Sealey 200XTD - Manual (Page 2)

INSTRUCTIONS FOR
ARC WELDERS
This instruction manual contains the information required to prepare your arc welding set for welding. For Individual model specifications refer
to part 2. The instructions are not intended to show you how to become a welder. If you have no experience, we recommend that you seek
training from an expert source. Arc welding is relatively easy to perform, but does require a steady hand and time practising with scrap metal,
as it is only with continued practice that you will achieve the desired results.
INTRODUCTION
Thank you for purchasing a Sealey Power Welder. 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: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL
REQUIREMENTS, WARNINGS, AND CAUTIONS. USE THIS 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.
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 dealer.
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.
1.1.3. Ensure that the insulation on all cables and 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.
1.1.4. Ensure that cables are always protected against short circuit and overload.
1.1.5. Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure that none is loose.
1.1.6. Important: Ensure that the voltage marked on the appliance matches the power supply to be used and that the plug is fitted with the
correct fuse - see fuse rating at right.
1.1.7. DO NOT pull or carry the appliance by the power cable.
1.1.8. DO NOT pull the plug from the socket by the cable.
1.1.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty item repaired or replaced by a qualified
electrician.
1. SAFETY INSTRUCTIONS
Original Language Version 180XT, 200XTD, 220XTD, 250XTD Issue: 1 - 01/06/12 © Jack Sealey Limited
1.3 MODELS 220XTD & 250XTD REQUIRE TO BE CONNECTED TO A 3 PHASE SUPPLY AND
MUST HAVE AN APPROPRIATE PLUG FITTED.
 WARNING! Electrical installation of welder to a 3 phase 415Volt supply must only be carried out by a
qualified electrician. Make sure the power supply cable is correctly connected to the Earth.
1.3.1 This product must be fitted with a 3 phase plug as shown on the right, and will require a minimum of
16AMPs per phase, (preferably 32AMP) electrical supply.
You must contact a qualified Electrician to ensure an appropriately fused supply is available.
Connect GREEN/YELLOW wire to Earth ‘E’
Connect BLUE wire to the NEUTRAL Terminal.
Connect BROWN wire to L1 Terminal.
L2 Terminal is in this instance, unused.
Connect the GREY wire to terminal L3.
When completed, check there are no bare wires, that all wires have been connected correctly and the
cable restraint is tight. (NOTE:The cable core colours found in the mains cable on this welder are
consistent with Amendment 2 to BS7671:2001 which harmonised UK cable core colours with those used
in Europe.)
1.3.2 DO NOT use this product with a standard extension cable. Only use ARMOURED extension cable.
1.2 IMPORTANT : THE 180XT AND THE 200XTD CAN BE CONNECTED TO EITHER A 16AMP SINGLE PHASE
SUPPLY OR A PROPERLY INSTALLED 13AMP SUPPLY. TO ACHIEVE MAXIMUM OUTPUT HOWEVER A
16AMP FUSED SUPPLY SHOULD BE USED. WE RECOMMEND YOU DISCUSS THE INSTALLATION OF AN
INDUSTRIAL ROUND PIN PLUG & SOCKET WITH A QUALIFIED ELECTRICIAN.
1.2.1. To fit a 13Amp plug proceed as shown on the right.
Ensure the unit is correctly earthed via a three-pin plug.
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’.
After wiring, check there are no bare wires, that all wires have been correctly connected and that the
wire restraint is tight.
1.2.2. Cable extension reels. When a cable extension reel is used it should be fully unwound before connection.
A cable reel with an RCD fitted is recommended since any product which is plugged into the cable reel will be
protected. The cross-section of the cable on the cable reel must be suitable for the unit and never lower than the
cross-section of the main cable supplied with unit.