SEALEY SUPERMIG200.V2 200A Professional MIG Welder with Binzel Euro Torch Instructions

SEALEY SUPERMIG200.V2 200A Professional MIG Welder with Binzel Euro Torch

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

SAFETY

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. 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.

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.

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).

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

5.  Regularly inspect power supply, leads, plugs for wear and damage and all electrical connectionsto ensure that none is loose.

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.

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

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

9. DO NOT use worn or damaged leads, plugs or connections. Immediately replace or have repaired by a qualified electrician.

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:

    • Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
    • Connect the BROWN live wire to live terminal ‘L’.
    • Connect the BLUE neutral wire to the neutral terminal ‘N’.
    • 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.

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.

GENERAL SAFETY

• DANGER! Unplug the welder from the mains power supply before performing maintenance or service.
• Keep the welder and cables in good condition. Take immediate action to repair or replace damaged parts.
• Use genuine parts and accessories only. Unapproved parts may be dangerous and will invalidate the warranty.
• Use an air hose to regularly blow out any dirt from the liner and keep the welder clean for best and safest performance.
• Check and spray the gas cup and contact tip regularly with anti-spatter spray which is available from your Sealey stockist.
• Locate the welder in a suitable work area. Ensure that the area has adequate ventilation as welding fumes are harmful.
• Keep 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.
• Remove ill fitting clothing, remove ties, watches, rings and other loose jewellery and contain long hair.
• Ensure that the workpiece is correctly secured before operating the welder.
• Avoid unintentional contact with workpiece. Accidental or uncontrolled use of the torch may be dangerous and will wear the nozzle.
• Keep unauthorised persons away from the work area. Any persons working within the area must wear protective head shield and gloves.
• Operators must receive adequate training before using the welder.
• Stand correctly, keeping a good footing and balance, and ensure that the floor is not slippery. Wear non-slip shoes.
• Turn voltage switch to OFF when not in use.
• DO 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.
• DO 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.
• DO NOT stand welder on a metal workbench, car bodywork or similar object.
• DO NOT touch any live metal parts of the torch or electrode while the machine is switched on.
• DO NOT pull the welder by the cable or the torch and DO NOT bend or strain cables.
• Protect 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.
• DO NOT touch the torch or workpiece immediately after welding as they will be very hot. Allow to cool.
• DO NOT operate welder while under the influence of drugs, alcohol or intoxicating medication, or if tired. When not in use store the welder in a safe, dry, childproof area.

GAS SAFETY

• Store gas cylinders in a vertical position only and ensure that the storage area is correctly secured.
• DO NOT store gas cylinders in areas where temperature exceeds 50°C. DO NOT use direct heat on a cylinder. Always keep gas cylinders cool.
• DO NOT attempt to repair or modify any part of a gas cylinder or valve and DO NOT puncture or damage a cylinder.
• DO NOT obscure or remove any official cylinder labels. Always check the gas identity before use. Avoid getting gas cylinders oily or greasy.
• O NOT lift a cylinder by the cap, guard or valve. Always keep caps and guards in place and close valve when not in use.

INTRODUCTION

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. 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.

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)

ASSEMBLY & PREPARATION

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.

2. 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.

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

5. 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.

6. 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.

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

8. 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.

9. 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.
   Drop the eyelet over the terminal and firmly fix with the bolt provided as shown in fig.3B.
   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.

10. 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 fig.4 the other side of the bracket leaving as little slack in the chain as possible.

11. 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.

12. CO² GAS. 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.

13. ARGON GAS OR ARGON MIXTURES. Cylinders containing Argon gas and Argon 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.

14. 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.

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

16. 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.

17. 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 fig.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 fig.6.
    NOTE : damage to torches and cables is not covered by warranty.

18. 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.

19. 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.

20. 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.

21. 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.

22. 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.

23. 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.

24. 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.

25. 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.

26. 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.

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

    • Grasp gas cup firmly in your right hand.Grasp gas cup firmly in your right hand.
    • Turn gas cup clockwise only and pull it ofurn gas cup clockwise only and pull it off f end of torch tip.end of torch tip.

28. WARNING! DO NOT turn gas cup anti-clockwise, as this will damage the internal spring.

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

29. 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.

30. 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.

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

    • Take torch in left hand, slide the contact tip over the wire and screw back into place.
    • Grasp gas cup in right hand, push onto torch head and turn clockwise onlyGrasp gas cup in right hand, push onto torch head and turn clockwise only. . DO NOTDO NOT turn gas cup anti-clockwise, as this will damage turn gas cup anti-clockwise, as this will damage the the internal internal spring.spring.
    • Cut wire so that it is just protruding from the cup.Cut wire so that it is just protruding from the cup.

32. 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. IMPORTIMPORTANTANT:: TToo little or too much tension will cause problematicoo little or too much tension will cause problematic wire feed and result in poor welding.wire feed and result in poor welding.

33. 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.

34. CLUTCH ADJUSTMENT. Note: It is essential that the clutch is adjusted correctly.

35. TTURNING/CHANGING THE DRIVE ROLLERURNING/ROLLER.. (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.

36. 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.

37. RReferring to fig.14, loosen and unscrew the black feed roller retaining knob (fig.14.C) and put to one side. eferring 4.12.3.

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

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

40. Turn the roller over to use the other groove or use a roller with difurn the roller over to use the other groove or use a roller with different sized grooves as required. ferent sized grooves as required. The groove to be used should beThe 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.

41. Check 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 carrieris aligned with the key and slide the roller back onto the carrier..

42. Screw 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.

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.

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. 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.

CONNECTING THE EARTH LEAD.
T o ensure a complete circuit, the earth lead must be securely attached to the work piece that is to be welded.

• Best connection is obtained by grinding clean the point of contact on the workpiece before connecting the earth clamp.
• The weld area must also be free of paint, rust, grease, etc.
• When welding a vehicle, be sure the vehicle battery is disconnected or fit an Electronic Circuit Protector available from your Sealey stockist.

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.

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. 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.

3. 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.

4. To weld aluminium use:

   • Argon gas,
   • 0.8mm Contact Tip,
   • 0.8mm Aluminium Wire,

OVERLOAD PROTECTION.
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 Spot Welding. Spot welding may be carried out as shown in fig.16. It will be necessary to fit a spot welding gas cup.

• Overlapping metal sheets with a maximum thickness of 0.8 mm may be welded as indicated.
• Alternatively they may be welded edge to surface as indicated.
• For thicker sheet pre drilled holes may be employed.

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.

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).

MAINTENANCE

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.

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.

3. CHANGING FEED ROLLER (See Section 4.12)

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.

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.

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.

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