Clarke CSW6T Installation and operation manual

OPERATING & MAINTENANCE
GC0418 rev 4
INSTRUCTIONS
SPOT WELDERS
MODEL NO: CSW6T & CSW13T
PART NO: 6030005 & 6030010

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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.

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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.

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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.

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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.

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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)

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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.

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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)

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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

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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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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
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.
WARNING: BE AWARE THAT THE MACHINE PRODUCES VERY INTENSE
ELECTROMAGNETIC FIELDS. THIS COULD SERIOUSLY EFFECT 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 SITING THE WELDER

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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 which
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.
NEVER 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
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.
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.

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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.

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SCHEMATIC WIRING DIAGRAMS

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SPARE PARTS-CSW6
NODESCRIPTION PART NONODESCRIPTION PART NO
1 Bush TT322518 10 Arm (see page 17)
2 Potentiometer Knob TT112299 11 Electrode (see page 17
3 Timer PCB TT114236 12 Electrode (see page 17
4. Microswitch TT122393 13 Cable Kit-bush/ringnut TT990046
5 Mains Cable TT132104 14 Upper Arm Clamp TT522020
6 Transformer TT169152 15 Lower Arm Clamp TT522023
7 Adjuster Screw TT121263 16 Left Shell TT322509
8 Operating Lever TT322512 17 Right Shell TT322526
9 Pivot Pin TT482887

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SPARE PARTS-CSW13T
NODESCRIPTION PART NONODESCRIPTION PART NO
1 Screw TT113908 10 Cable Kit-bush/ringnut TT990046
2 Control PCB TT114070 11 Pivot TT482887
3 Power PCB TT114085 12 Operating Lever TT322512
4. Microswitch TT122393 13 Adjuster Screw TT212163
5 Mains Cable TT132104 14 Upper Arm Clamp TT522020
6 Transformer TT169034 15 Lower Arm Clamp TT522023
16 Right Shell TT322510
17 Left Shell TT322511

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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

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SPECIFICATION
Please note that 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.
MODEL CSW6T CSW13T
Part No 60300005 60300010
Weight 10.5 kg 11 kg
Dimensions (L x W x H) mm 440 x 110 x 185
Power Supply 230V 50Hz 1 Ph
Max Absorbed Power 10 kW 15 kW
Power Rating 1.3 kW 1.5 kW
Mains Fuse 16 Amp 25 Amp
Spot Welding Current (Max) 3800 Amps 6900 Amps
Duty Cycle 3 spots/min with minimum downtime of 20 secs
Max. Welding Thickness 1 + 1 mm 2 + 2 mm

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DECLARATION OF CONFORMITY