Clarke CSW6T Spot Welder 230v 13kw Mild Steel 2mm+2mm Instruction Manual

Weld

SPOT WELDER

MODEL NO: CSW6T & CSW13T
PART NO: 6030005 & 6030010
OPERATING & MAINTENANCE INSTRUCTIONS
ORIGINAL INSTRUCTIONS
GC0221 rev 5

INTRODUCTION

Thank you for selecting this Clarke Spot Welder. This portable resistance welding machine, featuring electronic spot welding time control, is suitable for many spot welding applications including vehicle body repairs, general metal fabrication, and light industrial use. Robust and simple to operate, the welder delivers consistent results every time enabling the fast and efficient fusion of metal sheets.
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 affect your statutory rights.

ENVIRONMENTAL PROTECTION

Through the 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.

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 recognized 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.

SAFETY WARNINGS

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.
Please read these instructions carefully and retain them for future reference.

ELECTRIC SHOCK

1. Isolate from the power supply 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 that 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 workbench using a dry insulation mat.
7. Always ensure a second person is present in case of an 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 main socket when not in use.
11. Ensure the earth connector is secured to bare metal adjacent to the weand when not in use is insulated for safety.
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

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 vapor.
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 pressurized 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.
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 person 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, COor 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.

ELECTRICAL CONNECTION

WARNING: THE INSTALLATION OF THIS APPLIANCE SHOULD BE CARRIED OUT BY A COMPETENT ELECTRICIAN AND BE IN ACCORDANCE WITH THE CURRENT IEE WIRING REGULATIONS (BS7671-2:2008).

The power cable of this machine MUST be connected to a 230 Volt- 50Hz supply through a suitably fused isolator switch.
A standard 13amp plug MUST NOT BE USED with this machine.
The fuses required are;

• CSW6T – 16 Amp
• CSW13T – 25 Amp

We strongly recommend that this machine is connected to the main supply via a Residual Current Device (RCD).
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs yourself.

MACHINE FEATURES

MODEL CSW6T
This 230V 50Hz, portable Spot Welder is provided with an electronic timer that 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 the ‘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 weight of the machine 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 IDENTIFICATION

LOOSE COMPONENTS

Unpack and layout 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

WARNING: ENSURE THE WELDER IS DISCONNECTED FROM THE POWER SUPPLY BEFORE PROCEEDING

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.

2. Depress the operating lever fully and insert the M6 bolt 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 bolt and release the lever.

7. Adjust the pressure to be exerted by the electrodes by turning the adjuster screw (item 1, Fig.3), usinthe 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 adjustments of pressure and welding time, as necessary, until a perfect weld is achieved.

MODEL 13T only

1. Select the welding mode….normal or pulse, by pressing the appropriate button on the control panel accordingly. (Button 3, Fig 2)
2. Select the welding thickness by pressing the appropriate button on the control panel accordingly. (Button 2, Fig 2)

OPERATION

WARNING: BE AWARE THAT THE MACHINE PRODUCES VERY INTENSE ELECTROMAGNETIC FIELDS. THIS COULD SERIOUSLY AFFECT PEOPLE
WEARING PACEMAKERS OR FITTED WITH PROSTHESES. THESE PEOPLE SHOULD NOT BE ALLOWED TO USE THE MACHINE OR BE IN ITS VICINITY. MALFUNCTIONS OR DAMAGE TO WATCHES, MAGNETIC CARDS, INSTRUMENTATION, DATA TRANSMISSIONS, OR TELEPHONE RECEPTION COULD ALSO OCCUR. THESE POINTS MUST ALWAYS BE TAKEN INTO CONSIDERATION WHEN SITTING THE WELDER

IMPORTANT: 1. Ensure the work surfaces are perfectly clean. There should be no rust or other contaminants which would seriously impair the quality of the weld. Ideally, the workpieces should be clamped together.

IMPORTANT: 2. Ensure the electrode tips are correctly formed. They should be checked regularly when welding to ensure they make perfect contact with the work. A Spot Welding Tip dresser is available from your Clarke dealer.

• With the machine correctly adjusted, connect to the mains supply.
• Bring the lower electrode up to the work so that it is positioned directly beneath the point to be welded.
• Depress the operating lever fully so that the microswitch is activated, and hold in this position for a short period. Current to the electrodes, will automatically shut off after the welding time has been reached, at which time you may withdraw the welder. A short delay, from the end of the weld cycle to removing the electrodes, will improve the weld characteristics.

Should the welder not operate correctly or a particularly poor weld is produced, the following checks may determine the cause.

1. Ensure the work is perfectly clean.
2. Ensure the welding parameters are all correct.
3. Ensure the microswitch is actually pressed and held for the duration of the weld.
4. Ensure the thermal overload has not been activated.
   NOTE: The thermal overload is a protection device that operates when the electrical circuits have overheated. This prevents the machine from operating until it has cooled down to satisfactory levels. The device will operate if the DUTY cycle has been exceeded or if the ambient temperature becomes too high. mNEVER EXCEED THE DUTY CYCLE – See Specifications.
   NOTE: On model 13T, if the thermal overload has intervened, the two lamps shown in Fig 7 will flash alternately.

MAINTENANCE

WARNING: ELECTRICITY CAN KILL. NEVER TOUCH LIVE ELECTRICAL COMPONENTS. DISCONNECT THE POWER SUPPLY BEFORE ALL  INSPECTIONS AND MAINTENANCE OPERATIONS. BEWARE HOT SURFACES……ALWAYS LET THE MACHINE COOL DOWN BEFORE ACCESSING  INTERNAL COMPONENTS.

The frequency of maintenance operations depends on the operating conditions: how intensively the welder is used, how clean or dirty the welding site is (aggressive atmospheres, etc). Before use, always inspect the welder, checking for security and cleanliness of arms and electrodes to ensure they are in perfect condition. Ensure also that the power cable is in perfect condition at all times.
As a general rule the power supply should be inspected internally at least twice a year.

1. Access the inside of the machine by removing the screws securing the side cover and carefully hinge the cover down.
2. Clean the transformer using a blast of dry compressed air with a maximum pressure of 10 bar. NEVER direct the compressed air jet on to the circuit boards. These should be cleaned with a soft brush and vacuumed or blown with air at very low pressure. ALWAYS use a face mask for these operations.
3. Check all wiring for insulation damage or loose or oxidised connections. Repair/replace where necessary. Check all screws and connections are tight and there are no signs of oxidation or overheating.
4. Replace the cover.

WARNING: NEVER CONNECT THE MACHINE UNLESS THE COVER IS REPLACED.

SCHEMATIC WIRING DIAGRAMS

SPARE PARTS – CSW6

SPARE PARTS – CSW13T

ACCESSORIES

The following accessories are available from your Clarke dealer.

Description| Throat| Part No|
---|---|---|---
Electrodes ‘L’| 120mm| 6030105|
Electrodes ‘L’| 250mm| 6030107|
Electrodes ‘L’| 500mm| 6030109|
External Profile Electrodes| | 6030111|
Internal Profile Electrodes| | 6030113|
Electrodes| 120mm| 6030115|
Electrodes| 350mm| 6030117|
Electrodes| 350mm| 6030119|
Electrodes| 120mm| 6030121|

SPECIFICATION

Please note that the details and specifications contained herein, are correct at the time of going to print. However, CLARKE International reserve the rightto change specifications at any time without prior notice.

DECLARATION OF CONFORMITY

INTERNATIONAL
Memnon Street. Epping. Essex CM16 41G
DECLARATION OF CONFORMITY
This is an important document and should be retained.
We hereby declare that this product(s) complies with the following directive(s):
2014/30/EU Electromagnetic Compatibility Directive.
2014/35/EU Low Voltage Equipment Directive.
2011/65/EU Restriction of Hazardous substances.
The following standards have been applied to the product(s):
EN 62135-11008.
EN 62135-2:2008.
EN 50445:2008.
EN 50581:2012.
The technical documentation required to demonstrate that the product(s) meet(s) the requirement(s) of the aforementioned directive(s) has been compiled and is available for inspection by the relevant enforcement authorities.
The CE mark was first applied in 2006
Product Description: Spot Welder- 1.2kW & Automatic Spot Welder- 2 3kW.
Model number(s): CSW6T /CSW 13T
Serial batch Number: N/A
Date of Issue: 23/06/2016.
Signed:
J.A. Clarke
Director

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**** INTERNATIONAL Herrman Street, Epping, Essex CM16 4LG
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