Clarke AT165 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 - ISS 3
ARC TIG/MMA WELDER
MODEL NO: AT165
PART NO: 6012149

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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 AT165 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
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved 13 amp BS 1363 plug, or a suitably fused isolator switch.
If the plug has to be changed because it is not suitable for your socket, or
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely, as
insertion into a power socket could cause an electrical hazard.
If the colours of the wires in the power cable do not agree with the markings
on the plug.
• The BLUE wire must be
connected to the
terminal which is
marked N or coloured
black.
•TheBROWNwiremust
be connected to the
terminal which is
marked L or coloured
red.
• The YELLOW AND
GREEN wire 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
through a Residual Current Device (RCD)
If you are not sure, consult a qualified electrician. DO NOT try to do any
repairs.
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
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
Earth
(Green and
a 13 Amp
the cable is firmly held by the clamp
fuse.
Yellow)

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CABLE EXTENSION
Always use an approved extension cable suitable for the power rating of this
tool (see specifications), the conductor size should also be at least the same
size as that on the machine, or larger. When using a cable reel, always unwind
the cable completely.
If a cable extension is needed it is essential to comply with the following data.
Voltage Extension length Cable section
230V up to 20 m 2.5 mm2
230V 20 - 50 m 4 mm2

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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.

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TIG WELDING (REF FIG.2)
• The machine is not equipped with a TIG welding torch and cables;
these are available from your Clarke dealer (Part number 6012232).
• Additionally, before TIG welding, you must obtain a gas cylinder of
100% pure Argon.
To prepare the unit for TIG welding, it is important that you adopt the following
procedure.
1. Plug the work clamp lead in to the +ve terminal, and secure the work
clamp to the workpiece.
• For good contact, the work clamp must be attached to clean bare
metal. Clean with a wire brush where necessary.
2. Plug the torch lead to the -ve terminal.
3. Screw the pressure regulator on to
the gas bottle tightly, and attach
the gas hose to the inlet connector
securely, with a hose clip.
4. Turn the pressure regulator knob to
set a pressure of approx. 2.5kg/
cm2(35 lbf/in2).
5. Ensure the electrode at the torch
nozzle, protrudes by 4 - 5mm, also
ensure that the electrode is sharply
pointed with an angle of 40°-60°, if
it is not, grind it to shape. (Consult
your TIG Torch manual for the
procedure for adjusting the
electrode).
6. Set the welding current in
accordance with the thickness of
the material to be welded and the
size of tungsten electrode to be
used, (See page 14).
7. Switch ON using the switch
mounted on the rear panel. The green light on the front panel will glow.
8. If the machine stops at any time and the amber light comes ON, the
thermal overload has intervened. Wait until the welder has cooled
sufficiently (the amber light goes out) before restarting work.
Fig 2

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9. Open the gas valve on the torch handle,
• This will allow gas to flow from the torch nozzle.
10. Cover your face with the head shield, bring the torch to within 3-4mm of
the work, and at an angle of 45°, so that the ceramic nozzle gently touches
the work surface. See fig. 3.
11. Scratch the tip of the electrode against the piece to be welded, as soon as
the welding arc starts, remove the electrode to a distance of 3-4 mm, and
continue the weld. (See notes below).
• This method is referred to as ‘Scratch Arc’.
12. To stop welding, simply remove the torch from the workpiece.
13. Turn OFF the gas as soon as you finish welding.
NOTE:
• To avoid a visible strike mark on the surface of the workpiece, it is
advisable to strike the arc in the joint, where the mark will be
concealed by the weld.
• Thin sheet and stainless steel may be welded with or without filler,
similar to gas welding.
• The filler is fed in at the edge of the pool. The rod must not touch the
tip of the electrode or enter the arc. The end of the rod must always
be shielded by the argon atmosphere to prevent as far as possible
the formation of oxides of its surface. When welding stainless steel
and copper, it is often possible to feed in the filler continuously at the
edge of the pool.
• The arc length generally varies between 3 and 6 mm depending on
the type of joint, type and thickness of material, and so on.
• The torch is advanced in the direction of welding, without lateral
movement, maintaining the torch angle of 45oto the workpiece.
Fig 3

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Guidelines for the TIG welding current needed and recommended electrode
sizes etc. for different gauges of material are shown in the chart below:
Metal
Welding
Current
(Amps)
Workpiece
Thickness
(mm)
Filler Rod
Dia (mm)
Welding
Electrode
Dia (mm)
Gas Flow
ltr/min
Mild
Steel
20-30 1 0-1 1.6 4-5
60-80 2 1.2-1.6 1.6 4-5
80-110 3 1.6-2.0 1.6/2.4 4-5
100-130 3.5 2.0-2.4 2.4 5-6
130-140 4 2.4 2.4 6-7
140-150 4.5 2.4 2.4 7-8
150-160 5 2.4 2.4 7-8
Stainless
Steel
15-35 1 0-1 1.6 4-5
60-80 2 1.2-1.6 2.4 4-5
80-115 3 1.6-2.0 1.6/2.4 4-5
100-130 3.5 2.0-2.4 2.4 5-6
130-140 4 2.4 2.4 6-7
140-150 4.5 2.4 2.4 7-8
150-160 5 2.4 2.4 7-8
Copper 80 2 2.0 1.6 5-6
125 3 2.4 2.4 5-6
135-150 4 2.4 2.4 6-7
150-160 4.5 2.4 2.4 7-8

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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
DEFECT CAUSES SUGGESTIONS
Spark will not start Bad clamp connection.
Inverter printed circuit is
defective.
Check clamp connection.
Contact your nearest
CLARKE dealer.
No output voltage Overheated machine (the
yellow LED should be on).
Wait for thermal cutout to
be reset.
Under-voltage/over-voltage
limits exceeded. Yellow LED
on and green LED flashing.
Check the mains distribution
system.
Wait for internal check of
input voltage. When this is
within normal limits, the
yellow LED will go out and
the green LED will stay on.
Internal relay has failed.Contactyournearest
CLARKE dealer.
Inverter printed circuit is
defective.
Contact your nearest
CLARKE dealer.
Wrong output
current
Current selector control is
defective.
Contact your nearest
CLARKE dealer.
Low power supply voltage. Check the mains distribution
system.
Porosity of welds Acid electrode on steel
with high sulphur content.
Electrode oscillates too
much.
Workpieces are too far
apart.
Workpiece being welded is
cold.
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.
Clean workpiece before
welding is an essential
method of achieving neat
weld beads.
Limited
penetration
Low current, high welding
rate, reversed polarity.
Electrode inclined in
position opposite to it's
movement.
Ensure operating para -
meters are regulated and
improve preparation of
work pieces.

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MAINTENANCE
The welder, requires very little maintenance other than the following
guidelines. Under normal working conditions removing the covers and
cleaning with dry compressed air at reduced pressure once a year will be
quite sufficient. Cleaning at more frequent intervals is advisable however, if the
unit is operating in a dusty and dirty environment.
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 condition and secure. They must be in
good condition and not cracked.
3. Always avoid getting particles of metal inside the machine since they
could cause short circuits.
High Sprays Electrode is too inclined. Make appropriate
corrections.
Profile defects. Welding parameters are
incorrect.
Pass rate is not related to
operating parameter
requirements.
Electrode not inclined
constantly while welding.
Follow basic and general
welding principles.
Arc is unstable. Insufficient current. Check condition of
electrode and earth wire
connection.
Electrode melts
obliquely.
Electrode core is not
centred.
Magnetic blow
phenomenon.
Replace electrode.
Connect two earth wires
to opposite sites of the
work piece.
WARNING: DISCONNECT FROM MAINS BEFORE CLEANING.
WARNING: DO NOT ATTEMPT TO CARRY OUT REPAIRS YOURSELF, UNLESS
YOU ARE FULLY COMPETENT, ALL WORK MUST BE CARRIED OUT BY A
QUALIFIED TECHNICIAN.
DEFECT CAUSES SUGGESTIONS

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RATING PLATE
DUTY CYCLE
This welder is covered by regulations BS EN 60974-1:2012, where the Duty Cycle
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
5 British Standards applied 16 Rated 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.
18 N/A
8 Welding Current Symbol 19 N/A
9RatedNo-loadVoltage 20N/A
10 Range Of Output 21 N/A
11 Duty Cycle Symbol 22 Degree of Protection

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(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 105 Amps the machine may be used for 6 minutes (60%)
in any10 minute period,
SPECIFICATIONS
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.
ACCESSORIES
The following are some of the accessories available from your CLARKE dealer.
Please quote the part numbers shown below:
AT165
Unpacked Weight (kg) 7.85
Dimensions (l x w x h) (mm) 380 x 152 x 236
Power Supply 230V AC~ 50Hz
Rated Max Input Current (A) I1Max / I1eff(A) 24.1 / 12.1
No Load Voltage (V) Uo=70V
Max/Min Welding Current (A) 10A/160A
IP Rating IP21S
Suitable Electrodes (mm) 2.5 + 3.2 +4.0
DESCRIPTION PART NUMBER
Range of Arc Activated Welding Headshield See Your Clarke Dealer
2.5 mm Arc Welding Electrodes 3050584
3.2 mm Arc Welding Electrodes 3050586
4.0 mm Arc Welding Electrodes 3050588
TIG Welding Torch Assembly (AT162, AT165) 6012233
Argon Gas Regulator 8134140

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EXPLODED DIAGRAM & PARTS LIST AT165