Sealey 140XT - Manual (Page 2)

INSTRUCTIONS FOR:
ARC WELDER 140AMP, 160AMP WITH ACCESSORY KIT
MODEL Nos:
140XT.V2, 160XT.V2
1.2. GENERAL SAFETY
 WARNING! Arc welding produces sparks, fused metal projectiles and fumes which can be 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 can be 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). Permanent eye
damage may result if you do not use correct eye 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 person welding 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 or the electrode while the machine is switched on.
 DO NOT weld without a welding safety head shield, gauntlets and appropriate protective clothing.
 DANGER! DO NOT weld near inflammable materials - solids, liquids, or gases.
 DO NOT operate welder while under the influence of drugs, alcohol, 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.
* FUSE RATING 13AMP
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. When a BS 1363/A UK 3 pin plug is
damaged, cut the cable just above the plug and dispose of the plug safely.
Fit a new plug according to the following instructions (UK only).
a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check that there are no bare wires, that all wires have been correctly connected, that the cable outer
insulation extends beyond the cable restraint and that the restraint is tight.
Double insulated products, which are always marked with this symbol , are fitted with live (brown) and neutral (blue) wires only.
To rewire, connect the wires as indicated above - DO NOT connect either wire to the earth terminal.
1.1.10. Products which require more than 13 amps are supplied without a plug. In this case you must contact a qualified electrician to
ensure that a suitably rated supply is available. We recommend that you discuss the installation of an industrial round pin plug and
socket with your electrician.
1.1.11. If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance
plugged into it will be protected. The cable core section is important and should be at least 1.5mm², but to be absolutely sure that the
capacity of the reel is suitable for this product and for others which 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.
1.1.12. *IMPORTANT! IF USING WELDER TO FULL CAPACITY, WE RECOMMEND A 16AMP SUPPLY. WE RECOMMEND YOU
DISCUSS THE INSTALLATION OF A 16AMP INDUSTRIAL ROUND PIN PLUG AND SOCKET WITH YOUR ELECTRICIAN.
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 double vented, wraparound shell fitted to a heavy-duty chassis. Screw type,
stepless welding control allows fine adjustment of current. Each welder is fitted with carry handle. Models supplied with accessory kit including
electrode holder, earth clamp and chipping hammer/wire brush.
This instruction manual contains the information required to prepare your arc welding set for welding. 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.
Model No: .......................................................140XT.V2
Welding Current:................................................45-140A
Electrode Capacity: .................................... Ø1.6-3.2mm
Cooling: ..........................................................Forced Air
Output Cable: ......................................................10mm²
No Load Voltage: ......................................................48V
Absorbed Power: .....................................................3kW
Power Input: ................................................. 230V - 1ph
Weight: ................................................................... 17kg
Max. Permissable System Impedance: ..... Zmax(0.22Ω)
Model No: .......................................................160XT.V2
Welding Current:................................................55-160A
Electrode Capacity: .................................... Ø2.0-4.0mm
Cooling: ..........................................................Forced Air
Output Cable: ......................................................16mm²
No Load Voltage: ......................................................50V
Absorbed Power: .....................................................3kW
Power Input: ................................................. 230V - 1ph
Weight: ................................................................... 18kg
Max. Permissable System Impedance: ..... Zmax(0.18Ω)
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.
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these
instructions, and properly maintained, give you years of trouble free performance.
1. SAFETY
2. INTRODUCTION
3. SPECIFICATION
4. CONTENTS
Fig.1
140XT.V2, 160XT.V2 Issue: 2 (SP) - 30/04/15
Original Language Version © Jack Sealey Limited 140XT.V2, 160XT.V2 Issue: 2 (SP) - 30/04/15
Original Language Version © Jack Sealey Limited
Read Instuctions Wear A Welders Mask Wear Protective Gloves Wear Protective Clothing
4.1. See Fig.1.
Wear Eye Protection