Clarke EASI ARC 165, 6010982 User guide

WARNING: Read these instructions before using the machine

WARNING: A suitable welding headshield must be worn during use

160 AMP ARC WELDER

MODEL NO: EASIARC 165

PART NO: 6010982

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS

DL0422 ISS 6

INTRODUCTION

Thank you for purchasing this CLARKE Welder.

Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also 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.

ENVIRONMENTAL PROTECTION

Do not dispose of this product with general household waste. All
tools, accessories and packaging should be sorted, taken to a re­cycling centre and disposed of according to the laws governing
Waste Electrical and Electronic Equipment.

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GENERAL SAFETY INSTRUCTIONS

WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY.

WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO
OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.

ELECTRIC SHOCK

• Remove the plug from the socket and wait 5 minutes to allow the capacitors
to discharge before carrying out servicing or maintenance.

• Do not touch live electrical parts.

• Never use electrode holders or cables which are damaged.

• Keep the working environment, equipment, cables and clothing free from
grease, oil, moisture and dirt.

• Ensure the welding machine has been correctly earthed.

• The operator must be insulated from the floor and work bench, using a dry
insulation mat.

• Always ensure a second person is present in case of accident.

• Never change electrodes with bare hands or damp gloves.

• Keep welding cables away from power cables.

• Regularly inspect the condition 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 & GASES

• The welding process generates hazardous fumes as a by-product. Inhalation
of these fumes is hazardous to health.

• Keep your head away from the weld to avoid breathing the fumes.

• If welding in confined spaces, ensure adequate ventilation and use a fume
extractor.

• By-products of welding can react to create a toxic/explosive environment.

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FIRE OR EXPLOSION

Welding can cause fire and explosions. Precautions should be taken to
prevent these hazards.

• Before starting work ensure the area is clear of flammable materials.

• Move any combustible materials to a safe distance, especially substances
likely to generate a dangerous vapour.

• The welding arc can cause serious burns. Avoid contact with the skin.

• Sparks and molten metal are ejected during welding. Take precautions to
prevent fire.

• Sparks and molten metal can pass through gaps. Be aware that fire can
start out of sight.

• Do not weld pressurised containers. or containers containing flammable
vapours e.g. fuel tanks.

• Always have appropriate fire fighting equipment to hand suitable for use in
electrical environments.

• Avoid carrying any fuels with you e.g. cigarette lighters or matches.

PERSONAL PROTECTION

• The body should be protected by suitable 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 equipped with appropriate protective
filters.

• Where there are pedestrians and traffic, ensure a protective screen is used
to avoid accidental arc glare.

• Do not weld in the vicinity of children or animals and ensure no one is looking
before striking an arc.

• Wear hearing protection if required.

• Allow the weld time to cool. Hot metal should never be handled without
gloves.

• Take care when adjusting or maintaining the torch, make sure it has had
time to cool sufficiently and the welder is disconnected from the mains
supply.

• First aid facilities and a qualified first aid person should be available unless
medical facilities are close by, for immediate treatment of flash burns of the
eyes and for skin burns.

• A hard hat should be worn when others are working overhead.

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• Flammable hair sprays/gels should not be used by persons intending to weld
or cut.

PROTECTIVE CLOTHING

• Wear gauntlet gloves designed for use in welding,

• Wear an apron and protective shoes.

• Wear cuffless trousers to avoid entry of sparks and slag.

• Avoid oily, greasy clothing.

• Protective head and shoulder coverings should be worn when overhead
welding.

• Wear a welding headshield with appropriate filter lenses or plates
(protected by clear glass). This is a MUST for welding (and chipping) to
protect the eyes from radiant energy and splatter. Replace cover glass
when broken, pitted, or splattered.

NOTE: ALL protective wear inc. masks & head shields MUST comply with PPE
Directive 89/686/EEC

ADDITIONAL SAFETY PRECAUTIONS FOR ARC WELDERS

• NEVER attempt to remove any of the exterior panels unless the machine is
disconnected from the power 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.

• 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 available.

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SAFETY SYMBOLS

Read this instruction
booklet carefully
before use

Wear protective gloves Wear eye protection

Wear a dust mask

UNPACKING

Do not expose to rain.

Any damage or deficiency should be reported to your CLARKE dealer
immediately.

The components include the following:

• 1 x 160 Amp AC Arc Welder

• 1 x Combination Wire Brush & Hammer

• 1 x Face Shield

ACCESSORIES

The following are some of the accessories available from your CLARKE dealer.
Please quote the part numbers shown below:

DESCRIPTION PART NUMBER

CWH6 Arc Activated Welding Headshield 6000671

2 mm Welding Electrodes 3050555

2.5 mm Welding Electrodes 3050560

3.2 mm Welding Electrodes 3050565

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ELECTRICAL CONNECTIONS

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE SUPPLY.

WARNING: NEVER FIT A STANDARD 230V, 13AMP (BS1363) PLUG TO
THESE MACHINES

Connect the mains lead to a suitably fused 230 Volt (50Hz) electrical supply.
The fuse rating should be suitable to the current drawn by this unit, see the
rating plate for details. For a full explanation of the rating plate, see page 13.

WARNING! The wires in the power cable of this product are
coloured in accordance with the following code:
Blue = Neutral Brown = Live Yellow and Green = Earth

If the colours of the wires in the power cable of this product do not correspond
with the markings on the terminals of your plug, proceed as follows.

• The wire which is coloured Blue must be connected to the terminal
which is marked N or coloured Black.

• The wire which is coloured Brown must be connected to the terminal
which is marked L or coloured Red.

• The wire which is coloured Yellow and Green must be connected to
the terminal which is marked E or or coloured Green.

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OVERVIEW

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8

1

2

3

4

5

6

NO DESCRIPTION NO DESCRIPTION

1Handle 6On/Off Switch

2 Overload Indicator 7 Earth Clamp

3Welding Current Selector 8Combination Wire Brush/Hammer

4 Welding Rod (Electrode) Holder 9 Welding Mask

5Welding Current Scale

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ASSEMBLING THE WELDING SHIELD

1. The welding shield shown on
page 12 is supplied flat for
shipping. Fold the sides of the
shield around and clip to the top
panel.

2. Insert both the glass lens panels
into the recess inside the shield.

• The clear glass must be fitted

first to face the outside.

3. Insert the two plastic screws and
use the plastic wingnuts to clamp
the glass panels to the shield.

• The clear glass panel should be
replaced when it becomes badly
pitted.

4. When replacing the glass panels, only use parts supplied by Clarke
International. The dark panel is a certified, optical glass and should not be
exchanged for any other type.

5. Secure the handle in
position using the plastic
nuts provided.

• The handle will be on the
inside of the shield.

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PREPARATION FOR USE

FITTING THE WELDING ROD

6. Select the appropriate welding rod, and insert it into the welding rod
holder.

• It should be approximately the same thickness as the workpieces

being welded.

PREPARING THE WORKPIECE

The area being welded should be perfectly clean. Any coating, plating or
corrosion must be removed, otherwise a good weld will be impossible to
achieve.

OPERATING THE WELDER

THERMAL CUTOUT

If the machine stops at any time and
the amber light on the front panel
illuminates, the thermal cutout has
activated.

Wait until the transformer has cooled
sufficiently (the amber light goes out)
before restarting work.

ATTACHING THE EARTH CLAMP

Attach the earth clamp firmly to the workpiece as close as possible to the
point of weld.

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IMPORTANT: Ensure that the earth clamp is attached to clean, solid metal. If
necessary, thoroughly clean with a wire brush or similar to guarantee a
good connection.

SETTING THE WELDING CURRENT

1. Select the welding current by
turning the adjustment dial and
observing the setting on the scale
on top of the machine.

• The scale also recommends the

size of welding rod to be used.

•With practice you will get a feel

for the best current settings for
different welding rod
thicknesses.

STRIKING AN ARC

IMPORTANT: BEFORE YOU STRIKE AN ARC, ALWAYS BRING THE FACE SHIELD UP
TO PROTECT YOUR EYES.

1. Switch ON the machine.

2. Line up the electrode exactly over
the spot where you want to strike.

3. Position your shield in front of your
face and tap the electrode down
firmly. Once you tap down and
contact is made, you must
instantly raise the electrode to the
required arc gap.

• The arc gap should be roughly the same as the diameter of the

electrode.

• If you withdraw the electrode too far once the arc is struck, you will

lose the arc and have to try again.

NOTE: One thing that usually happens when you are striking an arc is that the

electrode sticks to the work. It should come unstuck with a sharp tug. If
it will not free easily, turn off the welder immediately as it will quickly
overheat, then give the join a tap from the chipping hammer. As you
get more experienced, this will happen less.

4. Once the arc is struck, move the electrode along its intended path,
keeping the tip in the molten pool at all times.

• You must also get used to feeding down the electrode steadily as it

burns away.

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• An even crackling noise should be heard, which is an indication of a

good weld.

5. Inspect the job carefully, the area of weld should be a complete fusion of
the electrode and parent metal(s).

• Any slag which forms on the surface should be chipped away with

the hammer/brush supplied.

• If the resultant weld looks messy and irregular, this is an indication of

porosity or slag contamination, and you have almost certainly failed
to achieve the correct combination of speed and current. This is a
common problem, so do not worry as practice will quickly cure this.

WELDING PITFALLS

The arc welding technique is an acquired skill and requires considerable
practice before perfect results are obtained. The diagrams below will help to
explain the pitfalls in your technique and how to overcome them.

ARC TOO SHORT

This causes irregular masses of weld to be deposited, with
slag contamination on an uneven surface.

ARC TOO LONG

This causes poor penetration resulting in a weak weld with
excessive spatter and porosity. Surface of the weld is rough
and the arc makes a hissing sound

ELECTRODE MOVED TOO SLOWLY

This causes a very wide and 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 very hard to remove.

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CURRENT TOO HIGH

This causes excessive penetration with spatter and deep
pointed crater. It may also cause holes to be burned in the
workpiece.

Burns electrodes very quickly.

THE PERFECT WELD

With the correct combination of arc length, current
regulation, inclination and speed of the electrode, you will,
with practice, produce the perfect weld.

This should be regular with uniform ripples and no slag
contamination. The arc will make a steady crackling sound.

MAINTENANCE

WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL
COMPONENTS.

WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS
AND MAINTENANCE OPERATIONS

WARNING: BEWARE HOT SURFACES.

Frequency of maintenance operations depends on the operating conditions,
how intensively the welder is used and how clean or dirty the welding site is
(aggressive atmospheres etc).

Always inspect the earth return and torch hose before use, to ensure they are
in perfect condition and that the earth clamp is clean and secured correctly
to the cable.

As a general rule, the power supply should be inspected at least annually.
Consult your CLARKE dealer for advice if necessary.

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SPECIFICATIONS

Model Easiarc165

Power Supply 230V @ 50Hz

Rated Max Input Current I1Max/I1eff 36/13.7 A

Open Circuit Voltage 48V

IP Rating IP21S

Output Min./Max Current 65 - 160 Amps

Usable Electrodes 2.0 mm, 2.5 mm, 3.2 mm, 4.0 mm

Dimensions (l x w x h) 346 x 182 x 270 mm

Weight 16.7 kg

Part Number 6010982

NOTE: 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.

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RATING PLATE

1 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

5British Standards Applied 16Rated Maximum Supply Current

6 Welding Process Symbol 17 Maximum Effective Supply Current

7 This symbol indicates that the unit is

suitable for carrying out welding
operations in an environment which
has an increased risk of electric
shock.

8Welding Current Symbol 19N/a

9 Rated No-load Voltage 20 N/a

10 Range Of Output 21 N/a

11 Duty Cycle Symbol 22 Degree Of Protection

18 N/a

DUTY CYCLE

This welder is covered by regulations EN60974-1 and EN 50199, where the Duty
Cycle (X) is expressed as a percentage of time the machine may be used in a
given period for a specified welding current.

i.e. When welding at 65 Amps the machine may be used for 6 minutes (60%) in
any10 minute period,

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DECLARATION OF CONFORMITY

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