INSTRUCTIONS FOR
ARC WELDERS
MODEL No's:
180XT
200XTD
220XTD
250XTD
Original Language Version
180XT, 200XTD, 220XTD, 250XTD Issue: 2(L)- 20/06/16© Jack Sealey Limited
INSTRUCTIONS FOR
ARC WELDERS
Thank you for purchasing a Sealey Power Welder. 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: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL
REQUIREMENTS, WARNINGS, AND CAUTIONS. USE THIS 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.
INTRODUCTION
This instruction manual contains the information required to prepare your arc welding set for welding. For Individual model specifications refer
to part 2. The instructions are not intended to show you how to become a welder. If you have no experience, we recommend that you seek
training from an expert source. Arc welding is relatively easy to perform, but does require a steady hand and time practising with scrap metal,
as it is only with continued practice that you will achieve the desired results.
1. SAFETY INSTRUCTIONS
1.1. ELECTRICAL SAFETY
WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following:
You must check all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and any other
connectors for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of appropriate safety devices. A
Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also recommend that a Residual Current
Device (RCD) is used. It is particularly important to use an RCD with portable products that are plugged into a supply which is not protected
by an RCCB. If in any doubt consult a qualified electrician. You 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 that all portable electrical appliances, if used on business premises, are tested by a
qualified electrician, using a Portable Appliance Tester (PAT), at least once a year.
1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those appliances
and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.
1.1.3. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1. and 1.1.2.
and use a Portable Appliance Tester.
1.1.4. Ensure that cables are always protected against short circuit and overload.
1.1.5. Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure that none is loose.
1.1.6. Important: Ensure that the voltage marked on the appliance matches the power supply to be used and that the plug is fitted with the
correct fuse - see fuse rating at right.
1.1.7. DO NOT pull or carry the appliance by the power cable.
1.1.8. DO NOT pull the plug from the socket by the cable.
1.1.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty item repaired or replaced by a qualified
electrician.
1.2 IMPORTANT : THE 180XT AND THE 200XTD CAN BE CONNECTED TO EITHER A 16AMP SINGLE PHASE
SUPPLY OR A PROPERLY INSTALLED 13AMP SUPPLY. TO ACHIEVE MAXIMUM OUTPUT HOWEVER A
16AMP FUSED SUPPLY SHOULD BE USED. WE RECOMMEND YOU DISCUSS THE INSTALLATION OF AN
INDUSTRIAL ROUND PIN PLUG & SOCKET WITH A QUALIFIED ELECTRICIAN.
1.2.1. To fit a 13Amp plug proceed as shown on the right.
Ensure the unit is correctly earthed via a three-pin plug.
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’.
After wiring, check there are no bare wires, that all wires have been correctly connected and that the
wire restraint is tight.
1.2.2. 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 since any product which is plugged into the cable reel will be
protected. The cross-section of the cable on the cable reel must be suitable for the unit and never lower than the
cross-section of the main cable supplied with unit.
1.3 MODELS 220XTD & 250XTD REQUIRE TO BE CONNECTED TO A 3 PHASE SUPPLY AND
MUST HAVE AN APPROPRIATE PLUG FITTED.
WARNING! Electrical installation of welder to a 3 phase 415Volt supply must only be carried out by a
qualified electrician. Make sure the power supply cable is correctly connected to the Earth.
1.3.1 This product must be fitted with a 3 phase plug as shown on the right, and will require a minimum of
16AMPs per phase, (preferably 32AMP) electrical supply.
You must contact a qualified Electrician to ensure an appropriately fused supply is available.
Connect GREEN/YELLOW wire to Earth ‘E’
Connect BLUE wire to the NEUTRAL Terminal.
Connect BROWN wire to L1 Terminal.
L2 Terminal is in this instance, unused.
Connect the GREY wire to terminal L3.
When completed, check there are no bare wires, that all wires have been connected correctly and the
cable restraint is tight. (NOTE:The cable core colours found in the mains cable on this welder are
consistent with Amendment 2 to BS7671:2001 which harmonised UK cable core colours with those used
in Europe.)
1.3.2 DO NOT use this product with a standard extension cable. Only use ARMOURED extension cable.
Original Language Version
180XT, 200XTD, 220XTD, 250XTD Issue: 2(L)- 20/06/16© Jack Sealey Limited
1.4 GENERAL SAFETY WARNING! Arc welding produces sparks, fused metal projectiles and fumes which are dangerous.
WARNING: Unplug from the mains power supply before performing maintenance or service.
Keep the welder and cables in good working order and condition. Take immediate action to repair or replace damaged parts.
Replace or repair damaged parts. Use genuine parts only, unauthorised parts may be dangerous and will invalidate the warranty.
Keep the welder clean for best and safest performance.
Locate welder in a suitable work area. Ensure area has adequate ventilation as welding fumes are harmful.
Keep work area tidy and free from unrelated materials. Also ensure work area has adequate lighting and a fire extinguisher is at hand.
WARNING: You MUST use an appropriate shaded lens welding face mask (contact your Sealey dealer for details). DANGER! Permanent
eye damage may result if you do not use correct protection. Also wear safety welding gauntlets and dry, oil free safety protective clothing
to protect yourself from sparks and hot droplets of fused metal. Cover exposed flesh to avoid potential burns from the ultraviolet rays of the
arc. Use non-reflective welding curtains to protect other people in the area.
Check you have good ventilation and that air can flow freely around the welder.
▲ DANGER! Ensure no flammable or combustible materials are near work area. Welding containers or pipes which hold, or have held dangerous
gases or substances may explode or burn. Materials cleaned with chlorinated solvents, or varnished surfaces pose danger of toxic fumes.
Keep unauthorised persons at a safe distance from the work area. Persons within the work area are subject to the same dangers as the
welder and must take the same precautions.
DO NOT weld on pressurised containers.
Remove ties, watches, rings and other jewellery and contain long hair.
DO NOT use the welder for any purpose other than that for which it is designed.
DO NOT use the welder in damp or wet locations.
DO NOT stand welder on a metal workbench, car bodywork or similar object.
DO NOT touch any live metal parts of the torch or electrode while the machine is switched on.
DO NOT weld without a welding safety head shield, gauntlets, clothing.
DANGER! DO NOT weld near inflammable materials - solids, liquids, or gases.
DO NOT operate welder while under the influence of drugs, alcohol or other medication, or if you are tired.
DO NOT operate the welder if it or the cables are damaged.
DO NOT allow untrained persons to operate the welder.
DO NOT pull welder by the cable, or electrode holder. DO NOT bend or strain cables, protect from sharp or abrasive items. DO NOT stand
on cables or leads. Protect from heat. Long lengths of slack must be gathered and neatly coiled. DO NOT place cables where they
endanger others.
DO NOT touch the electrode holder or workpiece immediately after welding as they will be very hot. Allow to cool.
DO NOT open the cover of the machine. Switch off machine and remove the plug from the power supply after use.
The electromagnetic fields generated by the welding process may interfere with the operation of electrical and electronic equipment.
Users of vital electrical or electronic devices (e.g.pace-makers, respirators etc.) should consult a doctor before entering areas where
welding machines are in use, (see Section 8).
Users of vital electrical or electronic devices should not use any welding machine.
2. DESCRIPTION & SPECIFICATIONS
Model No: 180XT 200XTD 220XTD 250XTD
Welding Current: 66-180A 55-200A 40-180A(230V), 60-220A(415V) 40-180A(230V), 60-250A(415V)
Electrode Capacity: Ø2.0-4.0mm Ø1.6-4.0mm Ø1.6-5.0mm Ø1.6-5.0mm
Cooling: Forced Air Forced Air Forced Air Forced Air
Output Cable 16mm² 25mm² 25mm² 25mm²
No-Load Voltage: 50V 50V 47V, 52V 47V, 55V
Absorbed Power: 10kW 11kW 8.6kW / 12.3kW 8.6kW / 15kW
Supply: 230V - 1ph 230V - 1ph 230V - 1ph, 415V 3ph 230V - 1ph, 415V 3ph
Weight: 23kg 30kg 34kg 34kg
Manufactured to exacting standards these models meet all relevant CE requirements. Fitted with forced air cooling system, these welders have
increased duty cycle and performance. All models feature a vented, wrap-around shell tted to a heavy-duty chassis. Screw type, stepless
welding control allows ne adjustment of current. Each welder is tted with carry handle and wheels. Model No's 220XTD and 250XTD feature
dual voltage input for use on 230V-1ph or, for higher performance, on 415V-3ph. All models supplied with accessory kit including electrode
holder, cables, earth clamp and chipping hammer/wire brush.
IMPORTANT INFORMATION: To operate all welders to their full capacity, you must run them on the correct power supply. To check the
amperage, use the following formula: kVA Rating x 4.35 = Correct Amps Supply
3. ASSEMBLY
3.1. Assembly, 180XT only: (Refer to fig.1)
3.1.1 Lay a protective covering such as some cardboard packaging onto the floor and, with the help of another person, carefully turn the
welder upside down onto it. Place the bent metal foot (6) onto the bottom of the casing just behind the front panel and fix it in place
using three self tapping screws (7).
3.1.2 Assemble the wheels and axle as follows. Attach a circlip (8) to one end of the axle (5). Slide a wheel (3) onto the far end of the axle
and move it across to the circlip ensuring that the recess in the wheel faces outwards. Insert the free end of the axle into the hole in
the side of the casing as shown in fig.1 and guide it through the casing to emerge from the hole on the far side of the casing. Slide the
other wheel (3) onto the axle and retain it with a circlip (8). Push a cap (4) into the recess in each wheel. With the help of another
person, carefully turn the welder the right way up.
3.1.3 Attach the handle extension to the handle as follows. Take the handle extension (1) and push the large recessed spigot on its
underside into the matching hole in the handle (2) as shown in fig.1. Secure the two parts together using the 25mm M5 bolt (9)
provided.
3.1.4 Place the handle assembly onto the top of the casing and align it with the fixing holes. Secure the back end of the handle using an M6
16mm bolt (11), a split washer (12) and a flat washer (13) as shown in fig.1. Secure the front end of the handle using an M6
25mm bolt (10), a split washer (12) and a flat washer (13) as shown in fig.1.
Original Language Version
180XT, 200XTD, 220XTD, 250XTD Issue: 2(L)- 20/06/16© Jack Sealey Limited
Loading...