Sealey TIG161HFACDC Instructions Manual
INSTRUCTIONS FOR:
TIG/MMA HF ACDC
INVERTER
WELDER 160Amp
230V
MODEL No:
TIG161HFACDC
Original Language Version
TIG161HFACDC Issue: 1 - 03/11/11
INSTRUCTIONS FOR:
TIG/MMA HF ACDC INVERTER
WELDER 160AMP 230V
Thank you for purchasing a Sealey Welder. Manufactured to a high standard this product will, if used according to these instructions and properly maintained, give
Model No. TIG161HFACDC
you years of trouble free performance.
IMPORTANT: BEFORE USING THI S PROD UCT, PLEA SE READ T HE INST RUCT IONS CARE FULLY. MAKE C AREF UL NOTE O F SAFETY INST RUCT IONS ,
WARN INGS AND CA UTIO NS. THIS PR ODUC T SHOULD ON LY BE USE D F OR I TS INTE NDED PU RPOS E. FA ILUR E TO DO SO MAY CAUS E DA MAGE
AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
1. SAFETY INSTRUCTIONS
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 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 all portable electrical appliances, if used on business premises, to be tested by a qualified person at least
once a year 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 qualified 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 (PAT).
1.1.4 Ensure that cables are always protected against short circuit and overload.
1.1.5 Regularly check power supply, leads, plugs and all electrical connections 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. Immediately replace or have repaired by qualified persons. In case of damage, cut off and fit a
new plug according to the following instructions.
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 30Amp 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 qualified electrician to assess your existing wiring installation and follow his 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 13Amp 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.
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 your 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 endanger others.
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.
Original Language Version
Yellow &
Green
Earth wire
Blue
Neutral
wire
FUSE RATING13AMP BUT
TO GAIN MAXIMUM OUTPUT THE
INVERTER MUST BE CONNECTED
TO A 30AMP SUPPLY
TIG161HFACDC Issue: 1 - 03/11/11
Brown
Live
wire
2. DESCRIPTION & SPECIFICATION
2.1 DESCRIPTION
Fan cooled AC/DC power supply suitable for TIG and MMA welding applications. Lightweight, compact unit with high quality technology, suitable for welding
aluminium, magnesium, stainless steel, steel, deoxidised copper, nickel and titanium. TIG cycle includes post gas and current down-slope regulation. Features
regulated HF push button arc that prevents having to touch the workpiece, keeping the tip in good condition for longer. Includes connector for foot pedal or hand
controller for when more control is required. Supplied with shoulder strap.
2.2 SPECIFICATION
Power Output: ................................ 5-160 A
Duty Cycle: .............................. 25% @ 130 A
Electrode Capacity: .......................Ø1.6 - 3.2mm
Maximum absorbed power: ...................... 4.3 KW
Mains Voltage: ..............................230V -1ph
Insulation Class: ....................................H
Protection: ......................................IP23
Weight: .......................................9.4kg
ARC Accessory Ref:.................. (optional) INVMMA2
Foot Pedal Power Control: ............. (optional) INV/TIG/5
Current Control: ..................... (optional) INV/TIG/7
3. PREPARING INVERTER FOR USE
3.1 CONNECTION TO MAINS.
3.1.1 Whilst welding at low power levels is possible on a 13Amp supply the Inverter will normally be connected to a 30Amp supply in order to TIG weld at higher
power levels and in order to perform ordinary ARC welding. See section 1, item 1.1.10.
3.2 WELDING CABLE CONNECTION.
3.2.1 The torch cable is supplied ready assembled but it may be necessary for you to assemble the work clamp cable. Attach the work clamp to one end of the
cable as shown in fig.1. To connect the Dinse Plug as shown in fig.2 first thread the cable through the outer cover of the plug (see fig.2 item 4). Now remove
20mm of insulation sheath from the end of the cable and fold back the copper wire all around the outside of the sheath (1). Push the cable end into the
copper sleeve (2) so that the folded back wire makes good contact with the inside of the sleeve. Push the copper sleeve into the brass plug body (3) and
tighten the large grub screw until the cable is firmly held. Now slide the outer plug cover up the cable and press the brass body into it as shown in fig.2.
fig 1
3.3 TIG CONNECTIONS:
3.3.1 TIG TORCH CABLE. Dinse plug at end of the torch cable will be connected to the negative socket (-)
on lower front panel see fig.3 item 2.
3 pin torch plug at end of torch cable will be connected to circular 3 pin socket on the lower front panel (see fig.3 item 3).
Black gas pipe with brass fitting at end of torch cable will be screwed to brass fitting on lower front panel (see fig.3 item 4).
3.3.2 WORK CLAMP CABLE. Dinse plug at end of the clamp cable will be connected to the positive socket (+) on lower front panel (see fig.3 item 1).
(*) Please note that the way the welding cables are connected to the inverter for ordinary ARC welding may be different to the way the cables are
connected for standard TIG welding. Whilst most stick electrodes are connected to the positive terminal certain types need to be connected to the
negative terminal. It is therefore essential that the user refers to the manufacturer’s instructions for the electrodes to ensure that the correct
polarity is selected.
3.4 ARC CONNECTIONS (You will need optional ARC Accessory Kit INVMMA2).
ELECTRODE HOLDER Plug at the end of electrode cable will normally (*) be connected to the positive socket (+) on the front panel (see fig.3 item 1).
WORK CLAMP CABLE. Plug at the end of the clamp cable will normally (*) be connected to the negative socket (-) on the front panel (see fig.3 item 2).
3.5 REAR PANEL LAYOUT (refer to Figs 4 & 5).
1. ON/OFF SWITCH: O = Off, I = On.
2. MAINS CABLE
3. GAS INLET FITTING. For connecting the gas cylinder to the welder using clear tubing provided.
4. REMOTE CONTROL CONNECTOR. For the connection of the optional remote controls shown below.
3.6 REMOTE CONTROLS. (Optional) Two types of remote control can be connected to the machine via the 14 pin connector situated on the back panel (See
fig.5 item 4). The device will be automatically recognised. The encoder knob on the main control panel will become inoperative for those functions taken over
by the remote control.
3.6.1 Remote control pedal. (Model No. INV/TIG/5) When activated the pedal will control the main welding current. Also in 2-stroke TIG welding mode the first
movement of the pedal will initiate the striking of the arc in place of the torch button.
3.6.2 Remote control with two potentiometers. (Model No. INV/TIG/7) The knob furthest away from the cable entry, controls the main welding current. The
second knob will control one other parameter depending on the active welding mode. The rotation of the second knob automatically selects the appropriate
parameter and brings it up on the display.
3.6.3 Welding mode set up. Parameter for second Knob.
MMA welding with stick electrode............. ARC FORCE (Not displayed)
TIG DC, HF or LIFT, 2 or 4 stroke, ..........................POST GAS
TIG AC , 2 or 4 stroke ....................................POST GAS
fig 2
fig 3
fig 4
fig 5
Original Language Version
TIG161HFACDC Issue: 1 - 03/11/11
Loading...