Sealey TIG160S.V2,TIG180S.V2,TIG200S.V2 Instructions Manual

INSTRUCTIONS FOR:

TIG/MMA INVERTER WELDERS
160A, 180A, 200A 230V

MODEL NOS:TIG160S.V2, TIG180S.V2, TIG200S.V2

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.

Refer to Instruction Manual Wear protective gloves

Warning:

Fumes & Gases

Warning:

Electric Shock

Warning:

Fire Risk

Warning:

Arc Rays

Warning:

Magnetic Fields

1. SAFETY

1.1 ELECTRICAL SAFETY.

 WARNING! It is the user’s responsibility to check the following: You must check all electrical equipment and appliances to ensure they
are safe before using. 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 installation of appropriate safety devices. An RCCB (Residual Current Circuit Breaker) should be
incorporated in the main distribution board. We recommend that an RCD (Residual Current Device) is used with all electrical products. It is
particularly important to use an RCD together with portable products that are plugged into an electrical supply not protected by an RCCB. If in
doubt consult a competent 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 all portable electrical appliances, if used on business premises, to be tested by a competent
person on a regular basis by using a Portable Appliance Tester (PAT).

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 competent electrician.

1.1.3 Ensure the insulation on all cables and product itself is safe before connecting to mains power supply. See 1.1.1. use a Portable
Appliance Tester (PAT).

1.1.4 Ensure that cables are always protected against short circuit and overload.

1.1.5 Check power supply, leads, plugs and all electrical connections regularly for wear or damage, especially power connections to ensure
none is loose.

1.1.6 Check the voltage marked on the product is the same as the electrical power supply to be used. Check fused plugs are fitted with correct
capacity fuse.

1.1.7 DO NOT pull or carry the powered appliance by its power supply lead. Products such as inverters must not be pulled or carried by their
output cables.

1.1.8 DO NOT pull power plugs from sockets by the power cable.

1.1.9 DO NOT use worn or damage leads, plugs or connections. Replace or have repaired immediately by competent persons. In case of
damage, cut off and fit a new plug

1.1.10 NO plug is fitted to this machine. Whilst it is possible to perform TIG welding at lower power settings using a 13Amp mains

source, ordinary ARC welding (without gas) and TIG welding at higher power settings will require the machine to be connected
to a 30A supply either by direct wiring into your mains circuit or by fitting an industrial round pin plug & socket for more
flexible usage. In either case we recommend you contact a competent electrician to assess your existing wiring installation and
follow the recommendations in full. Particular attention should be paid to the provision of adequate fuses on the mains circuit
and to the earthing of the machine.

If a 13A power source is used wire the plug as shown to the right.
a)  WARNING! Ensure the unit is correctly earthed via a three-pin plug.
b) Connect the Yellow/Green earth wire to the earth terminal ‘E’.
c) Connect the Brown live wire to live terminal ‘L’.
d) Connect the Blue neutral wire to the neutral terminal ‘N’.

 WARNING! Be very cautious if using a generator to power the Inverter. 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 inverter. If any of these requirements is not met the
electronics within the Inverter may be affected.
NOTE: The use of an unregulated generator may be dangerous and will invalidate the warranty on
the inverter.
 WARNING! The inverter may produce voltage surges in the mains supply which can damage other
sensitive equipment
(e.g. computers). To avoid this happening it is recommended that the Inverter 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 connecting 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.

© Jack Sealey Limited

Original Language Version

TIG160S.V2, TIG180S.V2, TIG200S.V2 Issue: 1 - 11/07/16

RECOMMENDED FUSE

RATING13AMP:

TO GAIN MAXIMUM OUTPUT THE

INVERTER MUST BE CONNECTED

TO A 30AMP SUPPLY

 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.

2. 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.

3. 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

Weight:.........................12.5kg .........................12.7kg .............................13kg

Accessories:

Arc Accessory Kit: ................MMA01 ........................MMMA01 .........................MMA01

TIG Torch: ......................TIG11S.........................TIG12S...........................TIG12S

4. OPERATION

Key to fig.1:

1: Gas Outlet
2: Torch Control Connection
3: Negative Socket
4: Positive Socket

Key to fig.2:

1: Welding Mode Selector Switch
2: DC/Pulse Selector Switch
3: 2/4 Step Selector Switch
4: Digital Display
5: Parameter Setting Control
(Push to select parameter, rotate
to adjust)
6: Power On Indicator
7: Overheat Indicator
8: Over/under Voltage Indicator

g.2

g.1

© Jack Sealey Limited

Original Language Version

TIG160S.V2, TIG180S.V2, TIG200S.V2 Issue: 1 - 11/07/16