Sealey TIG180S.V3 User manual

TIG/MMA INVERTER WELDERS
MODEL NO’S: TIG180S.V3, TIG200S.V3
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 DAMAGEAND/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 owner’s responsibility to read, understand and comply with the following:
You must check all electrical equipment and appliances to ensure that they are safe before use. 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 with portable products that are plugged into an electrical supply not protected by an RCCB. If in doubt consult a
qualified electrician.
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
 qualied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.
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).
Ensure that cables are always protected against short circuit and overload.
Regularly inspect power supply, leads, plugs for wear and damage and all electrical connections
to ensure that none is loose.
Important: Ensure the voltage marked on the product is the same as the electrical power supply
to be used and check that supply is correctly fused, see fuse rating at right.
8DO NOT pull or carry the powered appliance by its power supply lead.
8DO NOT pull power plugs from sockets by the power cable.
8DO NOT use worn or damaged leads, plugs or connections. Immediately replace or have
repaired by a qualified electrician.
This product comes without a plug. You must contact a qualified electrician to ensure an
adequate supply is available.
If fitting such a plug -
Ensure that the unit is correctly wired and earthed, as follows:
a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
b) Connect the BROWN live wire to live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check there are no bare wires, that all wires have been correctly connected, that the cable outer insulation is
clamped by the cable grip and that the grip is tight.
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.
9Keep the inverter and cables in good working order and condition. (Take immediate action to repair or replace damaged parts).
9Use genuine parts and accessories only. (Non recommended parts may be dangerous and will invalidate the warranty).
9Locate 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.
9Ensure 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.
THIS PRODUCT REQUIRES A
MINIMUM 32 AMP
SUPPLY
TIG180S.V3, TIG200S.V3 Issue 2 (1) 31/01/23
Original Language Version
© Jack Sealey Limited
Refer to
instructions Warning:
arc rays Warning:
fumes and gases Warning:
magneticeld
Wear protective
gloves Warning:
electric shock Warning:
rerisk

9Keep 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.
9Remove ill fitting clothing, remove ties, watches, rings, and other loose jewellery, and contain long hair.
9Ensure the workpiece is correctly secured before operating the inverter.
9Avoid unintentional contact with workpiece.Accidental or uncontrolled switching on of the torch may be dangerous and will cause the
nozzle to wear.
9Keep unauthorised persons away from the working area, and any persons working within the area must wear the same protective
items as the user.
9Operators must receive adequate training before using the inverter. The inverter must only be operated under supervision.
9Stand 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.
9Turn voltage switch to “0” (off) when not in use.
8DO NOT operate the inverter if it or its cables are damaged.
8DO NOT use welding cables over 10m in length. (Cables should be as short as possible).
8DO 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.
8DO 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.
8DO NOT hit the electrode on the workpiece, this may damage the electrode and make strike-up difficult.
8DO 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.
8DO 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.
8DO 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.
8DO NOT touch the workpiece close to the weld as it will be very hot. Allow to cool.
8DO NOT touch the torch immediately after use. Allow the torch to cool.
8DO NOT operate inverter while under the influence of drugs, alcohol or intoxicating medication, or if fatigued.
9When not in use store the inverter in a safe, dry, childproof area.
2. INTRODUCTION
Fan-cooledDCpowersupplyforTIGandarcweldingapplications.Outercasemanufacturedfrompressedsteelwithapowdercoatednish
forextracorrosionresistance.Digitaldisplayenablesusertoquicklydeterminewhichmodehasbeenselected.Portabilityallowsthewelder
to be taken to the job at hand making it ideal for the mobile technician. Features lift and high frequency starts enabling operations to start
smoothlyandefciently,alongwithtwoorfourtouchstartmodes.TIGcyclefeaturespulseTIGwhichincludespostgasandcurrentdown-
slope regulation. Supplied with MMA/TIG Accessories. Optional MMA Electrode Holder: Model No. MMA01.
3. SPECIFICATION
Model No: ......................TIG180S.V3.....................TIG200S.V3
PowerInput: ....................5-180A .........................5-200A
Duty Cycle:
20% @ ........................180A...........................200A
60% @ ........................104A...........................115A
100% @........................80A............................89A
Electrode Capacity: ...............Ø 1.6 - 3.2mm ...................Ø 1.6 - 3.2mm
 AbsorbedPower: .................7.6kW..........................8.8kW
Supply:.........................230V** .........................230V**
 Protection: ......................IP21S ..........................IP21S
Accessories:
Arc Accessory Kit (Optional):........MMA01 ........................MMA01
TIG Accessory Kit (Included): .......TIG11S.........................TIG12S
4. OPERATION
Key to fig.1:
1: Gas Outlet
2: Torch Control Connection
3: Negative Socket
4:PositiveSocket
g.1
Original Language Version
© Jack Sealey Limited TIG180S.V3, TIG200S.V3 Issue 2 (1) 31/01/23
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

4.1. LEAD CONNECTION
MMAMode:ConnecttheelectrodeholdertothePositive(+)connector(fig.1.4)andtheearthleadtotheNegative(-)connector(fig.1.3).
  TIGMode:ConnecttheearthclamptothePositive(+)connectorandtheTIGtorchtothenegative(-)connector.
4.2. GAS CONNECTION
4.2.1. Using the clear tubing supplied connect the regulator to the gas inlet on the back of the inverter and gas outlet on the front (fig.1.1).
Secure the tubing on each connector by using the worm drive clamps supplied.
4.2.2. Open the regulator before opening the cylinder valve. Test for leaks.
4.2.3. Set the gas flow to suit the welding parameters required.
4.2.4. If necessary the gas flow can be adjusted during welding using the regulator knob.
4.3. If using the optional torch kit, connect the control lead of the torch assembly to the torch control connection (fig.1.2).
4.4. MMA: DC STICK ARC WELDING
4.4.1. UsingtheUpandDownkeys,settheweldingmodeselector(g.2.1) to , the welding current may be adjusted by means of the
 adjustmentknob(g.2.5).
4.4.2. Thehotstartcurrent(g.3.B)andarcforcecurrentonly(g.3.K)canbeadjustedinthismodetomatchthematerialbeingwelded.
4.4.3. To select the parameter push the parameter setting control to cycle between functions. The value may be adjusted by using the
 adjustmentknob(g.2.1).Thevaluesaredisplayedonthedigitaldisplay.(g.2.4)
4.5. DC TIG WELDING
4.5.1. UsingtheUpandDownkeys,settheweldingmodeselector(g.2.1)to for high frequency start or for lift start.
4.5.2. Thepre-owtime(g.2.A),weldingcurrent(g.2.D)andgasdelaytimeindicator(g.2.J)maybeadjustedinthismode.
4.5.3. To select the parameter press the parameter setting control to cycle between functions. The value may be adjusted rotating the
 settingcontrol(g.2.5).
4.5.4. 2or4touchtriggercontrolmaybeselectedbyusingthetriggermodeselector(g.2.3).
4.5.5. 2 touch allows the power to be applied whilst the trigger is pressed.
4.5.6. 4 touch latches the trigger until the pressed for a second time.
4.5.7. The 4 touch mode is useful for long runs of weld, saving operator fatigue and allowing a steadier weld. In this mode the power will be
applied until the selected down slope time has elapsed.
4.6. DC PULSE TIG WELDING
4.6.1. UsingtheUpandDownkeys,settheweldingmodeselector(g.2.91to for high frequency start or for lift start.
4.6.2. Selectthepulsefunctionatg.2.2.
4.6.3. Thepre-owtime(g.2.A),pulsepeakcurrent(g.2.D),pulsewidth(g.2.F),pulsefrequency(g.2.G),pulsebackgroundcurrent
 (g.2.G)andgasdelaytime(g.2.J)mayallbeadjustedinthismode.
4.6.4. To select the parameter press the parameter setting control to cycle between functions. The value may be adjusted by rotating the
 settingcontrol(g.2.5).
4.7. STATUS WARNING LIGHTS
4.7.1. PowerIndicator(g.2.6).Indicatorilluminatedwhenswitchedon.
4.7.2. OverheatIndicator(g.1.7).Illuminatedwhenmachineisoverheated.Inthisconditionthemachinewillshutdownuntilthetemperature
falls to acceptable limits.
4.7.3. Over/under voltage. Indicates that the supply voltage is outside the required parameters.
5. MAINTENANCE
▲DANGER Unplug the inverter from the mains power supply before connecting or disconnecting cables, performing maintenance or
service. Direct contact with the inverter circuit is dangerous.
5.1. To avoid a build up of dust inside the machine which may block or restrict the ventilation system, periodically remove the covers and
remove the dust with a low pressure air jet or vacuum cleaner. Replace covers immediately. Under no circumstances should the
machine be operated with the covers removed.
5.2. TORCH. Avoid resting the the torch and its associated cable on any hot surfaces. If the insulation is damaged in any way the torch
must not be used.
5.3. Periodicallychecktheconditionofthegastubingandtheconnections.
6. RATINGS PLATE SYMBOLS
On the rear of the inverter is the ratings plate, giving the following
Data:
1 - The BS/EU standard relating to the safety and construction of
Arc welding and associated equipment.
2 - Inverter-transformer-rectifier symbols.
3 - Symbol indicating welding processes available. .
4 - Symbol for Single-phase AC supply.
5 - Rating of internal protection provided by casing.
6 - Output
U0: Maximum open-circuit voltage.
I2, U2: Current and corresponding voltage.
X: Welding ratio based on a 10 minute cycle.
20% indicates 2 minutes welding and 8 minutes rest,
100% would indicate continuous welding.
7 - Mains Supply U1: Rated supply voltage and frequency.
I1max: Maximum current. I1eff: Maximum effective current.
8 - A/V - A/V: Welding current adjustment range and corresponding voltages.
Original Language Version
© Jack Sealey Limited TIG180S.V3, TIG200S.V3 Issue 2 (1) 31/01/23

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 [e-mail] www.sealey.co.uk
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be
sorted, taken to a recycling centre and disposed of in a manner which is compatible with the environment. When
the product becomes completely unserviceable and requires disposal, drain any fluids (if applicable) into approved
containers and dispose of the product and fluids according to local regulations.
WEEE REGULATIONS
Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment
(WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid
waste authority for recycling information.
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior
notice. Pleasenotethatotherversionsofthisproductareavailable.Ifyourequiredocumentationforalternativeversions,pleaseemailorcall
our technical team on [e-mail] or 01284 757505.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
9-Serial Number. Specifically identifies each welder.
10 - Symbol for welding power sources which are suitable for supplying power to welding operations carried out in an environment with increased
risk of electric shock (if applicable).
11- Insulation Class.
Original Language Version
© Jack Sealey Limited TIG180S.V3, TIG200S.V3 Issue 2 (1) 31/01/23
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