Clarke ARC TIG 135, 6010790 User guide

ARC/TIG WELDER

Model No. Arc/T ig135

PART NO: 6010790

OPERATING & MAINTENANCE

INSTRUCTIONS

0612

INTRODUCTION

Thank you for purchasing this CLARKE Arc/Tig welder.

Before attempting to use the machine, 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 the welder giving you long and satisfactory service.

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.

TABLE OF CONTENTS

...................................................................................................... Page

List of Equipment ......................................................................... 3

Specifications ............................................................................... 3

Principles of Operation ................................................................. 4

General Safety Precautions ......................................................... 6

EMC in the Workplace ................................................................. 8

Safe Operation of Electric Arc Welders ...................................... 10

Preparation of the Welding Area ................................................. 14

Features of the ARC/TIG135 ....................................................... 15

The ARC/TIG135 Components .................................................... 17

Welding Techniques .................................................................. 18

Maintenance ................................................................................. 23

Fault Finding ................................................................................. 23

Parts Lists & Diagrams ................................................................ 24

Declarations of Conformity .......................................................... 27

Please note that the details and specifications contained herein, are correct at the time of going
to print. However, CLARKE International reserve the right to change specifications at any time
without prior notice. Always consult the machine’s data plate.

2

LIST OF EQUIPMENT

When unpacking, check for damage and /or omissions etc. Any found should be reported
to your CLARKE dealer where the appliance was originally purchased.

The AT135 Arc/Tig welder is delivered with the following components:

1 x Welding Inverter with Shoulder Strap
1 x Instruction Manual (this document)
1 x Electrode Holder with Lead
1 x Earth Clamp with Lead
1 x Welders Mask Assembly with Lens
1 x Wire Brush & Hammer

SPECIFICATIONS

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3

PRINCIPLES OF OPERATION

The ARC/TIG welder, as its name suggests, is designed to be used for both Metal ARC, AND TIG
welding. To accomplish this, two sets of welding leads are required, one for each method
employed.

ARC WELDING

Shielded Metal Arc welding is by far the most widely used of the various arc welding processes.
It employs the heat of the arc to melt the base metal and the tip of a consumable flux covered
electrode.

The electrode and the workpiece are part of an electric circuit. This circuit begins with the
electric power source and includes the welding cables, an electrode holder, a workpiece
connection, the workpiece, and an arc welding electrode. One of the two cables from the power
source is attached to the work. The other is attached to the electrode holder.

Welding commences when an electric arc is struck between the tip of the electrode and the work.
The intense heat of the arc melts the tip of the electrode and the surface of the work close to the
arc. Tiny globules of molten metal rapidly form on the tip of the electrode, then transfer through
the arc stream into the molten weld pool. In this manner, filler metal is deposited as the electrode
is progressively consumed.

The arc is moved over the work at an appropriate arc length and travel speed, melting and fusing
a portion of the base metal and continuously adding filler metal. Since the arc is one of the
hottest of the commercial sources of heat (temperatures above 90000F (50000C) have been
measured at its centre), melting of the base metal takes place almost instantaneously upon arc
initiation.

If welds are made in either the flat or the horizontal position, metal transfer is induced by the
force of gravity, gas expansion, electric and electromagnetic forces, and surface tension. For
welds in other positions, gravity works against the other forces.

The process requires sufficient electric current to melt both the electrode and a proper amount of
base metal. It also requires an appropriate gap between the tip of the electrode and the base
metal or the molten weld pool. These requirements are necessary to set the stage for
coalescence.

The sizes and types of electrodes for shielded metal arc welding define the arc voltage
requirements within the overall range and the current requirements within the overall range. The
current may be either alternating or direct, depending upon the electrode being used, but the
power source must be able to control the level of current within a reasonable range in order to
respond to the complex variables of the welding process itself.

4

TIG WELDING

TIG welding Is primarily a DC current process, but can also utilise AC, usually for very thin
materials and when welding Aluminium or other non ferrous metals. It uses a non-consumable
tungsten (or tungsten alloy) electrode, held in a torch.

Shielding gas (100% Argon), is fed through the torch to protect;

a. the electrode,
b. molten weld pool, and
c. solidifying weld metal from contamination by the atmosphere.

The electric arc is produced by the passage of current through the conductive, ionized shielding
gas. The arc is established between the tip of the electrode and the work. Heat generated by
the arc melts the base metal. Once the arc and weld pool are established, the torch is moved
along the joint and the arc progressively melts the joined surfaces. Filler wire, if used, is usually
added to the leading edge of the weld pool to fill the joint.

This process is ideally suited for welding thin metals, pressure vessels, heat exchangers, pipes
etc., where accuracy and a high quality weld is desired, as it produces a very low porosity weld.

TIG Welding Process Advantages

• It produces superior quality welds, generally free of defects.

• It is free of the spatter which occurs with other arc welding processes.

• It can be used with or without filler metal as required for the specific application.

• It allows excellent control of root pass weld penetration.

• It can produce inexpensive autogenous welds at high speeds.

• It can use relatively inexpensive power supplies.

• It allows precise control of the welding variables.

• Welds all metals

• Capable of welding very thin material without undue distortion.

Main Features of TIG Welding

1. Welds all metals.

2. Electronic control of welding current.

3. Forced air cooling.

4. A Thermal Overload Protection Device prevents overheating the transformer.

Limitations

1. Greater weld dexterity is required.

2. It is more expensive to weld thicker materials - greater than 4 - 5mm.

5

GENERAL SAFETY PRECAUTIONS

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
RESUL T IN SERIOUS PERSONAL INJURY

PREVENTION OF BURNS

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.

PREVENTION OF TOXIC FUMES

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 air- supplied 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
perchloroethylene 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.

PREVENTION OF FIRE & EXPLOSION

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.

6

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 combustible

materials to sparks.

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

radiant or conducted heat.

After the work is done, check that the 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 the 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, while
using personal 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.

7

ELECTROMAGNETIC INTERFERENCE (EMC) IN
THE WORKPLACE

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 THE WELDING 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 REDUCING EMC 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 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

8

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

2.3 Welding cables

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 Equi-potential 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.

9

SAFE OPERATION OF ELECTRIC ARC (MIG, TIG)
WELDERS

Comply with precautions 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, workpieces are hot. The wise operator avoids unnecessary risks and protects himself
and others from accidents.

Burn Protection

Comply with precautions above. 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.

Protective Clothing

Wear long sleeved clothing (particularly for gas shielded arc) in addition to gloves, hat and shoes
as necessary and use additional protective clothing such as leather jacket or sleeves, flameproof
apron and fire-resistant leggings. Avoid outer garments of untreated cotton. For bare skin
protection wear dark substantial clothing. Button the collar to protect chest and neck and button
any pockets to prevent entry of sparks.

Eye & Head Protection

Protect the eyes from exposure to arc. NEVER look at an electric arc without protection. The
welding helmet or shield containing a filter plate shade No. 12 or denser must be used when
welding. Place over the face before striking an arc. Protect the filter plate with a clear cover plate.
A 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 a 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.

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 anyone 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.

Toxic Fume Prevention

Welding fumes must be vented to the outside air. Carbon monoxide can kill if inhaled in large
quantities.

10

Fire & Explosion Prevention

Do not exceed the equipment’s rated capacity or overload the 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 rupture or lead to such a rupture later under rough handling.

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.

Protection of Wearers of Electronic Life Supoport 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 operations.

Protection Against Shock

Keep body and clothing dry. Never work in damp area without adequate insulation against electric
shock. Stay on a dry duckboard or rubber mat when dampness or sweat cannot 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.

Earthing the Equipment

When arc welding equipment is earthed according to the National Electrical Code, and the work
is also 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.

Electrode Holders

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

Connectors

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

11

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.

Terminals & other Exposed parts

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

Electrodes

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.

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. A power disconnect switch must be available near the welding power source.

Safety Precautions for ARC/TIG W elding

ALWAYS ensure that there is full free air circulating around the outer casing of the machine, and

that the louvres are unobstructed.
1 Welding arc can seriously damage your eyes. Both operator and spectators must ALWAYS

use a proper welding face shield or helmet, with suitable filter lenses. Proper gloves and

working clothes should be worn at all times.
2 ALWAYS check that the pressure regulator and gauges are working correctly. DO NOT

lubricate the regulator.
3 ALWAYS use the correct regulator. Each regulator is designed to be used with a specific

gas.
4 ALWAYS inspect the hose before use to ensure it is in good condition.

12

5 ALWAYS keep the free length of gas hose outside the work area.
6 ALWAYS remove all flammable materials from the welding area.
7 NEVER remove any of the panels unless the machine is disconnected from the supply, AND

never use the machine with any of the panels removed.
8 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.
9 NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN.
10 The TIG welding process uses an INERT gas to protect the weld pool. It is important to

ensure the appropriate gas is being used. NEVER use gas from a cylinder, the content of

which is unknown.
11 NEVER a. Use a damaged cylinder.

b. Lift the cylinder by the valve.
c. Expose the cylinder to a heat source or sparks.

12 NEVER continue to weld, if, at any time, you feel even the smallest electric shock. Stop

welding IMMEDIATELY, and DO NOT attempt to use the machine until the fault is diagnosed

and corrected.
13 NEVER use the welder with input connections greater than 10M in length.
14 NEVER point the TIG torch at any person or animal.
15 NEVER touch the TIG torch nozzle until the welder is switched OFF and the nozzle has

been allowed to cool off.
16 NEVER connect, disconnect, or attempt to service the TIG torch, until the machine is

switched OFF and disconnected from the mains supply.
17 NEVER allow the cables to become wrapped around the operator or any person in the

vicinity.

Additional Precautionary Measures

IMPORTANT:

The TIG machine generates both airborne and line interference due to the high
frequencies involved. It is important not to locate electronic or electrically sensitive
equipment in the vicinity of the welder or alternatively, do not locate the welder in
vicinity of electronic or electrically sensitive equipment.

13

PREPARATION OF THE WELDING AREA

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.

ELECTRICAL CONNECTIONS

WARNING! THIS APPLIANCE MUST BE EARTHED.

Connect the mains lead, through a suitably fused isolator switch, to a 230 Volt (50Hz) electrical
supply, with a fuse rating of 32amps.

A standard domestic 13 Amp plug MUST NOT be used with this welder.

IMPORTANT: The wires in the mains lead are coloured in accordance with the
following code:

Green & Yellow .......... Earth

Blue .......... Neutral

Brown ..........Live

As the colours of the flexible cord of this appliance may not correspond with the coloured markings
identifying terminals in your plug, proceed as follows:

• Connect GREEN & YELLOW cord to plug terminal marked with a letter “E” or Earth symbol

“ ”, or coloured GREEN or GREEN & YELLOW.

• Connect BROWN cord to plug terminal marked letter “L” or coloured RED.

• Connect BLUE cord to plug terminal marked letter “N” or coloured BLACK.

Extension Cables

If an extension cable is fitted, ensure the minimum cross section of the conductor is 1.5mm2 for
up to 15 metres in length, and 2.5mm2 for up to 25 metres.

14

FEATURES OF THE ARC/TIG 135 WELDER

The ARC/TIG 135 welder has been designed to work with
unstable input voltages. The use of power components
and of electrolytic capacitors with higher voltage and a
special control circuit grant a high welding current stability
in spite of the mains voltage fluctuations. The machine
allows coated electrode (MMA) welding by scratch
starting the tungsten inert gas (TIG) welding. The
technology used to manufacture the generator, combined
to both MMA and TIG functions, make it easy to use from
scratch.

The generator is composed of a control and printed circuit
(p.c.) board, a switching transformer, and a levelling
inductance. The pc board includes different electronic
functions in order to improve the arc striking and the
dynamics of the welding to achieve an optimum weld with any type of electrode with simplicity of
performance.

An IGBT bridge guarantees a fast speed of response and greater precision, together with a
drastic reduction in magnetic components and a consequent reduction in generator weight. The
unit is easy to carry using the carrying strap and the low electrcity consumption make it ideal for
all types of welding applications.

ASSEMBLING THE FACE SHIELD

1. Push the two halves of the

shield together as shown.

2. Place the handle into

position and secure using

the plastic screw and clip

provided

3. Working from the inside of

the shield, insert the clear

glass panel into the recess

in the shield, followed

by the dark glass panel.

4. Secure the glass panels

with the lens surround and

plastic screws/clips

provided. The clear glass MUST be on the outside of the shield.

5. Finally use the last plastic screw and clip as shown to fix the two halves of the

shield together.

WARNING:

NEVER look at an electric arc without eye protection as this can injure the

eyes permanently. ALWAYS use a protection mask or welding helmet.

15

ELECTRICAL SYMBOLS DISPLAYED ON THE MACHINE

The full technical specification for your inverter is to be found printed in a rating plate on the back
panel or underside of the ARC/TIG 135 machine. The meaning of the markings and symbols
shown are explained as follows.

EN 60974 -1: (2005) European Standard-Arc Welding Equipment

EN 50199: (1996) Electromechanical Compatability (EMC)

Single-phase static frequency converter/transformer/rectifier
Symbol for Drooping Characteristic

Direct Current
Symbol for manual metal arc welding with covered electrodes

U0=_ _ V Min rated no-load voltage

Symbol for mains supply & No of phases

IP_ _ Degree of protection (e.g. IP21)

_ _A/ _ _V to _ _A/_ _V Range of output, min & max welding current and their

X Duty Cycle (expressed as a %, e.g.35%)

12 A Max/min rated value of the welding current for the duty cycle
U2 _ _ V Conventional load voltage for the duty cycle
U1_ _V Rated value of the supply voltage
L 1max = _ _ A Symbol, rated value and dimension of the max. supply current
l1eff = _ _A Size of the necessary main fuse
H Code letter for degree of insulation (I.CL.)
COOLING Air Fan

corresponding load voltage

16

THE ARC/TIG 135 COMPONENTS

1 ON/OFF Switch

2 Adjusting weld current potentiometer

3 Green LED indicating power ON

LED ON = Power ON, when switching the unit on, it illuminates a short while after the orange
LED. Flashing LED = indicates an alarm condition due to an anomaly in the input voltage. During
the green LED flashing time, the unit checks the line voltage untill it reaches an acceptable value.
When there is no alarm condition, the green LED stays on.

4 Orange LED

LED on = indicates an alarm condition due to overheating of the primary circuit. If both orange
and green LEDs are on, the unit needs to cool down. After cooling, the orange LED will
automatically go out.

Flashing LED = an alarm condition exists due to undervoltage, overheating on the secondary or
an input short circuit. Leave the unit to cool down if the temperature has been exceeded. When
there is no alarm condition, the orange LED goes off and the green LED stays on.

5 25mm2 positive socket

6 25mm2 negative socket

7 Input (power) cable

17

WELDING TECHNIQUES

A ARC WELDING

Arc welding cables are supplied with this machine. The kit comprises all necessary cables, plus a

hand shield and wire brush with chipping pick.

To prepare the unit for ARC welding, it is
important that you follow the procedure below.

1. With the ON/OFF switch, located on the rear

panel, in the OFF position, connect the

welding leads as follows:
Welding Electrode lead to the +ve terminal.

Work Clamp lead to the -ve terminal.

2. 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

possible.

3. An appropriate current must then be set by

turning the Welding Current Selector 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.

Fig. 1

For beginners, the following table gives some useful guidelines.

SIZE OF WELDING THICKNESS OF CURRENT SETTING

ROD WORKPIECE (AMPS)

1.5mm 16 SWG - 1.5 MM 30 - 40

2.0mm 14 SWG - 2.0 MM 50 - 65

2.5mm 12 SWG - 2.5 MM 70 - 100

3.0mm 10 SWG - 3.25MM 100 - 130

4. Switch ON using the switch located on the rear panel. The green light on the front panel

should glow, indicating the machine is ON.

18

Note: If the machine stops at any time and the amber light comes ON the thermal
overload has intervened.

5. The most difficult aspect of the arc welding process, particularly for beginners, is that of
striking an arc. We strongly recommend that you practice on some pieces of scrap metal to
get the feel of the operation, before you start on an actual welding job.

6. Hold the electrode about 10mm from the work and at an angle of about 70° to 80° to the work
surface. Take care not to accidentally touch the workpiece until you are ready to start.

7. Holding the welding mask close-up to the face, give a short stroke with theelectrode on the
workpiece. As soon as the arc is primed, withdraw the electrode from the workpiece to
leave a tiny gap of around 1.5mm (1/16"). The current will flow across the gap with a
crackling noise and brilliant arc. Continue to weld in one direction, maintaining the small gap
as you go. At the end of the run just withdraw the electrode fully from the workpiece.

Note: When you prime the arc be sure to withdraw the electrode fairly swiftly
to leave the 1.5mm. gap, otherwise the electrode will weld itself to the workpiece.
Should this occur, 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.

8. Inspect the job carefully. With a correct combination of rod size and current setting, the area
of the weld should be a complete fusion of the electrode metal with the metals being joined.
Slag forming on the surface should be chipped away with a chipping hammer or pick.
ALWAYS wear your safety goggles when chipping away slag.

NOTE: If the resultant weld looks irregular or messy, or shows signs of porosity
or slag contamination, you have almost certainly failed to achieve the correct
combination, (orelse dirt /oil is present on workpiece). Do not worry as practice
will soon cure this.

HEALTH WARNING:

When welding, always ensure there is adequate ventilation in the work area as the
welding process gives off toxic fumes.

19

B TIG WELDING

To prepare the unit for TIG welding, it is important that you adopt the following procedure.

1. Plug the work return lead (earth clamp) in to the +ve terminal, and secure the work
clamp tothe workpiece.

For good contact, the work clamp must be attached to clean bare metal. Clean with a wire brush
where necessary.

2. Plug the Torch lead to the -ve terminal

3. Screw the pressure regulator on to the gas
bottle tightly, and attach the gas hose to the
inlet connector securely, with a hose clip.
Screw in the pressure regulator knob to set a
pressure of approx. 2,5Kg./cm2. (35 lbf/in2).

4. Ensure the electrode at the torch
nozzle,protrudes by 4 - 5mm., also ensure
that the electrode is sharply pointed withan
angle of 40°-60, if it is not, grind it
longitudinally.

5. Set the welding current in accordance with
the thickness of the material to be welded
and the size of tungsten electrode to be
used, (see chart on page 20), and switch ON
using the switch mounted on the rear panel.
The green light on the front panel will glow.

6. Open the gas valve on the torch handle,
allowing gas to flow from the torch nozzle.
Cover your face with the head shield, bring
the torch to within 3-4mm of the work, and at
an angle of 45°, so that the ceramic nozzle
gently touches the work surface. See fig. 3.

Fig. 2

Fig. 3

20

Scratch the tip of the electrode on soon as an arc develops, quickly withdraw the electrode to
maintain a gap of approx 3-4 mm, and proceed to weld. (See notes below).

To stop welding, simply remove the torch from the workpiece. This method is referred to as
‘Scratch Arc’.

REMEMBER to turn OFF the gas immediately you finish welding.

NOTES:

a) 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.

b) 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 must always be shielded by the argon
atmosphere to prevent as far as possible the formation of oxides of its surface.
When welding stainless steel and copper, it is often possible to feed in the filler
continuously at the edge of the pool.

c) The arc length generally varies between 3 and 6mm depending on the type of joint,

type and thickness of material, and so on.

d) The torch is advanced in the direction of welding, without lateral movement,

maintaining the torch angle of 450 to the workpiece.
Guidelines for the TIG welding current needed and recommended electrode sizes

etc. for different gauges of material are shown on the following chart:

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MAINTENANCE

The ARC/TIG Inverter, requires very little maintenance other than the guidelines shown below.
Under normal working conditions removing the covers and cleaning with dry compressed air at
reduced pressure once a year will be quite sufficient. Cleaning at more frequent intervals is
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 security: They must be in good condition and

not cracked.

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

IMPORTANT - Disconnect from mains before cleaning.

DO NOT attempt to carry out repairs yourself, unless you are fully competent, all work must
be carried out by a qualified technician.

FAULTFINDING

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P ARTS DIAGRAM

24

PARTS LIST

ON EDOC

1

234000222MEhctiwSeloPelbuoD12156050912MEksamcitsalP1

390050612MEpmalCelbaC13102050912MEssalGraelC2

425100640MEetelpmoc-tleB14112050912MEssalGkraD2

579153722MEhtiwretemoitnetoP

696450733MElenaPrevoC16111001122MEredloHedortcelE1

785200733MElenapraeR17145050234MEelbaCgnidleW1

878053

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Additional accessories and consumables are available from your CLARKE dealer.

For parts & Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

P ARTS & SERVICE FAX: [phone]

or e-mail as follows:

P ARTS: [email protected]

SERVICE: [email protected]

When disposing of this product, do not dispose of with general waste.
It must be disposed of according to the laws governing Waste
Electrical and Electronic Equipment, at a recognised disposal facility.
Such products should be recycled in an environmentally safe way
instead off disposing of them as waste.

25

WIRING DIAGRAM

26

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

This is an important document and should be retained.

We declare that this product complies with the following directives:

89/336/EEC Electromagnetic Compatibility directive, (amended 2004/108/EC).

73/23/EEC Low Voltage Equipment directive (amended 93/68/EEC).

The Following Standards have been applied to the product:

BS 638- 10:1990, EN 60974-1:1990:

BS EN 50199:1995: BS EN 60974-1:1998+A1+A,2

BS EN 50060:

The technical documentation required to demonstrate that the products meet the
requirements of the Low Voltage Equipment directive has been compiled and is available
for inspection by the relevant enforcement authorities.

The CE mark was first applied in: 2007

Product Description: Arc/Tig Welder

Model number(s): Arc /Tig 135

Serial / batch Number: Current Manufacture.

Date of Issue: 01/05/2008

Signed

A.C. AIKEN

Senior Manager Clarke International.

ARC-TIG135-RV1.doc Page 1 of 1

27