IMPORTANT:
These instructions contain information you require to prepare your machine for welding, together with maintenance and a trouble
shooting section.
If you have no previous experience the instructions are not intended to show 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 time practicing under supervision
with scrap metal. You will only gain the required skills through continued practice.
Dualmig machines weld without external gas by using a flux-cored wire that creates its own gas shroud as it welds (the gas protects the molten
weld pool from the atmosphere. Without the gas the weld would oxidise, resulting in porosity). Gasless welding is used for mild steel and has
the advantage of keeping costs down as you do not need to purchase and store gas bottles. You can also weld in wind, breeze or draughts.
The units have integral wire feed which prevents dust and dirt getting to the wire. They are supplied with a 0.9mm flux-cored wire with which
only mild steel and low alloy steel can be welded.
NOTE:
To weld stainless steel and aluminium, models PMG110, PMG135XT and PMG155XT must be converted to gas. PMG100 is for gasless operation only.
2. INTRODUCTION & DESCRIPTION
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Keep others away from the work area. Anyone working within the area must wear protective head shield and gloves.
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Operators must receive adequate training before using the welder.
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Stand correctly keeping good footing and balance. Ensure that the floor is not slippery and wear non-slip shoes.
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Turn voltage switch to "0" (off) when not in use.
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DO NOT operate the welder if it or the cables are damaged.
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DO NOT attempt to fit any unapproved torch, component, or part to the welder unit.
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DO NOT get the welder wet or use in damp or wet locations or areas where there is condensation.
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DO NOT weld without a welding safety head shield.
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DANGER! DO NOT weld near flammable materials - solids, liquids or gases.
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DO NOT weld containers or pipes which have held flammable materials - gases, liquids or solids. Avoid welding
materials which have been cleaned with chlorinated solvents and DO NOT weld near such solvents.
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DO NOT stand welder on a metal workbench, car bodywork or similar.
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DO NOT touch any live metal parts of the torch or electrode while the machine is switched on.
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DO NOT pull welder by the cable, or torch, and DO NOT bend or strain cables. Protect cables from sharp or
abrasive items, and DO NOT stand on them.
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Protect cables from heat. Long lengths of slack must be gathered and neatly coiled.
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DO NOT place cables where they endanger others.
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DO NOT touch the workpiece close to the weld as it will be very hot. Allow to cool.
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DO NOT touch the torch immediately after use. Allow the torch to cool.
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DO NOT operate welder while under the influence of drugs, alcohol or intoxicating medication, or if tired.
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When not in use store the welder in a safe, dry, childproof area.
1.3.
IF USING GAS
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Ensure that you understand the properties and associated hazards before using a gas.
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Spray the gas cup and contact tip regularly with anti-spatter spray available from your Sealey dealer.
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Store gas cylinders in a vertical position only and ensure that the storage area is correctly secured.
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DO NOT store gas cylinders in areas where the temperature exceeds 50°C.
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DO NOT attempt to repair or modify any part of a gas cylinder or valve, and DO NOT puncture or damage a cylinder.
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DO NOT obscure or remove any official labels from a cylinder and always check the identity of the gas before use.
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DO NOT use direct heat on a cylinder. Always keep gas cylinders cool.
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DO NOT get a gas cylinder oily or greasy.
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DO NOT lift a cylinder by its cap, guard or valve. Always keep caps and guards in place and close valve when not in use.
3. SPECIFICATIONS
PMG100
PMG110
PMG135XT
PMG155XT
Welding Current
. . . . . . . . . . . . . . . . .55-90A . . . . . . . . . . . . . .55-90A . . . . . . . . . . . . .50-130A . . . . . . . . . . . . .50-150A
No Gas/Gas Operation
. . . . . . . .No Gas only . . . . . . . .Dual Operation . . . . . . . .Dual Operation . . . . . . . .Dual Operation
Duty Cycle
. . . . . . . . . . . . . . . . . .20% @ 55A . . . . . . . . . .20% @ 55A . . . . . . . . .100% @ 35A . . . . . . . . .100% @ 45A
. . . . . . . . . . . . . . . . . . . . . . . . . . .10% @ 80A . . . . . . . . . .10% @ 80A . . . . . . . . . .20% @ 90A . . . . . . . . . .60% @ 55A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15% @ 105A . . . . . . . . .15% @ 115A
Penetration - Steel
. . . . . . . . . . . . . . . . .2mm . . . . . . . . . . 2 - 2.75mm . . . . . . . . . .2.5 - 3.0mm . . . . . . . . . . . . . .3.5mm
Penetration - Aluminium
. . . . . . . . . . . . . . . .- . . . . . . . . . . . . . .3.5mm . . . . . . . . . . . . . . . .4mm . . . . . . . . . . . . . .4.5mm
Cooling System
. . . . . . . . . . . . . . .Air Cooled . . . . . . . . . . .Air Cooled . . . . . . . . . . . .Forced Air . . . . . . . . . . . .Forced Air
Torch
. . . . . . . . . . . . . . . . . . . . . . . . . . . .Live . . . . . . . . . . . . .Non Live . . . . . . . . . . . . .Non Live . . . . . . . . . . . . .Non Live
Power Input
. . . . . . . . . . . . . . . . . . .230V 1ph . . . . . . . . . . . .230V 1ph . . . . . . . . . . . .230V 1ph . . . . . . . . . . . .230V 1ph
Power Efficiency
. . . . . . . . . . . . . . . . .2.8kVA . . . . . . . . . . . . . .2.9kVA . . . . . . . . . . . . . .4.1kVA . . . . . . . . . . . . . .4.3kVA
Conversion Kit
. . . . . . . . . . . . . . . . . . . . .N/A . . . . . . . . . . . . . .GM/CK . . . . . . . . . . . . . .GM/CK . . . . . . . . . . . . . .GM/CK
Flux-cored Wire (0.9kg x Ø0.9mm)
. .TG100/1 . . . . . . . . . . . . .TG100/1 . . . . . . . . . . . . .TG100/1 . . . . . . . . . . . . .TG100/1
Spare Tips (Pack of 5)
. . . . . . . . . . .TG100/2 . . . . . . . . . . . . .TG100/2 . . . . . . . . . . . . .TG100/2 . . . . . . . . . . . . .TG100/2
PMG100.V2, PMG110.V2, PMG135XT.V2, PMG155XT.V2 - 2 - 120407
