Clarke MMA200 Instruction Manual

WARNING: Read these instructions before using the machine
WARNING: A suitable welding headshield must be worn during use
OPERATION & MAINTENANCE
INSTRUCTIONS
LS1218 - ISS 1
ORIGINAL INSTRUCTIONS
200A MMA INVERTER WELDER
MODEL NO: MMA200
PART NO: 6012157

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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.
MAIN FEATURES
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:
ARC-FORCE automatically increases the current to prevent the elec-
trode sticking when operating with a short arc length .
HOT START increases the welding current at the beginning of the
welding process.
ANTI-STICK the electrode can be easily withdrawn without it becom-
ing damaged.
VOLTAGE REDUC-
TION SAFETY DEVICE
(VRD)
reduces open circuit voltage when not in use to prevent
accidental injury .
• 1 x MMA Inverter Welder • 1 x Wire Brush / Hammer
• 1 x Torch Cable with Electrode Holder • 1 x Earth Clamp & Cable

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GENERAL SAFETY INSTRUCTIONS
ELECTRIC SHOCK
• Always disconnent from the power
supply 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.
• Disconnent from the power supply
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.
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.
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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• 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. Replace cover glass when
broken, pitted, or splattered.
• 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.
• 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.
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,

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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 welder is earthed and must only be connected to the 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 the mains, a double pole, double throw isolator switch must be
fitted.
• The welder must be connected 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.
PREPARATION
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:
• Work clamp lead to the (-)
Negative terminal.
• Welding rod holder lead to the
(+) Positive terminal.
2. Select the appropriate welding rod and insert it into the welding rod holder.
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.
ROD DIAMETER MATERIAL THICKNESS
2.5 mm 1.0 - 2.0 mm
3.2 mm 2.0 - 5.0 mm
4.0 mm 2.0 - 8.0 mm

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4. Switch ON using the switch
located on the rear panel.
• The display on the front panel
will come on and show the
current setting in amps.
• If the machine stops at any
time and the thermal overload
indicator comes ON, the
thermal overload device has
intervened. Wait until the
welder has cooled sufficiently (the thermal overload indicator goes out)
before restarting work.
5. 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.
VRD-VOLTAGE REDUCTION DEVICE.
The VRD is a safety feature that It is also known as “Anti-shock”.
Its function is to lower the open ciruit voltage across the output terminals to a
safe 12V when the welder is not in use.
As soon as the welder is used (a load
of 200 ohms or less is detected), the
voltage will increase to the full output
to enable welding to comence.
The “VRD” will only turn the output of
the welder back to a reduced output
state of 12 volts once the electrode Is
removed from the work piece or If
the resistance across the output rises
above 200 ohms.
If you wish to turn off this feature, set the VRD switch on the front panel to OFF.
We reccommend that you leave it switched ON.

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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: WELDING ARCS PRODUCE HARMFUL UV/IR LIGHT WHICH CAN
SERIOUSLY DAMAGE YOUR EYS. ALWAYS USE A WELDING HELMET WITH A
SUITABLE FILTER THAT CONFORMS TO CURRENT STANDARDS.
WARNING: NEVER LOOK AT THE ARC WITHOUT A SUITABLE WELDING
MASK
WARNING: PROTECT BYSTANDERS BY USING WELDING SCREENS/
CURTAINS.

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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
red LED should be on).
Wait for thermal cutout to
be reset.
Internal relay has failed. Contact your nearest
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.
High Sprays Electrode is too inclined. Make appropriate
corrections.

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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.
DEFECT CAUSES SUGGESTIONS

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MAINTENANCE
The machine 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.
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.

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RATING PLATE
DUTY CYCLE
This machine is covered by regulations BS EN 60974-1:2012 / BS EN 60974-
10:2014,, where the Duty Cycle (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 200 Amps the machine may be used for 6 minutes (60%)
in any10 minute period,
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
19
20
21
N/A
8 Welding Current Symbol 22 Degree of Protection
9 Rated No-load Voltage 23 Symbol for class II
10 Range Of Output
11 Duty Cycle Symbol

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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.
Unpacked Weight (kg) 5.3
Dimensions (l x w x h) (mm) 365 x 133 x 248
Power Supply 230V AC~ 50Hz
Rated Max Input Current (A) I1Max / I1eff(A) 39.2 / 24.3
No Load Voltage (V) 60
Max/Min Welding Current (A) 20A/200A
IP Rating IP21S
Suitable Electrodes (mm) 2.5 - 4.0

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ARC ACTIVATED HEADSHIELDS
These highly popular headshields available from your Clarke dealer activate
the instant the arc is struck and allow you to have both hands free when
welding.
ACCESSORIES
Model Arc
Activated
Grinding
function
Solar
Powered
Fixed
Shade
Flip Up Part Number
GWH4 ✔✔✔ 6000706
GWH7 ✔✔✔ 6000709
GWH5 ✔✔✔ 6000707
GWH6 ✔✔✔ 6000708
PG4 ✔✔✔ 6000716
DESCRIPTION PART NUMBER
2.5 mm Arc Welding Electrodes 3050584
3.2 mm Arc Welding Electrodes 3050586
4.0 mm Arc Welding Electrodes 3050588

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EXPLODED DIAGRAM & PARTS LIST
NO DESCRIPTION PA R T NO NO DESCRIPTION PART NO
1 Front Panel TFMMA20001 17 Capacitor TFMMA20017
2 Potentiometer TFMMA20002 18 Silicon Bridge Radiator TFMMA20018
3 Indicator Light TFMMA20003 19 Silicon Bridge TFMMA20019
4 LCD Display TFMMA20004 20 IGBT Radiator TFMMA20020
5 Plug TFMMA20005 21 IGBT TFMMA20021
6 Gauge Cover TFMMA20006 22 Transformer TFMMA20022
7 Handle TFMMA20007 23 Rectifier Radiator TFMMA20023
8 Machine Shell TFMMA20008 24 Rectifier Tube TFMMA20024
9 Ventilating Window TFMMA20009 25 Thrust PCB TFMMA20025
10 Rear Panel TFMMA20010 26 Lortnoc TFMMA20026
11 Machine Bottom TFMMA20011 27 Vertical Beam TFMMA20027
12 Power Switch TFMMA20012 28 Positive Connector TFMMA20028
13 Waterproof Joint TFMMA20013 29 Negative Connector TFMMA20029
14 Power Wire TFMMA20014 30 Relay TFMMA20030
15 Fan TFMMA20015 31 Wind Shleld TFMMA20031
16 PCB TFMMA20016

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DECLARATION OF CONFORMITY