Clarke WE6495E Installation and operation manual

WE_85 80E@_- WE__ _E @

131E- ,2_TE

_SYA !50

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 Precautions 4

1A.0 Normes de Securite 6

2.0 Arc Welding - How it Works 8

3.0 Thermal Overload Protection 8

4.0 Electrical Connection 9

5.0 Preparation for Welding 9

Diagram 1 11

6.0 Welding Technique 12

7.0 Welding Pitfalls 13

8.0 Maintenance and Servicing 13

9.0 Welder Doesn't work? 16

10.0 Types 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.

1.0 SAFETY PRECAUTIONS

1.1 GENERAL INSTRUCTIONS

Make sure this manual is carefully read and understood by the

operator.

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 isfound unconscious and electric shock issuspected,

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 DE S¢:CURIT¢:

IA.I ]NSTRUCT]DNS G_.N_.RALES

Assurez-vous que I'operateur lit et comprend ce manuel.

1A.2 LIEU 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. IIconvient d'inserer

un verre transparent entre le verre inactinique et lazone 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 ou de soudage

endommages.

• La torche de soudage ne doit jamais 6tre dirigee contre

roperateur ou une autre personne.

• Le gen6rateur ne doitjamais 6tre utilise sans ses panneaux,

cas ceci pourrait provoquer de graves blessures & I'operateur et

des dommages & I'appareil.

1A.4 PRC:VENTIONS CONTRE LES INCENDIES

• S'assurer que des dispositifs antiincendie sont disponibles

pres de la zone de soudage.

•I_liminerde la zone de soudage et des alentours toutes sortes

de materiau inflammable.

1A.7 DIECHARGE IELECTRIQUE

ATTENTION! UNE DISCHARGE €:LECTRIQUE PEUT F:TRE

MORTELLE!

Si on trove une personne sans connaissance et si on ale suspect d'une

d6charge 616ctrique, il ne faut pas toucher la personne en question si

elle est encore en contact avec les commandes. Couper l'alimentation

la machine et pr6ter les premiers soins. Pour 61oigner les c_bles du

bless6, on peut utiliser, si n6cessaire, du bois sec ou un autre mat6riel

isolant.

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 30-90 40400 40-200 45-250 60-150

ELECTRODES 1/16-5/64 1/16-5/64 1/16-3/32 1/16-3/16 5/64-15/64 3/32-i/8

OPEN CRCUT

V(_)I_TS -37 -37 .48 .48 52 148

I I

VOLTS!PHASE 120/1 120/1 120/1 220/1 220/1 220/1

MAX INPUT

owE Ps 113 113 114 123 132 .13

DIM. 15X9X11 17X10X12 17X10X12 _11Xi5 3_16x1617x12x10

I I I I

V_IGHT 28LBS 29LBS 34LBS 75LBS 150LBS 31LBS

P TNuMBER'WEISS'WE 90'WE6519'WE65 WE6522

3.0 THERMAL OVERLOAD PROTECTION

If the duty cycle of the welder is exceeded, a thermostat will

automatically cut the power to prevent the machine from burning

out. If this should happen you will have to wait approximately 30

minutes until the 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.

Ifyou intend on using an extension cord make sure the wire cable

size is adequate in diameter.

Ifyou 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 Thesize(diameter)ofweldingrodshouldbeapproximately

thesameasthethicknessofmetalto bewelded.An appropriate

currentmustbe selectedbyturningthelargehandwheel(itemC)

untiltheslidingindicator(itemD)inthetopofthemachineshows

the required amperage setting. With practice you will gain a

feel for the correct amperage setting for different welding rod

thicknesses.

Forbeginnersthetablebelow givessome usefulguidelines.

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 Amperage Indicator

E Electrode Terminal

F Ground Terminal

G Welding Lead

H Electrode Holder

I Electrode

L Workpiece

M Ground Clamp

N Ground Cable

GROUND CLAMP SYMBOL -

IDENTIFIES GROUND

TERMINAL (BLACK KNOB)

ELECTRODE HOLDER SYMBOL -

IDENTIFIES ELECTRODE

TERMINAL (BLACK KNOB)

{H"

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