Clarke CSW6T Installations- und Betriebshandbuch

OPERATING & MAINTENANCE

GC0418 rev 4

INSTRUCTIONS

SPOT WELDERS

MODEL NO: CSW6T & CSW13T

PART NO: 6030005 & 6030010

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

INTRODUCTION

Thank you for selecting this Clarke Spot 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 product giving you long and satisfactory service.

Ensure the welder and its components suffered no damage during transit and

that all components are present. Should any loss or damage be apparent,

please contact your CLARKE dealer immediately.

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 its intended purpose.

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

Through purchase of this product, the customer is taking on the

obligation to deal with the Waste Electrical and Electronic

Equipment (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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

SAFETY WARNINGS

ELECTRIC SHOCK

1. Remove the plug from the socket and wait 5 minutes to allow the

capacitors to discharge before carrying out any servicing or maintenance

on this welder.

2. Do not touch live electrical parts.

3. Never use electrode holders or cables which are damaged.

4. Keep the working environment, equipment, cables and clothing free from

grease, oil, moisture and dirt.

5. Ensure the welding machine has been correctly earthed.

6. The operator must be insulated from the floor and work bench using a dry

insulation mat.

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

8. Keep welding cables away from power cables.

9. Regularly inspect the condition of the cables for signs of damage.

10. Remove the plug from the mains socket when not in use.

11. Ensure the earth connector is secured to bare metal adjacent to the weld,

and when not in use insulated for safety. - Keep all equipment well

maintained.

12. The operator must prevent any gas cylinders in the vicinity of the work

piece from becoming part of the welding circuit.

FUMES & GASES

1. The welding process generates hazardous fumes as a by-product.

Inhalation of these fumes is hazardous to health.

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

3. 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

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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

FIRE OR EXPLOSION

1. Welding can cause fire and explosions. Precautions should be taken to

prevent these hazards.

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

move any combustible materials to a safe distance, especially substances

likely to generate a dangerous vapours.

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

4. Sparks and molten metal may be ejected during welding. Take

precautions to prevent fire.

5. Sparks and molten metal can pass through gaps. Be aware that fire can

start out of sight.

6. Do not weld to pressurised containers. or containers containing flammable

vapours e.g. fuel tanks.

7. Always have appropriate fire fighting equipment to hand suitable for use in

electrical environments.

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

PERSONAL PROTECTION

1. The body should be protected by suitable clothing.

2. The use of neck protection may be necessary against reflected radiation.

3. Arc welding machines generate a magnetic field which is detrimental to

pacemakers. Consult your doctor before going near active welding

equipment/operations.

4. The UV and IR radiation generated by welding is highly damaging to the

eyes, causing burns. This can also affect the skin.

5. Always use suitable welding shields equipped with appropriate protection

filters.

6. Where there are pedestrians and traffic ensure a protective screen is used

to avoid accidental arc glare.

7. Do not weld in the vicinity of children or animals and ensure no one is

looking before striking an arc.

8. Wear hearing protection if required.

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

10. Take care when adjusting or maintaining the electrode/holder, that it has

had time to cool sufficiently and the welder is disconnected from the mains

supply.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

11. 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 burns.

12. Flammable hair sprays/gels should not be used by persons welding.

PROTECTIVE CLOTHING

1. Wear gauntlet type gloves designed for use when welding.

2. Wear an apron, and protective shoes.

3. Wear cuffless trousers (not turned up) to avoid catching sparks and slag.

4. Avoid wearing oily or greasy clothing.

5. Wear protective head and shoulder coverings if welding overhead.

6. Wear a 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.

NOTE: All protective wear inc. masks & head shields MUST comply with

Personal Protective Equipment Directive 89/686/EEC.

ADDITIONAL SAFETY PRECAUTIONS FOR SPOT WELDING

1. Always ensure that there is ample free air circulating around the outer

casing of the machine and that any louvres are unobstructed.

2. Always inspect the cable before use to ensure it is in good condition.

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

4. Always keep a fire extinguisher handy;-Dry Powder, CO2or BCF, NOT Water.

5. Never attempt any electrical or mechanical repair unless you are a

qualified technician. If you have a problem with the machine contact your

local CLARKE dealer.

6. Never use or store in a wet/damp environment.

7. 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.

8. Never change electrodes with bare hands or damp gloves.

Please read these instructions carefully and retain for future reference.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

ELECTRICAL CONNECTIONS

Before switching the product on, make sure that the voltage of your electricity supply is

the same as that indicated on the rating plate. This product is designed to operate on

230VAC 50Hz. Connecting it to any other power source may cause damage.

This product may be fitted with a non-rewireable plug. If it is necessary to change the

fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or

damaged, the plug must not be used until a suitable replacement is obtained.

If the plug has to be changed because it is not suitable for your socket, or due to

damage, it should be cut off and a replacement fitted, following the wiring instructions

shown below. The old plug must be disposed of safely, as insertion into a mains socket

could cause an electrical hazard.

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 Nor coloured Black.

• The wire which is coloured Brown must be connected to the terminal which

is marked Lor coloured Red.

• The wire which is coloured Yellow and Green must be connected to the

terminal which is marked E or or coloured Green.

We strongly recommend that this machine is connected to the mains supply via a Residual

Current Device (RCD)

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

WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS

THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE

MAINS SUPPLY.

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

Plug must be BS1363/A approved.

Always fit a 13 Amp fuse.

Ensure that the outer sheath of the cable is firmly held by the clamp

Neutral

(Blue)

Live

(Brown)

Earth

(Green and Yellow)

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

MACHINE FEATURES

MODEL CSW6T

This 230V 50Hz, portable Spot Welder is

provided with an electronic timer

which allows precise control of

welding time. The control knob is

arrowed in Fig 1. Electrode pressure

may be mechanically adjusted from

40 to 120kg, to spot weld low carbon

sheet steel up to 1 + 1 mm in thickness.

MODEL CSW13T

The most important features of this

230V 50Hz Portable Spot Welder are

controlled by a microprocessor,

managed from the control panel

shown in Fig. 2. These features are:

1. Welding time, set according to the

thickness of metal to be welded.

2. Changing selection for welding

thickness.

3. Changing resistance welding

machine operating mode...

normal or pulse.

Selecting ‘PULSE’ mode improves

welding capacity on material with

high yield points or materials with

protective coatings. The pulsation

period is preset and does nor require

adjustment.

4. Electrode pressure may be

mechanically adjusted from 40 to 120kg, to spot weld low carbon sheet

steel up to 2 + 2 mm in thickness.

BOTH MODELS

Both 120mm electrode arms and standard electrodes are provided.

• An eye bolt may be fitted to the machine (see your Clarke dealer),

for use in supporting the machines weight when repetitive welds are

required (see your Clarke dealer. IMPORTANT! When using the Eye

Bolt, take care NOT to screw it more than 8mm into the screw hole.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

PARTS IDENTIFICATION

No Description No Description

1Pressure Adjusting Screw 7Data Label

2Handle 8Micro-switch

3Control Panel (13T) 9Weld Time Adjuster (6T)

4Electrode Arm 10 Operating Lever

5Electrode (Large) 11 Spacer (optional)

6Screw locating hole 12 Lifting Eye (optional)

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

LOOSE COMPONENTS

Unpack and lay out the components, checking against the following list.

Please report any damage which may have occurred during transit, to your

CLARKE dealer immediately.

PREPARATION FOR USE

1. Fit the electrodes to the electrode arms. Whether or not the longer

electrode is located in the upper or lower arm, depends upon the work in

hand. It may be necessary for example to reach over a lip in a workpiece,

necessitating the longer electrode to be positioned in one particular arm.

Normally however, the longer electrode is located in the upper arm. Nip up

the clamps but do not fully tighten.

No Description No Description

A1 x Handle D2 X Hex Wrenches

B2 x Electrode Holders F1 x M6 screw

C2 x Electrodes (straight)

WARNING: ENSURE THE WELDER IS DISCONNECTED FROM THE POWER

SUPPLY BEFORE PROCEEDING

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

2. Depress the operating lever fully

and insert the M6 screw provided,

into the threaded hole as shown in

Fig 5.

3. Screw in fully so that the lever is

held in the fully down position as

shown. This is the position used for

adjusting the electrode gap.

4. Before setting the electrode gap

however, it is important to ensure

that the electrode arms are parallel to each other and the electrodes are

perfectly in line, on the same axis, when the operating lever is fully

depressed. This is achieved by slackening the respective arm clamp and

rotating the arms within the receptacle until the electrodes meet exactly

and are perfectly in line. When satisfied, tighten the clamps.

5. Slacken off the upper electrode clamp and move the electrode so that a

piece of material of the same total thickness as that to be welded, can be

inserted between the electrodes, then tighten the electrode clamp. The

correct gap is now set.

6. Remove the M6 screw and release

the lever.

7. Adjust the pressure to be exerted

by the electrodes by turning the

adjuster screw (item 1, Fig.4), using

the hex. wrench provided,

(clockwise to increase,

anticlockwise to decrease)

according to the scale shown in

Fig 6.

NOTE: Always remember that too high a pressure will result in damage to

the electrode tips, whereas too little pressure will result in a poor

weld. Pressure is also dependant upon the length of electrode

arms....the longer the arms the lighter the pressure setting. This

must be taken into account if/when replacing the electrode arms

with any of those available from you Clarke dealer, (see

Accessories).

8. Set the welding time by either turning the dial adjuster, shown in Fig 1,

(model 6T), or pressing the button shown at 1 Fig 2 (model 13T). Generally

the thicker the workpiece, the longer the welding time.

NOTE: The time scale shown on the control panel of the 13T is a general

guide only. It is advisable to make a few test welds on material

similar to the workpiece before commencing work, making

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