Clarke 180, 220, 260, 320, 420 User guide

ARC WELDERS

ARC WELDERS

(DC RECTIFIERS)

Model Nos.

180 - 220 - 260 - 320 - 420

OPERATING & MAINTENANCE

INSTRUCTIONS

1006

©

The full technical specification for your welder is to be found printed in a table on the top of
the machine.
The meaning of the markings and symbols shown in the table are explained as follows.

Symbol for dropping characteristic

Symbol for manual arc welding and covered electrodes

Symbol for the mains supply and No. of phases

1~

_ _ _ _ V

U

0

50Hz

_ _ _ _ AI

2

I

2

n

_ _ _

U

1

I

max_ _A

1

IP_ _

n

h

H

A

c

mm

Single Phase Transformer

1~

Min. and Max. rated no load voltage

Rated frequency for alternating current

Min. and Max. rated value of the welding current
Symbol and dimension for the diameter of reference electrodes
Symbol and dimension for the welding current

Symbol for the number of reference electrodes capable of being
melted with the welding power source, starting from the cold state
without operation of the thermal cut-out

Rated value of the supply voltage

V

Size of the necessary main fuse

A

_ _

Symbol, rated value and dimension of the max. supply current
Degree of protection (e.g. IP21)
Symbol for the No. reference electrodes being melted with the welding

power source at the hot state, without operation of the thermal cut-out
Code letter for degree of insulation

Spare Parts and Service Contacts

© Copyright Clarke International. All rights reserved, Nov, 1999

2

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

15

automatically cut the power to prevent damage to the machine. Should the cut­out operate, the amber light on the front panel will glow, and you will have to
wait until the transformer cools down (approx. 30 minutes), when 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.
However, if it is frequently over loaded, damage could eventually result.

MAINTENANCE

Your Clarke arc welder is a simple and robust unit, requiring virtually no
maintenance other than the guidelines shown below.

1. Keep the louvre passages clean to avoid a build up of dirt and oxides inside
the machine, which can reduce machine output.

2. Check all cables periodically; they must be in good condition and not
cracked.

3. Always try to avoid getting particles of metal inside the machine since they
could cause short circuits.

4. Periodically clean the inside of the welder with compressed air, ensuring you
wear a mask during the operation.

IMPORTANT - ALWAYS disconnect from the electrical supply before servicing or
cleaning.

Thank you for purchasing this CLARKE Arc Welder.

Before attempting to operate this machine, please read this leaflet 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 the welder giving
you long and satisfactory service.

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.

CONTENTS PAGE

EMC Regulations ................................................................................... 4

Safety -General ................................................................... 6

Safety -Arc Welding ........................................................... 7

SPECIFICATIONS

Model No. 180 220 260 320 420

Min/Max (Amps) 50-180 30-220 35-260 50-320 55-420

Electrode Dia. 2-4mm 1.6-5mm 1.6-5mm 2-6mm 2-6mm

Open Circuit Volts 64 59-66 59-66 56-68 70-78

Volts/Phase 400V, 3ph 400V, 3ph 400V, 3ph 400V, 3ph 400V, 3ph

Max Input kVA 7.8 11.8 13 16 28

Dimensions (mm)

Weight (kg) 41 80 89 100 162

Part No. 6010500 6010510 6010520 6010530 6010540

460x480x750 520x1000x595 520x1000x595 520x1000x595 620x710x1120

14

Preparation of Working Area .......................................... 11

Additional Safety Precautions ........................................................... 11

Electrical Connections ........................................................................ 10

Assembly ............................................................................................... 12

Preparation for Welding ...................................................................... 13

Operation ............................................................................................. 13

Maintenance ....................................................................................... 14

Specifications ....................................................................................... 14

Electrical Symbols Explained .............................................................. 15

Parts and Service contacts ................................................................ 15

This product must NOT be disposed of with general waste. Ensure it is disposed of according to all local
ordinances at you local disposal facility

3

ELECTROMAGNETIC INTERFERENCE (EMC)

PREPARATION FOR WELDING

Whilst this unit complies with EMC regulations, the user is responsible for installing
and using the welding equipment according to the manufacturers instructions. If
electromagnetic disturbances are detected then it shall be the responsibility of
the user of the welding equipment to resolve the situation. In some cases this
remedial action may be as simple as earthing the welding circuit, see ‘Note’. In
other cases it could involve constructing an electromagnetic screen enclosing
the power source and the work complete with associated input filters. In all cases
electromagnetic disturbances must be reduced to the point where they are no
longer troublesome.

Note - The welding circuit may or may not be earthed for safety reasons. Changing
the earthing arrangements should only be authorised by a person who is
competent to assess whether the changes will increase the risk of injury, e.g. by
allowing parallel welding current return paths which may damage the earth circuits
of other equipment.

1.ASSESSMENT OF AREA

Before installing welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. Avoid using your inverter in
the vicinity of:

a) other supply cables, control cables, signalling and telephone cables;

above, below and adjacent to the welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g. guarding of industrial equipment;

e) pacemakers and hearing aids etc;

f) equipment used for calibration or measurement;

g) other equipment in the environment. The user shall ensure that other

equipment being used in the environment is compatible. This may
require additional protection measures;

It may be possible to avoid the above by changing the time of day that welding
or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of
the building and other activities that are taking place. The surrounding area may
extend beyond the boundaries of the premises.

2. METHODS OF REDUCING EMISSIONS

2.1 Mains supply

Welding equipment should be connected to the mains supply according to the
manufacturers recommendations. If interference occurs, it may be necessary to

IMPORTANT.

For currents above 250 amps, you MUST use the filter contained in the

envelope - Shade No. 13.

1. Use only the welding leads supplied with the welder.
With the voltage selector switch in the OFF position, connect the welding leads
with the Welding Electrode lead to the +ve terminal, the Work Clamp lead to
the -ve terminal.
The work clamp must then be attached to the workpiece - to clean bare
metal, and as close as possible to the area being welded.

2. Select the appropriate voltage using the switch on the front panel.
An appropriate current must then be selected by turning the large hand wheel
located on the front panel of the machine. With practice you will gain a feel
for the correct current setting for different welding rod thicknesses.
The size (diameter) of welding rod should be approximately the same as the
thickness of metal to be welded.

For beginners, the table below gives some useful guidelines.

SIZE OF WELDING ROD/

THICKNESS OF METAL AMPERAGE SETTING

1/l6 16 swg 1.5 mm 40-55

14 swg 2.0 mm 50-70
12 swg 2.5 mm 75-95

1/8 10 swg 3.25mm 100-140

4.0 mm 140-180

5.0 mm 100-240

6.0 mm 240-250

OPERATION

The welding capabilities of your welder are given in the table printed on the front
panel of the machine (see list on page 15 for an explanation of markings and
symbols).

NOTE:
The smallest model in the range, Model 180, is provided with Thermal Overload Protection.

If the duty cycle of the welder is exceeded (see data plate), a thermostat will

4

13

ELECTRICAL CONNECTIONS

WARNING! THIS APPLIANCE MUST BE EARTHED

This machine MUST be connected to a 400 Volt, 3 PHASE 50Hz supply through a
suitably fused isolator switch. It cannot be operated from a single phase supply.

Connect the GREEN or GREEN & YELLOW coloured wire, to the terminal marked
with the letter “E” or Earth symbol “ ”

The three remaining wires are connected, each to one of the other phases.

NOTE: there is NO neutral conductor.

It is possible that the welder may cause interference to other appliances or to the
supply of other electricity users.

take additional precautions such as filtering of the mains supply. Consideration
should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically
continuous throughout its length. The shielding should be connected to the welding
power source so that good electrical contact is maintained between the conduit
and the welding power source enclosure.

2.2 Maintenance of the welding equipment

The welding equipment should be routinely maintained according to the
manufacturers 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 manufacturers

instructions. In particular, the spark gaps of arc striking and stabilizing devices should
be adjusted and maintained according to the manufacturers recommendations.

WARNING!

IF YOU ARE IN ANY DOUBT ABOUT ELECTRICAL CONNECTIONS, CONSULT A

QUALIFIED ELECTRICIAN.

DO NOT ATTEMPT ELECTRICAL REPAIRS YOURSELF.

ASSEMBLY

Take all necessary precautions regarding the weight of the machine. Assistance
should be used at all times.

All models are equipped with handles and wheels which require fixing.

Model 180 should be lifted and supported, in order that the axle and wheels may
be fitted. The handle can then be screwed on using the 4 self tapping screws
provided, and the feet attached to the ends of the handle extensions.
Other models are lifted and carefully supported, allowing the axles, wheels and
castors to be screwed on. The handles slot into holes provided in the rear panel,
and lifting eyes are screwed into the holes provided in the upper body.

To assemble the face shield, first place a darkened glass eye shield filter (see
IMPORTANT note under ‘Preparation for Welding’ on page 13), in the recessed
window area in the body. Secure in place using the screws provided. The same
screws also locate and secure the upper panel, which is then secured to the sides
of the shield with the screws provided. Finally, attach the handle to the shield
body, also with screws provided.

WARNING:

Never look direct at welding arc, it can seriously damage your eyes.

Always use the face-shield provided or any proper welding mask.

2.3 Welding cables

The welding cables should be kept as short as possible and should be positioned
close together, running at or close to the floor level.

2.4 Equipotential bonding

Bonding of all metallic components in the welding installation and adjacent to it
should be considered. However, metallic components bonded to the work piece
will increase the risk that the operator could receive a shock by touching these
metallic components and the electrodes at the same time. The operator should
be insulated from all such bonded metallic components.

2.5 Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected
to earth because of its size and position, e.g. ships hull or building steelwork, a
connection bonding the workpiece to earth may reduce emissions in some, but
not all instances.

Care should be taken to prevent the earthing of the workpiece increasing the risk
of injury to users, or damage to other electrical equipment.

Where necessary, the connection of the workpiece to earth should be made by
a direct connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitance, selected according to national regulations.

2.6 Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding
area may alleviate problems of interference. Screening of the entire welding
installation may be considered for special applications.

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5

SAFETY PRECAUTIONS

PREPARATION OF THE WORKING AREA

WARNING:

As with all machinery, there are certain hazards involved with their operation

and use. Exercising respect and caution will considerably lessen the risk of

personal injury. However, if normal safety precautions are overlooked, or

ignored, personal injury to the operator may result.

FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY

1. GENERAL PRECAUTIONS

A) Burn prevention

Wear protective clothing - gauntlet gloves designed for use in welding, hat, and
protective shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to
avoid entry of sparks and slag. Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates (protected by clear cover
glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes from
radiant energy and flying metal. Replace cover glass when broken, pitted, or
spattered. Avoid oily greasy clothing. A spark may ignite them. Hot metal such as
electrode stubs and workpieces should never be handled without gloves. First aid
facilities and a qualified first aid person should be available for each shift unless
medical facilities are close by for immediate treatment of flash burns of the eyes
and skin burns. Ear plugs should be worn when working overhead or in a confined
space. A hard hat should be worn when others work overhead. Flammable hair
preparations should not be used by persons intending to weld or cut.

The working area must be sufficiently spacious, not humid, and well-ventilated as
to avoid any fumes which develop from the welding process and from incidental
material adhering to the pieces to be welded (oils, paints, tars...) which may cause
annoyance to the operator.
Avoid welding by contact with humid parts nearby combustible liquids. Least of
all, do not weld upon tanks which may contain inflammable residuals.

SAFETY EQUIPMENT

A comprehensive range of CLARKE safety equipment for use when welding is
available from your local CLARKE dealer.

ADDITIONAL SAFETY PRECAUTIONS FOR ARC WELDERS

NEVER attempt to remove any of the panels unless the machine is

✗

disconnected from the 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.

✗

B) 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 toxic fumes. Adequate local exhaust ventilation must
be used, or each person in the area as well as the operator must wear an air­supplied respirator. For beryllium, both must be used. Metals coated with or
containing materials that emit toxic fumes should not be heated unless coating is
removed from the work surface, the area is well ventilated, or the operator wears
an air-supplied respirator. Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respirator. Vapours from chlorinated
solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE,
a highly toxic gas, and other lung and eye irritating products. The ultraviolet
(radiant) energy of the arc can also decompose trichloroethylene and
perichloroethylene vapours to form phosgene. DO NOT WELD or cut where solvent
vapours can be drawn into the welding or cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even minute amounts of
trichloroethylene or perchloroethylene.

6 11

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.

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 adequate ventilation or extraction in the work area

✔

as the welding process gives off toxic fumes.

ALWAYS ensure there is a fire extinguisher on hand.

✔

ALWAYS ensure that a medical supply is on hand, and that treatment for

✔

burns is provided.

2) Electrode holders

Fully insulated electrode holders should be used. Do NOT use holders with
protruding screws or with any form of damage.

3) Connectors

Fully insulated lock-type connectors should be used to join welding cable.

4) Cables

Frequently inspect cables for wear, cracks and damage. IMMEDIATELY
REPLACE those with excessively worn or damaged insulation to avoid
possibly lethal shock from bared cable. 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.

5) Terminals and other exposed parts

Terminals and other exposed parts of electrical units should have insulating
covers secured before operation.

6) Electrode

a) Equipment with output on/off control (contactor)

Welding power sources for use with the gas metal arc welding, gas
tungsten arc welding and similar processes normally are equipped with
devices hat permit on/off control of the welding power output. When
so equipped the electrode wire becomes electrically LIVE when the
power source switch is ON and welding gun switch is closed. Never
touch the electrode wire or any conducting object in contact with
the electrode circuit unless the welding power source is off.

b) Equipment without output on/off control (no contactor)

Welding power sources used with shielded metal arc welding and similar
processes may not be equipped with welding power output on/off
control devices. With such equipment the electrode is electrically LIVE
when the power switch is turned ON. Never touch the electrode unless
the welding power source is off.

7) Safety devices

Safety devices such as interlocks and circuit breakers should not be
disconnected or shunted out. Before installation, inspection, or service of
equipment, shut OFF all power and remove line fuses (or lock or red-tag
switches) to prevent accidental turning ON of power. Do not open power
circuit or change polarity while welding. If, in an emergency, it must be
disconnected, guard against shock burns, or flash from switch arcing.
Always shut OFF and disconnect all power to equipment. Power disconnect
switch must be available near the welding power source.

C) Fire and explosion prevention

Causes of fire and explosion are:

1) combustibles reached by the arc, flame, flying sparks, hot slag or heated
material;

2) misuse of compressed gases and cylinders;

3) short circuits.

BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes,
through windows or doors, and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 10M.

To prevent fires and explosion: keep equipment clean and operable, free of oil,
grease, and (in electrical parts) of metallic particles that can cause short circuits.
If combustibles are in area, do NOT weld or cut. Move the work if practicable, to
an area free of combustibles.

Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot
be moved, move combustibles at least 10M away out of reach of sparks and
heat; or protect against ignition with suitable and snug fitting, fire- resistant covers
or shields.

Walls touching combustibles on opposite sides should not be welded on (or cut).

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:

a) appreciable combustibles (including building construction) are within 10m.
b) appreciable combustibles are further than 10m but can be ignited by sparks.
c) openings (concealed or visible) in floors or walls within 10m can expose

combustibles to sparks.

d) combustibles adjacent to walls, ceilings, roofs or metal partitions can be

ignited by radiant or conducted heat.

After work is done, check that area is free of sparks, glowing embers, and flames.
An empty container that held combustibles, or that can produce flammable or
toxic vapours when heated, must never be welded on or cut, unless container
has first been cleaned. This includes a thorough steam or caustic cleaning (or a
solvent or water washing, depending on the combustible’s solubility) followed by
purging and inerting with nitrogen or carbon dioxide, and using protective
equipment.

Water filling just below working level may substitute for inerting.

A container with unknown contents should be cleaned (see paragraph above),
do NOT depend on sense of smell or sight to determine if it is safe to weld or cut.

Hollow castings or containers must be vented before welding or cutting - they
can explode.

In explosive atmospheres, never weld or cut where the air may contain flammable
dust, gas, or liquid vapours.

10

7

2. ELECTRIC ARC (MIG, TIG) WELDING

Comply with precautions in 1 above, and this section. Arc welding, properly done,
is a safe process, but a careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates, weldments are hot. The wise
operator avoids unnecessary risks and protects himself and others from accidents.

2A) BURN PROTECTION

Comply with precautions in 2. The welding arc is intense and visibly bright. Its
radiation can damage eyes, penetrate lightweight clothing, reflect from light
coloured surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn,
those from gas - shielded arcs are more severe and painful.

DON’T GET BURNED! COMPLY WITH PRECAUTIONS!

1) Protective clothing

Wear long sleeved clothing (particularly for gas shielded arc) in addition to
gloves, hat and shoes (2A). 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 collar to protect chest and neck and button
pockets to prevent entry of sparks.

2) Eye and head protection

Protect eyes from exposure to arc. NEVER look at an electric arc without
protection. Welding helmet or shield containing a filter plate shade no. 12 or
denser must be used when welding. Place over face before striking arc. Protect
filter plate with a clear cover plate. Cracked or broken helmet or shield should
NOT be worn; radiation can pass through to cause burns. Cracked, broken,
or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate
when broken, pitted, or spattered. WE SUGGEST you wear flash goggles with
side shields under the helmet, to give some protection to the eyes should the
helmet not be lowered over the face before an arc is struck. Looking at an
arc momentarily with unprotected eyes (particularly a high intensity
gas-shielded arc) can cause a retinal burn that may leave a permanent dark
area in the field of vision. Before welding whilst wearing contact lenses, seek
advice from your optician.

3) Protection of nearby personnel

For production welding, a separate room or enclosed bay is best.
In open areas, surround the operation with low reflective, non- combustible
screens or panels. Allow for free air circulation, particularly at floor level. Provide
face shields for all persons who will be looking directly at the weld. Others
working in the area should wear flash goggles. Before starting to weld, make
sure that screen or bay doors are closed.

2B) TOXIC FUME PREVENTION

Comply with precautions in 2-B. Generator engine exhaust must be vented to the
outside air. Carbon monoxide can kill.

2C) FIRE AND EXPLOSION PREVENTION

Comply with precautions in 2-C. Equipment’s rated capacity. Do not overload
arc welding equipment. It may overheat cables and cause a fire. Loose cable
connections may overheat or flash and cause a fire. Never strike an arc on a
cylinder or other pressure vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough handling.

2D) SHOCK PREVENTION

Exposed live conductors or other bare metal in the welding circuit, or in unearthed,
electrically-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.

2E) PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT DEVICES (PACEMAKERS)

Magnetic fields from high currents can affect pacemaker operation. Persons
wearing electronic life support equipment (pacemaker) should consult with their
doctor before going near arc welding, gouging, or spot welding operations.

2F) TO PROTECT AGAINST SHOCK:

Keep body and clothing dry. Never work in damp area without adequate insulation
against electrical shock. Stay on a dry duckboard, or rubber mat when dampness
or sweat can not be avoided. Sweat, sea water, or moisture between body and
an electrically LIVE part - or earthed metal - reduces the body surface electrical
resistance, enabling dangerous and possibly lethal currents to flow through the
body.

1) Earthing the equipment

When arc welding equipment is earthed according to the National Electrical
Code, and the work is earthed, a voltage may exist between the electrode
and any conducting object.

Examples of conducting objects include, but are not limited to, buildings,
electrical tools, work benches, welding power source cases, workpieces, etc.
Never touch the electrode and any metal object unless the welding power
source is off. When installing, connect the frames of each unit such as welding
power source, control, work table, and water circulator to the building earth.

Conductors must be adequate to carry earth currents safely. Equipment made
electrically LIVE by stray current may shock, possibly fatally. Do NOT EARTH to
electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such

as oil or fuel.

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