150A PROFESSIONAL MIG WELDER

MODEL NO: SUPERMIG150.V4

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 Pictograms:

ℹ️ Refer to instructions | ? Wear eye protection | ? Wear protective gloves | ? Wear safety footwear | ? Wear protective clothing | ? Arc rays can burn eyes and injure skin | ⚡️☠️ Electric shock from welding electrodes can kill | ♨️ Hot surfaces | ? Breathing welding fumes can be hazardous to your health | ? Electromagnetic fields can cause pacemaker malfunction | ✨ Welding sparks can cause explosions or fire | ?️ Warning! Keep away from rain | ⚡️ Warning! Electricity Shock hazard

1. 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, plugs and all electrical connections for wear and damage.
• Sealey recommend that an RCD (Residual Current Device) is used with all electrical products.
• If the product is used in the course of business duties, it must be maintained in a safe condition and routinely PAT (Portable Appliance Test) tested.

Electrical safety information:

• 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 (see fuse rating in these instructions).

DO NOT:

• ❌ Pull or carry the appliance by the power cable.
• ❌ Pull the plug from the socket by the cable.
• ❌ Use worn or damaged cables, plugs or connectors. Ensure that any faulty item is repaired or replaced immediately by a qualified electrician.

This product is fitted with a BS1363/A 13 Amp 3 pin plug.

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. Replace a damaged plug with a BS1363/A 13 Amp 3 pin plug. If in doubt contact a qualified electrician.

Wiring Instructions:

• Connect the GREEN/YELLOW earth wire to the earth terminal 'E'.
• Connect the BROWN live wire to the live terminal 'L'.
• Connect the BLUE neutral wire to the neutral terminal 'N'.
• Ensure that the cable outer sheath extends inside the cable restraint and that the restraint is tight.

Sealey recommend that repairs are carried out by a qualified electrician.

Recommended fuse rating: 13 Amp

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. The section of the cable on the cable reel is important and should be at least 1.5mm², but for this product and others, 2.5mm² section cable is recommended.

WARNING! Be very cautious if using a generator to power the welder. The generator must be self-regulating and stable with regard to voltage, waveform and frequency. The output must be greater than the power consumption of the welder. Unregulated generators may be dangerous and will invalidate the warranty.

WARNING! The welder may produce voltage surges that can damage sensitive equipment. Connect the welder to a power supply that does not feed any sensitive equipment.

IMPORTANT! If using the welder to full capacity, a 16amp supply is recommended. Discuss the installation of a 16amp industrial round pin plug and socket with your electrician.

1.2. GENERAL SAFETY

DANGER!

• 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.
• Locate welder in a suitable work area with adequate ventilation.
• Keep work area clean, tidy, and free from unrelated materials. Ensure adequate lighting and have a fire extinguisher 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, ties, watches, rings, and other loose jewellery. Contain long hair.
• Ensure the workpiece is correctly secured before welding.
• Avoid unintentional contact with the workpiece.
• 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 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.
• ❌ Attempt to fit any unapproved torches or other components to the welder.
• ❌ Get welder wet or use in damp or wet locations or areas with condensation.
• ❌ Weld near flammable solids, liquids or gases.
• ❌ Weld containers or pipes which have held flammable materials.
• ❌ Weld materials cleaned with chlorinated solvents or weld near such solvents.
• ❌ Stand welder on a metal workbench, car bodywork, or similar.
• ❌ Touch any live metal parts of the torch or electrode while the machine is switched on.
• ❌ 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. Gather slack neatly. Do not place cables where they endanger others.
• ❌ Touch the torch or workpiece immediately after welding as they will be very hot. Allow to cool.
• ❌ Operate welder while under the influence of drugs, alcohol, or if tired.

When not in use, store the welder in a safe, dry, childproof area.

1.3. GAS SAFETY

• Store gas cylinders in a vertical position only and ensure the storage area is correctly secured.
• ❌ DO NOT store gas cylinders in areas where the temperature may exceed 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.
• ❌ DO NOT puncture or damage a cylinder.
• ❌ DO NOT obscure or remove any official labels on a cylinder. Always check the gas identity before use.
• ❌ Avoid getting gas cylinders oily or greasy.
• ❌ DO NOT lift a cylinder by the cap, guard, or valve. Always keep caps and guards in place and close the valve when not in use.

2. INTRODUCTION

The welder features a Forced Air Cooling System for a high duty cycle. Its latest design chassis remains stable when used with medium-size industrial gas cylinders. The professional contour grip, heat-proof, non-live torch ensures no sparks until the trigger is pressed. It has a proven wire feed system for trouble-free welding and can weld stainless steel and aluminium.

IMPORTANT:

3. SPECIFICATION

4. ASSEMBLY

4.1. Wheels and Front Foot

Assemble the wheels by sliding the rear axle through the loops on the underside of the rear tray. Slide a wheel onto each end of the axle and retain with washers and split pins. Attach the front foot to the underside of the welder using the provided screws.

4.2. Handle Assembly

Take the front half of the handle moulding and align its mounting holes with the fixing holes in the top surface of the welder's front moulding (see fig.3A). Secure the handle with the two bolts provided (see fig.3B). Place the rear part of the handle moulding into the back of the front half and snap it into place. Insert the two self-tapping screws provided into the holes in the back of the handle and drive them fully home, but do not overtighten them (see fig.3C).

4.3. CONNECTING THE GAS CYLINDER (SEE SECTION 4.10 REGARDING GAS TYPES)

Place the lower end of the gas cylinder on the rear tray, between the two wheels (see fig.2-C). Allow the upper part of the cylinder to rest into the metal support (see fig.2-D). Secure the cylinder by hooking either end of the chain E through the metal support as shown in fig.2.

• When using Argon or Argon mixtures, use the "bull nose adaptor". Fit it to the cylinder with a spanner. (If using CO2 gas, the regulator fits directly onto the cylinder).
• Fit the gas regulator onto the bull nose adaptor as shown in fig.1.
• Push the black gas tube (see fig.2-A) onto the gas inlet nozzle and retain it with the wire clip (see fig.2-B).
• Push the other end of the tube onto the gas outlet nozzle on the regulator and retain it with the other wire clip (see fig.1).
• When ready to weld, set the regulator flow rate to 5-8 litres/min, depending on the material and any draughts.

4.4. FITTING A REEL OF WIRE

Open the side compartment by lifting the black catch and door. The welder is supplied with a mini spool of mild steel wire but accepts spools up to 5kg without modification.

• Referring to fig.5, rotate the pressure knob (F) anti-clockwise and remove it with the spring (E) and top disc (D). Small reels run on the spindle; larger 5kg reels run on the larger diameter flange at the base of the spindle (A).
• Place the wire reel (C) onto the spindle, ensuring the wire withdraws from the spool forwards and on the same side as the wire feed unit.
• Place the plastic top disc (D) over the spindle end, followed by the reel spring (E).
• Thread the pressure knob (F) onto the spindle end and screw it down clockwise until the spring is partially compressed. Set the reel take-off pressure for mild braking to prevent overrun. Do not overtighten, as this will conflict with wire tension.
• Referring to fig.4, turn the wire lock screw (B) anti-clockwise and unlatch it from the pressure roller moulding. Swing the pressure roller moulding (A) away from the drive roller.
• Straighten 40-50mm of spool wire (do not allow it to uncoil) and gently push it through the plastic guide, through the 6 or 8mm feed roller groove, and into the torch liner. (Refer to section 6.5 for reversing the roller for 6 or 8mm wire).
• Referring to fig.7, move the pressure roller moulding (A) back onto the grooved drive wheel and swing the wire lock screw (B) up to lock it in place. See section 4.5.2 regarding wire tension.

4.5. FEEDING THE WIRE THROUGH TO THE TORCH. (SEE FIG.6)

Remove the gas cup (a) and contact tip (b) from the torch end:

• Take the torch in your left hand with the tip facing right.
• Grasp the gas cup firmly in your right hand.
• Turn the gas cup clockwise only and pull it out to the right. WARNING! Do not turn the gas cup anti-clockwise, as this will damage the internal spring.
• Unscrew the copper contact tip (right-hand thread) to remove it.

Check the welder is switched off ("0") and the earth clamp is away from the torch tip. Connect the welder to the mains power supply and set the voltage switches to MIN/1.

Set the wire speed knob to position 5 or 6. Keeping the torch cable as straight as possible, press the torch switch. The wire will feed through the torch.

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

• Take the torch in your left hand and screw the contact tip back into place.
• Grasp the gas cup in your right hand, push it onto the torch head, and turn it clockwise only. WARNING! Do not turn the gas cup anti-clockwise, as this will damage the internal spring.
• Cut the wire so that it is just protruding from the cup.

4.6. SETTING WIRE TENSION

IMPORTANT:

• For mild steel 0.6mm wire, the wire tension screw must be fully tightened and then undone approximately two complete turns (fig.7).
• Correct tension is checked by slowing down the wire between your fingers. If the pressure roller skids, the tension is correct.
• Use the lowest tension possible, as too high a tension will deform the wire and may result in blowing a fuse on the printed circuit board.

When welding is completed, disconnect the unit from the mains supply and store it in a safe, dry place. Note: Damaged torches and cables are not covered under warranty.

4.7. CONTROL PANEL FUNCTIONS

Refer to the diagram of the control panel (fig.8):

• Thermal Cut-out Indicator: Amber light illuminates when the welder overheats.
• Power Switch: Turns the welder on/off.
• Settings: Controls voltage and wire speed. Typically includes MIN/1, MIN/2, MAX/1, MAX/2 settings.
• Wire Speed Control: Rotary knob to adjust wire feed speed.

Diagram Description (Fig. 9): Illustrates the MIG torch tip assembly, showing the contact tip, gas cup, shielding gas flow, electrode (wire), and workpiece.

4.8. MIG/MAG WELDING

Welding wire is fed through an insulated liner to the torch tip. The torch comprises a switch, liner, gas hose, and control cable. The switch activates the wire feed roller and gas flow; releasing it stops both. Weld current is transferred from the contact tip to the electrode (wire). Current is set using the two switches on the control panel. Wire speed is adjusted via the rotary control, correlating with the current output (higher current = faster wire speed). A gas cup covers the contact tip to direct gas flow towards the weld, shielding the arc from oxidation and assisting weld heating. The torch connects to the positive side of a DC rectifier, with the negative clamp attached to the workpiece.

4.9. PREPARATION FOR WELDING

IMPORTANT!

• 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.
• The weld area must be free of paint, rust, grease, etc.

4.10. GAS TYPES AND THEIR USE

• Welding mild steel with CO2 gas is suitable for most tasks where spatter and high build-up are not issues. For spatter-free and flat welds, an Argon/CO2 mixture is required.
• To weld aluminium, use Argon Gas, a 0.8mm Contact Tip, and 0.8mm Aluminium Wire (MIG/2/KAL08).

4.11. THERMAL PROTECTION

If the welder overheats due to prolonged use beyond its stated duty cycle, the thermal protection will cause it to cut out. The amber light on the front panel will illuminate. Wait fifteen minutes for the welder to cool down; it will then reconnect automatically.

5. RATINGS PLATE

The front panel rating plate provides the following data:

• 1: BS/EU standard for arc welding equipment safety and construction.
• 2: Inverter-transformer-rectifier symbols.
• 3: Symbol for welding with a continuous flow of welding wire.
• 4: Symbol for Single-phase AC supply.
• 5: Rating of internal protection provided by the casing (IP rating).
• 6: Output (U₀: Maximum open-circuit voltage; I₂, U₂: Current and corresponding voltage; X: Welding ratio based on a 10-minute cycle, e.g., 20% means 2 minutes welding and 8 minutes rest).
• 7: Mains Supply (U₁: Rated supply voltage and frequency; I₁max: Maximum current; I₁eff: Maximum effective current).
• 8: A/V - A/V: Welding current adjustment range and corresponding voltages.
• 9: Serial Number.
• 10: Symbol for welding power sources suitable for environments with increased risk of electric shock.
• 11: Insulation Class.

6. MAINTENANCE

DANGER!

6.1. WIRE FEED UNIT

• Check the wire feed unit at regular intervals. The feed roller wire guide is crucial for consistent results. Poor wire feed affects the weld.
• Clean the rollers weekly, especially the feed roller groove, removing all dust deposits.

6.2. TORCH

• Protect the torch cable assembly from mechanical wear.
• Clean the liner from the machine forwards using compressed air. If the liner is blocked, it must be replaced.

6.3. CONTACT TIP (to remove tip follow steps in section 4.5)

• 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 to ensure an unimpeded flow of gas.

6.4. GAS CUP (to remove cup follow steps in section 4.5)

• 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, potentially blowing the fuse or causing expensive repairs.
• To keep the contact tip free from spatter, use anti-spatter spray (MIG/722307) available from your Sealey stockist.

6.5. TURNING FEED ROLLER

IMPORTANT:

• There are two grooves on the feed roller: 0.6mm and 0.8mm. Always have the groove 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 down position (see fig.10-1). Then move the tensioning roller assembly to its up position (see fig.10-2).
• Take hold of the triangular knob on the roller retainer and rotate it 90° anti-clockwise to release it (fig.10.3). Pull the roller retainer off the drive spindle to reveal the roller (fig.11).
• Pull the roller off the drive spindle, flip it over, and put it back on the drive spindle (see fig.12). The required groove size should now be visible on the roller face.
• Push the roller retainer back onto the drive spindle with the opening facing left. Ensure the flanges at the base of the retainer seat fully into the circular recess in the main moulding, then rotate the retainer through 90° to lock it in place.

6.6. REPLACING WIRE LINER

• A worn or damaged wire liner will seriously affect welder performance and should be replaced immediately.
• 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.13) and take off the clamp.
• Undo the torch case (fig.14) and pull the wire liner from the insulation block.
• Pull the liner out of the torch cable and insert the new one. Reverse the process to re-assemble. Ensure the liner is fully inserted into the torch insulation block and reassemble the torch.
• Trim the other end of the liner as close to the feed roller as possible. Replace the torch cable clamp.

6.7. REPLACING GEARS

• An inexperienced welder can allow spatter to build up in the tip and shroud, potentially blocking the wire feed and causing gear damage in the wire drive.
• To check if the gears are worn, depress the button on the torch with the welder switched on. If the gears are worn, a grating sound will be heard from the wire feed motor, and the feed roller may vibrate instead of rotating smoothly.
• In this case, return the welder to your local Sealey stockist for repair.

7. TROUBLESHOOTING

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.

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 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.

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: Lifetime guarantee on Transformer - Comprises 1 year unconditional parts and labour on all parts, followed by a lifetime guarantee (parts and labour) conditional on registering your purchase with us online at www.sealey.co.uk.

Contact Information:

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR

Phone: 01284 757500 | Fax: 01284 703534 | Email: sales@sealey.co.uk | Website: www.sealey.co.uk