CLARKE 160 AMP ARC WELDER

ELECTRIC SHOCK

• Remove the plug from the socket and wait 5 minutes to allow the capacitors to discharge before carrying out servicing or maintenance.
• Do not touch live electrical parts.
• Never use electrode holders or cables which are damaged.
• Keep the working environment, equipment, cables and clothing free from grease, oil, moisture and dirt.
• Ensure the welding machine has been correctly earthed.
• The operator must be insulated from the floor and work bench, using a dry insulation mat.
• Always ensure a second person is present in case of accident.
• Never change electrodes with bare hands or damp gloves.
• Keep welding cables away from power cables.
• Regularly inspect the condition of the cables for signs of damage.
• Remove the plug from the mains socket when not in use, do not leave the machine unattended.
• Ensure the earth clamp is secured to bare metal adjacent to the weld seam, and when not in use, is insulated for safety. - Keep all equipment well maintained.
• The operator shall prevent gas cylinders in the vicinity of the workpiece from becoming part of the welding circuit.

FUMES & GASES

• The welding process generates hazardous fumes as a by-product. Inhalation of these fumes is hazardous to health.
• Keep your head away from the weld to avoid breathing the fumes.
• If welding in confined spaces, ensure adequate ventilation and use a fume extractor.
• By-products of welding can react to create a toxic/explosive environment.

FIRE OR EXPLOSION

• Welding can cause fire and explosions. Precautions should be taken to prevent these hazards.
• Before starting work ensure the area is clear of flammable materials.
• Move any combustible materials to a safe distance, especially substances likely to generate a dangerous vapour.
• The welding arc can cause serious burns. Avoid contact with the skin.
• Sparks and molten metal are ejected during welding. Take precautions to prevent fire.
• Sparks and molten metal can pass through gaps. Be aware that fire can start out of sight.
• Do not weld pressurised containers. or containers containing flammable vapours e.g. fuel tanks.
• Always have appropriate fire fighting equipment to hand suitable for use in electrical environments.
• Avoid carrying any fuels with you e.g. cigarette lighters or matches.

PERSONAL PROTECTION

• The body should be protected by suitable clothing.
• The use of neck protection may be necessary against reflected radiation.
• Arc welding machines generate a magnetic field which is detrimental to pacemakers. Consult your doctor before going near active welding equipment/operations.
• The UV and IR radiation generated by welding is highly damaging to the eyes, causing burns. This can also affect the skin.
• Always use a suitable welding shield equipped with appropriate protective filters.
• Where there are pedestrians and traffic, ensure a protective screen is used to avoid accidental arc glare.
• Do not weld in the vicinity of children or animals and ensure no one is looking before striking an arc.
• Wear hearing protection if required.
• Allow the weld time to cool. Hot metal should never be handled without gloves.
• Take care when adjusting or maintaining the torch, make sure it has had time to cool sufficiently and the welder is disconnected from the mains supply.
• First aid facilities and a qualified first aid person should be available unless medical facilities are close by, for immediate treatment of flash burns of the eyes and for skin burns.
• A hard hat should be worn when others are working overhead.

PROTECTIVE CLOTHING

• Flammable hair sprays/gels should not be used by persons intending to weld or cut.
• Wear gauntlet gloves designed for use in welding.
• Wear an apron and protective shoes.
• Wear cuffless trousers to avoid entry of sparks and slag.
• Avoid oily, greasy clothing.
• Protective head and shoulder coverings should be worn when overhead welding.
• Wear a welding headshield with appropriate filter lenses or plates (protected by clear glass). This is a MUST for welding (and chipping) to protect the eyes from radiant energy and splatter. Replace cover glass when broken, pitted, or splattered.

NOTE: ALL protective wear inc. masks & head shields MUST comply with PPE Directive 89/686/EEC

ADDITIONAL SAFETY PRECAUTIONS FOR ARC WELDERS

• NEVER attempt to remove any of the exterior panels unless the machine is disconnected from the power supply.
• NEVER use the machine with any of the panels removed.
• NEVER attempt any electrical or mechanical repair unless your are a qualified technician. If you have a problem with the machine contact your local CLARKE dealer.
• NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN.
• NEVER allow children or animals in the vicinity of a welding operation.
• ALWAYS remove all flammable materials from the welding area.
• ALWAYS ensure that there is full free air circulating around the outer casing of the machine, and that the louvres are unobstructed.
• Welding arc can seriously damage your eyes. Both the operator and any spectators should always use a proper welding face shield or helmet, with suitable filter lenses. Proper gloves and working clothes should be worn at all times.
• ALWAYS wear a pair of safety spectacles/goggles when chipping away slag after welding. Remember, ordinary eye glasses are not safety gasses.
• ALWAYS ensure there is adequate ventilation or extraction in the work area, as the welding process gives off toxic fumes.
• ALWAYS ensure there is a fire extinguisher on hand.
• ALWAYS ensure that a medical supply is on hand, and that treatment for burns is available.

FITTING THE WELDING ROD

6. Select the appropriate welding rod, and insert it into the welding rod holder.

• It should be approximately the same thickness as the workpieces being welded.

PREPARING THE WORKPIECE

The area being welded should be perfectly clean. Any coating, plating or corrosion must be removed, otherwise a good weld will be impossible to achieve.

OPERATING THE WELDER

SETTING THE WELDING CURRENT

IMPORTANT: Ensure that the earth clamp is attached to clean, solid metal. If necessary, thoroughly clean with a wire brush or similar to guarantee a good connection.

1. Select the welding current by turning the adjustment dial and observing the setting on the scale on top of the machine.

• The scale also recommends the size of welding rod to be used.
• With practice you will get a feel for the best current settings for different welding rod thicknesses.

Image shows the welder's front panel with the 'Adjustment Dial' and 'Scale' for welding current indicated.

STRIKING AN ARC

IMPORTANT: BEFORE YOU STRIKE AN ARC, ALWAYS BRING THE FACE SHIELD UP TO PROTECT YOUR EYES.

1. Switch ON the machine.
2. Line up the electrode exactly over the spot where you want to strike.
3. Position your shield in front of your face and tap the electrode down firmly. Once you tap down and contact is made, you must instantly raise the electrode to the required arc gap.
   • The arc gap should be roughly the same as the diameter of the electrode.
   • If you withdraw the electrode too far once the arc is struck, you will lose the arc and have to try again.
4. Once the arc is struck, move the electrode along its intended path, keeping the tip in the molten pool at all times.
   • You must also get used to feeding down the electrode steadily as it burns away.

NOTE: One thing that usually happens when you are striking an arc is that the electrode sticks to the work. It should come unstuck with a sharp tug. If it will not free easily, turn off the welder immediately as it will quickly overheat, then give the join a tap from the chipping hammer. As you get more experienced, this will happen less.

Image shows the welder's front panel with controls highlighted for striking an arc.

An even crackling noise should be heard, which is an indication of a good weld.

5. Inspect the job carefully, the area of weld should be a complete fusion of the electrode and parent metal(s).

• Any slag which forms on the surface should be chipped away with the hammer/brush supplied.
• If the resultant weld looks messy and irregular, this is an indication of porosity or slag contamination, and you have almost certainly failed to achieve the correct combination of speed and current. This is a common problem, so do not worry as practice will quickly cure this.

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.

• ARC TOO SHORT: Diagram shows a weld bead that is too thick and uneven, with slag contamination.
• ARC TOO LONG: Diagram shows a weld bead with poor penetration, excessive spatter, and a rough surface. The arc sound is hissing.
• ELECTRODE MOVED TOO SLOWLY: Diagram shows a wide, heavy weld deposit that overlaps the sides.
• ELECTRODE MOVED TOO QUICKLY: Diagram shows a thin, 'stringy' weld deposit with poor penetration and difficult-to-remove slag.
• CURRENT TOO LOW: Diagram shows poor penetration, the electrode sticking to the workpiece, and an irregular, high weld deposit with hard-to-remove slag.
• CURRENT TOO HIGH: Diagram shows excessive penetration, spatter, a deep pointed crater, and potential burn-through holes in the workpiece. Electrodes burn quickly.
• THE PERFECT WELD: Diagram shows a weld with uniform ripples, no slag contamination, and a steady crackling sound.

MAINTENANCE

[warning-icon] WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL COMPONENTS.

[warning-icon] WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS AND MAINTENANCE OPERATIONS

[warning-icon] WARNING: BEWARE HOT SURFACES.

Frequency of maintenance operations depends on the operating conditions, how intensively the welder is used and how clean or dirty the welding site is (aggressive atmospheres etc).

Always inspect the earth return and torch hose before use, to ensure they are in perfect condition and that the earth clamp is clean and secured correctly to the cable.

As a general rule, the power supply should be inspected at least annually. Consult your CLARKE dealer for advice if necessary.

SPECIFICATIONS

NOTE: The details and specifications contained herein, are correct at the time of going to print. However, CLARKE International reserve the right to change specifications at any time without prior notice.

RATING PLATE

Diagram shows the rating plate of the welder with numbered identification points and a key explaining each point from 1 to 22. Key items include Manufacturer, Model/Part Number, Serial/Batch Number, Power Source, Standards, Welding Process Symbol, Welding Current Symbol, No-load Voltage, Output Range, Duty Cycle Symbol, Rated Welding Current, Supply Voltage, Maximum Supply Current, and Degree of Protection.

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