Sealey TIG160S.V2 TIG/MMA Inverter Welders Instruction Manual
- June 13, 2024
- SEALEY
Table of Contents
TIG/MMA INVERTER WELDERS
160A, 180A, 200A 230V
MODELS:TIG160S.V2, TIG180S.V2, TIG200S.V2
TIG160S.V2 TIG/MMA Inverter Welders
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions and maintained properly, 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.
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Refer to instructions| Wear protective gloves| Warning: fumes & gases|
Warning: electric shock| Warning: fire risk| Warning: arc rays| Warning:
magnetic fields
SAFETY
1.1 ELECTRICAL SAFETY.
WARNING! It is the owner’s responsibility to read, understand and comply
with the following:
You must check all electrical equipment and appliances to ensure that they are
safe before use. 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 nstallation of appropriate safety devices. An RCCB (Residual
Current Circuit Breaker) should be incorporated in the main distribution
board. We also recommend that an RCD (Residual Current Device) is used with
all electrical products. It is particularly important to use an RCD with
portable products that are plugged into an electrical supply not protected by
an RCCB. If in doubt consult a qualified electrician.
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 business premises, to be tested by a
qualifiedelectrician,usingaPortableApplianceTester(PAT),atleastonceayear.
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.
Ensure the insulation on all cables and the product itself is safe before
connecting to the mains power supply.
See 1.1.1. & 1.1.2. above and use a Portable Appliance Tester (PAT).
Ensure that cables are always protected against short circuit and overload.
Regularly inspect power supply, leads, plugs for wear and damage and all
electrical connections to ensure that none is loose.
Important : Ensure the voltage marked on the product is the same as the
electrical power supply
to be used and check that supply is correctly fused, see fuse rating at right.
X DO NOT pull or carry the powered appliance by its power supply lead.
X DO NOT pull power plugs from sockets by the power cable.
X DO NOT use worn or damaged leads, plugs or connections. Immediately replace
or have repaired by a qualified electrician.
This product comes without a plug. You must contact a qualified electrician to
ensure an adequate supply is available.
If fitting such a plug –
Ensure that the unit is correctly wired and earthed, as follows:
a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
b) Connect the BROWN live wire to live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check there are no bare wires, that all wires have been
correctly connected, that the cable outer insulation is clamped by the cable
grip and that the grip is tight.
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.
To achieve maximum output this welder will require a 32A fused supply. We
recommend you discuss the installation of an industrial round pin plug and
socket with a competent electrician.
WARNING! Be very cautious if using a generator to power the welding set. 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
welding set.
‰ If any of the requirements are not met the electronics within the welding
set may be affected.
NOTE: The use of an unregulated generator may be dangerous and will invalidate
the warranty on the welding set.
‰ WARNING! The welding set 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 welding set is connected to a power
supply that
does not feed any sensitive equipment.
1.2 GENERAL SAFETY
DANGER! Unplug the inverter from the mains power supply before conneting or
disconnecting cables or performing maintenance or service. Direct contact
with the inverter circuit is dangerous.
- Keep the inverter and cables in good working order and condition. (Take immediate action to repair or replace damaged parts).
- Use genuine parts and accessories only. (Non recommended parts may be dangerous and will invalidate the warranty).
- Locate inverter in an adequate working area for its function. Ensure area has adequate ventilation as welding fumes are harmful.
- WARNING! If it is necessary for you to assemble the work clamp cable, ensure that sufficient copper strands are exposed and turned back to make full contact within the dinse plug to ensure a good electrical contact. Loose connection will cause overheating, rapid deterioration and loss in efficiency.
- Ensure there is no obstruction to the flow of clean cool air through the ventilation apertures and ensure there are no conductive dusts, corrosive vapours or humidity which could enter the inverter and cause serious damage.
- Keep working area clean and tidy and free from unrelated materials. Also ensure the working area has adequate lighting.
- 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 operating the inverter.
- Avoid unintentional contact with workpiece. Accidental or uncontrolled switching on of the torch may be dangerous and will cause the nozzle to wear.
- Keep unauthorised persons away from the working area, and any persons working within the area must wear the same protective items as the user.
- Operators must receive adequate training before using the inverter. The inverter must only be operated under supervision.
- Stand correctly keeping a good footing and balance, ensure the floor is not slippery, and wear non-slip shoes.
- WARNING! When unit is switched off wait for 15 seconds whilst capacitors discharge before opening the case.
- Turn voltage switch to “0” (off) when not in use.
- DO NOT operate the inverter if it or its cables are damaged.
- DO NOT use welding cables over 10m in length. (Cables should be as short as possible).
- DO NOT attempt to fit any non genuine torches, components, or parts to the inverter unit. To do so may cause damage and will invalidate the warranty.
- DO NOT use any metallic structure which is not part of the work piece as a substitute for the return cable. This may jeopardise results and may be dangerous. Exception: Metallic work bench, but connect as near to weld as possible.
- DO NOT hit the electrode on the workpiece, this may damage the electrode and make strike-up difficult.
- DO NOT get inverter wet or use in damp or wet locations or areas where there is condensation.
- DANGER! DO NOT weld near inflammable materials, solids, liquids, or gases.
- DO NOT weld containers or pipes which have held flammable materials or gases, liquids or solids. Avoid operating on materials cleaned with chlorinated solvents or near such solvents.
- DO NOT pull the inverter by the cable, or the torch, and DO NOT bend or strain cables, protect from sharp or abrasive items, and DO NOT stand on cables or leads. Protect from heat. Long lengths of slack must be gathered & neatly coiled. DO NOT place cables where they may cause a hazard.
- DO NOT touch the workpiece close to the weld as it will be very hot. Allow to cool.
- DO NOT touch the torch immediately after use. Allow the torch to cool.
- DO NOT operate inverter while under the influence of drugs, alcohol or intoxicating medication, or if fatigued.
- When not in use store the inverter in a safe, dry, childproof area.
INTRODUCTION
Lightweight, powerful and incredibly versatile. Inverters offer many advantages over traditional transformer type welders. Inverters use high quality state-of-the-art technology for the perfect weld. For example, TIG160S will produce up to 160Amps at 20% duty cycle whereas a conventional 160Amp welder would have a duty cycle of around 10%. Fan-cooled DC power supply for TIG and arc welding applications. Suitable for welding steel, stainless steel, copper, nickel, titanium and their alloys. Outer case manufactured from pressed steel with a powder coated finish for extra corrosion resistance. Ideal for the mobile technician or applications where the power unit needs to be taken to the job. Features high frequency starts enabling operations to start smoothly and efficiently. Supplied with TIG accessories.
SPECIFICATION
Model No: ………………….TIG160S.V2 …………………TIG180S.V2 ……………….TIG200S.V2
Power Input: ………………..5-160A …………………….5-180A ……………………… 5-200A
Duty Cycle:
20% @ ……………………160A………………………180A………………………….200A
60% @ ……………………92A……………………….104A………………………….115A
100% @……………………72A……………………….80A……………………………89A
Electrode Capacity: ……………Ø 1.6 – 3.2mm ……………….Ø 1.6 – 3.2mm …………… Ø 1.6 –
3.2mm
Absorbed Power: ……………..6.7kW……………………..7.6kW ………………………..8.8kW
Supply:…………………….230Vac…………………….230Vac ………………………230Vac
Protection: ………………….IP21S …………………….IP21S ……………………… IP21S
Accessories:
Arc Accessory Kit (Optional):……..MMA01 ……………………MMMA01 …………………….MMA01
TIG Torch: ………………….TIG11S…………………….TIG11S ………………………TIG12S
OPERATION
Key to fig.1:
1: Gas Outlet
2: Torch Control Connection
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3: Negative Socket
4: Positive Socket
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Key to fig.2:
1: Welding Mode Selector Switch
2: DC/Pulse Selector Switch
3: 2/4 Step Selector Switch
4: Digital Display
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5: Parameter Setting Control (Pushtoselectparameter,rotate to adjust)
6: Power On Indicator
7: Overheat Indicator
8: Over/under Voltage Indicator
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4.1. LEAD CONNECTION
MMA Mode: Connect the electrode holder to the Positive (+) connector (fig.1.4) and the earth lead to the Negative (-) connector (fig.1.3).
TIG Mode: Connect the earth clamp to the Positive (+) connector and the TIG torch to the negative (-) connector.
4.2. GAS CONNECTION
4.2.1. Using the clear tubing supplied connect the regulator to the gas inlet on the back of the inverter and gas outlet on the front (fig.1.1). Secure the tubing on each connector by using the worm drive clamps supplied.
4.2.2. Open the regulator before opening the cylinder valve. Test for leaks.
4.2.3. Set the gas flow to suit the welding parameters required.
4.2.4. If necessary the gas flow can be adjusted during welding using the regulator knob.
4.3. If using the optional torch kit, connect the control lead of the torch assembly to the torch control connection (fig.1.2).
4.4. MMA: DC STICK ARC WELDING
4.4.1. Using the Up and Down keys, set the welding mode selector (fig.2.1) to , the welding current may be adjusted by means of the adjustment knob (fig.2.5).
4.4.2. The hot start current (fig.3.B) and arc force current only (fig.3.K) can be adjusted in this mode to match the material being welded.
To select the parameter push the parameter setting control to cycle between functions. The value may be adjusted by using the adjustment knob (fig.2.1).The values are displayed on the digital display. (fig.2.4)
4.5. DC TIG WELDING
4.5.1. Using the Up and Down keys, set the welding mode selector (fig.2.1) to for high frequency start or for lift start.
4.5.2. The pre-flow time (fig.2.A), welding current (fig.2.D) and gas delay time indicator (fig.2.J) may be adjusted in this mode.
4.5.3. To select the parameter press the parameter setting control to cycle between functions. The value may be adjusted rotating the setting control (fig.2.5).
4.5.4. 2 or 4 touch trigger control may be selected by using the trigger mode selector (fig.2.3).
2 touch allows the power to be applied whilst the trigger is pressed.
4 touch latches the trigger until the pressed for a second time.
The 4 touch mode is useful for long runs of weld, saving operator fatigue and allowing a steadier weld. In this mode the power will be applied until the selected down slope time has elapsed.
4.6. DC PULSE TIG WELDING
4.6.1. Using the Up and Down keys, set the welding mode selector (fig.2.91 to
for high frequency start or for lift start.
4.6.2. Select the pulse function at fig.2.2.
4.6.2. The pre-flow time (fig.2.A), pulse peak current (fig.2.D), pulse width (fig.2.F), pulse frequency (fig.2.G), pulse background current (fig.2.G) and gas delay time (fig.2.J) may all be adjusted in this mode.
4.6.3. To select the parameter press the parameter setting control to cycle between functions. The value may be adjusted by rotating the setting control (fig.2.5).
4.7. STATUS WARNING LIGHTS
4.7.1. Power Indicator (fig.2.6). Indicator illuminated when switched on.
4.7.2. Overheat Indicator (fig.1.7). Illuminated when machine is overheated. In this condition the machine will shut down until the temperature falls to acceptable limits.
4.7.2.Over/under voltage. Indicates that the supply voltage is outside the required parameters.
MAINTENANCE
DANGER! Unplug the inverter from the mains power supply before connecting or
disconnecting cables, performing maintenance or service. Direct contact with
the inverter circuit is dangerous.
5.1. To avoid a build up of dust inside the machine which may block or
restrict the ventilation system, periodically remove the covers and remove the
dust with a low pressure air jet or vacuum cleaner. Replace covers
immediately. Under no circumstances should the machine be operated with the
covers removed.
5.2. TORCH. Avoid resting the the torch and its associated cable on any hot
surfaces. If the insulation is damaged in any way the torch must not be used.
5.3. Periodically check the condition of the gas tubing and the connections.
RATING PLATE SYMBOLS
On the rear of the inverter is the ratings plate, giving the following data:
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The BS/EU standard relating to the safety and construction of arc welding and associated equipment.
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Inverter-transformer-rectifier symbols.
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Symbol indicating welding processes available.
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Symbol for Single-phase AC supply.
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Rating of internal protection provided by casing.
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Output
U0 : Maximum open-circuit 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.
I1 max: Maximum current. I1 eff: Maximum effective current. -
A/V – A/V: Welding current adjustment range and corresponding voltages.
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Serial Number. Specifically identifies each welder.
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Symbol for welding power sources which are suitable for supplying power to welding operations carried out in an environment with increased risk of electric shock (if applicable).
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Insulation Class.
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 12 months from purchase date, proof of which is
required for any claim.
Sealey Group, Kempson Way, Suffolk Business
Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500
sales@sealey.co.uk
www.sealey.co.uk
© Jack Sealey Limited
Original Language Version
TIG160S.V2, TIG180S.V2, TIG200S.V2 Issue: 2(1) 01/02/23
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