4.1.
Mig/Mag Welding.
A spool of welding wire is positioned on the welders spool holder and automatically fed through an insulated
liner in the torch to the tip. The torch assembly consist 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.
4.2.
Spot Welding.
Remove the gas cup and fit a spot welding gas cup. Turn the voltage to the highest setting allowed by your machine. Drill
a small hole in the top plate. Push the spot gas cup onto the material to be welded. The castellations on the cup keep it the correct
distance from the weld pool and allow you to push the two pieces being welded together. Press the torch trigger and hold it for 2 to 3 seconds.
The wire will feed through during the allotted time and create the weld.
4.3. 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 YOU HAVE READ AND UNDERSTOOD THE
ELECTRICAL SAFETY INSTRUCTIONS IN CHAPTER 1.
4. 3. 1. 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 the point of contact on the workpiece before connecting clamp to the workpiece.
b) The weld area must also be free of paint, rust, grease, etc.
c) If welding a vehicle, disconnected or fit a Electronic Circuit Protector available from your Sealey dealer.
4. 3. 2. Wire feed switch controls the speed of the wire feed. In principle, the lower the amperage number the slower the wire speed.
4. 3. 3. To weld mild steel, CO2 gas is suitable for most tasks where spatter and the high build up of weld do not pose a problem.
To achieve a spatter free and flat weld however,
you must use an Argon/CO2 mixture.
4. 3. 4. To weld aluminium use:
3
Argon gas,
3
0.8mm contact tip (AK957),
3
0.8mm aluminium wire.
Note:
Ensure you feed the wire through the correct sized groove in the feed roller (see 6.3).
4. WELDING PRINCIPLES & PREPARATION
The position of the torch,
its angle and direction of travel in
relation to the workpiece
is essential for the appearance
and quality of the weld.
Illustrations demonstrate various
positions and directions.
Rightward Welding
Welding in general
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.
Leftward Welding
Vertical Rightward Downhard leftward
Down Rightward
5. VARIOUS WELDING METHODS
1. Direction of
Welding
3. Fillet Weld
3. Butt Weld
Normal
Welding
Arc
Short
Welding
Arc
Long
Welding
Arc
IMPORTANT:
Should you have no welding experience, we recommend you seek training from an expert source to ensure your own personal
health and safety. Good mig welding may be achieved only with continued supervised practice.
3.4
Setting wire tension
IMPORTANT
: You must set the correct tension, too little or too much tension will cause problematic wire feed and result in poor welding.
3.4.1
The wire tension mechanism should only apply sufficient tension to the wire to successfully drive it out of the torch. Too much
tension will deform the wire causing wire feed problems and the possible blowing of a fuse on the printed circuit board. Too little
tension will result in the wire driving unevenly or not at all. To test for the correct tension wear welding gloves and attempt to
momentarily slow the wire down as it emerges from the torch. If the wire stops immediately the tension is too low. If the wire cannot
be stopped the tension is too high. If the upper roller slows down as the wire is gripped then the tension is correct. NOTE: Torches
and liners damaged as a result of incorrect wire tension settings are not covered by warranty.
p
WARNING!
When testing the wire tension as described above the wire emerging from the torch is live and should be directed
away from the welding unit and any other metallic / conductive materials in the area. Welding gloves must be worn during this operation.
3.5
Setting up drive roller / access for maintenance.
3.5.1
The drive roller is reversible and has two drive grooves on it, one for 0.6mm wire and one for
0.8mm wire. When the roller is in place it is always the groove that is nearest to you that is driven.
Each groove size is stamped onto the nearest face of the roller and the groove size in use will be
visible on the roller face when the roller retainer lock is removed.
3.5.2
To access the drive roller, first release the counter roller arm and hinge it up and
away from the drive roller. Take hold of the triangular roller retainer lock
( see fig.6B ) and turn it anticlockwise through 90
O
until it stops. Then pull it off the drive spindle to
reveal the drive roller beneath. Pull the roller off the square drive shaft and reverse it and/ or clean
it as necessary. When the roller is back in place take the roller retainer and orientate it so that the
hole in the side of it ( see fig.7-A ) is facing to the left and the two wings at the base of its rim are
orientated up and down. Push the roller retainer over the roller and spindle and turn it through 90
O
clockwise to lock it in place.
fig 7 .
SUPERMIG150/5.V2 - (1) - 241002
