Clarke 6012143, Operation & Maintenance Instructions Manual

Page 1: ... 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 AT133 PART NO 6012143 ...

Page 2: ...duct 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 prio...

Page 3: ...n 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...

Page 4: ...e 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 equi...

Page 5: ...e 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 e...

Page 6: ...EE 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 a...

Page 7: ...ected to the terminal which is marked N or coloured black The BROWN wire must be 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 electrici...

Page 8: ...e 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 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 ...

Page 9: ... 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 ...

Page 10: ... 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 5 mm 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 electr...

Page 11: ...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 prev...

Page 12: ...sure regulator on to the gas bottle tightly and attach the gas hose to the inlet connector securely with a hose clip 5 Turn the pressure regulator knob to set a pressure of approx 2 5kg cm2 35 lbf in2 6 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...

Page 13: ...ou finish welding NOTE To avoid a visible strike mark on the surface of the workpiece it is advisable to strike the arc in the joint where the mark will be concealed by the weld Thin sheet and stainless steel may be welded with or without filler similar to gas welding The filler is fed in at the edge of the pool The rod must not touch the tip of the electrode or enter the arc The end of the rod mu...

Page 14: ...rial are shown in the chart below Metal Welding Current Amps Workpiece Thickness mm Filler Rod Dia mm Welding Electrode Dia mm Gas Flow ltr min Mild Steel 20 30 1 0 1 1 6 4 5 60 80 2 1 2 1 6 1 6 4 5 80 110 3 1 6 2 0 1 6 2 4 4 5 100 130 3 5 2 0 2 4 2 4 5 6 Stainless Steel 15 35 1 0 1 1 6 4 5 60 80 2 1 2 1 6 2 4 4 5 80 115 3 1 6 2 0 1 6 2 4 4 5 100 130 3 5 2 0 2 4 2 4 5 6 Copper 80 2 2 0 1 6 5 6 125...

Page 15: ... heavy deposit which overlaps at the sides It is wasteful both in terms of time and electrode use ELECTRODE MOVED TOO QUICKLY This causes poor penetration with a stringy and incomplete weld deposit Slag is very hard to remove CURRENT TOO LOW This causes poor penetration and causes the electrode to stick to the workpiece too readily Also results in a very irregular and high weld deposit Slag is ver...

Page 16: ...arest CLARKE dealer Inverter printed circuit is defective Contact your nearest CLARKE dealer Wrong output current Current selector control is defective Contact your nearest CLARKE dealer Low power supply voltage Check the mains distribution system Porosity of welds Acid electrode on steel with high sulphur content Electrode oscillates too much Workpieces are too far apart Workpiece being welded is...

Page 17: ...ndition and not cracked 3 Always avoid getting particles of metal inside the machine since they could cause short circuits High Sprays Electrode is too inclined Make appropriate corrections Profile defects Welding parameters are incorrect Pass rate is not related to operating parameter requirements Electrode not inclined constantly while welding Follow basic and general welding principles Arc is u...

Page 18: ...address of manufacturer 12 Rated Welding Current Symbol 2 Model Number Part Number 13 Conventional Load Voltage Symbol 3 Serial Batch Number 14 Energy Supply Symbol 4 Welding Power Source 15 Rated Supply Voltage 5 British Standards applied 16 Rated Maximum Supply Current 6 Welding Process Symbol 17 Maximum Effective Supply Current 7 This symbol indicates that the unit is suitable for carrying out ...

Page 19: ...es available from your CLARKE dealer Please quote the part numbers shown below AT133 Unpacked Weight kg 5 3 Dimensions l x w x h mm 300 x 132 x 212 Power Supply 230V AC 50Hz Rated Max Input Current A I1Max I1eff A 25 5 12 8 No Load Voltage V Uo 85V Max Min Welding Current A 10A 130A IP Rating IP21S Suitable Electrodes mm 2 5 3 2 DESCRIPTION PART NUMBER Range of Arc Activated Welding Headshield See...

Page 20: ...20 Parts Service 020 8988 7400 E mail Parts clarkeinternational com or Service clarkeinternational com EXPLODED DIAGRAM PARTS LIST AT133 ...

Page 21: ... Inductance 2 Top Housing 15 Temi160 rectifier radiator 3 Switch 16 Fast recovery diode 4 Cable Gland 17 Control PCB 5 Fan hood 18 Main PCB 6 Power cable 19 Base Frame 7 Fan 20 Rubber Foot 8 Bridge heatsink 21 Quick connector ASM 9 LGBT Radiator 22 Knob 10 Support bar 23 Digital display 11 Rectifier bridge 24 Shade 12 LGBT 25 PCB 13 Transformer ...

Page 22: ...22 Parts Service 020 8988 7400 E mail Parts clarkeinternational com or Service clarkeinternational com DECLARATION OF CONFORMITY UKCA ...

Page 23: ...23 Parts Service 020 8988 7400 E mail Parts clarkeinternational com or Service clarkeinternational com DECLARATION OF CONFORMITY CE ...

Page 24: ...24 Parts Service 020 8988 7400 E mail Parts clarkeinternational com or Service clarkeinternational com ...