Clarke 6012161, Operation & Maintenance Instructions Manual

Page 1: ...OPERATION MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC1221 140A MMA INVERTER WELDER MODEL NO MMA140A PART NO 6012161 ...

Page 2: ...arc melts the core of the electrode to produce drop s of molten metal weld pool that cool to create the welded joint Because of the versatility and simplicity of MMA welding it requires less skill and is used primarily to weld iron and steel including stainless steel but nickel and copper can also be welded using this method MAIN DESIGN FEATURES INVENTORY The items supplied include the following 1...

Page 3: ...ead shields MUST comply with PPE Regulation EU 2016 425 TOXIC FUME PREVENTION Severe discomfort illness or death can result from fumes vapours heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury and beryllium bearing materials when welded or cut may produce harmful concentrations of ...

Page 4: ...nst ignition with suitable fire resistant covers or shields Walls ceilings and floor near work should be protected by heat resistant covers or shields Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if 1 appreciable combustibles including building construction are within 10m 2 appreciable combustibles are further than 10...

Page 5: ...ed arc in addition to gloves apron and strong shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark substantial clothing Button collars closed to protect the chest and neck and button any pockets to prevent entry of sparks EYE AND HEAD PROTECTION Pr...

Page 6: ...trically LIVE equipment can fatally shock a person whose body becomes a conductor DO NOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT DEVICES PACEMAKERS Magnetic fields from high currents can affect pacemaker operation Persons wearing pacemakers should consult with their doctor before going near arc welding ...

Page 7: ...ble Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks TERMINALS AND OTHER EXPOSED PARTS Terminals and other exposed parts of electrical units should have insulating covers secured before operation SAFETY DEVICES Safety devices such as interlocks and circuit breakers should not be disc...

Page 8: ...f the panels unless the machine is disconnected from the supply and never use the machine with any of the panels removed 5 NEVER use or store in a damp environment DO NOT EXPOSE TO RAIN 6 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 7 ALWAYS keep a fire extinguisher handy Dry Powder ...

Page 9: ...acturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according...

Page 10: ...when necessary If directly wired to the mains a double pole double throw isolator switch must be fitted The welder must be connected 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 ENVIRONMENTAL RECYCLING P...

Page 11: ... in the OFF position connect the welding leads as follows Work clamp lead to the Negative terminal Welding rod holder lead to the Positive terminal 2 Select the appropriate welding rod and insert it into the welding rod holder 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 possib...

Page 12: ...l for the correct current setting for different welding rod thicknesses VRD VOLTAGE REDUCTION DEVICE The VRD is a safety feature that It is also known as Anti shock Its function is to lower the open circuit voltage across the output terminals to a safe 12V when the welder is not in use As soon as the welder is used a load of 200 ohms or less is detected the voltage will increase to the full output...

Page 13: ...p 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 a...

Page 14: ... 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 15: ... 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 cold Use basic electrode Move edges to be welded closer together Move slowly at the beginning Cracks in weld Material being welded is dirty e g oil paint rust...

Page 16: ...parameter requirements Electrode not inclined constantly while welding Follow basic and general welding principles Arc is unstable Insufficient current Check condition of electrode and earth wire connection Electrode melts obliquely Electrode core is not centred Magnetic blow phenomenon Replace electrode Connect two earth wires to opposite sites of the work piece DEFECT CAUSES SUGGESTIONS ...

Page 17: ...s advisable however if the unit is operating in a dusty and dirty environment 1 Keep the louvres clean to avoid a build up of dirt and oxides inside the machine which can reduce machine output 2 Check all cables periodically for condition and secure They must be in good condition and not cracked 3 Always avoid getting particles of metal inside the machine since they could cause short circuits WARN...

Page 18: ... Name and 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 car...

Page 19: ...ate 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 Unpacked Weight ...

Page 20: ...VATED HEADSHIELDS These highly popular headshields activate instantly when the arc is struck and allow you to have both hands free when welding DESCRIPTION PART NUMBER 2 5 mm Arc Welding Electrodes 3050584 3 2 mm Arc Welding Electrodes 3050586 Model Arc Activated Grinding function Solar Powered Fixed Shade Flip Up Part Number GWH4 6000706 GWH7 6000709 GWH5 6000707 GWH6 6000708 GWH3 6000698 GWH2 60...

Page 21: ...itor 3 Indicator light 18 Silicon bridge radiator 4 Digital display 19 Silicon bridge 5 Plug 20 IGBT radiator 6 Gauge cover 21 IGBT 7 Handle 22 Main transformer 8 Cover 23 Rectifier radiator 9 Air Vent 24 Rectifier tube 10 Rear panel 25 Driver transformer 11 Machine base 26 Control PCB 12 Power switch 27 CBB 13 Waterproof joint 28 Positive connector 14 Power cable 29 Negative connector 15 Fan asse...

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

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

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