ARC WELDERS 0807 OPERATING & MAINTENANCE INSTRUCTIONS
Thank you for purchasing this CLARKE Arc Welder. Before attempting to operate this machine, please read this leaflet thoroughly and follow the instructions carefully, in doing so you will ensure the safety of yourself and that of others around you, and you can look forward to the welder giving you long and satisfactory service. GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase.
ELECTROMAGNETIC INTERFERENCE (EMC) Whilst this unit complies with EMC regulations, the user is responsible for installing and using the welding equipment according to the manufacturers instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation. In some cases this remedial action may be as simple as earthing the welding circuit, see ‘Note’.
take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure. 2.
SAFETY PRECAUTIONS WARNING: As with all machinery, there are certain hazards involved with their operation and use. Exercising respect and caution will considerably lessen the risk of personal injury. However, if normal safety precautions are overlooked, or ignored, personal injury to the operator may result. FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY 1.
C) Fire and explosion prevention Causes of fire and explosion are: 1) combustibles reached by the arc, flame, flying sparks, hot slag or heated material; 2) misuse of compressed gases and cylinders; 3) short circuits. BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks and slag can fly 10m.
2. ELECTRIC ARC WELDING Comply with precautions in 1 above, and this section. Arc welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot. The wise operator avoids unnecessary risks and protects himself and others from accidents. 2A) BURN PROTECTION Comply with precautions in 2.
2B) TOXIC FUME PREVENTION Comply with precautions in 2-B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. 2C) FIRE AND EXPLOSION PREVENTION Comply with precautions in 2-C. Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire. Loose cable connections may overheat or flash and cause a fire. Never strike an arc on a cylinder or other pressure vessel.
2) Electrode holders Fully insulated electrode holders should be used. Do NOT use holders with protruding screws or with any form of damage. 3) Connectors Fully insulated lock-type connectors should be used to join welding cable. 4) Cables Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable.
PREPARATION OF THE WORKING AREA The working area must be sufficiently spacious, not humid, and well-ventilated as to avoid any fumes which develop from the welding process and from incidental material adhering to the pieces to be welded (oils, paints, tars...) which may cause annoyance to the operator. Avoid welding by contact with humid parts nearby combustible liquids. Least of all, do not weld upon tanks which may contain inflammable residuals.
ELECTRICAL CONNECTIONS WARNING! THIS APPLIANCE MUST BE EARTHED. A. MODELS FITTED WITH 13AMP PLUG Welders fitted with a standard 13 amp BS 1363 plug, should be connected to a to a 230 volt (50Hz) domestic electrical supply and we strongly recommend that this be done via a Residual Current Device (RCD). IMPORTANT: If the welder is fitted with a plug which is moulded onto the electric cable (i.e. non- re-wirable) please note: 1. The plug must be thrown away if it is cut from the electric cable.
Dual Supply For machines capable of operating on 110/230V and 230/400V, the voltage selector is designed so that it can select only one voltage. In order to change voltages on earlier models, it is necessary to change the switch gate as follows: 1. With the voltage selector knob in the OFF position, slacken the knobs’ grub screw and remove the knob, to reveal a circular plate. 2. Remove the two screws securing the plate, then reverse the plate. 3.
FEATURES The welding capabilities of your welder are given on the data label printed on the rear panel of the machine (see list on page 22 for an explanation of markings and symbols). Thermal Overload Protection If the duty cycle of the welder is exceeded (see Specifications), the Overload Protection Device will automatically cut the power to prevent damage to the machine.
This is an illustration of a typical layout. Although with some models, the major components may differ slightly in design and location. Fig.
ASSEMBLING THE FACE SHIELD Fig.2 To assemble the welding shield, insert the clear glass panel first, followed by the dark glass panel into the recess in the shield, i.e. the clear glass MUST be on the outside of the shield. Securing them with the plastic screws provided. Enter the threaded end of the handle through the holes provided. Thread on the plastic nut and tighten. It is important to pay attention to the notes on welding shield maintenance, given on page 19.
WELDING TECHNIQUE 1. With the welder correctly connected to the mains supply and the leads attached to the machine, ensure the earth clamp is firmly attached to the workpiece on CLEAN, SOLID metal, and as close to the proposed weld as is practical, and the appropriate current setting for the job has been set. 2. Switch ON the machine. NOTE: If the machine stops at any time and the amber light on the front panel illuminates, the thermal cutout has intervened.
WELDING PITFALLS The arc welding technique is an acquired skill and requires considerable practice before perfect results are obtained. The diagrams below will help to explain the pitfalls in your technique and how to overcome them. 1. Arc too short 5. Current too low This causes irregular masses of weld to be deposited, with slag contamination on an uneven surface. This causes poor penetration and causes the electrode to stick to the workpiece too readily.
MAINTENANCE Your Clarke arc welder is a simple and robust unit, requiring virtually no maintenance other than the guidelines shown below. 1. Keep the louvre passages clean to avoid a build up of dirt and oxides inside the machine, which can reduce machine output. 2. Check all cables periodically; they must be in good condition and not cracked. 3. Always try to avoid getting particles of metal inside the machine since they could cause short circuits. 4.
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DUTY CYCLES Example 1. 230TE Data Plate Models up to and including 230TE are covered by Reg’s EN 50060 and EN 50199, where the Duty Cycle is expressed as a number of electrodes that may be burned continuously in a given time. Referring to the table opposite, nc indicates the number of electrodes that may be burned before the thermal cutout will operate at a specified welding current. i.e. using the example above: .......... using 2.5mm dia rods, 34 may be burned continuously at 80 A welding current or .....
ELECTRICAL SYMBOLS EXPLAINED The full technical specification for your welder is to be found printed in a table on the rear panel of the machine. The meaning of the markings and symbols shown in the table are explained as follows. Symbol for dropping characteristic Symbol for manual arc welding and covered electrodes Symbol for the mains supply and No. of phases X Duty Cycle, expressed as a % in a 10 min period 1~ Single Phase Transformer _1~ _ V Min. and Max.
