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Summary of Contents for Clarke TIG200
- Page 1 AC/DC TIG WELDER MODEL NO: TIG200 PART NO: 6012103 OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC10/24...
- Page 2 INTRODUCTION Thank you for purchasing this CLARKE 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 welder giving you long and satisfactory service.
- Page 3 PRINCIPLES OF THE MACHINE The TIG200 Multi is an AC/DC inverter type welding machine which adopts advanced pulse width modulation (PWM) technology and insulated gate bipolar transistor (IGBT) to convert the power frequency to intermediate frequency, thereby replacing the bulky in the traditional arc welding machine with a small intermediate frequency transformer.
- Page 4 SUITABILITY OF DIFFERENT METHODS 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. Metal Being Welded Suitable Gas Part number Mild Steel Carbon Dioxide (CO 2 ) 6000642 Stainless Steel Argon...
- Page 5 SAFETY PRECAUTIONS FOR ALL WELDING WARNING: AS WITH ALL MACHINERY, THERE ARE CERTAIN HAZARDS INVOLVED WITH THEIR OPERATION AND USE. EXERCISING RESPECT AND CAUTION WILL CONSIDERABLY LESSEN THE RISK OF PERSONAL INJURY. HOWEVER, IF NORMAL SAFETY PRECAUTIONS ARE OVERLOOKED, OR IGNORED, PERSONAL INJURY TO THE OPERATOR MAY RESULT.
- Page 6 atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene. FIRE AND EXPLOSION PREVENTION Causes of fire and explosion are: 1. Combustibles reached by the arc, flying sparks, hot slag or heated material; 2.
- Page 7 DO NOT overload arc welding equipment. It may overheat cables and cause a fire. Loose cable connections may overheat or flash and cause a fire. NEVER strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling.
- Page 8 persons who will be looking directly at the weld. Others working in the area should wear flash goggles. Before starting to weld, make sure that screen or bay doors are closed. SHOCK PREVENTION Exposed live conductors or other bare metal in the welding circuit, or in unearthed, electrically-LIVE equipment can fatally shock a person whose body becomes a conductor.
- Page 9 5. NEVER use or store in a damp environment. DO NOT expose to rain. 6. 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.
- Page 10 The welding equipment should be routinely maintained according to the manufacturer’s recommendations (see page 28). Any access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions.
- Page 11 SAFETY SYMBOLS The following symbols may be displayed on the machine or its packaging. Read this instruction Do not expose to rain. booklet carefully before use. Wear welding mask Recycle unwanted materials under WEEE Directive Wear protective gloves General Hazard Danger:- Arc Rays Wear a dust mask Caution:- Hot surface...
- Page 12 Before switching on, make sure that the voltage of your electricity supply is correct. Connecting it to another power source may cause damage. A suitable plug is available from your CLARKE dealer. The user may also purchase a suitable...
- Page 13 MACHINE OVERVIEW The TIG200 Multi- welder has the following features: Quick connector (positive) Welding waveform selection button Remote control socket Channel and save selection button Welding torch switch socket 2T/4T selection button Solenoid valve output Repeat/spot weld selection button Quick connector (negative)
- Page 14 THE MACHINE FEATURES AND CONTROL FUNCTIONS 1. Positive Quick connector • Positive quick connector socket, for connection of grounding clamp. 2. Remote control cable socket • Quick connecting remote control terminal. 3. Welding gun switch socket • Quick connecting control switch cable of the welding gun. 4.
- Page 15 13.2T/4T selection button • The 2T/4T function can be selected through this button. 14.Repeat/spot welding selection button • Use this button to select the repeat and spot welding functions according to the workpiece material and process requirements. 15.Pulse parameter selection button •...
- Page 16 PREPARING THE WELDER FOR USE To prepare the machine for welding it is important that you follow the following procedure. Making sure that the ON/OFF switch, located on the rear panel is in the OFF position. Connect the welding leads and gas bottle as follows and set the selector switch to the position shown.
- Page 17 PREPARING THE TIG TORCH Alternative torch components are supplied with the unit and are assembled is as follows. Unscrew and remove the end cap (E). 2. Select the size of electrode required, and ensure you select the correct size collet body for that particular electrode.
- Page 18 NOTE: Before assembly, file or grind the tip of the electrode to a point (from 40-60 deg) as this will give optimum performance. The following electrode sizes can be used and are available from your CLARKE dealer. ELECTRODE DIAMETER WORKPIECE THICKNESS 1.6 mm...
- Page 19 CONTROL SETTINGS DISPLAYED Refer to page 14 for basic control panel functions UPPER SCREEN 1. Set the AC/DC setting as required. • AC is for aluminium. • DC is for carbon steel/stainless steel. 2. This selects the welding method;- either •...
- Page 20 5. When selecting 4T, there is no need to hold the trigger continuously during welding. 6. If selecting Repeat, the machine repeats the output between the two currents set, from strong to weak and from weak to strong. Spot welding should be easy to use.
- Page 21 OPERATING THE WELDER (MMA) WARNING: WHEN WELDING ALWAYS ENSURE THERE IS ADEQUATE VENTILATION IN THE WORK AREA DUE TO TOXIC FUMES. WARNING: DO NOT STRIKE THE ELECTRODE ON THE WORKPIECE, AS THIS MAY DAMAGE THE ELECTRODE. WARNING: WELDING ARCS PRODUCE HARMFUL UV/IR LIGHT WHICH CAN SERIOUSLY DAMAGE YOUR EYES.
- Page 22 OPERATING THE WELDER (TIG WELDING) TIG welding is primarily for very thin materials using a non-consumable tungsten (or tungsten alloy) electrode held in the torch. A shielding gas (100% Argon), is fed through the torch to protect: • The electrode •...
- Page 23 TIG WELDING Before TIG welding, you must obtain the correct torch and a gas cylinder of 100% pure Argon. To prepare the machine for TIG welding, adopt the following procedure. 1. Plug the work clamp lead in to the +ve terminal and connect the work clamp to the workpiece.
- Page 24 • This method is referred to as ‘Scratch Arc’. 11. To stop welding, simply remove the torch from the workpiece. 12. Turn off the gas as soon as you finish welding. Notes: • 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.
- Page 25 WELDING PITFALLS The MMA and TIG 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.
- Page 26 TROUBLESHOOTING Your CLARKE Welder has been designed to give long and trouble free service. If however, having followed the instructions in this booklet carefully you still encounter problems, the following points should help identify and resolve them. DEFECT CAUSES SUGGESTIONS Spark will not start Bad clamp connection.
- Page 27 DEFECT CAUSES SUGGESTIONS High Sprays Electrode is too inclined. Make appropriate corrections. Arc is unstable Insufficient current. Check condition of electrode and earth wire connection. Electrode melts Electrode core is not centred. Replace electrode. obliquely Magnetic blow phenomenon. Connect two earth wires to opposite sites of the work piece.
- Page 28 To keep the contact tip free from spatter, we recommend the use of anti-spatter spray (6000715) available from your CLARKE dealer. Torch shroud The torch shroud must also be kept clean and free from spatter. Build-up of spatter inside the gas cup can cause a short circuit at the contact tip which will result in expensive machine repairs.
- Page 29 COMPONENT PARTS Potentiometer & knob 14 Rear panel Output copper bar 2 Fix panel Upper windshield? Gun switch plate Panel Circuit breaker Output copper bar Front control PCB Cable gland Current transformer Casing Soft-start fan Base plate Lifting handle Solenoid valve Express socket AC converter board Radiator 1...
- Page 30 TORCH COMPONENT PARTS No Description No Description End Cap c/w O-ring Ceramic Nozzle Front Cup Gasket Tungsten Electrode 1.6/2.4 mm Torch Body Short end cap & O-ring Collet Hose & protective sleeve Collet Sleeve Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
- Page 31 THE MACHINE RATING PLATE Name/address of manufacturer Energy Supply symbol Model Number Electrode symbol Part number Rated No-load Voltage Welding Power Source Max Effective Supply Current Standards applied Insulation grade Welding Process symbols Rated Supply Voltage Degree of Ingress Protection Rated Maximum Supply Current Min &...
- Page 32 WSC2 and replacement screen 6000945 6000910 A Gas Regulator, Arc Activated Headshields, Anti-spatter Spray, Swan Necks, Torch Shrouds and Torch Liner are also available from your CLARKE dealer or our parts division. Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
- Page 33 6000705 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.
- Page 34 DECLARATION OF CONFORMITY -UK Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
- Page 35 DECLARATION OF CONFORMITY - CE Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
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