SEALEY SUPERMIG100 Gasless MIG Welder Instructions
- May 15, 2024
- SEALEY
Table of Contents
100A NO-GAS MIG WELDER
MODEL NO: SUPERMIG100
SUPERMIG100 Gasless MIG Welder
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.
SAFETY
1.1. ELECTRICAL SAFETY
‰ WARNING! It is the user’s responsibility to check the following:
Check all electrical equipment
and appliances to ensure that they are safe before using. Inspect power supply
leads, plug and all electrical connections for wear and damage. Sealey
recommend that an RCD (Residual Current Device) is used with all electrical
products.
Electrical safety information. It is important that the following information
is read and understood:
Ensure that the insulation on
all cables and on the appliance is safe before connecting it to the power
supply.
Regularly inspect power supply
cables and plugs for wear or damage and check all connections to ensure that
they are secure.
Important: Ensure that the voltage rating on the appliance suits the
power supply to be used and that the plug is fitted with the correct fuse.
DO NOT pull or carry the appliance by the power cable.
DO NOT pull the plug from the socket by the cable.
DO NOT use worn or damaged cables, plugs or connectors. Ensure that any
faulty item is repaired or is replaced immediately by a qualified electrician.
If the cable or plug is damaged during use, switch off the electricity supply
and remove from use.
Ensure that repairs are carried out by a qualified electrician.
1.2. 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 cable on the cable reel is important and should
be at least 1.5mm², but to be absolutely sure that the capacity of the cable
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.
‰ WARNING! Be very cautious if using a generator to power the welder. The
generator must be self-regulating and stable with regard to voltage, wave form
and frequency. The output must be greater than the power consumption of the
welder. If any of these requirements is not met the electronics within the
welder may be affected.
NOTE: The use of an unregulated generator may be dangerous and will
invalidate the warranty on the welder.
‰ WARNING! The welder may produce voltage surges in the mains supply which
can damage other sensitive equipment (e.g. computers). To prevent this
happening, it is recommended that the welder is connected to a power supply
that does not feed any sensitive equipment.
IMPORTANT! If using welder to full capacity, we recommend a 16amp supply.
We recommend you discuss the installation of a 16amp industrial round pin plug
and socket with your electrician.
1.3. GENERAL SAFETY
▲ DANGER! Unplug the welder from the mains power supply before performing
maintenance or service.
Keep the welder and cables in
good working order and 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, available from your Sealey
stockist.
Locate 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 the working 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 the workpiece is
correctly secured before welding.
Avoid unintentional contact
with the 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 a protective
head shield and gloves.
Operators must receive adequate
training before using the welder.
Stand correctly keeping a good
footing and balance, ensure the floor is not slippery and wear non-slip shoes.
DO NOT operate the welder if it or the cables are damaged and DO NOT attempt
to fit any unapproved torches or other components to the welder.
DO NOT get welder wet or use in damp or wet locations or areas where there
is condensation.
▲ DANGER! DO NOT weld near flammable solids, liquids or gases and DO NOT weld
containers or pipes which have held flammable materials. Avoid welding
materials which have been cleaned with chlorinated solvents or welding near
such solvents.
DO NOT stand welder on a metal workbench, car bodywork or similar.
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. Protect cables from sharp
or abrasive items. DO NOT bend, strain or stand on cables or leads.
Protect from heat. Long lengths
of slack must be gathered and neatly coiled. DO NOT place cables where they
endanger others.
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.
INTRODUCTION
IMPORTANT: These instructions contain the information you require to
prepare your machine for welding, together with a maintenance and a
troubleshooting section. The 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.
One of our SUPERMIG® range, this compact no-gas welder offers excellent
performance at an extremely competitive price. High output transformer and
forced-air cooling to maximize duty cycle performance. Supplied with 2m live
torch and 1.4m earth cable. Suitable for gasless operation only. For use with
flux cored wire only.
SPECIFICATION
Model No:………………………………………… SUPERMIG100
Welding Current: ………………………………………… 40 – 100A
Wire Capacity: …………………………………. 1kg Gasless only
Duty Cycle: ……. 100% @ 32A, 35% @ 54A, 10% @ 100A
Cooling System: ………………………………………… Forced Air
Spot Welding Timer: ……………………………………………… No
Gas Type: …………………………………………………………… N/A
Torch: ……………………………………………………………….. Live
Supply: ……………………………………………………. 230V-13A
Absorbed Power: …………………………………………….. 3.3kW
Case Size:………………………………………………….. Compact
Note: To achieve maximum power a 32A supply may be required.
ASSEMBLY
4.1. FIT HANDLE: Slide handle onto top cover. Secure with screw (19), see
Parts Diagram.
4.2. FIT COVER LOCKING SPRING: Fix Cover Locking Spring (8), see Parts
Diagram, to top of front panel. Use screw, washer and spring washer supplied.
See also fig.1.A.
4.3. FITTING A REEL OF WIRE
4.3.1. Depress the silver button in the front of the handle and open the top
compartment. See A & B in fig.1.
4.3.2. Referring to fig.2, rotate the butterfly nut (5) anti-clockwise and
remove it from the threaded spindle together with the pressure disc (4). Leave
the spring (1) on the spindle (2).
4.3.3. Place the wire reel (3) over the spindle and down onto the spring
ensuring that the wire will withdraw from the spool in a forwards direction
and on the same side of the compartment as the wire feed unit.
4.3.4. Push lightly down on the top of the reel of wire and screw the pressure
disc (4) onto the end of the spindle and down onto the top of the wire reel.
The reel take off pressure should be set to provide a mild braking effect to
prevent overrun where loose coils of wire form on the reel. DO NOT over
tighten the pressure disc as too much braking will conflict with the wire
tension set on the wire drive unit.
4.3.5. Lock the position of the pressure disc by screwing the butterfly nut
(5) down on top of it.
4.3.6. Referring to fig.1 turn the knob on the wire lock screw (C) anti-
clockwise and lift it up and away from the pressure roller moulding.
4.3.7. Swing the pressure roller moulding (D) away from the drive roller.
4.3.8. Release the wire from the spool (DO NOT allow wire to uncoil) and
straighten 40-50mm of wire and gently push through the flexible plastic guide
and through the same size groove on the feed roller as the wire you choose to
use.
4.3.9. Referring to fig.4, move the pressure roller moulding back round onto
the grooved drive wheel and swing down the wire lock screw to lock it in
place. See section 4.3 regarding wire tension.
4.3.10. Feeding the wire through to the torch. (See fig.5) Remove gas cup (a)
and contact tip (b) from end of torch as follows:
a) Take torch in left hand with the torch tip facing to the right.
b) Grasp gas cup firmly in your right hand.
c) Turn gas cup clockwise only and pull cup out to the right.
‰ WARNING! DO NOT turn gas cup anti-clockwise, as this will damage
internal spring.
d) Unscrew the copper contact tip (fig.5.b) (right hand thread) to remove.
4.3.11. Check welder is switched OFF 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 MIN.
4.3.12. Set the wire speed knob to position 5 or 6. Keeping the torch cable as
straight as possible and press the torch switch. The wire will feed through
the torch.
4.3.13. When 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 it
back into place.
b) Grasp gas cup in right hand, push onto torch head and turn clockwise only.
‰ WARNING! DO NOT turn gas cup anti-clockwise, as this will damage
internal spring.
c) Cut wire so that it is just protruding from the cup.
4.4. SETTING WIRE TENSION
IMPORTANT: You must set the correct tension, too little or too much
tension will cause problematic wire feed and result in a poor weld.
4.4.1. Correct tension between the rollers is checked by slowing down the wire
between gloved fingers. If the pressure roller skids the tension is correct.
Try to use the lowest tension possible as too high a tension will deform the
wire. When you have completed welding allow the welder to cool before storing
in a safe, dry place. Note: Damaged torches and cables are not covered under
warranty.
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.
RATINGS PLATE
On the front panel of the welder is the ratings plate, giving the following data:
-
The BS/EU standard relating to the safety and construction of arc welding and associated equipment.
-
Single phase transformer.
-
Symbol indicates welding with a continuous flow of welding wire.
-
Symbol for Single-phase AC supply.
-
Rating of internal protection provided by casing.
-
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. -
Mains Supply U1 Rated supply voltage and frequency.
I1max Maximum current.
I1eff Maximum effective current. -
Welding current range.
-
Serial Number. Specifically identifies each welder.
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.
7.3.2. Pull the roller off the drive spindle, flip it over and put it back on
the drive spindle. (See fig.10) The groove size you require should now be
visible on the face of the roller. Push the roller retainer back onto the
drive spindle with the opening facing right. Ensure that the flanges at the
base of the retainer, seat fully into the circular recess in the main moulding
and then rotate the retainer through 90° to lock it in place.
7.4. CONTACT TIP (to remove tip follow steps in 4.3.10.):
7.4.1. The contact tip is a consumable item and must be replaced when the bore
becomes enlarged or oval. The contact tip MUST be kept free from spatter.
7.5. GAS CUP (to remove cup follow steps in 4.3.10.):
7.5.1. 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 expensive machine repairs. To keep the contact tip free from
spatter, we recommend the use of anti-spatter spray (MIG/722308) available
from your Sealey stockist.
7.6. REPLACING WIRE LINER
7.6.1. A worn or damaged wire liner will seriously affect the performance of
the welder and should be immediately replaced. First wind the wire back onto
the spool and secure it. Remove the four screws securing the torch cable clamp
to the wire feed unit (fig.11) and take off the clamp.
7.6.2. Open the torch case by gripping the torch with one hand and turning the
grooved ring at the base of the torch anticlockwise until it stops, then pull
it off the torch onto the torch cable. See fig.12-1.
7.6.3. Take hold of the back end of the moulding which contains the switch and
pull it outwards and downwards to release it from the other moulding as shown
in fig.12.
7.6.4. Push the liner lock ring (2) firmly towards the brass nut and withdraw
the liner from the nut. With the torch cable as straight as possible pull the
liner from the torch cable.
7.6.5. Insert the new liner into the torch cable and secure it in the wire
drive unit by replacing the torch cable clamp. See fig.11. Insert the other
end of the liner through the locking ring and fully into the brass nut in the
torch head, see 2 in fig.12.
7.6.6. Check that the torch inner parts are properly seated in their
respective mouldings then close the torch by inserting the tongue on the
switch moulding (fig.12-5) into the slot at the front of the other moulding.
Swing the switch moulding downwards and forwards until both parts have closed
around the torch cable. Slide the ribbed ring (fig.12-1) onto the end of the
torch handle turn it clockwise to lock.
TROUBLESHOOTING
| PROBLEM | POSSIBLE CAUSE | REMEDY |
|---|---|---|
| Weld current interrupted | Overheating protection activated due to overload |
Protection automatically resets when transformer has cooled (approx. 15 min)
No weld current| Rectifier blown| Replace rectifier
No weld current| Bad connection between clamp and 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
Feed motor not working| Gear damaged or worn| Replace gears
Motor defective| Replace motor (Contact service agent)
Wire does not feed. feed roller rotates| Pressure roller improperly adjusted|
Adjust tension
Dirt. copper. dust, etc. have collected in torch liner| Clean the liner from
the machine forward. Use compressed air.
Gas cup (nozzle) or tip defective| Replace gas cup (nozzle) and/or tip. Check
roller tension
Deformed wire| Adjust roller tension
Wire feeds unevenly| Dirt, etc, in liner| Clean the liner from the machine
forward using compressed air
Gas cup (nozzle) or tip defective| Replace gas cup (nozzle) and/or tip
Gas cup (nozzle) spattered| Clean or replace gas cup (nozzle)
Feed roller groove clogged| Clean feed roller
Feed roller groove deformed| Replace feed roller
Pressure roller tension incorrect| Adjust tension
Unstable arc| Incorrect settings| Check settings
Impurities in weld area| Clean and/or grind workpiece
Worn or defective gas cup (nozzle)| Replace gas cup (nozzle)
Porous weld| Rusty/dirty joints| Clean or grind the workpiece
Torch too far from, or at wrong angle to. workpiece| Gas cup to workpiece
should be 8-10mm. Torch angle approx 75°
Wire sticking in gas cup (nozzle)| Worn or defective gas cup (nozzle)| Replace
gas cup (nozzle)
Wire deformed| Check roller tension
Wire speed too slow| Increase wire speed
Irregular weld head| Torch incorrectly held| Use correct torch angle
Wire weaving in weld pool| Check roller tension and adjust
Weld bead too narrow and raised| Weld current too low| Increase power and wire
speed
Weld speed too fast| Move torch slower and weave a little more
Weld bead too wide| Weld current too high| Increase power and wire speed
Weld speed too slow| Move torch faster and weave less
Poor penetration| Weld current too low| Increase current and wire speed
Arc too long| Bring torch closer to workprece
Excessive penetration| Weld current too high| Decrease current and wire speed
Weld current too slow| Decrease current and wire speed
Incorrect distance of torch to workpiece| Torch distance should be 8-10mm
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. Please note that other versions of this product are available.
If you require documentation for alternative versions, please email or call
our technical team on technical@sealey.co.uk
or 01284 757505.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 36 months from purchase date, proof of which is
required for any claim. Lifetime guarantee on Transformer.
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk.
IP32 7AR
01284 757500
sales@sealey.co.uk
www.sealey.co.uk
Original Language Version
© Jack Sealey Limited
SUPERMIG100 Issue 3 (1) 24/10/23
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