Sealey 150XL.V3, Instructions Manual

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.

1.2

GENERAL SAFETY

!

!

WARNING! 

Arc welding produces sparks, fused metal projectiles and fumes which are dangerous.

!

!

WARNING:

Unplug from the mains power supply before performing maintenance or service.

"

Keep the welder and cables in good working order and condition. 

Take immediate action to repair or replace damaged parts.

"

Replace or repair damaged parts. 

Use genuine parts only, unauthorised parts may be dangerous and will invalidate the warranty.

"

Keep the welder clean for best and safest performance.

"

Locate welder in a suitable work area. Ensure area has adequate ventilation as welding fumes are harmful.

"

Keep work area tidy and free from unrelated materials. Also ensure work area has adequate lighting and a fire extinguisher is at hand.

!

!

WARNING:

You MUST use an appropriate shaded lens welding face mask (contact your Sealey dealer for details). DANGER! Permanent 

eye damage may result if you do not use correct protection. Also wear safety welding gauntlets and dry,  oil free safety protective clothing 
to protect yourself from sparks and hot droplets of fused metal. Cover exposed flesh to avoid potential burns from the ultraviolet rays of the 
arc. Use non-reflective welding curtains to protect other people in the area.

"

Check you have good ventilation and that air can flow freely around the welder.

#

#

DANGER!

Ensure no flammable or combustible materials are near work area. Welding containers or pipes which hold, or have held dangerous

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. When a BS 1363/A UK 3 pin plug is 
damaged, cut the cable just above the plug and 

dispose of the plug safely. 

Fit a new plug according to the following instructions (UK only).

a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check that there are no bare wires, that all wires have been correctly connected, that the cable outer insulation

extends beyond the cable restraint and that the restraint is tight.

Double insulated products, which are always marked with this symbol      , are fitted with live (brown) and neutral (blue) wires only.
To rewire, connect the wires as indicated above - 

DO NOT

connect either wire to the earth terminal.

1.1.10. Products which require more than 13 amps are supplied without a plug. In this case you must contact a qualified electrician to ensure that a

suitably rated supply is available. We recommend that you discuss the installation of an industrial round pin plug and socket with your electrician.

1.1.11. If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance

plugged into it will be protected. The cable core section is important and should be at least 1.5mm

2

, but to be absolutely sure that the

capacity of the reel is suitable for this product and for others which may be used in the other output sockets, we recommend the use of
2.5mm

2

section cable.

1.

SAFETY INSTRUCTIONS

FUSE RATING 13 AMP

Blue
Neutral 
Wire

Yellow & Green 
Earth Wire 

Cable 
Restraint

Brown
Live 
Wire

Arc Welders 150XL.V3,150XTC.V3,160XTC.V3,200XTC.V3  - 1 - 200707