SEALEY MW140i MMA Inverter Welders Instructions
MMA INVERTER WELDERS
MODEL NO’S: MW140i , MW160i
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.
SAFETY
1.1. ELECTRICALSAFETY
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.
230V 1ph
THE INVERTER MUST BE
CONNECTED TO A
32AMP SUPPLY FOR
MAXIMUM OUTPUT
1.1.3. We recommend a 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.
The 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
1.2.2. Cable Connections
▲ DANGER! Avoid welding on materials cleaned with chlorinated solvents or near such solvents. Vapors 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 vapors to form phosgene.
▲ 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 the coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.
1.2.3. Protection from Arc
1.2.4. Welding Environment.
1.2.5. Fire Hazard
1.3. PRODUCT CARE & MAINTENANCE
INTRODUCTION
Compact and lightweight unit. The unit can arc weld a variety of rods including rutile, basic and stainless from Ø1.6mm up to Ø4mm (see spec table for details). Features thermal cut-out protection. Portability allows the welder to be taken to the job at hand, ideal for mobile technicians. Supplied with 2m 16mm² cable with electrode holder and a 2m 16mm² earth clamp and cable, both with 35-70 quick connectors. Forced air cooling system with 2 fans.
SPECIFICATION
Model No. | MW140i | MW160i |
Welding Current | 20-140A | 20-160A |
Duty Cycle | 100%@63A | 100%@72A |
60%@81A | 60%@92A | |
20%@140A | 20%@160A | |
Electrode Capacity | 01.6-3.2mm | 01.6-4mm |
Absorbed Power | 5.75kW | 6.9kW |
Supply | 230V | 230V |
Protection | IP21S | I P21S |
PREPARATION
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.
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 workpiece, or
b) A metallic workbench. The connection must be as close to the proposed weld as possible.
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 jeopardize weld quality and may be dangerous.
4.3 BACK PANEL (FIG.1)
Rocker switch. Turns mains power on and off.
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 the machine is switched on and 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 it for 2 seconds. The display will read `VRD’ and by turning the Welding Current control dial it can be turned `On’ or `Off’.
4.4.5 The 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
4.4.7 Arc Force function (or dig) is a feature that senses the drop of the arc’s voltage caused by arc length shortening. Arc force compensates for the voltage drop by increasing the amperage. Increased amperage ensures that the heat stays the same and that the electrode will not stick to the base metal. 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 Arc Force function. Rotate the knob left to adjust to -10 or right to adjust to +10. 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.
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 |
WELDING PROCEDURE
5.1 ARC WELDING
5.1.1 Strike the electrode tip on the workpiece as if you were striking a match.
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 between 20º and 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.
MAINTENANCE
6.1. Periodically remove the casing and, with a low-pressure airflow (max 1bar or15psi), remove dust from inside the machine.
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.
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 the main 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.
7.1.5Check 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.
RATING PLATE
The rating plate on the inverter gives the following data:
- Rating of internal protection provided by the casing.
- The symbol for the power supply line: 1= Single-phase AC.
- This indicates that welding may be carried out in environments with a heightened risk of electric shock e.g. very close to large metallic objects.
- Welding procedure: manual arc welding with covered electrode
- The symbol for the internal structure of the welding machine.
- Model No.
- Manufacturers Serial Number for welding machine identification.
- The EUROPEAN standard relates to the safety and construction of arc welding machines.
- Output.
Uº: Maximum no load voltage.
I², U²: Current and corresponding normalized 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, and 100 indicates continuous welding.
A/V-A/V: Shows the amount of adjustment for the welding current (min-max) at the corresponding arc voltage. - 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.
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 a 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.
9.3 INSTALLATION AND USE. The user is responsible for installing and using the equipment according to these instructions. If electromagnetic disturbances are detected, then it shall be the responsibility of the user of the equipment to resolve the situation with the technical assistance of the supplier. In some cases, this remedial action may be as simple as earthing the circuit (see Note). In other cases it would involve constructing an electromagnetic screen, enclosing the welding power source and the work, complete with associated input filters. In all cases, the electromagnetic disturbances shall be reduced to a level where they are no longer troublesome. Note: The welding/cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding/cutting circuit return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC 974-13 ‘Arc Welding Equipment – Installation and Use.
9.4 ASSESSMENT OF AREA. Before installing the equipment the user shall make an assessment of potential electromechanical problems in the surrounding area. The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. The following shall be taken into account:
a) Other supply cables, control cables, signalling, and telephone cables, above, below, and adjacent to the welding equipment.
b) Radio and television transmitters and receivers.
c) Computer and other control equipment.
d) Safety critical equipment, e.g. security monitoring of industrial equipment.
e) The health of people in the vicinity, e.g. persons fitted with a pacemaker or hearing aid.
f) Equipment used for calibration or measurement.
g) The immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protective measures.
h) The time of day that welding and other activities are to be carried out.
9.5 RATING PLATE The equipment should be connected to the main supply according to these instructions. If interference occurs, it may be necessary to take additional precautions such as filtering the mains supply. Consideration should also be given to shielding the supply cable of permanently installed equipment in metallic conduit or equivalent. This shielding should be connected to the power source so that good electrical contact is maintained between the conduit and the welding power source enclosure. 9.6 MAINTENANCE OF THE EQUIPMENT should be routinely maintained according to these instructions. All-access and service covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in these instructions. In particular, the spark gaps of any arc striking and stabilizing devices should be adjusted and maintained according to the instructions.
9.7 CABLES The welding/cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.
9.8 EQUIPOTENTIAL BONDING Bonding of all metallic components in the welding/cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.
9.9 EARTHING OF THE WORKPIECE Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to others or damage to other electrical equipment. Where necessary, the connection of the workpiece to the earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by a suitable capacitance, selected according to national regulations.
9.10 Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding/cutting installation may be considered for special applications.
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories, and packaging should be sorted, taken to a recycling center, and disposed of in a manner that 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.
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.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 36 months from purchase date, proof of which is required for any claim.
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
www.sealey.co.uk
© Jack Sealey Limited
Original Language Version
MW140i, MW160i Issue:1 24/11/21