Sealey TIG160S - Manual (Page 2)

INSTRUCTIONS FOR:
TIG/MMA INVERTER WELDERS
160Amp, 180Amp, 200Amp - 230V
MODEL No's :
TIG160S, TIG180S, TIG200S
IMPORTANT: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. MAKE CAREFUL NOTE OF SAFETY INSTRUCTIONS,
WARNINGS AND CAUTIONS. THIS PRODUCT SHOULD ONLY BE USED FOR ITS INTENDED PURPOSE. FAILURE TO DO SO MAY CAUSE DAMAGE
OR PERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
1. SAFETY INSTRUCTIONS
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 the inverter in a suitable working area. Ensure that the area has adequate ventilation as welding fumes are harmful.
 Ensure there is no obstruction to the flow of clean cool air through the ventilation apertures and ensure that there are no conductive dusts, corrosive
vapours or humidity which could enter the inverter and cause serious damage.
 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. A loose connection will cause overheating, rapid deterioration and loss
of efficiency.
 Keep working area clean and tidy and free from unrelated materials. Also ensure the working area has adequate lighting.
 WARNING! Use welding headshield 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 operator.
 Operators must receive adequate training before using the inverter.
 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.
 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 could damage your machine and invalidate your
warranty.

DO NOT use any metallic structure which is not part of the workpiece to substitute for the return cable of the welding current. 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 when tired or under the influence of drugs, alcohol or intoxicating medication.
 When not in use store the inverter in a safe, dry, childproof area.
1.1. ELECTRICAL SAFETY

WARNING! It is the user’s responsibility to read, understand and comply with 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 also 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 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 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 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).
1.1.4. Ensure that cables are always protected against short circuit and overload.
1.1.5. Regularly inspect power supply leads, plugs and all electrical connections for wear and damage and especially
power connections, to ensure that none is loose.
1.1.6. Important: Ensure the voltage marked on the product is the same as the electrical power supply to be used and check that plugs are fitted with the
correct capacity fuse.
1.1.7. DO NOT pull or carry the powered appliance by its power supply lead.
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
a qualified electrician.
1.1.10. A plug is not fitted to these welders. For maximum performance, these models require at least a 32Amp fused supply either by direct wiring into
the mains circuit or by fitting an industrial round pin plug & socket for more flexible usage. In either case we recommend that you discuss the
installation with a competent qualified electrician to assess your existing wiring installation and to 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 welder.
1.1.11. 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 section of the cable on the cable reel is important and should
be at least 1.5mm², but to be absolutely sure that the capacity of the cable is suitable for this product and for others that may be used in the other output
sockets, we recommend the use of 2.5mm² section cable.
 WARNING! Be very cautious if using a generator to power the welder. 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 welder. If any of these requirements is
not met the electronics within the welder may be affected.
NOTE: The use of an unregulated generator may be dangerous and will invalidate the warranty on the welder.
 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.
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
you years of trouble free performance.
Original Language Version
TIG160S, TIG180S, TIG200S Issue: 1 - 05/06/13 © Jack Sealey Limited