Sealey MW180i User manual

180/200AMP MMA INVERTER WELDERS
MODEL NO’S: MW180i , MW200i
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.
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.
1. SAFETY
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 stockist. 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.
9Ensure that the insulation of all cables 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.
9Ensure that cables are always protected against short circuit and overload.
9Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure
that none is loose.
9Ensure that the voltage marked on the appliance matches the power supply to be used.
8DO NOT pull or carry the appliance by the power cable.
8DO NOT pull the plug from the socket by the cable.
8DO NOT use worn or damaged cables, plugs or connectors. Have any faulty item repaired or replaced
8immediately by a qualified electrician.
1.1.3. We recommend connection to a supply with a type C breaker. If in doubt you must contact a qualified
electrician to ensure that a suitably rated supply is available.
WARNING! Be very cautious if using a petrol or diesel generator. The generator must be stable
with regard to frequency (H3), voltage and wave form. The output must be higher than the
power (kVA) of the inverter. The generator must also be self regulating. If any A.M. feature is
not respected the working of the regulation card may be affected. Use of a generator without a
regulator may be dangerous and will invalidate your inverter warranty.
1.2. GENERAL SAFETY
1.2.1. Operator Safety
9Operators must receive adequate training before using the inverter.
9Remove ill fitting clothing, remove ties, watches, rings and other loose jewellery and contain long hair.
8DO NOT operate the inverter while under the influence of drugs, alcohol or intoxicating medication, or if tired.
9Stand correctly keeping a good footing and balance, ensure that the floor is not slippery and wear non-slip shoes.
9Keep unauthorised persons away from the work area. Any persons working within the area must wear the same protective items.
9Avoid oily greasy clothing. A spark may ignite them.
8DO NOT touch the work piece close to the weld as it will be very hot. Allow to cool.
8DO NOT touch the electrode holder immediately after use. Allow the electrode holder to cool.
9Wear safety welding gauntlets.
1.2.2. Cable Connections
9Keep the inverter and cables in good working order and condition. Take immediate action to repair or replace damaged parts.
9Ensure that there is no obstruction to the flow of clean, cool air and ensure that there are no conductive dusts, corrosive vapours or
humidity which could enter the inverter and cause serious damage.
8DO NOT weld containers or pipes which have held flammable materials - gases, liquids or solids.
▲DANGER! Avoid welding on materials cleaned with chlorinated solvents or near such solvents. Vapours from chlorinated solvents
(such as de-greasers) can be decomposed by the heat of the arc to form PHOSGENE, a highly toxic gas, and other lung and eye
irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapours to
form phosgene.
MW180i, MW200i Issue:2 (3) 14/03/22
Original Language Version
© Jack Sealey Limited
Refer to
instruction
manual
Fire
hazard
Arc rays
wear
eye protection
Electric shock
hazard
Fumes / gases
Use in ventilated
area
Hot surfaces
wear protective
gloves
Magnetic fields
produced
230V 1ph
THE INVERTER MUST BE
CONNECTED TO A
32AMP SUPPLY FOR
MAXIMUM OUTPUT

8DO NOT weld where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to
atmospheres containing even minute amounts of trichloroethylene or perchloroethylene.
9Prevent dangerous conditions arising by providing adequate ventilation. NEVER ventilate with oxygen.
▲DANGER! Lead-, cadmium-, zinc-, mercury- and beryllium-, bearing materials, when welded (or cut) may produce harmful
concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator
must wear an air- supplied respirator. For beryllium, both must be used. Metals coated with or containing materials that emit toxic fumes
should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied
respirator.
8DO NOT work in an unventilated confined space. If necessary, wear an air-supplied respirator.
WARNING!:Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill.
1.2.3. Protection from Arc
WARNING!:Use welding head shield to protect eyes and avoid exposing skin to ultraviolet rays given off by electric arc. Looking at
an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave
a permanent dark area in the field of vision.
9Before welding whilst wearing contact lenses, seek advice from your optician.
9Avoid unintentional contact with workpiece. Accidental or uncontrolled arcing on the electrode holder may be dangerous.
8DO NOT hit the electrode on the workpiece, this may damage the electrode and make strike-up difficult.
9Wear safety welding gauntlets.
1.2.4. Welding Environment.
9Locate the inverter in a suitable work area.
9See Section 11 regarding Electromagnetic Compatibility.
9Keep the work area clean and tidy and free from unrelated materials. Also ensure that the work area has adequate lighting.
8DO NOT get inverter wet or use in damp or wet locations or areas where there is condensation.
9First aid facilities and a qualified first aid person should be available during welding operations.
9For production welding, a separate room or enclosed bay should be provided. In open areas, surround the operation with low reflective,
non-combustible screens or panels. Allow for free air circulation, particularly at floor level. Provide face shields for all persons who will
be looking directly at the weld. Before starting to weld, make sure that screen or bay doors are closed.
9Always ensure that there is full free air circulating around the outer casing of the machine, and that the louvres are unobstructed.
1.2.5. Fire Hazard
WARNING: Be aware that flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and
through wall or floor openings, out of sight of the operator. Sparks and slag can fly 10m.
8DO NOT weld within 10 metres of combustible materials (including building construction materials).
8DO NOT weld adjacent to openings (concealed or visible) in floors or walls within 10m that can expose combustibles to sparks.
8DO NOT weld near to walls, ceilings, roofs or metal partitions where there are combustibles that can be ignited by radiant or
conducted heat.
9 Havesuitablereextinguishingequipmentavailableandsomeonetouseitduringweldingoperationsandforsometimeafter 
weldingceases.Afterworkisdone,checkthatareaisfreeofsparks,glowingembers,andames.
1.3. PRODUCT CARE & MAINTENANCE
8DO NOT attempt to fit any unapproved electrode holder, components, or parts to the inverter unit.
9Keep the inverter clean for best and safest performance.
WARNING: If the case is opened for maintenance or repair, wait 10-15 seconds after the unit is switched off for the capacitor to discharge.
2. INTRODUCTION
Compact and lightweight unit, suitable for arc welding and TIG using the lift start method. Unit can arc weld a variety of rods including rutile, basic
and stainless from Ø1.6mm up to Ø5mm (see table below). Features thermal cut-out protection. Portability allows the welder to be taken to the job
at hand, ideal for the mobile technicians. Supplied with 2m 16mm² cable with electrode holder and 2m 16mm² earth clamp and cable, both with 35-
70 quick connectors. Forced air cooling system. Optional TIG accessory kit available Model No. TIG10S.
3. SPECIFICATION
Model No. MW180i MW200i
Welding Current 20-180A 20-200A
Duty Cycle 100%@80A 100%@89A
60%@104A 60%@115A
20%@180A 20%@200A
Electrode Capacity Ø1.6-4.0mm Ø1.6-5mm
Absorbed Power 7.8kW 9.2kW
Supply 230V 230V
Protection IP21S IP21S
TIG Accessory Kit
(Optional)
TIG10S - Inverter TIG Welding Torch 16mm²
4. PREPARATION
WARNING! Ensure that the inverter is not plugged into the mains power supply before connecting or disconnecting cables.
For electrical installation, see Safety Instructions (Section 1).
WARNING! Failure to follow the electrical safety instructions may affect the operating performance and could damage the
built-in safety system which, in turn, could result in personal injury or fatality and will invalidate the warranty.
4.1. WELDING CABLE “ELECTRODE HOLDER” CONNECTION
4.1.1. Before connecting cables it is important to refer to the electrode manufacturer’s instructions on the electrode packaging which will
indicate the correct polarity connection for the electrode, together with the most suitable current to use.
Original Language Version
© Jack Sealey Limited MW180i, MW200i Issue:2 (3) 14/03/22

4.2. ARC WELDING
4.2.1. In principle, when ARC welding the Electrode Holder ”POSITIVE” is normally connected to the “POSITIVE” (+) terminal (fig.1).
4.2.2. The WORK CLAMP cable is connected to the terminal not occupied by the electrode holder cable. The clamp is connected to:
a) The work piece, or
b) A metallic work bench. The connection must be as close to the proposed weld as possible.
WARNING! Cable connectors must be turned into the quick plugs fully to ensure a good electrical contact. Loose connections will
cause overheating, rapid deterioration and loss in efficiency.
8DO NOT use welding cables over 10m in length.
With the exception of a metallic workbench DO NOT connect the return cable to any metallic structure which is not part of
the workpiece, as this will jeopardise weld quality and may be dangerous.
4.3. BACK PANEL (FIG.1)
 Rockerswitch.Turnsmainspoweronando󰀨.
4.4. FRONT PANEL (FIG.2)
4.4.1. Welding Current Control: Regulates welding current.
The set value will be displayed in the display panel.
4.4.2. Power Indicator: Illuminates when machine is
switched on ready for use.
4.4.3. Alarm Indicator: Illuminates when the circuitry within the machine overheats. Allowing the inverter to cool down naturally will
restore operation after a period of time. See rating plate for details of duty cycle.
4.4.4. VRD Indicator illuminates when the voltage reduction device is active. To operate the VRD, press the function button and hold for 2
 seconds.Thedisplaywillread‘VRD’andbyturningtheWeldingCurrentcontroldialitcanbeturned‘On’or‘O󰀨’.
4.4.5. Hot Start function is a feature that pumps up the amperage for a short time when you start the arc. Higher amperage helps
to start the arc easier without sticking the electrode to the base metal. To enable this feature, press the function button and hold for
2 seconds and VRD is displayed. Press the function button once more to engage this feature. Rotate the knob left to adjust to -10
or right to adjust to +10
4.4.6. Lift TIG Indicator: WithLift-ArcIgnitionfeature,tostartthearcthetungstenelectodeistouchedonthejobandliftedo󰀨.Thestart-
up current is very low and therefore the tungsten barely sticks to the job and the sharpened point is not damaged. The tungsten
 istheneasilyliftedo󰀨thejob.Themachinesensesthatthecontactisbrokenandbeginssupplyingfullweldingcurrent.Toenable
this feature, press the function button and hold for 2 seconds, VRD will be displayed. Press the function button once more to
display HS and press the downward arrow one more time to engage the Lift TIG function. Press the button again in order to exit the
menu system.
4.5. ELECTRODES
The welding current must be regulated according to the diameter of the electrode in use and the type of joint to be welded. See
diameter/current chart below.
5. WELDING PROCEDURE
WARNING! Ensure that you read, understand and follow the safety instructions. Place the welding mask in front of your
face before striking the arc.
5.1. ARC WELDING
5.1.1. Strike the electrode tip on the workpiece as if you were striking a match.
Fig. 1
Original Language Version
© Jack Sealey Limited
Fig. 2
VRD Indicator
Alarm Indicator
Power Indicator
Hot Start
Lift TIG
Indicator
Function
Selector
Welding
Current
Control
Electrode Ømm Minimum Welding Current Amps Maximum Welding Current Amps
1.6 25 50
2.0 40 80
2.5 60 110
3.2 80 160
4.0 120 200
MW180i, MW200i Issue:2 (3) 14/03/22

WARNING! DO NOT hit the electrode on the workpiece, as this may damage the electrode.
5.1.2. As soon as the arc is struck, maintain a distance from the workpiece equal to the diameter of the electrode. Keep this distance as
constant as possible for the duration of the weld. As you advance along the workpiece the angle of the electrode must be maintained
at between 20ºand 30º. See fig.4.
5.1.3. At the finish of the weld, bring the end of the electrode backward in order to fill the weld crater and then quickly lift the electrode from
the weld pool to extinguish the arc.
WARNING! Hot metal such as electrode stubs and workpieces should never be handled without gloves.
6. MAINTENANCE
WARNING! Before carrying out routine maintenance, switch off the welding and disconnect it from the mains power supply.
WARNING! If the welding machine is not functioning properly repairs should be carried out only and by authorised service
engineers.
WARNING! Before removing the welding machine panels switch off the machine and disconnect it from the mains power
supply. Wait 10-15 seconds after the unit is switched off for the capacitor to discharge.
6.1. Periodically remove the casing and, with a low pressure air flow (max 1bar or15psi),remove dust from inside the machine.
8DO NOT direct compressed air onto the electronic circuit boards, these should be cleaned with a very soft brush.
6.2. Ensure that all electrical connections are tight and check the wiring for damage to the insulation.
6.3. Ensure that the casing is correctly replaced and secured before attempting to use the inverter.
6.4. Keep the outside of the machine clean by wiping with a soft, dry cloth.
6.5. For any other service or maintenance, contact your local Sealey service agent.
7. TROUBLESHOOTING
7.1. If you have a problem with the inverter, check to ensure that the following are correct:
7.1.1. Check that the welding current is suitable for the diameter and type of electrode being used.
7.1.2. When the mains switch is on, check that the power lamp is on. If this is not the case then there may be a mains supply problem.
7.1.3. Check the overheat indicator - has the thermal cut-out activated? This indicates either an over or under voltage or short circuit. If the
thermal interrupter has activated, wait for the machine to cool down before restarting.
7.1.4. Ensure that you are using the correct supply voltage.
7.1.5. Check the machine output and ensure there is nothing causing a short-circuit.
7.1.6. Check that all circuit connections are correct. In particular check that the work clamp is correctly attached to the workpiece. Ensure that
there is no grease, paint etc. on the surface.
8. RATING PLATE
The rating plate on the inverter gives the following data:
1 - Rating of internal protection provided by casing.
2 - Symbol for power supply line: 1= Single-phase AC.
3 - Indicates that welding may be carried out in
environments with a heightened risk of electric shock eg very close to
large metallic objects.
4 - Welding procedure: manual arc welding with covered electrode
5 - Symbol for internal structure of the welding machine.
6 - Model No.
7 - Manufacturers Serial Number for welding machine identification.
8 - The EUROPEAN standard relating to the safety and construction of
arc welding machines.
9 - Output.
Uº: Maximum no load voltage.
I², U²: Current and corresponding normalised voltage that the welding machine can supply during welding.
X: Welding ratio based on a 10 minute duty cycle. 30% indicates 3 minutes welding and 7 minutes rest, 100% indicates continuous
welding. A/V-A/V: Shows the adjustment for the welding current (min - max) the corresponding arc voltage.
10 - Power Supply
U1: Alternating voltage and power supply frequency of welding machine.(allowed limit ±10%)
I1 max: Maximum current absorbed by the line.
I1 eff: Effective current supplied.
9. ELECTRONIC COMPATIBILITY
9.1. THIS EQUIPMENT IS IN CONFORMITY WITH THE EUROPEAN STANDARD ON THE ELECTROMAGNETIC COMPATIBILITY
OF ARC WELDING EQUIPMENT AND SIMILAR PROCESSES (e.g. ARC AND PLASMA CUTTING)
9.2. PROTECTION AGAINST INTERFERENCE. (E.M.C.) The emission limits in this standard may not, however, provide full protection
against interference to radio and television reception when the equipment is used closer than 30m to the receiving antenna. In special
cases, when highly susceptible apparatus is being used in close proximity, additional mitigation measures may have to be employed in
order to reduce the electromagnetic emissions. At the same time there could occur some potential difficulties in having electromagnetic
compatibility in a non-industrial environment (e.g. in residential areas). Therefore it is most important that the equipment is used and
installed according to the following instructions.
Fig. 4
Original Language Version
© Jack Sealey Limited MW180i, MW200i Issue:2 (3) 14/03/22