SPOT WELDER

OPERATING & MAINTENANCE

INSTRUCTIONS

Part No. 6030005 & 60300010 0204

SPOT WELDERModels CSW11 & CSW11T

SPECIFICATIONS

Power Supply.............................................................230V 50Hz 1Ph

Max Absorbed Power...............................................3kW

Mains Fuse..................................................................13Amp

Duty Cycle.................................................................3 spots/min. w/min

down time of 20 secs.

Max. Welding Thickness...........................................1+1mm

Dimensions (mm)......................................................440x90x300

Weight.........................................................................10kg

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

prior notice. Always consult the machine’s data plate

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The meaning of the markings and symbols shown on data plate are explained asfollows.

EXPLANATION OF ELECTRICAL SYMBOLS

Symbol and dimension for the welding current

I2cc Short Circuit Secondary Current

50Hz Rated frequency for alternating current

I2

A

U1 R ated value of the supply voltage

F max Electrode max. strength

U 20 No Load Secondary Voltage

S max Max. Absorbed Power

IP_ _ Degree of protection (e.g. IP21)

Thank you for purchasing this CLARKE Spot Welder.

Before attempting to operate this machine, please read this leaflet thoroughlyand follow the instructions carefully, in doing so you will ensure the safety of yourselfand that of others around you, and you can look forward to the welder giving youlong and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12months 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 tamperedwith 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 bereturned to us without prior permission.

This guarantee does not effect your statutory rights.

CONTENTS PAGE

Explanation of Electrical Symbols............................................................2

Electromagnetic Interference (EMC).......................................................4

Safety Precautions.....................................................................................6

Electrical Connections..............................................................................7

Preparation for Use -..................................................................................8

Operation....................................................................................................8

Maintenance............................................................................................10

Specifications...........................................................................................10

Parts List and Diagram.....................................................................11 - 12

Parts & Service Contacts.........................................................................12

Wiring Diagrams.......................................................................................13

Accessories...............................................................................................14

Declaration of Conformity.......................................................................15

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When disposing of this product, ensure it is disposed of according to all local ordinances.

ELECTROMAGNETIC INTERFERENCE (EMC)

Whilst this unit complies with EMC regulations, the user is responsible for installingand using the welding equipment according to the manufacturers instructions. Ifelectromagnetic disturbances are detected then it shall be the responsibility ofthe user of the welding equipment to resolve the situation. In some cases thisremedial action may be as simple as earthing the welding circuit, see ‘Note’. Inother cases it could involve constructing an electromagnetic screen enclosingthe power source and the work complete with associated input filters. In all caseselectromagnetic disturbances must be reduced to the point where they are nolonger troublesome.

Note - The welding circuit may or may not be earthed for safety reasons. Changingthe earthing arrangements should only be authorised by a person who iscompetent to assess whether the changes will increase the risk of injury, e.g. byallowing parallel welding current return paths which may damage the earth circuitsof other equipment.

1.ASSESSMENT OF AREA

Before installing welding equipment the user shall make an assessment of potentialelectromagnetic problems in the surrounding area. Avoid using your inverter inthe vicinity of:

a) other supply cables, control cables, signalling and telephone cables;above, below and adjacent to the welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g. guarding of industrial equipment;

e) pacemakers and hearing aids etc;

f) equipment used for calibration or measurement;

g) other equipment in the environment. The user shall ensure that otherequipment being used in the environment is compatible. This mayrequire additional protection measures;

It may be possible to avoid the above by changing the time of day that weldingor other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure ofthe building and other activities that are taking place. The surrounding area mayextend beyond the boundaries of the premises.

2. METHODS OF REDUCING EMISSIONS

2.1 Mains supply

Welding equipment should be connected to the mains supply according to themanufacturers recommendations. If interference occurs, it may be necessary to

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take additional precautions such as filtering of the mains supply. Considerationshould be given to shielding the supply cable of permanently installed weldingequipment, in metallic conduit or equivalent. Shielding should be electricallycontinuous throughout its length. The shielding should be connected to the weldingpower source so that good electrical contact is maintained between the conduitand the welding power source enclosure.

2.2 Maintenance of the welding equipment

The welding equipment should be routinely maintained according to themanufacturers recommendations. All access and service doors and covers shouldbe closed and properly fastened when the welding equipment is in operation.The welding equipment should not be modified in any way except for thosechanges and adjustments covered in the manufacturers

instructions. In particular, the spark gaps of arc striking and stabilizing devices shouldbe adjusted and maintained according to the manufacturers recommendations.

2.3 Equipotential bonding

Bonding of all metallic components in the welding installation and adjacent to itshould be considered. However, metallic components bonded to the work piecewill increase the risk that the operator could receive a shock by touching thesemetallic components and the electrodes at the same time. The operator shouldbe insulated from all such bonded metallic components.

2.4 Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connectedto earth because of its size and position, e.g. ships hull or building steelwork, aconnection bonding the workpiece to earth may reduce emissions in some, butnot all instances.

Care should be taken to prevent the earthing of the workpiece increasing the riskof injury to users, or damage to other electrical equipment.

Where necessary, the connection of the workpiece to earth should be made bya direct connection to the workpiece, but in some countries where directconnection is not permitted, the bonding should be achieved by suitablecapacitance, selected according to national regulations.

2.5 Screening and shielding

Selective screening and shielding of other cables and equipment in the surroundingarea may alleviate problems of interference. Screening of the entire weldinginstallation may be considered for special applications.

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ALWAYS✔ Wear suitable safety goggles, manuf. to the latest European Safety Standards.✔ Use appropriate safety equipment, such as protective footwear, overalls,

gloves etc., with NO metal accessories.✔ Make sure there is adequate ventilation. Don’t weld in confined or en closed areas✔ Switch off and disconnect the Spot welder from the mains supply when it isnot in use, and before any adjustment or maintenance.✔ Comply with ALL instructions regarding Electrical Connections.✔ Disconnect the machine from the power supply before servicing or performing

other maintenance tasks.✔ Ensure the working area is clean and well lit. NEVER work in your own shadow.✔ Use only original CLARKE spare parts and accessories. Improper accessories

could be hazardous.✔ Keep proper footing and balance at all times.✔ Keep children and visitors away from the machine. Only qualified personnel

should be authorised to use this machine.✔ Maintain the machine in top condition. Keep it clean for best and safest performance.✔ Keep the work area as childproof as possible by using padlocks and master switches.✔ Switch machine OFF when changing/substituting fittings.

NEVER✗ Use the Spot welder in wet or damp conditions or in the rain.✗ Attempt any electrical or mechanical repairs yourself. Contact CLARKE

Service Department for advice.✗ Place your hands close to the electrodes.✗ Pull the plug from the power supply by the power cable.✗ Use the machine in an area where fumes from paint, solvents, or flammable

liquids pose a potential hazard. Keep flammable material away from themachine when operating. All flammable waste, such as cleaning rags etc.,should be placed in a closed metal container and disposed of properly.

✗ Weld containers which have held liquid or gaseous combustibles unless theyhave been cleaned thoroughly in accordance with COSHH regulations.

✗ Operate the machine while under the influence of drugs, alcohol or other medication.✗ Force the machine to do a job for which it was not designed. Use it ONLY for

its’ intended function.✗ Use machine if power cable is worn or chafed or suspect in any way.✗ Allow inexperienced personnel to operate this machine unless they are under

direct supervision

SAFETY PRECAUTIONS

ELECTRICAL CONNECTIONS

Connect the mains lead, through a suitably fused isolator switch, to a 230 Volt(50Hz) electrical supply, through a suitably fused, good quality 13 amp, BS 1363

plug or suitably fused isolator switch.

WARNING! THIS APPLIANCE MUST BE EARTHED

IMPORTANT: The wires in the mains lead are coloured in accordance with thefollowing code:

Green & Yellow - Earth

Blue - Neutral

Brown - Live

As the colours of the flexible lead of this appliance may not correspond with thecoloured markings identifying terminals in your electrical supply, proceed as follows:

• Connect GREEN & YELLOW cord to terminal marked with a letter “E” or Earthsymbol “ ” or coloured GREEN or GREEN & YELLOW.

• Connect BROWN cord to terminal marked with “L” or coloured RED.

• Connect BLUE cord to terminal marked with “N” or coloured BLACK.

WARNING!IF YOU ARE IN ANY DOUBT ABOUT ELECTRICAL CONNECTIONS, CONSULT A

QUALIFIED ELECTRICIAN.

NEVER ATTEMPT ELECTRICAL REPAIRS YOURSELF.

If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.non-rewirable) please note:1. The plug must be thrown away if it is cut from the electric cable. There is a

danger of electric shock if it is subsequently inserted into a socket outlet.2. Never use the plug without the fuse cover fitted.3. Should you wish to replace a detachable fuse carrier, ensure that the correct

replacement is used (as indicated by marking or colour code).4. Replacement fuse covers can be obtained from your local dealer or most

electrical stockists.

FUSE RATING

The fuse in the plug must be replaced with one of the same rating (5 amps) andthis replacement must be ASTA approved to BS1362.

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Cable Extensions:

IMPORTANT:

For extensions up to 10M, the size of the conductors MUST be at least the samesize as that used on the machine - 2.5mm 2 . It is NOT advised to use extensionsgreater than this, but if it is absolutely necessary, the conductor size must be4mm 2 up to a maximum of 25M in length.

PREPARATION

IMPORTANT!

Switch off and disconnect from the mains supply before any adjustment ormaintenance.

Good preparation is the key to successful welding.

• Make sure that both sides of the components to be welded are clean, andfree from rust, paint, grease or oil etc. The outer surfaces must be clean toallow the electrodes to achieve a good contact, and the inner surfacesmust be clean to allow a strong weld.

• Make sure that the two pieces to be welded are well shaped, and fit togetherclosely, with no large gaps.

• Make sure that the welding electrode tips are clean and properly shaped.The electrodes must meet squarely and in line with each other. Check thatthe electrode securing screws are tight.

The weld quality depends upon the pressure applied by the tips of theelectrodes and the length of time that the welding current flows.

• The pressure will depend upon the length of the welding arms and thedistance between the tips. Adjust the pressure by moving the positionsof the electrodes and using the adjusting screw at the rear of themachine. Too great a pressure will lead to damage to the welding tips,whilst insufficient pressure will result in a poor weld.

• Vary the welding time by using the timer (CSW11T), or manually with theoperating lever (CSW11).

We recommend that you practice using the welder on some scrap metal beforeattempting to weld your workpiece. This will allow you to get a feel for the pressureneeded, and for the length of time the current needs to flow, for differentthicknesses of metal.

Caution: Do not operate the Spot welder without a workpiece in place.

ASSEMBLY

1. Screw the handle into the threaded hole provided on either the left or rright hand side, as desired.

2. Insert the Electrode Arms, to their fullest extent, into their receptacles and nipup the clamps using the Hex. wrench provided...do not fully tighten at this

stage.

NOTE: Whenever removing and replacing the holders, ensure they, and thereceptacles, are clean and free from oil, grease or other contaminants.

3. Connect the machine to the electrical supply in accordance with IEEregulations and the instructions on the preceding page:

OPERATION

WARNING!The Spot welder produces sparks during use. Always wear suitable safety

goggles and protective clothing when using the Spot welder. Checkthere is nothing which might catch fire in the working area.

1. Position the two sheets of metal to be welded and clamp into place if possible.Ensure that they meet closely and neatly.

2. Switch on the mains supply.

3. Place the spot welder into position with the tips above and below the pointto be welded.

4. Press the operating lever firmly to close the electrodes. Welding will begin assoon as good contact is made by both electrodes on the workpiece.

5. Hold the Spot welder closed on the workpiece for a few seconds after thewelding current has switched off to allow the two pieces to fuse togetherand cool slightly.

CONTROLLING WELD TIME - CSW11

The weld time is controlled semi-automatically on the CSW11. The current isswitched off as soon as the operating lever is fully depressed.

The weld will begin when the electrodes make contact with the workpiece, andfinish when the lever reaches the end of its travel.

The weld time therefore, depends upon the speed with which the lever isoperated. The faster you operate the lever to the end of its travel, the shorter willbe the weld time. Operate the lever too slowly and you may burn through theworkpiece. Too quickly will result in an incomplete and weak weld.

It is important that you practice using the welder with scrap metal to get a feel forthe length of time needed with different metal thicknesses.

CONTROLLING WELD TIME CSW11T

The CSW11T is fitted with a timer (on theback face of the machine) to set the weldtime. The timer will switch off the weldingcurrent automatically after thepredetermined time.

The weld will begin when the electrodesmake contact with the workpiece, andfinish when the timer switches off.

Practice using the welder with scrap metalto get a feel for the timer setting neededwith different metal thicknesses.

ELECTRODE ARMS

The Clarke Spot welder is supplied with a standard set of electrode arms and tips,

suitable for general purpose spot welding. For more specialist applications a wide

range of different electrode arms and tips are available. For more details contact

your supplier or our Spares Department on 020 8988 7400.

When fitting replacement electrode arms, care must be taken to ensure that the

arms cannot come into contact with each other, particularly in the case of a set

where one arm passes “through” the other. Do not “mix and match” electrode

arms. Always ensure that the tips of the arms are directly opposed to each other

and securely locked.

MAINTENANCE

WARNING!

Switch off and disconnect from the mains supply before any adjustment or

maintenance.

Keep the welder electrode tips clean and properly shaped, using a small file and

emery cloth.

Keep the machine properly adjusted, with the tips meeting in line, straight and

square to each other.

Occasionally lubricate the moving parts of the Spot welder using a very light

application of a general purpose oil or grease as appropriate.

Item Description Part Number Part number

CSW11 CSW1T

1 Control lever TT523003 TT523006

2 Spring TT452046 TT452044

3 Spring TT452047 TT452047

4 Tooth for mechanical trip TT990314 TT990315

5 Pressure regulator TT513035 TT513035

6 Cover Plate TT408100 TT432109

7 Contacts TT990216 TT990216

8 Cable Bush TT990046 TT990046

9 Cable holder TT312189 TT312189

10 Mains Cable TT132102 TT132149

11 Switch TT513034 n/a

12 Back panel TT522034 TT522034

14 Connecting rod TT681153 TT681153

15 Side panel TT912036 TT912036

17 Transformer TT990248 TT990250

19 Insulating bush TT322079 TT322079

21 Flexible element TT513038 TT513038

22 Control Knob n/a TT112299

23 Potentiometer n/a TT112283

24 Triac n/a TT112152

25 Timer n/a TT112151

26 Arm 120mm TT690029 TT690029

27 Electrode fixing plug TT422342 TT422342

28 Electrode 50mm TT690012 TT690012

28 Electrode 125mm TT690028 TT690028

29 Moving arm TT523001 TT523001

30 Jaw for spot arms TT990228 TT990228

31 Insulating bush TT322080 TT322080

32 Pin TT422346 TT422346

33 Head set TT523007 TT523007

35 Handle with pin TT312161 TT312161

SPARE PARTS

SPARE PARTS

SPARE PARTS AND SERVICE CONTACTS

For Spare Parts and Service, please contact your nearest dealer, orCLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: Parts@clarkeinternational.com

SERVICE: Service@clarkeinternational.com

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SCHEMATIC WIRING DIAGRAMS

CSW11

CSW11T

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 - 6030111Electrodes

Internal Profile - 6030113Electrodes

Electrodes 120mm 6030115

Electrodes 350mm 6030117

Electrodes 350mm 6030119

Electrodes 120mm 6030121

Electrode Tip Dressing Tool ....................See your Clarke Dealer

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© Copyright Clarke International. All rights reserved. October, 2001

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