Clarke AT101 Manual de instrucciones

WARNING: Read these instructions before using the machine

WARNING: A suitable welding headshield must be worn during use

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0114

ARC/TIG WELDER

MODEL NO: AT101, AT132, AT161

PART NO: 6012237, 6012231, 6012250

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

INTRODUCTION

Thank you for purchasing this CLARKE ARC/TIG 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.

The ARC/TIG welder, as its name suggests, is designed to be used for both

Metal ARC/ TIG welding. To accomplish this, two sets of welding leads are

required, one for each method employed.

TIG welding leads are not supplied with the machine. These are however

readily available from your CLARKE dealer. For the AT101 and AT132 (Part

number 6012232) for the AT161 (part number 6012233)

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.

UNPACKING

Any damage or deficiency should be reported to your CLARKE dealer

immediately. you should find inside the following:

• 1 x ARC / TIG Inverter Welder • 1 x Wire Brush / Hammer

• 1 x Electrode Clamp & Cable • 1 x Carrying Strap (fitted)

• 1 x Earth Clamp & Cable • 1 x Instruction Manual

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

GENERAL SAFETY INSTRUCTIONS

ELECTRIC SHOCK

• Always 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.

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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

• 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.

• Flammable hair sprays/gels should not

be used by persons intending to weld or

cut.

PROTECTIVE CLOTHING

• 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

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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 there is adequate

ventilation or extraction in the work

area, as the welding process gives off

toxic fumes.

• ALWAYS ensure that a medical supply is

on hand, and that treatment for burns is

available.

SAFETY SYMBOLS

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this

product, the customer is

taking on the obligation to

deal with the WEEE in

accordance with the WEEE

regulations in relation to the

treatment, recycling & recovery and

environmentally sound disposal of

the WEEE.

In effect, this means that this product

must not be disposed of with general

household waste. It must be

disposed of according to the laws

governing Waste Electrical and

Electronic Equipment (WEEE) at a

recognised disposal facility.

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

ELECTRICAL CONNECTIONS

Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through an

approved 13 amp BS 1363 plug, or a suitably fused isolator switch.

If the plug has to be changed because it is not suitable for your socket, or because of

damage, it must be removed and a replacement fitted, following the wiring instructions

shown below. The old plug must be discarded safely, as insertion into a power socket

could cause an electrical hazard.

If the colours of the wires in the power cable do not agree with the markings on the

plug.

• The BLUE wire must be

connected to the

terminal which is marked

N or coloured black.

•TheBROWNwiremustbe

connected to the

terminal which is marked

L or coloured red.

• The YELLOW AND GREEN

wire must be connected

to the terminal which is

marked E or or

coloured green.

We strongly recommend that this machine is connected to the mains supply through a

Residual Current Device (RCD)

If you are not sure, consult a qualified electrician. DO NOT try to do any repairs.

CABLE EXTENSION

Always use an approved extension cable suitable for the power rating of this tool (see

specifications), the conductor size should also be at least the same size as that on the

machine, or larger. When using a cable reel, always unwind the cable completely.

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS

THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS

SUPPLY.

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 a cable extension is needed it is essential to comply with the following data.

Voltage Extension length Cable section

230V up to 20 m 2.5 mm2

230V 20 - 50 m 4 mm2

Plug must be BS1363/A approved.

Always fit

Ensure that the outer sheath of

Neutral

(Blue)

Live

(Brown)

Earth

(Green and

a 13 Amp

the cable is firmly held by the clamp

fuse.

Yellow)

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

ARC WELDING

A consumable electrode is connected to a high ampage low voltage supply

which creates an electric arc between the electrode and the workpiece.

NOTE: 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

• Arc welding cables are supplied with this machine.

To prepare the unit for ARC welding, it is important that you follow the

procedure below.

1. Making sure that the ON/OFF switch, located on the rear panel is in the OFF

position, connect the welding leads as follows:

• Welding rod holder lead to the +ve terminal.

• Work clamp lead to the -ve terminal.

2. Select the appropriate welding rod and insert it into the welding rod holder.

• The size (diameter) of the welding rod should be approximately the

same as the thickness of metal to be welded.

3. Attach the work clamp to the workpiece as close as possible to the area

being welded. Clean with a wire brush where necessary to ensure the

connection is as clean as possible.

4. Set the required current using the

current selector.

• With practice you will gain a feel

for the correct current setting for

different welding rod thicknesses.

• The following table gives a useful

guideline.

Welding Rod Size Current (Amps)

1.5 mm 30-40

2.0 mm 50 - 65

2.5 mm 70 - 100

3.0 mm 100 - 125

Fig 1

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5. Switch ON using the switch located on the rear panel.

• The green light on the front panel should glow, indicating the machine is

ON.

• If the machine stops at any time and the amber light comes ON, the

thermal overload device has intervened. Wait until the welder has

cooled sufficiently (the amber light goes out) before restarting work.

STRIKING THE ARC - WELDING

The most difficult aspect of the arc welding process, particularly for beginners,

is that of striking an arc. We strongly recommend that you practice on some

pieces of scrap metal to get the feel of the operation, before you start on an

actual welding job.

1. Hold the electrode about 10 mm from the work and at an angle of about

70° to 80° to the work surface; take care not to accidentally touch the

workpiece until you are ready to start.

2. Holding the welding mask close-up to your face, give a short stroke with

the electrode on the workpiece. As soon as the arc is primed, withdraw the

electrode from the workpiece to leave a tiny gap of around 1.5mm (1/16").

The current will flow across the gap with a crackling noise and a brilliant

arc. Continue to weld in one direction, maintaining the small gap as you

go.

NOTE: When you prime the arc, be sure to withdraw the electrode swiftly

to leave the 1.5 mm. gap, otherwise the electrode will weld itself

to the workpiece. If this occurs give the electrode a short sharp

jerk to free it and, if necessary, prime the arc again. If you cannot

free the electrode, switch the machine off immediately and free

it. Take care the electrode will get red hot very quickly and will be

capable of burning through welding gloves.

3. At the end of the run, just lift the electrode away from the workpiece.

• Inspect the job carefully. Any slag forming on the surface should be

chipped away with a chipping hammer or pick. ALWAYS wear your

safety goggles when chipping away slag.

WARNING: WHEN WELDING ALWAYS ENSURE THERE IS ADEQUATE

VENTILATION IN THE WORK AREA AS THE WELDING PROCESS GIVES OFF

TOXIC FUMES.

WARNING: ALWAYS USE A SUITABLE WELDING MASK OR SHIELD WHEN

USING ANY WELDER.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

TIG WELDING

TIG welding is primarily for very thin materials. It uses a non-consumable

tungsten (or tungsten alloy) electrode, held in a torch.

A shielding gas (100% Argon), is fed through the torch to protect:

• The electrode,

• Molten weld pool,

• Solidifying weld metal from contamination by the atmosphere.

The electric arc is produced by the passage of current through the

conductive, ionized shielding gas. The arc is established between the tip of the

electrode and the work. Heat generated by the arc melts the base metal.

Once the arc and weld pool are established, the torch is moved along the

joint and the arc progressively melts the joined surfaces. Filler wire, if used, is

usually added to the leading edge of the weld pool to fill the joint.

This process is ideally suited for welding thin metals such as car body panels,

pressure vessels, heat exchangers, pipes etc., where accuracy and a high

quality weld is desired, as it produces a very low porosity weld.

MAIN FEATURES OF TIG WELDING

1. Electronic control of welding current.

2. Forced air cooling.

3. A thermal overload protection device prevents overheating.

TIG WELDING PROCESS ADVANTAGES

• It produces superior quality welds, generally free of defects.

• It is free of the spatter which occurs with other arc welding processes.

• It can be used with or without filler metal as required.

• It allows excellent control of root pass weld penetration.

• It can produce welds at high speeds.

• It allows precise control of the welding variables.

• Capable of welding very thin material (0.5mm), without undue

distortion.

LIMITATIONS

1. Greater weld dexterity is required.

2. These units have a DC output which is not suitable for welding aluminium.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

TIG WELDING (REF FIG.2)

• The machine is not equipped with a TIG welding torch and cables;

these are available from your Clarke dealer. For the AT101 and AT132

(Part number 6012232) for the AT161 (part number 6012233).

• Additionally, before TIG welding, you must obtain a large gas

cylinder of 100% pure Argon.

To prepare the unit for TIG welding, it is important that you adopt the following

procedure.

1. Plug the work clamp lead in to the +ve terminal, and secure the work

clamp to the workpiece.

• For good contact, the work clamp must be attached to clean bare

metal. Clean with a wire brush where necessary.

2. Plug the torch lead to the -ve terminal.

3. Screw the pressure regulator on to

the gas bottle tightly, and attach

the gas hose to the inlet

connector securely, with a hose

clip.

4. Turn the pressure regulator knob to

set a pressure of approx. 2.5kg/

cm2. (35 lbf/in2).

5. Ensure the electrode at the torch

nozzle, protrudes by 4 - 5mm, also

ensure that the electrode is

sharply pointed with an angle of

40°-60°, if it is not, grind it to shape.

(Consult your TIG Torch manual for

the procedure for adjusting the electrode).

6. Set the welding current in accordance with the thickness of the material to

be welded and the size of tungsten electrode to be used, (See page 12),

7. Switch ON using the switch mounted on the rear panel. The green light on

the front panel will glow.

• If the machine stops at any time and the amber light comes ON, the

thermal overload has intervened. Wait until the welder has cooled

sufficiently (the amber light goes out) before restarting work.

Fig 2

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