Clarke CGW1 User manual

ORIGINAL INSTRUCTIONS GC0917 iSSUE 2

USER INSTRUCTIONS

WELDING KIT

MODEL CGW1

PART NO: 6000670

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

INTRODUCTION

Thank you for purchasing this CLARKE Welding Kit.

Before attempting to use this product, please read this manual thoroughly and

follow the instructions carefully. In doing so you will ensure the safety of yourself

and that of others around you, and you can look forward to your purchase

giving you long and satisfactory service.

Please note, these instructions are designed to aid you in the basic principles

of welding, flame cutting, brazing, silver soldering, heating and the safe use of

gases, regulators and torches, they are NOT a definitive instruction manual.

With practice, a beginner can become proficient in the art of gas welding

and flame cutting. Once acquired, this skill will prove to be very useful and

possibly profitable.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12

months from the date of purchase. Please keep your receipt which will be

required 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.

GENERAL SAFETY PRECAUTIONS

IMPORTANT: In addition to the following precautions, you should read, and

fully comply with, all instructions and safety precautions that were supplied

with your TIG Welder. Please keep these instructions in a safe place for

future reference.

1. NEVER point the torch at any person or animal.

2. NEVER touch the nozzle unless the welder is switched OFF and the nozzle

has been allowed to cool off.

3. NEVER connect, disconnect, or attempt to service the torch, unless the

welding machine is switched OFF and disconnected from the mains

supply..

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

4. When welding, users and bystanders must ALWAYS use a protective

headshield fitted with the correct shade of lens. Failure to do so can cause

serious damage to your eyes.

5. ALWAYS learn the product applications, limitations and the specific

potential hazards peculiar to it. Read and become familiar with the entire

operating manual.

6. ALWAYS check for damage. Before using the equipment, any damaged

part should be checked to ensure that it will operate properly and perform

its intended function. Any damage should be properly repaired or the part

replaced. If in doubt, DO NOT use the product. Consult your local dealer.

7. ALWAYS wear safety goggles, manufactured to the latest European Safety

Standards.

8. ALWAYS keep the work area clean. Cluttered areas and benches invite

accidents.

9. ALWAYS ensure that adequate lighting is available. A minimum intensity of

300 lux should be provided. Ensure that lighting is placed so that you will

not be working in your own shadow.

10. ALWAYS keep children away. All visitors should be kept a safe distance

from the work area, especially whilst welding.

11. ALWAYS concentrate on the job in hand, no matter how trivial it may seem.

Be aware that accidents are caused by carelessness due to familiarity.

12. ALWAYS keep your proper footing and balance at all times - don’t

overreach. For best footing, wear rubber soled footwear. Keep floor clear

of oil, scrap wood, etc.

13. ALWAYS prepare the work area before welding/cutting, work in a well

ventilated area.

14. ALWAYS wear the correct safety wear specified for welding, i.e. welding

goggles, welding gloves, apron and safety shoes etc.

ADDITIONAL SAFETY PRECAUTIONS

ALWAYS handle gas cylinders with care, chain or otherwise secure cylinders to

a permanent fixture. Take care when moving.

ALWAYS use acetylene cylinders in an upright position, NEVER lying down.

ALWAYS store gas cylinders and related equipment according to local

regulations.

ALWAYS ensure all hoses and connections are tight and leak free. Test for

leaking joints etc using soapy water, NEVER use an open flame. DO NOT

overtighten connections.

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ALWAYS ensure the non return valves/flash back arrestors supplied are fitted to

both lines.

ALWAYS use recommended pressure settings. Improper settings are wasteful.

Extreme pressure build up in regulators is a warning to have them checked

and repaired.

ALWAYS “crack” the oxygen cylinder valve before installing the regulator, this

is carried out by briefly opening the valve and allowing the escaping oxygen

to clear away any dust which could damage the regulator.

ALWAYS prime oxygen and acetylene lines separately before lighting up, this

will help prevent incorrect mixing of gases.

NEVER use oxygen to blow off work or clothing. Pure oxygen supports

combustion and a spark can ignite oxygen-saturated clothing.

NEVER use oil or grease on the equipment, oil and grease is easily ignited and

burns violently in the presence of oxygen.

NEVER work with damaged/leaking hoses and equipment, check for leaks

using soapy water, any defects must be rectified before continuing.

INVENTORY

The welding kit comprises the following items:

Item Qty

Moulded Carry Case 1

Oxygen Regulator 1

Acetylene Regulator 1

Welding Torch/Handle 1

Welding Nozzle Adapter 1

Cutting Torch 1

Welding Nozzles 3

Cutting Nozzles 3

Hoses 2

Non Return Valve/Flashback Arrestor (oxygen) 2

Non Return Valve/Flashback Arrestor (acetylene) 2

Spark Igniter 1

Tip Cleaners 1

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SETTING UP INSTRUCTIONS

ATTACHING THE REGULATORS (FIG 1)

Open the oxygen cylinder valve

(arrowed) briefly to blow out any dust

etc, ensure the valve is fully closed

before continuing.

Attach the oxygen regulator (Blue)

and tighten the connector using

25mm open ended spanner.

DO NOT overtighten.

Repeat the above procedure for

attaching the acetylene regulator

(Red).

NOTE: The acetylene connections are all left handed whilst the oxygen

connections are all right handed.

ATTACHING THE HOSES (FIG 2)

Connect the hoses (complete with

flashback arrestors on each one) to

the regulator outlets, blue to the

oxygen outlet marked ‘OUT’ and red

to the acetylene outlet marked ‘OUT’,

again observing left and right

handed threads.

Tighten both connectors using a

19mm open ended spanner.

DO NOT overtighten.

WARNING: ENSURE THERE ARE NO NAKED FLAMES OR SPARKS WHICH

COULD IGNITE WHEN PRIMING OR PURGING THE HOSES ETC. ENSURE A

FIRE EXTINGUISHER IS ALWAYS AT HAND IN CASE OF ACCIDENTS.

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ATTACHING THE TORCH (FIG 3)

Attach the acetylene hose complete

with flame arrestor (Red) to the torch

inlet valve marked ‘GAS’ and the

oxygen hose complete with flame

arrestor (Blue) to the torch inlet valve

marked ‘OX’.

Tighten both connectors using a

19mm open ended spanner, DO NOT

overtighten. Ensure both valves are

closed fully before continuing.

OPENING THE VALVES (FIG 4)

Ensure both regulator knobs are

opened fully (turned anticlockwise),

carefully using cylinder key, slowly

open both cylinder valves in turn,

starting with the oxygen one.

ADJUSTING THE OPERATING PRESSURE (FIG 5)

When adjusting the operating

pressures, refer to the relevant table

on page 9, depending whether

welding or cutting etc.

Adjust the operating pressure on both

cylinders by turning the regulator

valve knobs in a clockwise direction,

observe the low pressure gauge

(Right Hand Gauge) until the gauge

reading is at the correct pressure

setting.

NOTE: The left hand gauge shows the pressure in the cylinder and is not

adjustable. This is an indication how much oxygen/acetylene

remains inside the cylinder.

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INSTALLING THE CUTTING/WELDING NOZZLE (FIG 6, 7 & 8)

WELDING

Remove the cutting torch if fitted,

attach the welding nozzle adapter to

the welding torch/handle, tightening

hand tight only.

Select the required welding nozzle

and screw into the adapter. To

prevent the adaptor from turning,

hold in position with a 11mm open

ended spanner. Adjust the nozzle

position by turning to the desired position using an 11mm open ended

spanner on the nozzle connector.

CUTTING

Remove the welding nozzle and

nozzle adapter if fitted. Attach the

cutting torch to the welding torch/

handle, tighten the securing collar by

hand, ensuring the operating lever

does not foul on the valve knobs etc.

Remove the cutting nozzle securing

nut, select the required nozzle and

place into the securing nut. Screw

into the cutting torch and lock in

place using a 23mm open ended

spanner.

DO NOT overtighten.

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LIGHTING THE TORCH (FIG 9)

Open the torch acetylene valve

approximately one half turn and

ignite using the supplied spark igniter.

Open the torch valve until the flame

stops excessive smoking and leaves

the end of the nozzle tip about 3mm,

then reduce slightly to bring the

flame back to the tip.

Open the torch oxygen valve until a

bright inner cone appears in the

flame.

The point at which the feathery edges of the flame disappear and a sharp

inner cone is visible is called the “Neutral Flame”.

BASIC WELDING PROCEDURES

Gas welding is a method of joining similar metals by heating the adjacent

surfaces to melting point with an oxyacetylene flame and allowing the two

parts to fuse together with a filler metal being required on materials 5mm thick

or more. The resulting weld is as strong as the parent metal.

All metal to be joined should be thoroughly cleaned before welding. Oil,

grease, rust, scale or other impurities affect the weld quality and the tensile

strength. Metal of 5mm and over should be bevelled before attempting to

weld and when bevelled edges are to be joined. A filler rod of the same

material must be used.

The table below is a guide only showing recommended, oxygen and

acetylene pressures relating to the size of the material to be welded etc.

If a too larger tip is used and the flame is softened, the tip heats up

unnecessarily and is often accompanied by a popping noise which splatters

the weld puddle. Too hot a flame burns the steel and too small a flame is not

big enough to get the job done.

WELDING ROD

Welding rods are available in various sizes with the most common being

1.6mm, 2.4mm and 3.2mm. They are also available for welding mild steel, cast

iron and aluminium.

The size of rod will be determined by the type of weld, the metal thickness and

the amount of filler metal required.

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WELDING FLAME

A neutral flame is used for almost all

gas welding. The oxyacetylene flame

consumes all oxygen in the welding

area which leaves an

uncontaminated weld area and a

weld of maximum strength.

An oxidizing flame is rarely used.

A carbonizing flame is used mainly for

flame hardening and brazing.

Metal

Thickness

(mm)

Tip Size Rod Size Oxygen

Pressure

(PSI)

Acety-

lene Pres-

sure (PSI)

Number

of Passes

1.6mm 2 1.6mm 3 3 1

2.4mm 5 2.4mm 5 5 1

3.2mm 5 3.2mm 5 5 1

6.4mm103.2mm992

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WELDING - PRACTICES AND EXERCISES

Gas welding is not a difficult art. The following exercises of torch movement

are good practice and make subsequent welding easy.

EXERCISE 1

Using a small welding nozzle and

correct pressures (see table on page

9), point the flame directly onto the

steel (3.2mm stock recommended)

with the flame cone just above the

metal surface. When a puddle

begins to form, slowly move the torch

back and forth to move the puddle

across the steel. This action has to be

done slowly as it is necessary to have

good penetration, which comes from

a deep puddle. When moving the puddle, it is helpful to lean the nozzle at an

angle of approx 45º away from the direction you want the puddle to move.

EXERCISE 2

Place two pieces of 3.2mm steel

together as shown. Make the puddle

again with a back and forth torch

motion, move the puddle along the

seam. Move the torch slowly for a

good penetration. This can be

checked by turning the parts over.

The penetration should be visible

from the bottom side. Test the weld

strength by attempting to pull the

pieces apart.

EXERCISE 3

Repeat exercise 2, but add welding

rod this time. While the flame is

directed at the steel to form the

puddle, put the rod into the flame.

when it becomes red, maintain this

temperature by moving it in and out

of the flame. Once the weld is started

dip the rod into the puddle, the rod

will melt and build up the weld so

that the top is rounded instead of

concave. Remember, welding rod is

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