Welding Procedure - Sealey MW140PLUS.V2 Instructions Manual

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Table Of Contents

Table of Contents

CONNECTING CABLES & GAS

WARNING! Ensure that the inverter is not plugged into the power supply before assembling, connecting or

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disconnect cables. See Safety Instructions (Section 1).

WARNING! Failure to follow the electrical safety instructions will affect the operating performance and may

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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.

WARNING! Dinse cable connectors must be turned fully into the dinse sockets to ensure a good electrical contact.

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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.

5. CONTROLS & PREPARATION

5.1

FRONT PANEL CONTROLS (See fig.7)

5.1.1 POTENTIOMETER: (fig.7-2) To regulate welding current with scale graduated in Amps. May be regulated during welding.

5.1.2 GREEN LED: (fig.7-3) Mains power indicator, machine ready.

5.1.3 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 high or

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.

5.1.4 FUNCTION SELECTION SWITCH: (fig.7-5) Selects the desired welding mode:

1. TIG - SCRATCH: Left hand position for TIG welding with scratch strike (without HOT START and ARC FORCE).

2. ARC WELDING WITH ELECTRODE: Right hand position for electrode welding (with HOT START and ARC FORCE).

(NOTE: Arc welding with particular rutile electrodes may result in excessive spattering. In this case we

advise moving the selection switch to the TIG position.)

5.2

REAR PANEL FACILITIES (See fig.8)

5.2.1 MAINS ON/OFF SWITCH. The mains ON/OFF switch is located on the rear panel and illuminates

when in the ON position.

5.2.2 PRODUCT RATING PLATE. The product rating plate is printed on the rear panel. Refer to

Section 10 for an explanation of the symbols used.

5.3

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.

5.3.1 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

! ! 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.

6.1.4 ARC WELDING PROCEDURE: (Optional Arc welding accessory kit INV/16 is available your Sealey dealer.)

(a) Strike the electrode tip on the workpiece as if you were striking a match.

! ! WARNING! DO NOT hit the electrode on the workpiece, as this may damage the electrode.

(b) 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

(c) 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. 5

fig. 6

fig. 7

fig. 8

Electrode Diameter (mm)

1.6 . . . . . . . . . . . . . . . . . . . . .25 . . . . . . . . . .50

2.0 . . . . . . . . . . . . . . . . . . . . .40 . . . . . . . . . .80

2.5 . . . . . . . . . . . . . . . . . . . . .60 . . . . . . . . .110

3.2 . . . . . . . . . . . . . . . . . . . . .80 . . . . . . . . .160