Clarke MMA150 User guide

MMA INVERTER WELDER

MODEL NO: MMA150

PART NO: 6013053

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC09/25

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.

When unpacking, any damage or deficiency should be reported to your CLARKE
dealer immediately.

SPECIFICATIONS

Model MMA150

Unpacked Weight (kg) 3.95

Dimensions (L x W x H) (mm) 280 x 140 x 207

Power Supply 230V-50Hz

Connecting plugs (32A)

Peak Input Power 5980 W

Max Input Current I1Max / I1eff 26A/16.4A

Output Welding Current MMA 10A-20.4V / 140A/25.6V

IP Rating IP21S

Insulation Grade Class 1 - Grade H

Electrode size 1.6mm - 4.0mm

Welding Capacity (Mild Steel) 1-6 mm (MMA)

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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PRINCIPLES OF THE MACHINE

The MMA150 is an inverter type welding machine, suitable to carry out No Gas
welding with the advantages of high energy efficiency, strong arc penetration and
small welding deformation.

Weldable materials include low carbon steel, low alloy steel, high strength steel,
stainless steel and aluminium alloy.

Manual Metal Arc (MMA) welding uses a coated consumable electrode (stick) to lay
the weld, therefore an additional welding torch kit is not used. The arc melts the core
of the electrode to produce drops 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.)

A wide selection of accessories and consumables are available from your CLARKE
dealer (see page 24).

When using the welder outside you may need to erect a wind break to make sure the
shielding gas is not blown away, thereby leaving a poor quality weld.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the obligation
to deal with the WEEE in accordance with the WEEE regulations in relation
to the treatment, recycling & recovery and environmentally sound disposal
of the WEEE.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing Waste
Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.

If disposing of this product or any damaged components, do not dispose of with
general waste. This product contains valuable raw materials. Metal products should
be taken to your local civic amenity site for recycling of metal products.

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SAFETY PRECAUTIONS FOR ALL WELDING

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.

GENERAL PRECAUTIONS

BURN PREVENTION

Wear protective clothing - gauntlet gloves designed for use in welding, apron, 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 glass). This
is a MUST for welding (and chipping) to protect the eyes from radiant energy and
spatter. Replace cover glass when broken, pitted, or spattered. Avoid oily or greasy
clothing. A spark may ignite them. Hot metal should NEVER be handled without
gloves. 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
skin. A hard hat should be worn when others work overhead. Flammable hair
preparations should not be used by persons intending to weld or cut.

NOTE: ALL protective wear incl. masks & head 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 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 when it is being force 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 by-products. The ultraviolet (radiant) energy of the
arc can also decompose trichloroethylene and perchloroethylene vapours to form
phosgene. DO NOT WELD where solvent vapours can be drawn into the welding

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atmosphere or where the radiant energy can penetrate to atmospheres containing
even minute amounts of trichloroethylene or perchloroethylene.

FIRE AND EXPLOSION PREVENTION

Causes of fire and explosion are:

1. Combustibles reached by the arc, flying sparks, hot slag or heated material;

2. 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.

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 the area, DO NOT weld. Move the work if practicable, to an area
free of combustibles.

Avoid working in paint spray rooms, dip tanks, storage areas, ventilators. If the work
cannot be moved, move combustibles away from sparks and heat; or protect against
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 10m, but can be ignited by sparks.

3. Openings (concealed or visible) in floors or walls can expose combustibles to
sparks.

4. Combustibles adjacent to walls, ceilings, roofs or metal partitions can be ignited
by radiant or conducted heat.

After work, 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 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, and using protective equipment.

Water filling just below the 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 as they can explode.

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

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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.

ELECTRIC ARC WELDING

Comply with precautions in 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 and work pieces are hot. The wise operator
avoids unnecessary risks and protects himself and others from accidents.

BURN PROTECTION

The welding arc is intense and visibly bright. It’s 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 (PPE) MUST BE WORN

Wear long sleeved clothing (particularly for gas shielded 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

Protect eyes from exposure to arc. NEVER look at an electric arc without protection.
Welding helmet or shield containing an appropriate filter plate (Please refer to the
section ‘Welding Shield on page 13). 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 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, well vented 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

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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.

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 or 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 or spot
welding operations.

PROTECTION AGAINST SHOCK

Keep your 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 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.

EARTHING THE EQUIPMENT

When arc welding equipment is earthed according to the National Electrical Code and
the workpiece 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.

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 AND OTHER EXPOSED PARTS

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

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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.

PREPARATION OF THE WORKING AREA

WARNING: ELECTRIC SHOCK CAN BE FATAL. A PERSON QUALIFIED
IN FIRST AID SHOULD ALWAYS BE PRESENT IN THE WORKING
AREA. IF PERSON IS UNCONSCIOUS AND ELECTRIC SHOCK IS
SUSPECTED, DO NOT TOUCH THE PERSON IF HE OR SHE IS IN
CONTACT WITH THE WELDER OR CABLES. DISCONNECT THE
WELDER FROM THE POWER SOURCE AND THEN USE FIRST AID. DRY
WOOD OR OTHER INSULATING MATERIAL CAN BE USED TO MOVE
CABLES, IF NECESSARY, AWAY FROM THE PERSON.

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 danger to
the operator.

Avoid welding tanks which may contain flammable residuals.

PRECAUTIONS FOR MMA WELDING

1. ALWAYS ensure that there is full free air circulating around the outer casing of
the machine and that the louvres are unobstructed.

2. A 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.

3. ALWAYS remove all flammable materials from the welding area.

4. 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.

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.

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7. ALWAYS keep a fire extinguisher handy (Dry Powder, C02 or BCF, NOT Water).

8. 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.

9. NEVER allow the earth cable or torch to become wrapped around the operator or
any person in the vicinity.

A comprehensive range of CLARKE safety equipment for use when welding is available
from your local dealer. See page 24.

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.

The welding equipment should be routinely maintained according to the
recommendations (see page 25). All covers should be closed and properly fastened
when the machine is in operation. The welding equipment should not be modified in
any way except for those changes and adjustments covered in these instructions.

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SAFETY SYMBOLS

The following symbols may be displayed on the machine or its packaging.

Read this instruction
booklet carefully before
use.

Wear welding mask Recycle unwanted

Wear protective gloves General Hazard

Wear a dust mask Warning;- Magnetic field

Do not expose to rain.

materials under WEEE
Directive

created

Caution:- Hot surface Danger! Harmful fumes

Risk of Electric Shock Do not weld near

flammable or combustible
materials

May interfere with
pacemakers

Danger:- Arc Rays

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ELECTRICAL CONNECTION

Earth

WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO A
POWER SUPPLY. THE INSTALLATION OF THIS APPLIANCE
SHOULD BE CARRIED OUT BY A COMPETENT ELECTRICIAN AND
BE IN ACCORDANCE WITH CURRENT IEE WIRING
REGULATIONS (BS4343).

This welder MUST be connected to a 230 Volt, 1 phase 50Hz supply through a
suitably rated isolator switch. Before switching on, ensure the voltage of your power
supply is correct. Connecting it to any other power source may cause damage.

The user should purchase a suitable connecting cable capable of handling 32 Amps
with a supply plug rated at 32A or better. A length of 2-3 metres is recommended
giving mobility to the appliance but without becoming a trip hazard.

If the plug has to be changed due to damage a replacement should be fitted following
the wiring instructions shown below.

WARNING: THE WIRES IN THE POWER CABLE OF THIS
PRODUCT ARE COLOURED IN ACCORDANCE WITH THE
FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW = EARTH

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

• The Blue wire must be

connected to the terminal which
is marked N or Neutral.

• The Brown wire must be

connected to the terminal which
is marked L or Live.

• The Yellow wire must be

connected to the terminal which
is marked E or Earth.

Plug must be BS60309 approved.

Live

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If in any doubt, consult a qualified
electrician. DO NOT attempt any
repairs yourself.

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OVERVIEW

The MMA150 welder comes with the following features:

1 Power-On LED 6 Negative socket

2 Overheating LED 7 Welding Mask

3 Digital voltage display meter (V) 8 Electrode holder/cable

4 Welding voltage selector knob 9 Wire brush

5 Positive socket 10 Earthing cable

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FEATURES OF THE MACHINE

1. Power-On LED

When the power is switched on at the back of the machine the switch will be
illuminated, as will the green ‘Power On’ LED.

2. Thermal overload LED

If the duty cycle is exceeded as a result of welding for too long with a high current,
the overload light will illuminate and the welder will turn off. When the welder has
cooled down (approx. 5 to 10 minutes), the power will be restored and welding can
recommence.

3. Digital voltage display meter

• Displays selected output voltage the machine.

4. Welding voltage selector knob

Adjusts the output voltage according to the welding task being performed.

5. Positive Output Terminal

• Connect the electrode holder cable to the positive terminal

6. Negative Output Terminal

• Connect the earth clamp cable to the negative terminal

LOOSE ITEMS SUPPLIED INCLUDE:

7. Welding Mask

• c/w handle, lenses & locking nuts for assembly

8. Welding electrode holder/cable

9. Wire Brush/chipping hammer

10.Earth Cable/clamp

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ASSEMBLING THE WELDING SHIELD

1. The welding shield shown 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 wing-nuts 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 mounted
on the inside of the shield.

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PREPARING THE WELDER FOR USE

FITTING THE WELDING ROD

1. Make sure that the ON/OFF switch,
located on the rear panel is in the
OFF position.

2. Connect the earth clamp to
the positive terminal and
the electrode holder to the
negative as shown.

3. Switch on using the switch
located on the rear panel.

4. 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.

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The following sizes of rods can be used and are available from your CLARKE dealer.

ROD DIAMETER WORKPIECE THICKNESS

1.6 mm wire 1.5 - 2.0 mm

2.5 mm wire 2.5 - 3.0 mm

3.2 mm wire 3.5 - 4.5 mm

4.0 mm wire 5.0 - 6.5 mm

5. Attach the earth clamp to the workpiece as close as possible to the area being
welded. Clean the workpiece with a wire brush where necessary to ensure the
connection is as clean as possible.

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.

CONTROL SETTINGS

Refer to page 12 for control panel functions.

1. Set the Welding Current Selector knob (4) according to the size of the weld being
performed.

2. Confirm the electrode and cables are configured as shown on page 15.

3. Aim at the welding line and scratch the work piece to start the arc. The “working”
indicator will be on.

With practice you will gain a feel for the correct current setting for different welding
rod thicknesses.

THERMAL OVERLOAD

The ‘Thermal Overload’ shuts off the welder when it becomes too hot, due to the duty
cycle being exceeded. This is to prevent any damage to the machine.

When this occurs, the warning lamp will light up. Allow the welder to cool until the
amber light extinguishes before resuming work.

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OPERATING THE WELDER (MMA)

WARNING: WHEN WELDING ALWAYS ENSURE THERE IS ADEQUATE
VENTILATION IN THE WORK AREA DUE TO TOXIC FUMES.

WARNING: DO NOT STRIKE THE ELECTRODE ON THE WORKPIECE,
AS THIS MAY DAMAGE THE ELECTRODE.

WARNING: WELDING ARCS PRODUCE HARMFUL UV/IR LIGHT
WHICH CAN SERIOUSLY DAMAGE YOUR EYES. ALWAYS USE A
WELDING FACE-SHIELD WITH A SUITABLE FILTER THAT CONFORMS
TO CURRENT STANDARDS.

WARNING: PROTECT BYSTANDERS BY USING WELDING SCREENS.

The consumable electrode is connected to a high amperage low voltage supply which
creates an electric arc between the electrode and the workpiece.

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 an actual welding job.

1. Holding the welding mask close-up to your face, give a short stroke with the
electrode on the workpiece. As soon as the arc is primed, withdraw the electrode
from the workpiece to leave a gap. The current will flow across the gap with a
crackling noise and a brilliant arc. Continue to weld in one direction, maintaining
the small gap as you go.

2. As soon as the arc is struck, maintain a distance from the workpiece equal to the
diameter of the electrode. Keep this distance as constant as possible for the
duration of the weld. As you advance along the workpiece the angle of the
electrode must be maintained at between 20º and 30º.

NOTE: When you prime the arc be sure to withdraw the electrode swiftly to

leave the 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 and will be capable of burning through welding
gloves.

3. At the finish of the weld, bring the end of the electrode backward in order to fill
the weld crater and then quickly lift the electrode from the weld pool to extinguish
the arc.

4. Inspect the job carefully. Any slag forming on the surface should be chipped away
with a chipping hammer or pick. ALWAYS wear your safety goggles when chipping
away slag.

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WELDING SETTINGS TABLES

L-SHAPED BUTT WELDING

Metal thickness
(mm)

0.8 60-70 16-16.5

1.0 75-85 17-17.5

1.2 80-90 17-18

1.6 95-105 18-19

2.0 110-120 19-19.5

2.3 120-130 19.5-20

3.2 140-150 20-21

4.5 140-150 22-23

6.0 170-185 24-26

9.0 320-340 32-34

Electrode
diameter (mm)

Welding
current (A)

Welding
voltage (V)

ANGLE JOINT (THIN PLATE)

Metal thickness
(mm)

Electrode
diameter (mm)

Welding
current (A)

Welding
voltage (V)

1.6 65-75 16-17

2.3 80 - 100 19-20

3.2 130 - 150 20-22

4.5 150 - 180 21-23

FLAT FILLET WELDING LAP JOINT (THIN PLATE)

Metal thickness
(mm)

0.2 60-70 16-17

1.2 80-90 18-19

1.6 90-100 19-20

2.3

Electrode
diameter (mm)

Welding
current (A)

100-130 100-130

120-150 120-150

Welding
voltage (V)

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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.

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.

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TROUBLESHOOTING

Your CLARKE Welder has been designed to give long and trouble free service. If
however, having followed the instructions in this booklet carefully you still encounter
problems, the following points should help identify and resolve them.

DEFECT CAUSES SUGGESTIONS

Spark will not start Bad clamp connection.

Inverter printed circuit is
defective.

No output voltage Overheated machine (the

amber LED should be on).

Internal relay has failed. Contact your nearest CLARKE

Inverter printed circuit is
defective.

Wrong output
current

Porosity of welds Acid electrode on steel

Current selector control is
defective.

Low power supply voltage. Check the mains distribution

with high sulphur content.
Electrode oscillates too
much.
Workpieces are too far
apart.
Workpiece being welded is
cold.

Check clamp connection.
Contact your nearest CLARKE
dealer.

Wait for thermal cutout to be
reset.

dealer.

Contact your nearest CLARKE
dealer.

Contact your nearest CLARKE
dealer.

system.

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,
oxides).
Not enough current.

Limited
penetration

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

Low current, high welding
rate, reversed polarity.
Electrode inclined in
position opposite to it's
movement.

20

Clean workpiece before
welding is an essential method
of achieving neat
weld beads. Also increase cur­rent output.

Ensure operating
parameters are regulated and
improve preparation of work
pieces.

DEFECT CAUSES SUGGESTIONS

Profile defects Welding parameters are

incorrect.

Follow basic and general

welding principles.
Pass rate is not related to
operating parameter
requirements.
Electrode not inclined
constantly while welding.

High Sprays Electrode is too inclined. Make appropriate

corrections.

Arc is unstable Insufficient current. Check condition of

electrode and earth wire

connection.

Electrode melts
obliquely

Electrode is not centred.
Magnetic blow phenomenon.

Replace electrode.

Connect two earth wires

to opposite sides of the

work piece.

No response from
welder.

Check fuses and power cable. Replace fuses as necessary. If

problem persists return welder

to your local dealer.

Poor quality welds. Rusty, painted, damp, oil or

greasy workpiece.

Poor earth contact. Check earth clamp/workpiece

Welder cuts out
whilst in use.

Duty cycle exceeded (auto cut­out operates).

Check fuse size.

Ensure workpiece is clean and

dry.

connection.

Allow welder to cool 15-30

mins before continuing.

Note: If duty cycle is

continually exceeded, damage

to the welder may result and

welder output is probably too

small for application.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

COMPONENT PARTS

1 Lifting strap 11 Support bar 21 IGBT diode

2 Outer shell 12 Control board 22 Capacitor

3 Protective foot 13 Main board 23 Relay

4 Front panel 14 Transformer 24 Cooling fan

5 Potentiometer knob 15 IGBT diode 25 Fan guard

6 Digital display 16 Rectifier bridge radiator 26 Power switch

7 Indicator lamp 17 Plastic support 27 Power cable

8 Base frame 18 Quick recovery radiator 28 Rear panel

9 Euro quick socket 19 IGBT radiator

10 Bracket 20 Fast recovery diode

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

THE MACHINE RATING PLATE

1 Name/address of manufacturer 9 Energy Supply symbol

2 Model Number 10 Range of Output

3 Part number 11 Rated No-load Voltage

4 Welding Power Source 12 Conventional Load Voltage

5 Standards applied 13 Insulation grade

6 Welding Process symbols 14 Rated Supply Voltage

7 Degree of Ingress Protection 15 Rated Maximum Supply Current

8 Welding Current symbol 16 Max Effective Supply Current

This welder is covered by regulations EN 60974-1:2018+A1:2019 / EN 60974­10:2014+A1:2015, where the Duty Cycle is expressed as a percentage of time the
machine may be used in a given period for a specified welding current. e.g. When
welding at 140 Amps the machine may be used for 6 minutes (60%) in any10 minute
period,

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

CONSUMABLES

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

Item Description Part number

Welding Rods 1.6 x 300mm 3050590

2.0 x 350mm 3050592

2.5 x 350mm 3050594

3.25 x 350mm 3050596

4.0 x 400mm E6013 3050598

Welding Apron 610mm x 915mm 6000920

Gauntlets Leather (EN407 rated) 8133492

Welding screen WSC2 and replacement screen 6000945

6000910

A Gas Regulator, Arc Activated Headshields, Anti-spatter Spray are also available from
your CLARKE dealer or our parts division.

ARC ACTIVATED HEADSHIELDS

These highly popular head-shields activate instantly when the arc is struck and allow
you to have both hands free when welding.

Model Arc

Activated

GWH4 X X X 6000706

GWH5 X X X 6000707

GWH6 X X X 6000708

GWH7 X X X 6000709

GWH8 X X X 6000714

Grinding
function

Solar
Powered

Fixed
Shade

Flip Up Part

Number

PG4 X X X 6000716

HS1 X X 6000700

HSF1 X X 6000705

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

CARE AND MAINTENANCE

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

WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL
INSPECTIONS AND MAINTENANCE OPERATIONS. BEWARE HOT
SURFACES.

The machine requires no maintenance other than the following guidelines. Cleaning is
advisable if the unit is operating in a very dusty environment. Avoid getting particles
of metal inside the machine since they could cause short circuits.

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 good condition and security.

3. Always inspect the earth cable 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.

4. Check the hose for security and damage.

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.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATION OF CONFORMITY -UK

26

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATION OF CONFORMITY - CE

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]