensure the welder is stable and is not in danger of falling over. Ensure the welder is sufficiently secured.

5.2. 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 stockist.

5.2.1. Power Output switch. Set the switch to position 1 or 2 for welding

up to 2mm thickness. Use settings 3,4,5,6. for thicker welds.

5.2.2. Setting the welder controls. In principle, the lower the amperage

required, the slower the wire speed. See setting chart below for

voltage and corresponding wire speeds. Note: these settings are

only a guide and will vary according to the operator’s experience.

5.2.3. 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.

5.2.4. To weld aluminium use:

✓Argon gas,

✓0.8mm Contact Tip,

✓0.8mm Aluminium Wire,

5.3. OVERLOAD PROTECTION.

5.3.1. 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

5.3.2. Spot Welding. Spot welding may be carried out as shown in fig.16.

It will be necessary to fit a spot welding gas cup.

(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.

may be employed.

5.3.3. Use the wire feed control

in conjunction with the spot

weld timer beside 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.

g.15

Spot Welding Timer 6

Wire 0.6mm Steel

Argon / CO² Mix

Voltage

Step: 1 2 3 4 5 6

Wire

Speed: 5 6 7 8 9 10

SETTINGS SHOWN

AS GUIDE ONLY

g.16

Original Language Version

6. RATINGS PLATE

On the front of the welder is the ratings plate, giving the

following data:

1 - The standard relating to the safety and construction

of arc welding and associated equipment.

2 - Single phase transformer - rectifier.

3 - Welding with a continuous flow of welding wire.

4 - Single-phase AC supply.

5 - Rating of internal protection provided by casing.

6 - Output

U0: Rated minimum & 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% indicates continuous welding.

7 - Mains Supply U1: Rated supply voltage and frequency. Imax: Maximum current. I1eff: Maximum effective current.

8 - Welding current range.

9 - Serial Number. Specifically identifies each welder. (example shown).

7. MAINTENANCE

7.1. 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 feed affects welding. Clean the rollers weekly, especially the feed roller groove, removing all dust deposits.

7.2. TORCH Protect the torch cable assembly from mechanical wear. Clean the liner from the machine forwards by using compressed air. If

the liner is clogged it must be replaced.

7.3. CHANGING FEED ROLLER (See Section 4.12)

7.4. CONTACT TIP 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. Refer to fig.11 and section 4.9.4 to 4.9.7 for removal and

replacement.

7.5. GAS CUP 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/722308) available from your Sealey Stockist. Refer to

fig.11 and section 4.9.4 to 4.9.7 for removal and replacement.

7.6. REPLACING THE LINER Wind the wire back on to the spool and secure it. Unscrew the torch from the machine and undo the brass

nut. The liner should now be visible. Pull it out and replace with a new one.

Original Language Version

8. TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE REMEDY

1. Power source stops Overheating protection activated due

to overload Protection automatically resets when transformer has cooled

(about 15 min)

2. No weld current Rectifier blown Replace rectifier

3. No weld current Bad connection between clamp &

workpiece Clean or grind contact surface and weld area

Break in earth lead Repair or replace earth lead.

Break in torch lead Repair or replace torch

4. Feed motor not working, lamp is

on Gear damaged or worn Replace gears. (Contact service agent)

Motor defective Replace motor (Contact service agent)

5. Wire does not feed, feed roller

rotates Pressure roller improperly adjusted Adjust tension

Dirt, copper, dust, etc, has collected

in torch liner Clean the liner from the machine forward. Use compressed

air. If too much dirt, replace the liner.

Gas cup (Nozzle) or tip defective Replace gas cup (nozzle) and/or tip. (Section 4.9.4 to 4.9.7)

Deformed wire Check roller tension and adjust it if necessary (Section 4.10)

6. Wire feeds unevenly Dirt, etc, in liner Clean the liner from the machine forward. Use compressed

air

Gas cup (Nozzle) or Tip defective Replace gas cup (nozzle) and/or tip. (Section 4.9.4 to 4.9.7)

Gas cup (Nozzle) spattered Clean or replace gas cup (nozzle) (Section 4.9.4 to 4.9.7)

Feed roller groove clogged Clean feed roller. (Section 4.12).

Feed roller groove deformed Replace feed roller. (Section 4.12)

Pressure roller tension improper Adjust tension. (Section 4.12)

7. Unstable arc Incorrect settings Check settings. (Section 5)

Impurities in weld area Clean and/or grind workpiece. (Section 5.1)

Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 4.9.4 to 4.9.7)

8. Porous weld No gas Open gas cylinder, regulate gas flow

Gas cup clogged Clean or replace cup. (nozzle) (Section 4.9.4 to 4.9.7)

Draft blowing away shielding gas Screen off welding site or increase gas flow

Rusty or dirty joints Clean and/or grind workpiece. (Section 5.1)

Torch too far from or at wrong angle

to work The distance from gas cup to workpiece should be 8 to 10mm

Gas leak Check hoses, connections and torch assembly. (Section 4.5).

Press the gas cup in correction position

Faulty Electrovalve Clean out or replace

9. Electrode sticking in gas cup

(nozzle) Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 4.9.4 to 4.9.7)

Electrode deformed Check roller tension. (Section 4.10)

Wire speed too slow See recommendations for wire speed

10. Irregular weld bead Torch incorrectly held Use correct torch angle

Wire weaving in weld pool Check roller tension and adjust as needed. (Section 4.10)

11. Weld bead too narrow and

raised Weld current too low Increase power and wire speed. (Section 5)

Weld speed too high Move torch slower and weave a little more

12. Weld bead too wide Weld current too high Decrease power and wire speed. (Section 5)

Weld speed too low Move torch faster and weave less

Arc too long Bring torch closer to workpiece

13. Poor penetration Weld current too low Increase power and wire speed. (Section 5)

Arc too long Bring torch closer to workpiece

14. Excessive penetration Weld current too high Decrease power and wire speed. (Section 5)

Weld speed too slow Move torch faster

Incorrect distance of torch to

workpiece Torch distance should be 8-10mm

SUPERMIG200.V2 Issue 1 11/07/22

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR

01284 757500 01284 703534 sales@sealey.co.uk www.sealey.co.uk

ENVIRONMENT PROTECTION

Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to

a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely

unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids

according to local regulations.

WEEE REGULATIONS

Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment

(WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid

waste authority for recycling information.

Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior

notice.

Important: No Liability is accepted for incorrect use of this product.