Clarke EASIARC 165 Instruction manual

WARNING: A suitable welding headshield must be worn during use
WARNING: Read these instructions before using the machine
160 AMP ARC WELDER
MODEL NO: EASIARC 165
PART NO: 6010982
OPERATION & MAINTENANCE
INSTRUCTIONS
LS0413
INTRODUCTION
Thank you for purchasing this CLARKE Welder.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also 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.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
ENVIRONMENTAL PROTECTION
Do not dispose of this product with general household waste. All
tools, accessories and packaging should be sorted, taken to a recycling centre and disposed of according to the laws governing
Waste Electrical and Electronic Equipment.
2
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
GENERAL SAFETY INSTRUCTIONS
WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY.
WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO
OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.
ELECTRIC SHOCK
FUMES & GASES
• Remove the plug from the socket and
wait 5 minutes to allow the capacitors
to discharge before carrying out
servicing or maintenance.
• The welding process generates
hazardous fumes as a by-product.
Inhalation of these fumes is hazardous
to health.
• Do not touch live electrical parts.
• Keep your head away from the weld to
avoid breathing the fumes.
• Never use electrode holders or cables
which are damaged.
• If welding in confined spaces, ensure
adequate ventilation and use a fume
extractor.
• Keep the working environment,
equipment, cables and clothing free
from grease, oil, moisture and dirt.
• By-products of welding can react to
create a toxic/explosive environment.
• Ensure the welding machine has been
correctly earthed.
FIRE OR EXPLOSION
• The operator must be insulated from the
floor and work bench, using a dry
insulation mat.
Welding can cause fire and explosions.
Precautions should be taken to prevent
these hazards.
• Always ensure a second person is
present in case of accident.
• Before starting work ensure the area is
clear of flammable materials.
• Never change electrodes with bare
hands or damp gloves.
• Move any combustible materials to a
safe distance, especially substances
likely to generate a dangerous vapour.
• Keep welding cables away from power
cables.
• The welding arc can cause serious
burns. Avoid contact with the skin.
• Regularly inspect the condition of the
cables for signs of damage.
• Sparks and molten metal are ejected
during welding. Take precautions to
prevent fire.
• Remove the plug from the mains socket
when not in use, do not leave the
machine unattended.
• Sparks and molten metal can pass
through gaps. Be aware that fire can
start out of sight.
• 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.
• Do not weld pressurised containers. or
containers containing flammable
vapours e.g. fuel tanks.
• The operator shall prevent gas cylinders
in the vicinity of the workpiece from
becoming part of the welding circuit.
• Always have appropriate fire fighting
equipment to hand suitable for use in
electrical environments.
3
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
PROTECTIVE CLOTHING
• Avoid carrying any fuels with you e.g.
cigarette lighters or matches.
• Wear gauntlet gloves designed for use
in welding,
PERSONAL PROTECTION
• Wear an apron and protective shoes.
• The body should be protected by
suitable clothing.
• Wear cuffless trousers to avoid entry of
sparks and slag.
• The use of neck protection may be
necessary against reflected radiation.
• Avoid oily, greasy clothing.
• Protective head and shoulder
coverings should be worn when
overhead welding.
• Arc welding machines generate a
magnetic field which is detrimental to
pacemakers. Consult your doctor
before going near active welding
equipment/operations.
• 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
andsplatter.Replacecoverglasswhen
broken, pitted, or splattered.
• 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.
NOTE: ALL protective wear inc. masks &
head shields MUST comply with PPE
Directive 89/686/EEC
• Where there are pedestrians and traffic,
ensure a protective screen is used to
avoid accidental arc glare.
ADDITIONAL SAFETY PRECAUTIONS FOR
ARC WELDERS
• Do not weld in the vicinity of children or
animals and ensure no one is looking
before striking an arc.
• NEVER attempt to remove any of the
exterior panels unless the machine is
disconnected from the power supply.
• Wear hearing protection if required.
• NEVER use the machine with any of the
panels removed.
• Allow the weld time to cool. Hot metal
should never be handled without
gloves.
• 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.
• 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.
• NEVER use or store in a wet/damp
environment. DO NOT EXPOSE TO RAIN.
• 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.
• NEVER allow children or animals in the
vicinity of a welding operation.
• ALWAYS remove all flammable materials
from the welding area.
• A hard hat should be worn when others
are working overhead.
• ALWAYS ensure that there is full free air
circulating around the outer casing of
the machine, and that the louvres are
unobstructed.
• Flammable hair sprays/gels should not
be used by persons intending to weld or
cut.
• Welding arc can seriously damage your
eyes. Both the operator and any
spectators should always use a proper
welding face shield or helmet, with
4
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
• ALWAYS ensure there is adequate
ventilation or extraction in the work
area, as the welding process gives off
toxic fumes.
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 a fire
extinguisher on hand.
• ALWAYS ensure that a medical supply is
on hand, and that treatment for burns is
available.
SAFETY SYMBOLS
Read this instruction
booklet carefully
before use
Do not expose to rain.
Wear eye protection
Recycle unwanted
materials instead of
disposing of them as
waste. All tools,
accessories and
packaging should be
sorted, taken to a
recycling centre and
disposed of in a manner
which is compatible
with the environment.
Wear protective gloves
Wear a dust mask
5
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
ELECTRICAL CONNECTIONS
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
Before switching the product on, make sure that the voltage of your electricity
supply is the same as that indicated on the rating plate. This product is designed to
operate on 230VAC 50Hz. Connecting it to any other power source may cause
damage.
This product may be fitted with a non-rewireable plug. If it is necessary to change
the fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost
or damaged, the plug must not be used until a suitable replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring
instructions shown below. The old plug must be disposed of safely, as insertion into
a mains socket could cause an electrical hazard.
WARNING! The wires in the power cable of this product are
coloured in accordance with the following code:
Blue = Neutral Brown = Live Yellow and Green = Earth
If the colours of the wires in the power cable of this product do not correspond with
the markings on the terminals of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal
which is marked N or coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked L or coloured Red.
• The wire which is coloured Yellow and Green must be connected to the
terminal which is marked E or
or coloured Green.
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Earth
(Green and Yellow)
Live
Neutral
(Brown)
(Blue)
Ensure that the outer sheath of the cable is firmly held by the clamp
We strongly recommend that this machine is connected to the mains supply via a
Residual Current Device (RCD)
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.
6
UNPACKING
Any damage or deficiency should be reported to your CLARKE dealer
immediately.
The components include the following:
• 1 x 160 Amp AC Arc Welder
• 1 x Combination Wire Brush & Hammer
• 1 x Clarke Instruction Manual
• 1 x Face Shield
OVERVIEW
1
5
2
6
3
7
4
NO
DESCRIPTION
8
NO DESCRIPTION
1
Handle
5
Welding Current Scale
2
Overload Indicator
6
On/Off Switch
3
Welding Current Selector
7
Earth Clamp
4
Welding Rod (Electrode) Holder
8
Combination Wire Brush & Hammer
7
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
ARC WELDING PRINCIPLES
A consumable electrode is connected to a high voltage supply which creates
an electric arc between the electrode and the workpiece. The arc is used to
create the required heat to turn the metal into a molten state. The electrode is
also used as a filler.
The shielding gas is created from the flux within the welding rod (electrode).
When using the welder outside, you may need to take measures to erect a
wind break to make sure the shielding gas is not blown away, thereby leaving
a poor quality weld.
PREPARATION FOR USE
FITTING THE WELDING ROD
1. 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.
8
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
OPERATING THE WELDER
THERMAL CUTOUT
If the machine stops at any time and
the amber light on the front panel
illuminates, the thermal cutout has
activated.
Wait until the transformer has cooled
sufficiently (the amber light goes out)
before restarting work.
ATTACHING THE EARTH CLAMP
Attach the earth clamp firmly to the workpiece as close as possible to the
point of weld.
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.
SETTING THE WELDING CURRENT
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.
9
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
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.
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.
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.
• 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.
10
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
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
This causes irregular masses of weld to be deposited, with
slag contamination on an uneven surface.
ARC TOO LONG
This causes poor penetration resulting in a weak weld with
excessive spatter and porosity. Surface of the weld is rough
and the arc makes a hissing sound
ELECTRODE MOVED TOO SLOWLY
This causes a very wide and heavy deposit which overlaps
at the sides. It is wasteful both in terms of time and electrode
use.
ELECTRODE MOVED TOO QUICKLY
This causes poor penetration with a ‘stringy’ and incomplete
weld deposit. Slag is very hard to remove.
CURRENT TOO LOW
This causes poor penetration and causes the electrode to
stick to the workpiece too readily. Also results in a very
irregular and high weld deposit. Slag is very hard to remove.
CURRENT TOO HIGH
This causes excessive penetration with spatter and deep
pointed crater. It may also cause holes to be burned in the
workpiece.
Burns electrodes very quickly.
THE PERFECT WELD
With the correct combination of arc length, current
regulation, inclination and speed of the electrode, you will,
with practice, produce the perfect weld.
This should be regular with uniform ripples and no slag
contamination. The arc will make a steady crackling sound.
11
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
MAINTENANCE
WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL
COMPONENTS.
WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS
AND MAINTENANCE OPERATIONS
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.
12
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
RATING PLATE
1
Name And Address Of Manufacturer
12
Rated Welding Current Symbol
2
Model Number, Part Number
13
Conventional Load Voltage Symbol
3
Serial / Batch Number
14
Energy Supply Symbol
4
Welding Power Source
15
Rated Supply Voltage
5
British Standards Applied
16
Rated Maximum Supply Current
6
Welding Process Symbol
17
Maximum Effective Supply Current
7
This symbol indicates that the unit is
suitable for carrying out welding
operations in an environment which
has an increased risk of electric
shock.
18
N/a
8
Welding Current Symbol
19
N/a
9
Rated No-load Voltage
20
N/a
10
Range Of Output
21
N/a
11
Duty Cycle Symbol
22
Degree Of Protection
DUTY CYCLE
This welder is covered by regulations EN60974-1 and EN 50199, where the Duty
Cycle (X) is expressed as a percentage of time the machine may be used in a
given period for a specified welding current.
i.e. When welding at 65 Amps the machine may be used for 6 minutes (60%) in
any10 minute period,
13
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
SPECIFICATIONS
Model
Easiarc165
Power Supply
230V @ 50Hz
Rated Max Input Current I1Max/I1eff
36/13.7 A
Open Circuit Voltage
48V
IP Rating
IP21S
Output Min./Max Current
65 - 160 Amps
Usable Electrodes
2.0 mm, 2.5 mm, 3.2 mm, 4.0 mm
Dimensions (l x w x h)
346 x 182 x 270 mm
Weight
16.7 kg
Part Number
6010982
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.
ACCESSORIES
The following are some of the accessories available from your CLARKE dealer.
Please quote the part numbers shown below:
DESCRIPTION
PART NUMBER
CWH6 Arc Activated Welding Headshield
6000671
2 mm Welding Electrodes
3050555
2.5 mm Welding Electrodes
3050560
3.2 mm Welding Electrodes
3050565
14
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
DECLARATION OF CONFORMITY
15
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com