Clarke AT162 Instruction Manual

WARNING: Read these instructions before using the machine
WARNING: A suitable welding headshield must be worn during use
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL0821 - REV 3
ARC TIG/MMA WELDER
MODEL NO: AT162
PART NO: 6012145

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INTRODUCTION
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.
The AT162 is designed to be used for both metal ARC (MMA) and TIG welding
(TIG welding leads are not supplied with the machine. These are however,
readily available from your CLARKE dealer (Part number 6012233)).
SUITABILITY
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.
UNPACKING
Any damage or deficiency should be reported to your CLARKE dealer
immediately. You should find inside the box the following:
MMA/Arc Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron.
TIG Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron,
Titanium, Copper + Brass.
• 1 x 160A ARC / TIG Inverter Welder • 1 x Wire Brush / Hammer
• 1 x Electrode Clamp & Cable • 1 x Earth Clamp & Cable

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GENERAL SAFETY INSTRUCTIONS
ELECTRIC SHOCK
• Always 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.
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.

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FIRE OR EXPLOSION
Welding can cause fires 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.
• The 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 a fire extinguisher on hand.
• ALWAYS ensure there is adequate ventilation or extraction in the work area,
as the welding process gives off toxic fumes.
• ALWAYS ensure that a medical supply is on hand, and that treatment for
burns is available.

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SAFETY SYMBOLS
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.
Read this instruction
booklet carefully
before use.
Do not expose to rain.
Wear eye protection Recycle unwanted
materials instead of
disposing of them as
waste. All tools,
accessories and
packaging should be
sorted, taken to a
recycling centre and
disposed of in a manner
which is compatible
with the environment.
Wear protective gloves
Wear a dust mask

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ELECTRICAL CONNECTIONS
CONNECTING TO MAINS
NOTE: This tool is earthed and must only be connected to mains with an
earth connection. Do not attempt to use it without an earth
connection.
• This welder is not supplied with a mains electrical plug because at
full capacity it will draw far too much power for a normal domestic
230V mains plug and socket. This welder must not be fitted with a
standard 13A UK plug.
• A high current 230V mains socket or terminal must be installed by a
qualified and accredited professional electrician. A 16A socket and
plug conforming to IEC 60309 is recommended.
• A non-socketed mains connection also requires welder connection
by a qualified and accredited professional electrician. However, a
socketed connection is safer and more strongly recommended so
the welder can be safely isolated when necessary. If directly wired
to mains, a double pole, double throw isolator switch must be fitted.
• The welder must be connected to a consumer unit with a built-in
RCD, using a circuit protected by an RCD.
• Please refer to the Specification for details of the maximum current
required by this welder.
• If in any doubt, do not attempt to connect or use this welder until a
professional electrician has been consulted.

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MMA/ARC WELDING
A consumable electrode is connected to a high amperage low voltage
supply which creates an electric arc between the electrode and the
workpiece.
Benefits over TIG welding include, less experience needed, torch kit or
shielding gas are not required.
PREPARATION
• Arc welding cables are supplied with this machine.
To prepare the unit for ARC welding, it is important that you follow the
procedure below.
1. Making sure that the ON/OFF switch, located on the rear panel is in the OFF
position, connect the welding leads as follows:
• Welding rod holder lead to the +ve terminal.
• Work clamp lead to the -ve terminal.
2. Select the appropriate welding rod and insert it into the welding rod holder.
• The size (diameter) of the welding rod should be approximately the
same as the thickness of metal to be welded.
3. 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.
4. Set the required current using the
current selector.
• With practice you will gain a feel
for the correct current setting for
different welding rod thicknesses.
• The following table gives a useful
guideline.
Material
Thickness
Welding
Rod Size
Current
(Amps)
1-2 mm 2.5 mm 70 - 100
2-5 mm 3.2 mm 100 - 125
5-8 mm 4.0 mm 125 - 160
Fig 1

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5. Switch ON using the switch located on the rear panel.
• The green light on the front panel should glow, indicating the machine is
ON.
• If the machine stops at any time and the amber light comes ON, the
thermal overload device has intervened. Wait until the welder has
cooled sufficiently (the amber light goes out) before restarting work.
STRIKING THE ARC - WELDING
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.
1. Hold the electrode about 10 mm 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.
2. 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 tiny gap of around 1.5mm (1/16").
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.
NOTE: When you prime the arc, be sure to withdraw the electrode swiftly
to leave the 1.5 mm. 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 end of the run, just lift the electrode away from the workpiece.
• 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.
WARNING: WHEN WELDING ALWAYS ENSURE THERE IS ADEQUATE
VENTILATION IN THE WORK AREA AS THE WELDING PROCESS GIVES OFF
TOXIC FUMES.
WARNING: ALWAYS USE A SUITABLE WELDING MASK OR SHIELD WHEN
USING ANY WELDER.

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TIG WELDING
TIG welding is primarily for very thin materials. It uses a non-consumable
tungsten (or tungsten alloy) electrode, held in a torch.
A shielding gas (100% Argon), is fed through the torch to protect:
• The electrode,
• Molten weld pool,
• 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 such as car body panels,
pressure vessels, heat exchangers, pipes etc., where accuracy and a high
quality weld is desired, as it produces a very low porosity weld.
MAIN FEATURES OF TIG WELDING
1. Electronic control of welding current.
2. Forced air cooling.
3. A thermal overload protection device prevents overheating.
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.
• It allows excellent control of root pass weld penetration.
• It can produce welds at high speeds.
• It allows precise control of the welding variables.
• It is capable of welding very thin material (0.5mm), without undue
distortion.
LIMITATIONS
1. Greater weld dexterity is required.
2. These units have a DC output which is not suitable for welding aluminium.