Clarke AT162 Instruction Manual

WARNING: Read these instructions before using the machine

WARNING: A suitable welding headshield must be worn during use

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL0821 - REV 3

ARC TIG/MMA WELDER

MODEL NO: AT162

PART NO: 6012145

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

INTRODUCTION

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 AT162 is designed to be used for both metal ARC (MMA) and TIG welding

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

readily available from your CLARKE dealer (Part number 6012233)).

SUITABILITY

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 box the following:

MMA/Arc Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron.

TIG Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron,

Titanium, Copper + Brass.

• 1 x 160A ARC / TIG Inverter Welder • 1 x Wire Brush / Hammer

• 1 x Electrode Clamp & Cable • 1 x Earth Clamp & Cable

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.

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

FIRE OR EXPLOSION

Welding can cause fires 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.

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

• 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.

• The 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 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.

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

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

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

ELECTRICAL CONNECTIONS

CONNECTING TO MAINS

NOTE: This tool is earthed and must only be connected to mains with an

earth connection. Do not attempt to use it without an earth

connection.

• This welder is not supplied with a mains electrical plug because at

full capacity it will draw far too much power for a normal domestic

230V mains plug and socket. This welder must not be fitted with a

standard 13A UK plug.

• A high current 230V mains socket or terminal must be installed by a

qualified and accredited professional electrician. A 16A socket and

plug conforming to IEC 60309 is recommended.

• A non-socketed mains connection also requires welder connection

by a qualified and accredited professional electrician. However, a

socketed connection is safer and more strongly recommended so

the welder can be safely isolated when necessary. If directly wired

to mains, a double pole, double throw isolator switch must be fitted.

• The welder must be connected to a consumer unit with a built-in

RCD, using a circuit protected by an RCD.

• Please refer to the Specification for details of the maximum current

required by this welder.

• If in any doubt, do not attempt to connect or use this welder until a

professional electrician has been consulted.

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

MMA/ARC WELDING

A consumable electrode is connected to a high amperage low voltage

supply which creates an electric arc between the electrode and the

workpiece.

Benefits over TIG welding include, less experience needed, torch kit or

shielding gas are not required.

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.

Material

Thickness

Welding

Rod Size

Current

(Amps)

1-2 mm 2.5 mm 70 - 100

2-5 mm 3.2 mm 100 - 125

5-8 mm 4.0 mm 125 - 160

Fig 1

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

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.

• It is 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.

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