5.1
FRONT PANEL CONTROLS (See fig.7)
5.2
POTENTIOMETER: (fig.7-2) To regulate welding current with scale graduated in Amps. May be
regulated during welding.
5.3
GREEN LED: (fig.7-3) Mains power indicator, machine ready.
5.4
YELLOW LED: (fig.7-4) Normally off. When on it means no welding current due to one of the
following faults:
1. Thermal protection:
Inside machine the temperature is excessive. The machine is ON
but will not deliver current until a normal temperature is reached. Once this happens the re-
start is automatic.
2. Mains over/under voltage protection:
Shuts down the machine if the power supply voltage
is too low.
3. Short circuit protection:
If there is a short-circuit lasting more than 1.5 seconds (i.e.
electrode sticking), machine stops. Re-start is automatic.
5.5
REAR PANEL FACILITIES (See fig.8)
MAINS ON/OFF SWITCH. The mains ON/OFF switch is located on the rear panel and
illuminates when in the ON position.
5.6
PRODUCT RATING PLATE. The product rating plate is printed on the rear panel. Refer to
Section 10 for an explanation of the symbols used.
5.7
SITING THE INVERTER.
When commencing work the inverter should be placed on a stable
flat surface to prevent it from tipping or moving hazardously. The surface used should be
capable of supporting the weight of the inverter.
5.8
Ensure that the ventilation slots on the front and rear panels are not obstructed and at the
same time make sure conductive dusts, corrosive vapours, humidity etc will not be sucked into
the machine. Leave at least 250mm free space around the inverter.
6. WELDING PROCEDURE
fig. 8
p
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WARNING! Ensure that the inverter is not plugged into the power supply before assembling, connecting or
disconnect cables. See Safety Instructions (Section 1).
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WARNING! Failure to follow the electrical safety instructions will affect the operating performance and may
damage the built-in safety system which could result in personal injury or fatality and will invalidate the
warranty.
4.1
ELECTRODE HOLDER CABLE CONNECTION:
BEFORE CONNECTING CABLES IT IS IMPORTANT TO REFER TO
THE INSTRUCTIONS ON THE ELECTRODE PACKAGING WHICH WILL INDICATE THE CORRECT POLARITY FOR
THE ELECTRODE, TOGETHER WITH THE MOST SUITABLE CURRENT TO USE.
4.2
ARC WELDING.
Normally, when ARC welding, the ELECTRODE HOLDER is connected to the
POSITIVE
(+) terminal (fig. 5).
4.3
TIG WELDING
Normally, when TIG welding alloys, the ELECTRODE HOLDER is connected to the
NEGATIVE
(-) terminal (fig. 5).
4.4
WORK CLAMP CABLE CONNECTION
The work clamp cable is connected to the inverter terminal which is not occupied by the electrode holder cable.
The clamp is connected to:
a) The workpiece.
b) A metal work bench. The connection must be as close to the proposed weld as possible.
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WARNING!
Dinse plug connectors must be inserted into the dinse sockets and turned fully to ensure a good electrical
contact. Any loose connections will cause overheating, rapid deterioration and loss in efficiency.
DO NOT use welding cables over 10m in length. With the exception of a metallic workbench, DO NOT connect
the work clamp to a metal structure which is not part of the workpiece, as this will jeopardise weld quality and may be dangerous.
4.5
CONNECTING THE GAS FOR TIG WELDING ( Using optional kit INV/TIG )
4.5.1 When using Argon gas fit the Bull Nose Adaptor to the cylinder with a spanner.
4.5.2. Fit the gas regulator onto the Bull Nose Adaptor ( see fig.6 ).
4.5.3 The black gas supply tube is an integral part of the INV/TIG Torch/Cable assembly. Screw the female brass connector at the
end of the tube directly to the gas regulator as shown in fig.6.
4.5.4 Close the regulator before opening the cylinder valve. Test for leaks.
4.5.5. Set the gas flow to suit the welding parameters required. See WELDING PARAMETER TABLES for general guidance.
4.5.6 If necessary the gas flow can be adjusted during welding using the regulator knob.
fig. 5
4.
CONNECTING CABLES & GAS
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WARNING! Ensure that you read, understand and follow the safety instructions. Place the welding mask in front of your face before striking the arc.
6.1
ARC WELDING
6.1.1 ELECTRODE POLARITY: It is essential that the user refers to the makers instructions on the
stick electrode packaging to determine the correct polarity of the stick electrode and the
recommended current.
6.1.2 WELDING CURRENT: In general the welding current must be regulated according to the
diameter of the electrode in use (see chart on right) and the type of joint to be welded.Further
consideration must be given to the location of a weld, for example: Welds that are performed
on a horizontal surface require a higher voltage than those performed on a vertical or overhead
surface. The mechanical characteristics of the weld will be determined not only by the current intensity used, but also by the diameter and quality of the
electrode, the length of arc and the work rate and position of the user. The condition of the electrode is an important factor and must never be wet or damp.
6.1.3 ARC FORCE: The properties of the weld also depend on the arc force value (dynamic behaviour ) of the welder. The arc force function is automatically active
when the welding mode switch is set to the right hand arc welding position. It should be noted that higher arc force values achieve better penetration and
allow welding in any position typically with basic and cellulose electrodes. If lesser penetration is required the switch can be set to the TIG - SCRATCH
position which will disable the arc force and hot start functions.
6.2
ARC WELDING PROCEDURE: (Optional Arc welding accessory kit INV/16 is available your Sealey dealer.)
6.2.1. Strike the electrode tip on the workpiece as if you were striking a match.
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WARNING! DO NOT hit the electrode on the workpiece, as this may damage the electrode.
6.2.2. As soon as the arc is ignited, maintain a distance from the workpiece equal to the diameter of the electrode being used. 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 20
O
to 30
O
.
See fig.9.
6.2.3. At the end of the weld bead, bring the end of the electrode backward in order to fill the weld crater, quickly lift the electrode from the weld pool to
extinguish the arc. See fig.10 for guidance on achieving a satisfactory weld bead.
fig. 6
5. CONTROLS & PREPARATION
Electrode Diameter (mm)
Welding Current (Amp)
Min
Max
1.6 . . . . . . . . . . . . . . . . . . . . .25 . . . . . . . . . .50
2.0 . . . . . . . . . . . . . . . . . . . . .40 . . . . . . . . . .80
2.5 . . . . . . . . . . . . . . . . . . . . .60 . . . . . . . . .110
3.2 . . . . . . . . . . . . . . . . . . . . .80 . . . . . . . . .160
MW140.V3 - 1 - 220205
fig. 7
