Sealey SUPERMIG 250 - User Manual

INSTRUCTIONS
SUPERMIG 250/10
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.
01284 757500 01284 703534
E-mail sales@sealey.co.uk
SUPERMIG250-Job181-280198
2. INTRODUCTION & DESCRIPTION
These instructions are to assist you prepare your mig set for welding together with information on maintenance, and trouble shooting. Read this
manual carefully in order to get the best results from your welding set. The instructions are not intended to show you how to be an expert welder.
It is with continued practice that you will achieve the desired results. Mig welding requires a steady hand, time spent practising with scrap metal
will gain rewards when you progress to an actual workpiece.
Supermig 250/10 is a compact power source fitted with a heavy duty wire feed motor. The wire feed system itself is automatic thus providing
the best possible opportunity to achieve the most effective weld. The machine operates on a forced air cooling system to slow the transformer
heating in order to increase the duty cycle, and a non live torch to prevent the risk of accidentally striking an arc.
IMPORTANT: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. MAKE CAREFUL NOTE OF SAFETY iNSTRUCTIONS,
WARNINGS AND CAUTIONS. THIS PRODUCT SHOULD ONLY BE USED FOR ITS INTENDED PURPOSE. FAILURE TO DO SO MAY CAUSE DAMAGE
OR PERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY.
1. SAFETY INSTRUCTIONS
1.1 ELECTRICAL SAFETY. WARNING! It is the users responsibility to check the following:
You must check all electrical equipment and appliances to ensure they are safe before using. 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. W
e recommend that an RCD (Residual Current Device) is used with all electrical
products. It is particularly important to use an RCD together with portable products that are plugged into an electrical supply not protected by an RCCB. If in doubt
consult a professional electrician. Y
ou 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 a business premises, to be tested
by a qualified person at least once a year by using a Portable Appliance Tester (PAT).
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 product itself is safe before connecting to mains power supply. See 1.1.2. use a (PAT).
1.1.4. Ensure that cables are always protected against short circuit and overload.
1.1.5. Regularly check power supply, leads, plugs and all electrical connections for wear or damage, especially power connections
to ensure none are loose.
1.1.6. Check the voltage marked on the product is the same as the electrical power supply to be used. Check fused plugs
are fitted with correct capacity fuse.
1.1.7. DO NOT pull or carry the powered appliance by its power supply lead. Products such as welders
must not be pulled or carried by their output cables.
1.1.8. DO NOT pull power plugs from sockets by the power cable.
1.1.9. DO NOT use worn or damage leads, plugs or connections. Immediately replace or repair
by qualified persons. A U.K. 3 pin plug with ASTA/BS approval is fitted. In case of damage,
cut off and fit a new plug according to the following instructions (UK only - see diagram at right).
1.2 GENERAL SAFETY
p p
p
WARNING: unplug the welder from the mains power supply before performing maintenance or service.
3Keep the welder and cables in good working order and condition. Take immediate action to repair or replace damaged parts.
3Use recommended parts and accessories only. Non recommended parts may be dangerous and will invalidate the warranty.
3Check the gas cup and contact tip, and spray regularly with anti-spatter spray available from your Sealey dealer.
Note: to remove gas cup ready instruction part 3.3.6. carefully.
3Use an air hose to regularly blow out any dirt from the liner, and keep the welder clean for best and safest performance.
3Locate the welder in an adequate working area for its function, and ensure the area is well ventilated.
3Keep working area clean and tidy and free from unrelated materials. Also ensure the working area has adequate lighting.
p p
p
WARNING: use welding head shield to protect your eyes against ultraviolet rays, and safety welding gauntlets.
3Keep children and unauthorised persons away from the working area.
3T
urn voltage switch to "0" (off) when not in use.
3Stand correctly keeping a good footing and balance, and ensure the floor is not slippery.
3Remove ill fitting clothing, remove ties, watches, rings, and other loose jewellery, and contain long hair.
7DO NOT store gas cylinders in areas where temperature exceeds 50°C.
7DO NOT puncture or damage the gas cylinder.
7DO NOT use the welder in damp or wet locations.
p p
p
DANGER! DO NOT weld near inflammable materials, solids, liquids, or gases.
7DO NOT operate welder while under the influence of drugs, alcohol or intoxicating medication, or if fatigued.
7DO NOT operate the welder if it or its cables are damaged.
7DO NOT allow untrained persons to operate the welder
.
7DO NOT pull the welder by the cable, or the torch, and DO NOT bend the torch.
Blue
Neutral
wire
Yellow
& Green
Earth wire
Brown Live wire
13 amp
3 pin
plug
a) Ensure the unit is correctly earthed via a three-pin plug.
b) Connect the Green/Yellow earth wire to the earth terminal E.
c) Connect the Brown live wire to live terminal L.
d) Connect the Blue neutral wire to the neutral terminal N.
WARNING! If you use the machine constantly at its higher power
settings, the welder must be plugged into a 30amp fused power
supply. If you are unsure if there is a 30amp supply at your premises,
contact a qualified electrician before proceeding further. (For the use
of a normal 13amp supply follow plug fitting instructions.

Summary

SAFETY INSTRUCTIONS

ELECTRICAL SAFETY

User responsibility to check electrical equipment, leads, plugs for wear and damage.

GENERAL SAFETY

General safety precautions for welder, cables, working area, and personal protection.

ASSEMBLY

Wheel Assembly

Instructions for attaching castor and rear wheels to the welder body.

Connecting the Gas Cylinder

Steps for connecting the gas cylinder, regulator, and hose to the machine.

Fitting a Reel of Wire

Procedure for mounting wire spool, threading wire through the torch.

Setting Wire Tension

How to adjust wire tension for optimal feed and weld quality.

Clutch Adjustment

Steps to adjust the clutch to prevent spool overrunning.

Euro Connection

How to connect and disconnect the Euro connection torch.

MIG;MAG WELDING

Principles of MIG;MAG Welding

Explains the MIG/MAG welding process, torch connection, and shielding gas.

Preparation for Welding

Steps for connecting the earth lead and preparing the workpiece for welding.

Setting Up

Guidance on selecting voltage step and adjusting wire feed for optimal welds.

Welding Mild Steel

Advice on using CO2 or Argon/CO2 mixtures for welding mild steel.

Welding Aluminium

Recommended settings and consumables for welding aluminium.

VARIOUS WELDING METHODS

Welding Torch Positioning

Importance of torch position, angle, and direction for weld appearance and quality.

Welding in General

Explains how arc length affects penetration, weld width, and spatter.

Welding Methods Explained

Illustrations and descriptions of Rightward, Leftward, Vertical, and Fillet welding.

Markings and Symbols

Explains common markings and symbols used on welding equipment and specifications.

MAINTENANCE

Wire Feed Unit Maintenance

Regular checks and cleaning of the wire feed unit and rollers.

Torch Maintenance

Protecting the torch cable, cleaning the liner, and checking connections.

Contact Tip Care

Importance of keeping the contact tip clean and replacing it when worn.

Gas Cup (Nozzle) Maintenance

Keeping the gas cup clean to prevent short circuits and ensure gas flow.

Liner Replacement

Procedure for replacing the torch liner when it is clogged.

Changing Fuses

Reasons for fuse blowing and location on the circuit board.

Changing Feed Roller

Procedure for removing, cleaning, or replacing the feed roller.

Electrical Safety Checks

Requirement for qualified persons to perform electrical integrity checks.

WIRING DIAGRAM

TROUBLESHOOTING

Declaration of Conformity

Sealey SUPERMIG 250 Specifications

General

Max Output	250A
Output Current Range	40-250A
Wire Feed Speed	1.5-16 m/min
Wire Capacity	15kg
Wire Diameter	0.6 - 1.0mm
Duty Cycle	60% @ 250A