Clarke ARC Instruction manual

WARNING: A suitable welding headsheild must be worn during use
WARNING: Read these instructions before using the machine
200 AMP ARC WELDER
MODEL NO: EASIARC 200
PART NO: 6010980
OPERATION & MAINTENANCE
INSTRUCTIONS
LS0411
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.
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
3.25 mm Welding Electrodes
3050565
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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
insulated for safety. - Keep all
equipment well maintained.
• Remove the plug from the socket
and wait 5 minutes to allow the
capacitors to discharge before
carrying out servicing or
maintenance.
• The operator shall prevent gas
cylinders in the vicinity of the work
piece from becoming part of the
welding circuit.
• Do not touch live electrical parts.
FUMES & GASES
• Never use electrode holders or
cables which are damaged.
• The welding process generates
hazardous fumes as a by-product.
Inhalation of these fumes is
hazardous to health.
• Keep working environment,
equipment, cables and clothing
free from grease, oil, moisture and
dirt.
• Keep your head away from the
weld to avoid breathing the fumes.
• Ensure welding machine has been
correctly earthed.
• If welding in confined spaces
ensure adequate ventilation and
use a fume extractor.
• The operator must be insulated
from the floor and work bench
using a dry insulation mat.
• By-products of welding can react
to create a toxic/explosive
environment.
• Always ensure a second person is
present in case of accident.
FIRE OR EXPLOSION
• Never change electrodes with
bare hands or damp gloves.
Welding can cause fire and
explosions. Precautions should be
taken to prevent these hazards.
• Keep welding cables away from
power cables.
• Before starting work ensure the
area is clear of flammable
materials.
• Regularly inspect the condition of
the cables for signs of damage.
• Remove plug from the mains
socket when not in use, do not
leave the machine unattended.
• Move any combustible materials to
a safe distance, especially
substances likely to generate a
dangerous vapour.
• Ensure earth clamp is secured to
bare metal adjacent to weld
seam, and when not in use is
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• The welding arc can cause serious
burns. Avoid contact with skin.
• Do not weld in the vicinity of
children or animals and ensure noone is looking before striking an
arc.
• Sparks and molten metal are
ejected during welding. Take
precautions to prevent fires.
• Wear hearing protection if
required.
• Sparks and molten metal can pass
through gaps. Be aware that fire
can start out of sight.
• Allow the weld time to cool. Hot
metal should never be handled
without gloves.
• Do not weld pressurised containers.
or containers containing
flammable vapours e.g. fuel tanks.
• Take care when adjusting or
maintaining the torch, that it has
had time to cool sufficiently and
the welder is disconnected from
the mains supply.
• Always have appropriate fire
fighting equipment to hand
suitable for use in electrical
environments.
• 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 skin
burns.
• Avoid carrying any fuels with you
e.g. cigarette lighters or matches.
PERSONAL PROTECTION
• The body should be protected by
suitable clothing.
• A hard hat should be worn when
others are working overhead.
• The use of neck protection may be
necessary against reflected
radiation.
• Flammable hair sprays/gels should
not be used by persons intending
to weld or cut.
• Arc machines generate a
magnetic field which is detrimental
to pacemakers. Consult your
doctor before going near active
welding equipment/operations.
PROTECTIVE CLOTHING
• Wear gauntlet gloves designed for
use in welding,
• The UV and IR radiation generated
by welding is highly damaging to
the eyes, causing burns. This can
also affect the skin.
• Wear an apron, and protective
shoes.
• Always use a suitable welding
shield equipped with appropriate
protective filters.
• Avoid oily greasy clothing.
• Wear cuffless trousers to avoid
entry of sparks and slag.
• Protective head and shoulder
coverings should be worn when
welding overhead.
• Where there are pedestrians and
traffic ensure a protective screen is
used to avoid accidental arc glare.
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• Wear a helmet or safety goggles or
glasses with side shields
underneath, 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 spatter.
Replace cover glass when broken,
pitted, or spattered.
• NEVER allow children or animals in
the vicinity of a welding operation.
NOTE: ALL protective wear inc. masks
& head shields MUST comply with PPE
Directive 89/686/EEC
• 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 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.
ADDITIONAL SAFETY PRECAUTIONS
FOR ARC WELDERS
• NEVER attempt to remove any of
the panels unless the machine is
disconnected from the power
supply.
• ALWAYS wear a pair of safety
spectacles/goggles when
chipping away slag after welding.
Remember, ordinary eye glasses
are not safety gasses.
• NEVER use the machine with any of
the panels removed.
• ALWAYS ensure there is adequate
ventilation or extraction in the work
area as the welding process gives
off toxic fumes.
• 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.
• ALWAYS ensure there is a fire
extinguisher on hand.
• NEVER use or store in a wet/damp
environment. DO NOT EXPOSE TO
RAIN.
• ALWAYS ensure that a medical
supply is on hand, and that
treatment for burns is available.
SAFETY SYMBOLS
General Warning,
indicates that failing to
follow these instructions
could result in injury or
damage to the machine.
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.
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ELECTRICAL CONNECTIONS
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE SUPPLY.
WARNING: NEVER FIT A STANDARD 230V, 13AMP (BS1363) PLUG TO
THESE MACHINES
230V SUPPLY
Connect the mains lead to a suitably fused 230 Volt (50Hz) electrical supply.
The fuse rating should correspond to that shown on the data plate on the rear
panel of the machine. For a full explanation of the rating plate, see page 15.
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.
400V SUPPLY
For connecting to a 400V (Single Phase) supply, the colour codes of the wires
are as follows: Green and Yellow - Earth Blue - Live (L1) Brown - Live (L2)
If in any doubt, consult a qualified electrician.
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UNPACKING
Any damage or deficiency should be reported to your CLARKE dealer
immediately.
The components include the following:
• 1 x 200 Amp AC Arc Welder
• 1 x Combination Wire Brush & Hammer
• 1 x Clarke Instruction Manual
OVERVIEW
1
5
9
6
2
3
8
7
4
NO
DESCRIPTION
NO DESCRIPTION
1
Handle
6
On/Off Switch / Voltage Selector
2
Overload Indicator
7
Earth Clamp
3
Welding Current Selector
8
Combination Wire Brush & Hammer
4
Welding Rod Electrode Holder
9
Power Indicator
5
Welding Current Scale
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ASSEMBLY
FITTING THE HANDLE
1. Remove the two bolts at the top of
the welder.
2. Position the handle as shown and
secure with the two bolts.
FITTING THE WHEELS
1. Place a circlip on the inner groove
on the axle.
2. Carefully remove the wheel cover.
3. Slide the wheel onto the axle.
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4. Place the second circlip on the
outer grove on the axle.
5. Replace the wheel cover
6. Slide the axle through the body of
the welder as shown.
7. Fix the second wheel to the other
end of the axle as described.
DUAL SUPPLY
This machine is capable of operating
on 230V or 400V (single phase), the
voltage selector is designed so that it
can select only one voltage.
The position of the screw,arrowed in
the illustration opposite will determine
the voltage selection.
With the screw in:
POSITION 1, the switch may be turned from O - OFF to 400V.
POSITION 2, the switch may be turned from O - OFF to 230V.
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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 wire.
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 metal 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.
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.
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FEATURES
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.
USING THE WELDER
SETTING THE WELDING CURRENT
1. Select the welding current by
turning the welding current
selector and observing the setting
on the scale, on top of the
machine.
The chart below is an indicator of the
thickness of material/ welding rod
thickness and the corresponding
welding current. This is intended as a
guide only.
SIZE OF WELDING ROD /
THICKNESS OF METAL
AMPERAGE SETTING
1/16”
14 swg
2.0 mm
60-70
12 swg
2.5 mm
75-95
1/8”
10 swg
3.25 mm
100-140
4 mm
140-180
NOTE: With practice you will get a feel for the best current settings for
different welding rod thicknesses.
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STRIKING AN ARC
IMPORTANT: BEFORE YOU STRIKE AN ARC, 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 down firmly
with the electrode. 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, then turn off the welder
immediately as it will quickly overheat, then give the join a tap from
the chipping ham mer. 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 working speed and current.
This is a common problem, so do not worry as practice will quickly
cure this.
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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
easily stick to the workpiece. 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.
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MAINTENANCE
WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL
COMPONENTS.
WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTION
AND MAINTENANCE OPERATION BEWARE HOT SURFACES.
WARNING: ALWAYS LET THE POWER SUPPLY COOL DOWN BEFORE
ACCESSING INTERNAL COMPONENTS.
The fequency 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.
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 80 Amps the
machine may be used for 6 minutes
(60%) in any10 minute period, or, the
machine may be used continuously,
(100%) when welding at 60 Amps.
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RATING PLATE
1
Name and address of manufacturer
13
Conventional Load Voltage
2
Model number, part number
14
Energy Input symbol
3
Batch number
15
Rated supply voltage
4
Single phase transformer
16
Rated maximum supply current
5
British Standards applied
17
Maximum effective supply current
6
Manual metal arc welding with
covered electrode
18
N/A
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.
19
N/A
8
Welding Current symbol
20
N/A
9
Rated no-load voltage
21
N/A
10
Max welding current and
corresponding load voltages
22
Degree of protection
11
Duty Cycle Percentage
23
Class of protection.
12
Rated Welding current
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SPECIFICATIONS
Model
Easiarc 200
Power Supply
230V / 400V @ 50Hz Single Phase
Rated Max Input Current I1Max/I1eff
45/14.8 A (230V) , 26/7.3A(400V)
Open Circuit Voltage
48V
IP Rating
IP21S
Output Min./Max Current
60 - 200 Amps
Usable Electrodes
2 mm - 4 mm
Dimensions (l x w x h)
498 x 355 x 410 mm
Weight
19.6 kg
Part Number
6010980
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.
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DECLARATION OF CONFORMITY
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NOTES
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NOTES
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