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Congratulations on the purchase of your new 1311"1_ welder. Before attempting
to operate this machine, please read this manual thoroughly and follow all
instructions carefully. By doing so you wilt help to ensure the safety of both
yourself and others around you, and at the same time, you should look forward
to long and trouble free service from your I_lll'_J welder.
1.0
Safety
1A.0
Precautions
Normes
2.0
Arc
Welding
3.0
Thermal
4.0
Electrical
5.0
Preparation
4
de Securite
- How
Overload
6
it Works
8
Protection
8
Connection
9
for Welding
Diagram
9
1
11
6.0
Welding
Technique
12
7.0
Welding
Pitfalls
13
8.0
Maintenance
9.0
Welder
10.0
Types
Doesn't
and
Servicing
13
work?
16
of Joints
17
Parts
drawing
and
list - Wiring
diagram
WE6485
18-19
Parts
drawing
and
list - Wiring
diagram
WE6490
20-21
Parts
drawing
and
list - Wiring
diagram
WE6519
22-23
Parts
drawing
and
list - Wiring
diagram
WE6534
24-25
Parts
drawing
and
list - Wiring
diagram
WE6537
26-28
Parts
drawing
and
list - Wiring
diagram
WE6522
29-30
GUARANTEE
For 12 months from the date of purchase, Clarke warranties this welder against failures
due to defects in material or workmanship. This warranty does not cover expendable
parts such as contact tips or nozzles, which are consumed during normal welder
operation. If the welder fails within 12 months from the date of purchase, you must
contact Clarke Power Products at 1-800-227-9603 to acquire a Return Authorization
Number. Once you have acquired a Return Authorization Number from Clarke, return the
product to the following address - postage or UPS paid:
Clarke Power Products, Inc.
28740 Glenwood Road
Perrysburg, OH 43551
Attn: Warranty Repair
We will examine the product. If the problem is due to a manufacturing defect, we will
repair or replace the product at no charge and return it to you postage or UPS paid. If the
problem is due to misuse, abuse, the product has been modified, or is out of warranty, we
will contact you with a repair estimate and ask for a credit card number for payment. After
the product has been repaired, it will be returned postage or UPS paid. This warranty
applies only while this product is used in the United States. This warranty gives you
specific legal rights, and you may also have other rights which vary from state to state.
2
1.0
SAFETY
1.1 GENERAL
PRECAUTIONS
INSTRUCTIONS
Make sure this manual is carefully read and understood
operator.
by the
1.2 LOCATION
Welding processes of any kind can be dangerous not only to
the operator but to any person situated near the equipment if
safety and operating rules are not strictly observed.
These are the main precautionary measures to observe:
•
Operators should protect their body by wearing closed,
non-flammable protective clothing, without pockets or turned up
trousers.
•
The operators should wear a non-flammable
welding
helmet designed so as to shield the neck and the face. It is
necessary to keep the protective lens always clean and to
replace it when broken or cracked. It is advisable to put a
transparent
glass between the lens and the welding area.
Welding should be done in a close area that does not open into
other working areas.
•
The operators should never look at the welding arc without
the correct protection for the eyes. They should always wear
safety glasses with side shields to protect from flying particles.
•
The welding process must be performed on metal coatings
thoroughly cleaned from layers of rust or paint to avoid production
of harmful fumes. The parts degreased with a solvent must be
dried before welding.
•
Welding should never be done on metals or coated metals
containing zinc, mercury, chronium, graphite, lead cadmium or
beryllium unless the operator and the people standing in the same
area use an air-supplied respirator.
1.3
SAFETY
INSTRUCTIONS
For your safety, before plugging in the welder, closely follow these
instructions:
•
When working in a confined space, the welder must be
kept outside the welding area and the ground cable should be
fixed to the workplace. Never work in a damp or wet area, in
these conditions.
•
Do not use damaged
input or welding cables.
•
The welding torch should never be pointed at the operator's
or another person's body.
•
The welder must never be operated without its panels as
this could cause serious injury to the operator and could damage
the equipment.
1.4
FIRE
PREVENTION
Make sure that appropriate fire prevention devices are available
near to the welding area;
All combustible material must be removed from the welding area.
1.6 ELECTRIC
SHOCK
DANGER - ELECTRIC SHOCK
CAN BE FATAL
Ifa person is found unconscious and electric shock is suspected,
do not touch the person ifthey are in contact with any electrical
wires. Disconnect power from the machine and then use First
Aid. Dry wood, and other insulating material can be used to move
electrical cables, if necessary, away from the person.
1A.0
NORMES
IA.I
]NSTRUCT]DNS
Assurez-vous
1A.2
LIEU
DE S¢:CURIT¢:
G_.N_.RALES
que I'operateur
lit et comprend
ce manuel.
D'UTILISATION
Si les normes de securite et d'utilisation ne sont pas soi,qneusement
respectees,
les operations
de soudaqe peuvent devenir
dan,qereuses non seulement pour I'operateur, mais aussi pour les
personnes se trouvant & proximite du lieu ot_ le soudaqe a lieu.
Precautions principales & suivre:
• Les operateurs
doivent
se proteger
en portant des
combinaisons de protection fermees et non inflammables, sans
poches ni revers.
• Les operateurs doivent utiliser un casque de soudage, non
inflammable, realis6 de fagon & proteger le cou et le visage. Les
verres de protection doivent toujours 6tre propres et il faut les
remplacer des qu'ils sont casses ou fissures. II convient d'inserer
un verre transparent entre le verre inactinique et la zone de soudage.
L'operation de soudage doit 6tre effectuee dans un lieu isole des
autres zones de travail.
• Les operateurs ne doiventjamais, pour aucune raison, regarder
un arc voltafque sans porter une protection adequate pour les yeux.
IIfaudra toujours utiliser des lunettes de protection avec des verres
transparents afin d'eviter les eclats et d'autres corps etrangers qui
pourraient blesser les yeux.
• Le soudage doit 6tre effectu6 sur des surfaces m6talliques sans
couches de rouilles ou de peinture, afin d'eviter la formation de
fumees nuisibles. Avant de souder, il faut essuyer les parties ayant
ete degraiss6es avec des solvants.
•
II ne faut jamais souder des metaux ou des metaux vernis
contenant du zinc, du mercure, du chrome, du graphite, du plomb,
du cadmium ou du beryl, si roperateur et les personnes & proximite
ne portent pas un respirateur adequat.
1A.3
INSTRUCTIONS
POUR
LA S¢:CURIT¢:
Pour sauvegarder
votre securit6, suivez attentivement
ces
instructions avant de brancher le gen6rateur & la ligne:
• Si le lieu de travail est exigu, I'appareil doit 6tre place en dehors
de la zone de soudage et le c&ble de masse doit _tre fixe & la
piece en travail. Dans ces conditions, il ne faut pas travailler dans
des zones humides ou mouillees.
• Ne jamais utiliser des c&bles d'alimentation
endommages.
• La torche de soudage ne doit jamais 6tre
roperateur ou une autre personne.
• Le gen6rateur ne doitjamais 6tre utilise sans
cas ceci pourrait provoquer de graves blessures
des dommages & I'appareil.
1A.4
PRC:VENTIONS
CONTRE
ou de soudage
dirigee contre
ses panneaux,
& I'operateur et
LES INCENDIES
• S'assurer que des dispositifs antiincendie sont disponibles
pres de la zone de soudage.
• I_liminer de la zone de soudage et des alentours toutes sortes
de materiau inflammable.
1A.7
DIECHARGE
ATTENTION!
IELECTRIQUE
UNE
DISCHARGE
€:LECTRIQUE
PEUT
F:TRE
MORTELLE!
Si on trove une personne
d6charge
616ctrique,
elle est encore
la machine
sans connaissance
il ne faut pas toucher
en contact
avec les commandes.
et pr6ter les premiers
bless6, on peut utiliser,
isolant.
et si on ale suspect
la personne
si n6cessaire,
Couper
en question
d'une
si
l'alimentation
soins. Pour 61oigner les c_bles du
du bois sec ou un autre mat6riel
2.0 ARC WELDING
- HOW
IT WORKS
Arc welding is a process by which two pieces of metal are joined
together using the heat developed by an electric arc between
the workpiece and an electrode (welding material).
The electrode is connected to one output side of the same
transformer. When the electrode comes into contact with the
workpiece an arc is struck. The high temperature of the arc melts
the electrode into the joint of the work piece and fusion occurs.
MIN/MAX AMPS 55-90
ELECTRODES
OPEN CRCUT
V(_)I_TS
VOLTS!PHASE
I
30-90
1/16-5/64
-37
120/1
40400
1/16-5/64 1/16-3/32
-37
.48
I
I
120/1
40-200
45-250
1/16-3/16
5/64-15/64 3/32-i/8
.48
120/1
52
220/1
220/1
60-150
148
220/1
MAX INPUT
owE Ps 113 113 114 123 132 .13
DIM.
15X9X11
V_IGHT
28LBS
17X10X12 17X10X12 _11Xi5
I
I
29LBS
I
34LBS
I
75LBS
P TNuMBER
'WEISS'WE 90'WE6519
'WE65
3.0 THERMAL
If the duty cycle
automatically cut
out. If this should
minutes until the
OVERLOAD
3_16x1617x12x10
150LBS
31LBS
!
WE6522
PROTECTION
of the welder is exceeded, a thermostat will
the power to prevent the machine from burning
happen you will have to wait approximately 30
transformer cools down. Then the thermostat
will automatically reset itself and you can continue welding: The
thermostat is a protective safety device and no harm will normally
be done to the transformer unless it is frequently over loaded, in
which case damage will eventually result. For the modes180E,
95E and EasiArc 150 the intervention
of the thermostat
is
indicated by the lighting of the ON/OFF switch.
4.0 ELECTRICAL
CONNECTION
The wires in the input cable of this machine are colored in
accordance with the following code:
120V.
230V.
Green
Ground
Green & Yellow
Ground
White
Neutral
Blue
Live
Black
Live
Brown
Live
120 Volts 20Amp grounded plug: Model 80E - 95E - 131E.
230 Volts grounded plug: Model 240TE
WARNING:
This machine
must be grounded.
If you intend on using an extension cord make sure the wire cable
size is adequate in diameter.
If you are in doubt about electrical connections consult a qualified
electrician. Do not attempt electrical repairs yourself.
5.0
PREPARATION
FOR WELDING
1
With the On/Off switch (item B) in the Off position, connect
the welding leads as follows. (Does not apply to models 80E,
95E and Easi Arc 150 which have fixed leads):
• Connect the ground lead (item N) to the ground terminal
which is the black knob (item F) identified by the ground
symbol (see diagram 1), and secure the ground clamp (item
M) to the workpiece (item L). Note: For good contact the
ground clamp must be attached to the clean bare metal, not
painted.
• Connect the welding lead (item G) to the electrode terminal,
which is the black knob (item E) identified by the electrode
holder symbol (diagram 1) and secure an appropriate welding
rod (item I) by its bare end into the jaws of the elctrode holder
(item H). Note: All connections should be a good metal contact.
Clean with a wire brush where necessary.
2
The size (diameter)ofweldingrod shouldbe approximately
the same as the thicknessof metalto bewelded.An appropriate
currentmustbe selectedby turning the large handwheel(itemC)
untilthe slidingindicator(item D) inthe top of the machineshows
the required amperage setting. With practice you will gain a
feel for the correct amperage setting for different welding rod
thicknesses.
For beginners the table below gives some useful guidelines.
I
I
15/64"
240-250
3
To assemble face shield, first place the darkened plastic
window in the recessed window area in the body. Secure in place
using the two plastic screws fasteners provided. Locate the
handle fixing into the slot in the shield body, press firmly and
rotate through 90 degrees until the lug locates into the hole in
the shield body.
DIAGRAM
1
A
Power Cable
B
ON/OFF Switch
C
Handwheel
D
E
F
Amperage Indicator
Electrode Terminal
Ground Terminal
G
H
I
Welding Lead
Electrode Holder
Electrode
L
M
N
Workpiece
Ground Clamp
Ground Cable
\
GROUND CLAMP SYMBOL IDENTIFIES GROUND
TERMINAL (BLACK KNOB)
ELECTRODE HOLDER SYMBOL IDENTIFIES ELECTRODE
TERMINAL (BLACK KNOB)
{H"
lu
6.0 WELDING
TECHNIQUE
1
Plug your welder into the correct socket and switch on using
the ON/OFF switch (Item B). NOTE (for models 80E, 95E and Easi
Arc 150): If the machine stops at any time and the ON/OFF switch
lights, the thermostat has intervened. Wait for a few minutes while
the transformer cools down and when the ON/OFF switch goes out
again welding can begin.
2
Particularly for beginners, the most difficult aspect of the arc
welding process is that of striking an arc. We strongly recommended
that you practice on pieces of scrap metal to get the feel of
the operation, before you start on an actual welding job.
3
Hold the electrode about 3/8" from the workpiece and at an
angle of about 70 degrees to 80 degrees to the work surface; take
care not to accidentally touch the workpiece until you are ready to
begin.
4
Holding the welding mask close to your face, give a short
stroke with the electrode on the workpiece. As soon as the arc is
struck, lightly withdraw the electrode from the workpiece to leave a
tiny gap of around 1/16". The current will flow across the gap with a
crackling noise and brilliant arc. Continue to weld in one direction,
maintaining the small gap as you go. At the end of the run, just
withdraw the electrode fully from the workpiece.
NOTE: When you strike an arc be sure to withdraw the electrode
fairly swiftly to leave the 1/16" gap, otherwise the electrode will weld
itself to the workpiece. Should this happen give the electrode a short
sharp jerk to free it and, if necessary strike the arc again.
5
Inspect the job carefully. With a correct combination of rod
size and amperage setting, the area of the weld should be a complete fusion of the electrode metal being joined. Slag forming on
the surface should be chipped away with a hammer.
11
If the resulting weld looks irregular or messy, or shows signs of
porosity or slag contamination, you have almost certainly failed
to achieve the correct combination.
Do not worry as practice
will soon cure this, and the following tips on welding pitfalls should
help to improve your technique quite quickly.
WARNING:
Never look at welding arc, it can seriously
damage your eyes. Always use the face shield provided
or any proper welding
mask.
HEALTH WARNING:
When welding always
there is adequate ventilation in the working
welding process gives off toxic fumes.
7.0 WELDING
make sure
area as the
PITFALLS
The arc welding technique is an acquired skill and will almost
certainly require considerable practice before perfect results are
obtained. The diagrams below should help to explain pitfalls in
your technique and how to overcome them.
1
Arc distance too short - this causes irregular masses of
weld to be deposited with slag contamination
on the uneven
surface.
2
Arc distance too long - this causes poor penetration
resulting in a weak weld with excessive spatter and porosity.
Surface of weld is rough and the arc makes a hissing sound.
12
3
Electrode moved over workpiece too slowly - this causes
a very wide and heavy deposit which overlaps at the sides. It is
wasteful in terms of both time and electrodes used.
4
Electrode moved over the workpiece too quickly - this
causes poor penetration with a "stringy" and incomplete weld
deposit. Slag is very difficult to remove.
5
Amperage too low - this causes poor penetration and
causes the electrode to stick to the workpiece easily. Also results
in a very irregular and high weld deposit with difficult slag removal.
6
Amperage too high - this causes excessive penetration
with spatter and a deep and pointed crater. It may even cause
holes to be burnt in the workpiece. Burns electrodes very quickly.
/f_"
13
\
7
The perfect weld - with the correct combination of arc length,
amperage regulation and inclination 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.
8.0 MAINTENANCE
AND
SERVICING
Your CLARKE arc welder is a simple and robust unit, requiring
virtually no maintenance other than the guidelines shown below:
Keep the ventilation holes in welder clean to avoid the build up
of dirt and oxides inside the machine, this can reduce machine
output.
Check all cables periodically; they must be in a good condition
and free of cracks or cuts.
Always try to avoid getting particles of metal inside the machine
since they could cause short circuits.
Periodically clean the inside of the welder with compressed air
IMPORTANT: unplug the welder before cleaning.
Should you have a problem with your machine contact your local
service agent or CLARKE POWER PRODUCTS,
Inc. at
(800)227-9603
14
9.0
WELDER
DOESN'T
WORK?
PROBLEM
PROBABLE
Power source
Thermostatic overload
activated due to
stops.
CAUSE
overload.
POSSIBLE
SOLUTION
The thermostatic overload
automatically resets when
the transformer has cooled
(approx. 15 minutes).
Power switch light Bad connection
on but no weld
between ground clamp
Clean or wire brush the
work surface.
current,
and workpiece.
Unstable arc.
Impurities on base
metal.
Clean with wire brush.
Porous weld.
Dirty base metal.
Clean with wire brush.
15
10.0
TYPES
OPEN
OF
SQUARE
BUTT
JOINTS
JOINT
CORNER
JOINT
÷11
Gap varies from _ 6ram to 4 8ram depending
on p_ate thickness
SINGLE
VEE
BUTT
JOINT
SINGLE
/
...........
NOT £ESS THAN
FILLET
LAP
JOINT
70 °
/
I L
1.6mm
DOUBLE
VEE
BUTT
JOINT
NOT LESS THAN
1.6mm
_
70 °
DOUBLE
FILLET
BEVEL
JOINT
t
SINGLE
SINGLE
LAP
STRAP
JOINT
JOINT
/
DOUBLE
DOUBLE
DOUBLE
BEVEL
FILLET
STRAP
JOINT
JOINT
TEE
JOINT
SINGLE
FILLET
TEE
JOINT
WE6485
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WE6522 EASYARC
150
OPERATING
MANUAL
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