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MIG 160TM

OPERATING & MAINTENANCEINSTRUCTIONS

0108

Part No: 6015530

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WELDER SPECIFICATIONS

PRIMARY or INPUT POWER DATA

Primary Volts 230V / 1PH

Primary Amps 16 AmpsFrequenc y 50Hz

SECONDARY or OUTPUT POWER DATA

Sec . Volts 18 - 28 V

Max. Sec . Amps 150 Amps

USABLE WIRE SIZES

Mild Steel Wire 0.6-0.8mm

Sta inless Steel Wire 0.8mm

Aluminium Wire 0.8mm

USABLE GASES MAIN USES

75% Arg on 25% C O2 - Thin She et Me ta l, M ild Ste el

100% Argon - Weld ing Aluminium, Sta inless Steel

100% CO2 - Mild Steel

This model is covered byregulations EN 60974-1 andEN 50199, where the DutyCyc le (X) is expressed a s a

percentage of t ime themachine may be used in agiven period for a specifiedwelding current.

i.e. When welding at 75Amps the ma chine may beused for 6 minutes (60%) in

any 10 minute period..

............or, the ma chine may

be used continuously,(100%) when welding at 55Amps

Interpolate for other

welding currents

DUTY CYCLE

Please note that the details and specifications contained herein, are correct a t the time ofgoing to print. However, CLARKE International reserve the right to cha nge specifica tions at any

time without prior notice. ALWAYS CONSULT THE MACHINES DATA PLATE

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CONTENTS PAGE

Welder Specifica tions............................................................................ 2

Parts & Service Contacts....................................................................... 3

Guarantee .............................................................................................. 4

Electroma gnetic Interference (EMC) .................................................. 5

Safety Precautions................................................................................. 7

Additional Safety Precautions for MIG Welding ............................... 12

Principles of Operation ........................................................................ 14

Electrica l Connections........................................................................ 15

Unpacking and Parts Identification ................................................... 16Assembly ....................... Attaching the Torch ................................... 17

Installing the Welding Wire ....................... 18

Connecting the Gas Supply ..................... 20

Welding Shield ........................................... 20

Prepa ration for Use ....... Tuning the Welder....................................... 21

MIG Welding Operation ...................................................................... 21

Wire Specifica tion Chart ..................................................................... 22

Welding Tips & Maintenance .............................................................. 22

Troubleshooting .................................................................................... 23

Parts Lists and Diagrams ............................................................. 24 - 29

Wiring Diagrams........................................................................... 30 - 31

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE 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.comSERVICE: Service@clarkeinternationa l.com

PARTS AND SERVICE CONTACTS

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Tha nk you for purchasing this CLARKE MIG Welder, designed to opera te using agas c ylinder with p la in meta l we ld ing wire ONLY. This is explained in g rea ter deta il

within the ma nua l.Before a ttemp ting to operate the machine, it is essent ia l tha t you rea d this ma nua lthoroughly a nd c arefully fo llow a ll instruct ions g iven. In d oing so you will ensurethe sa fety of yourself and tha t of o thers around you, and you c an a lso look forwardto the we lder giving you long and sa tisfac tory servic e.

GUARANTEE

This CLARKE prod uc t is guaranteed aga inst fa ulty manufac ture for a periodof 12 mo nths from the d a te of p urc hase. Plea se keep your rec eipt a s p roo fof purc hase.

This guarantee is inva lid if the p rod uc t is found to have b een a bused ortampered with in any way, or not used for the purpose for which it wasintended.

Faulty goods should be returned to their place of purchase, no productc an be returned to us without p rior permission.

This gua rantee doe s not e ffec t your sta tuto ry rights.

When disposing of this product, do not dispose of with general waste. It must be disposed of ac cording to the lawsgoverning Waste Electrica l and Electronic equipment, at a rec ognised disposal facility.

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ELECTROMAGNETIC INTERFERENCE (EMC)

Whilst this unit complies with EMC regulations, the user is responsible for insta llingand using the w elding equipme nt ac cording to the m anufac turers instruc tions. Ifelec tromagnetic d isturbanc es are d ete c ted then it sha ll be the responsib ility of

the user of the welding equipment to resolve the situation. In some cases thisremed ia l ac tion m ay be a s simp le a s ea rthing the we ld ing c irc uit, see Note . Inother cases it could involve constructing an electromagnetic screen enclosingthe pow er source and the wo rk co mp lete with assoc ia ted input filters. In a ll caseselec tromagne tic d isturbances must be reduc ed to the point where they a re nolong er troub lesom e.

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 circuits

of other equipment.

1.ASSESSMENT OF AREA

Befo re insta lling welding equipment the user sha ll make an assessment of potentialelectromagnetic problems in the surrounding area. Avoid using your inverter inthe vic inity of:

a ) other supp ly c ab les, c ontrol c ab les, signa lling and te lep hone c ab les;ab ove, be low a nd adjac ent to the weld ing equipm ent;

b ) rad io a nd te levision transmitters and receivers;c) computer and other control equipment;

d) safety c ritic al equipment, e.g. gua rding of industrial equipm ent;

e) pa cema kers and hearing aids etc.;

f) equipme nt used for ca libration or mea surement;

g) other equipment in the environment. The user shall ensure tha t othereq uipme nt b eing used in the environment is com patib le. This ma yreq uire add itiona l protec tion measures;

It ma y be p ossib le to a void the above b y cha nging the time of day that we ld ingor other ac tivities a re to be c arried out.

The size of the surround ing area to be considered will depend on the struc ture ofthe b uild ing and othe r ac tivities tha t a re ta king p lace. The surround ing a rea ma yextend beyond the b ound aries of the p remises.

2. METHODS OF REDUCING EMISSIONS

2.1 Mains supply

Weld ing equipment should be c onnec ted to the mains supp ly ac c ord ing to thema nufac turers rec omme ndations. If interference oc c urs, it may be nec essary to

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take additional precautions such as filtering of the mains supply. Considerationshould b e g iven to shielding the supp ly ca b le o f pe rma nently insta lled we ld ingeq uipme nt, in me ta llic c ond uit or equiva lent . Shielding should be e lec tric a llycontinuous throug hout its leng th. The shielding should be connec ted to the we ld ingpower sourc e so tha t good elec tric a l conta c t is ma intained b etween the c ond uitand the we ld ing p ow er source enc losure.

2.2 Ma intenance of the welding equipment

The w eld ing eq uip me nt should b e routinely ma intained a c c ording to thema nufac turers rec omme ndations. All access and service d oo rs and cove rs shouldbe c losed and prop erly fastened when the w elding eq uipment is in op era tion.The w elding eq uipme nt should not b e m od ified in any wa y exc ep t for thosechanges and ad justments covered in the manufac turers instruct ions. In partic ula r,the spark gaps of arc striking and stabilizing devices should be adjusted andma intained a cc ord ing to the manufac turers rec ommenda tions.

2.3 Welding cables

The welding cab les should b e kept a s short a s possib le and should b e positionedc lose to gether, running a t or c lose to the floor leve l.

2.4 Equipotential bonding

Bond ing o f all me ta llic compone nts in the welding insta lla tion a nd a d jac ent to itshould be c onsidered . However, meta llic components bond ed to the work p iec ewill inc rea se the risk that the op erato r c ould rec eive a shoc k by touc hing theseme ta llic c omponents and the e lec trod es a t the same time . The operato r shouldbe insula ted from a ll such bond ed meta llic components.

2.5 Earthing of the workpiece

Where the workp iec e is not b ond ed to ea rth for elec trica l sa fety, nor connec tedto earth because of its size and position, e.g. ships hull or building steelwork, ac onnec tion b ond ing the workpiec e to earth ma y red uce em issions in some, butnot a ll insta nc es.

Ca re should b e ta ken to p revent the ea rthing of the wo rkpiec e increasing the riskof injury to users, or dama ge to othe r elec trica l eq uipment.

Where nec essary, the c onnec tion o f the workp iec e to ea rth should be m ade b ya direct connection to the workpiece, but in some countries where directconnection is not permitted, the bonding should be achieved by suitablec apac itance, selec ted ac cord ing to na tiona l reg ula tions.

2.6 Screening and shielding

Selec tive sc reening and shielding o f other cables and eq uipment in the surroundingarea ma y alleviate p rob lems of interferenc e. Sc reening of the entire weldinginsta lla tion ma y be c onsidered for spec ia l ap p lica tions.

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SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING

1. WARNING:As with all machinery, there are certain hazards involved with their operationand use. Exercising respect and caution will considerably lessen the risk of

personal injury. However, if normal safety precautions are overlooked, orignored, personal injury to the operator ma y result.

FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY

2. GENERAL PRECAUTIONS

A)Burn prevention

Wea r protec tive c lothing - gauntlet g loves designed for use in welding, ap ron, andprotec tive shoes. Button shirt collar and poc ket flap s, and wear cuffless trousers toavoid entry of sparks and slag. Wear helmet with safety goggles or glasses with sideshields underneath, appropriate filter lenses or plates (protected by clear coverglass). This is a MUST for weld ing or cutting , (and chipp ing) to protec t the eyes fromradiant energy and spatter. Rep lace c over glass when broken, pitted , or spattered.Avoid oily greasy clothing. A spark may ignite them. Hot metal such as electrodestubs and workpieces should neve r be hand led without g loves. First a id fac ilities anda qua lified first a id person should be availab le unless medical fac ilities are c lose byfor immediate trea tment of flash burns of the eyes and skin burns. Ear p lugs should

be worn when working overhead or in a confined space. A hard hat should beworn when others work overhea d. Flammable ha ir prep arations should not be usedby persons intend ing to we ld or cut.

B) Toxic fume prevention

Severe d isc omfort, illness or dea th c an result from fumes, va pours, hea t, or oxygenenric hment or dep letion tha t we ld ing (or c utting) may produce. Prevent themwith adeq ua te ve ntila tion. NEVER ventila te w ith oxygen. Lea d-, c admium-, zinc -,me rcury- and b eryllium-, bea ring ma teria ls, whe n welded (or c ut) ma y produce

harmful c onc entrations of toxic fumes. Adequate loc a l exhaust vent ila tion m ustbe used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used. Metals coated with orc onta ining ma teria ls tha t emit toxic fumes should no t b e he ated unless c oa ting isremoved from the work surfac e, the a rea is we ll ventila ted , or the op erato r wearsan a ir-supp lied respira tor. Work in a c onfined space only while it is being ventila tedand, if nec essary, while wearing an air-supplied respira tor. Vapours from c hlorina tedsolvents can be d ec omposed by the heat of the arc (or flame) to form PHOSGENE,a highly toxic gas, and other lung and eye irrita ting p rod uc ts. The ultraviolet( radiant) energy of the arc can also decompose tr ichloroethylene and

perchloroethylene vapours to form p hosgene . DO NOT WELD or cut where solventvap ours can be drawn into the weld ing o r cutting a tmosphere or where the rad iantenergy can penetrate to atmospheres containing even minute amounts oftric hloroethylene or perchloroe thylene .

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C) Fire and explosion prevention

Ca uses of fire and explosion a re:

1) c ombustib les rea c hed by the a rc , flame , flying sparks, hot slag or heate dmaterial;

2) misuse o f compressed gases and cylinders;

3) short c irc uits.

BE AWARE THAT flying sparks or fa lling slag c an pass throug h c rac ks, a long p ipe s,throug h w indow s or doo rs, and throug h wa ll or floo r openings, out o f sight o f thegog gled op erato r. Sparks and slag c an fly 10M.

To p revent fires and explosion: keep eq uipme nt c lea n and op erab le, free of o il,grea se, and (in elec trica l parts) of me ta llic particles tha t can cause short c ircuits.If combustib les a re in area , do NOT we ld or cut. Move the w ork if prac tic ab le, toan area free of c ombustib les.

Avoid p a int spray room s, dip ta nks, storage a rea s, ventila tors. If the work ca nnotbe moved, move combustibles at least 10M, away out of reach of sparks andheat; or protec t a ga inst ignition with suitab le a nd snug fitting, fire- resista nt c oversor shie lds.

Walls, c eilings, and floor nea r wo rk should be p rotec ted by hea t resistant c oversor shields. Fire watcher must be standing by with suitable fire extinguishingeq uipment d uring and for some time a fter weld ing or cutting if:

a ) apprec iab le c ombustib les (inc luding b uild ing construc tion) a re w ithin 10m.

b) apprec iable combustib les are further than 10m but ca n be ignited by sparks.

c ) op enings (conc ea led or visib le) in floo rs or wa lls within 10m can expo sec ombustibles to sparks.

d ) c ombustib les ad jac ent to wa lls, ce ilings, roo fs or meta l pa rtitions can b eignited by rad iant or cond ucted heat.

Afte r work is done, c heck that a rea is free of sparks, glowing em bers, and flames.An emp ty container that held c ombustib les, or that c an prod uce flammable ortoxic vapours when heated, must never be welded on or cut, unless containerhas first b ee n c lea ned. This inc ludes.......a thorough steam or c austic c lea ning (ora solvent o r water wa shing , depend ing on the c ombustib le s solubility) follow ed

by purging and inerting with nitrogen or carbon dioxide, and using protectiveequipment.

Water filling just below w orking level may sub stitute for inerting .

A c onta iner with unknown contents should be c lea ned (see paragrap h ab ove),do NOT dep end on sense o f smell or sight to determine if it is sa fe to w eld or cut.

Hollow castings or containers must be vented before welding or cutting - theyca n explod e.

In explosive a tmospheres, never weld o r cut where the a ir ma y conta in flammable

dust, gas, or liquid vapours.

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3. ELECTRIC ARC (MIG, TIG) WELDING

Comp ly with precautions in 1 ab ove, and this sec tion. Arc we ld ing, p rop erly done,is a sa fe p rocess, but a c areless op erator invites troub le. The eq uipment c arrieshigh c urrents at significant vo lta ges. The arc is very bright a nd hot. Sparks fly, fumesrise, ultraviolet and infrared ene rgy rad ia tes, weldments a re hot. The wise op erator

avoids unnecessary risks and protec ts himself and others from acc idents.

3A) BURN PROTECTION

Comply with p rec autions in 2. The we ld ing a rc is intense and visib ly b right. Itsradiation can damage eyes, penetrate lightweight clothing, reflect from lightcoloured surfaces, and burn the skin and eyes. Skin burns resem ble a cute sunb urn,those from g as - shielded a rcs a re more severe and pa inful.

DONT GET BURNED! COMPLY WITH PRECAUTIONS!

1) Protective clothing

Wea r long sleeved c lothing (partic ula rly for ga s shielded a rc ) in a dd ition tog loves, apron a nd shoes (2A). As necessary, use a dditiona l protec tive c lothingsuch as lea ther jacket or sleeves, flamep roof a pron, and fire-resistant leggings.Avoid outer garments of untrea ted c otton. Bare skin protection: Wea r darksubstantia l clothing, Button c olla r to p rotec t c hest a nd nec k and buttonpoc kets to p revent ent ry of spa rks.

2) Eye and head protection

Protec t eyes from exposure to a rc . NEVER look a t a n elec tric a rc withoutprote c tion. Welding he lme t o r shield c onta ining a filter plate shade no. 12 ordenser must be used when welding. Place over fac e before striking a rc . Protec tfilter plate with a c lea r c over p la te. Crac ked or broken he lme t o r shield shouldNOT be worn; rad ia tion can pass throug h to c ause b urns. Crac ked, b roken,or loose filte r p lates must be rep lac ed IMMEDIATELY. Replac e c lear cover p latewhen b roken, p itted , or spa ttered . WE SUGGEST you wear flash goggles withside shields und er the he lme t, to g ive som e p rotec tion to the eyes should the

helmet no t be lowered ove r the fa c e b efore a n arc is struc k. Loo king a t anarc mo menta rily with unprote c ted eyes (particula rly a high intensity

ga s-shielded arc ) ca n cause a retinal burn that may lea ve a perma nent darkarea in the field of vision. Befo re w elding whilst wea ring conta c t lenses, see kadvic e from your op tic ian.

3) Protection of nearby personnel

For produc tion w elding, a sep ara te room or enc losed bay is best.In open area s, surround the op eration w ith low reflec tive, non- combustib le

sc reens or panels. Allow fo r free a ir c irculat ion, particularly at floor level. Provideface shields for all persons who will be looking d irec tly a t the weld. Othersworking in the area should wea r flash goggles. Befo re sta rting to we ld , makesure tha t sc ree n or ba y do ors a re c losed .

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3B) TOXIC FUME PREVENTION

Comp ly with p rec autions in 2B. Generato r eng ine exhaust must be vented tothe outside a ir. Carbon mo noxide c an kill.

3C) FIRE AND EXPLOSION PREVENTION

Comply with prec autions in 2C. Equipments rated capacity. Do not overload arcwelding equipment. It may overheat cables and cause a fire. Loose c ableconnections may overheat or flash and cause a fire. Never strike an arc on a cylinderor other pressure vessel. It c rea tes a brittle area that can cause a violent rupture orlead to such a rupture later under rough handling.

3D) SHOCK PREVENTION

Exposed live cond uc tors or othe r bare me ta l in the we ld ing c irc uit, or in

unea rthed , elec trica lly-LIVE eq uipment c an fa ta lly shoc k a person whose bod ybec omes a cond uc tor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wetsurfac e when welding, without suitab le p rote c tion.

3E) PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPT DEVICES (PACEMAKERS)

Magnetic fields from high currents can affec t pacemaker operation. Persons wearingelectronic life supp ort equipment (pacemaker) should consult with their doc torbefore going near arc welding, gouging, or spot welding operations.

3F) TO PROTECT AGAINST SHOCK:Keep b od y and c lothing d ry. Never work in da mp area without ad eq uateinsula tion aga inst e lec tric a l shoc k. Stay on a d ry duckboard , or rubber ma twhe n damp ness or sweat c an not be a voided. Swe at, sea wa ter, or mo isturebetw een bod y and an elec trica lly LIVE part - or earthed me ta l - red uces thebod y surfac e elec tric a l resistanc e, ena b ling dangerous and possib ly letha lc urrents to flow through the b od y.

1) Earthing the equipment

When a rc we ld ing equipment is ea rthed acc ord ing to the Nationa lElec trica l Code, and the workp iec e is ea rthed , a voltag e may existbetwee n the elec trod e a nd a ny conducting ob jec t.

Examp les of c ond uc ting ob jec ts inc lude, but a re no t limited to, b uild ings,elec tric a l tools, wo rk benches, welding p ow er source c ases, workp iec es,etc . Never touch the e lec trod e a nd any meta l ob jec t unless the weldingpow er sourc e is off. When insta lling , c onnec t the frames of eac h unit suc has we ld ing p ow er source , control, wo rk tab le, and wa ter circ ula tor to thebuild ing e arth.

Conduc tors must be a deq uate to c arry ea rth c urrents sa fely. Equipme ntmade e lec tric a lly LIVE by stray current may shoc k, possibly fata lly. Do NOTEARTH to elec trica l conduit, or to a p ipe c arrying ANY gas or a flam ma bleliquid suc h a s oil or fuel.

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2) Electrode holders

Fully insulated elec trod e ho lders should b e used . Do NOT use holde rs withprotruding sc rews or with any form of da ma ge.

3) Connectors

Fully insula ted loc k-type c onnec tors should be used to join we ld ing cab le.

4) Cables

Frequently inspec t c ab les for wear, crac ks and damage. IMMEDIATELYREPLACE tho se with e xc essive ly worn or damaged insulation to avoidpossib ly letha l shoc k from bared c ab le. Cab les with da ma ged area s ma ybe ta ped to g ive resistance equivalent to o riginal c ab le. Keep c ab le d ry,free of o il and grease, and protec ted from hot meta l and sparks.

5) Terminals and other exposed parts

Terminals and other exposed parts of elec trica l units should ha ve insulat ingc overs sec ured before op eration.

6) Electrode

a) Equipment with output on/o ff control (co ntac tor)

Welding p ow er source s for use w ith the gas me ta l a rc we ld ing, ga stungsten arc we ld ing and simila r proc esses normally are eq uipped withdevic es that p ermit on/ off control of the welding p ower outp ut. Whenso e quipped the e lec trod e w ire b ec omes elec tric a lly LIVE when the

pow er sourc e switc h is ON and welding gun switc h is c losed . Neve rtouch the elec trod e w ire o r any c onducting o bject in contac t withthe elec trod e c ircuit unless the we ld ing pow er source is off.

b) Equipment without output on/off c ontrol (no c ontac tor)

Welding pow er sources used with shielded me ta l arc we ld ing and similarproc esses ma y not be equipped with we ld ing p ower outp ut on/ offcontrol devices. With suc h eq uipment the elec trode is elec tric a lly LIVEwhen the power switch is turned ON. Never touc h the elec trod e unlessthe we ld ing pow er source is off.

7) Safety devices

Safety devices suc h a s inte rlocks and c irc uit b rea kers should not b ed isc onnec ted or shunted out. Befo re insta lla tion, inspec tion, or servic e o feq uipment, shut OFF a ll pow er and rem ove line fuses (or lock or red -tagswitches) to p revent a cc identa l turning ON of power. Do not open p owerc ircuit or c hange p olarity while w elding. If, in an em ergenc y, it must b ed isc onnec ted , gua rd aga inst shock burns, or flash from switc h arc ing .Always shut OFF and d isconnec t all power to eq uipment. Power disconnec tswitch must be a va ilab le near the welding pow er source .

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PREPARATION OF THE WORKING AREA

The working area must be sufficiently spac ious, not humid , and we ll-ventila ted asto a void any fumes which develop from the weld ing p roc ess and from inc identa lma teria l adhering to the p iec es to be welded (oils, pa ints, tars...) which ma y causeannoyanc e to the op erato r.Avoid w elding b y conta c t w ith humid parts nea rby combustib le liquids. Lea st o fa ll, do no t we ld upon ta nks which may co nta in flamm able residua ls.

ADDITIONAL SAFETY PRECAUTIONS for MIG WELDING

ALWAYSensure tha t the re is full free a ir c irculating around the outer c asing ofthe mac hine, and that the louvres are unobstruc ted .

Welding a rc c an seriously da ma ge your eyes. Both o perato r and spec ta torsmust ALWAYS use a p rop er weld ing fac e shield or helmet , with suita b le filterlenses. Proper g loves and working c lothes should be worn a t a ll times.

ALWAYSc hec k tha t the p ressure regulato r and gauges (where fitted), a reworking correc tly. DO NOT lub ric a te the reg ula tor.

ALWAYSuse the c orrec t regula tor. Reg ula tors a re designed to be used witha spec ific gases.

ALWAYS inspec t the hose b efo re use to ensure it is in good cond ition.

ALWAYS keep the free leng th of gas hose outside the wo rk a rea .

ALWAYS remove a ll flammable ma teria ls from the we ld ing area .

ALWAYSKeep fire extinguisher ha nd y....Dry Powder, C02 or BCF, NOT Water

NEVER remove any of the panels unless the ma chine is d isconne c ted fromthe supp ly, AND never use the ma chine w ith any of the p anels removed.

NEVER attemp t any elec trica l or mechanica l rep a ir unless your are a qualifiedtec hnic ian. If you have a problem with the ma chine c ontac t your loc al

CLARKE dea ler.

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PREPARATION OF THE WORKING AREA NEVERuse or sto re in a wet/ damp environment. DO NOT EXPOSE TO RAIN.

The MIG weld ing p roc ess uses an INERT gas to p rotec t the weld p ool. It isimp ortant to ensure the a pprop ria te gas is being used . NEVER use gas from

a cylinder, the c onte nt o f which is unknow n.

NEVER a . Use a damaged cylinde r.

b . Lift the cylinder by the va lve.

c . Expose the cylinder to a hea t source or spa rks.

NEVERcontinue to weld, if, at any time, you feel even the sma llest elec tric shoc k.Stop welding IMMEDIATELY, and DO NOT attempt to use the machine until the fault

is diagnosed and correc ted .

NEVERpoint the MIG to rc h at a ny person or anima l.

NEVER touc h the MIG torch nozzle until the we lder is switc hed OFF and thenozzle ha s been a llow ed to c oo l off.

NEVER c onnec t, d isconne c t, or attemp t to service the MIG to rch, until themac hine is switc hed OFF and d isconnec ted from the mains supp ly.

NEVERallow the c ab les to bec ome wrap pe d a round the op erato r or anyperson in the vicinity.

DANGER - ELECTRIC SHOCK CAN BE FATAL.

A p erson qua lified in first a id should a lways be p resent in the working area .

If person is unconscious and elec tric shock is suspec ted, do not touch the person ifhe or she is in contact with the welder or cables. Disconnect the welder from the

power source and then use First Aid. Dry wood, or other insulating ma terial can beused to move c ables, if nec essary, awa y from the person.

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SAFETY EQUIPMENT

A comprehensive range of CLARKE safety equipment for use whenwe ld ing is ava ilab le from your loc a l dea ler.

MIG WELDING - PRINCIPLES OF OPERATION

MIG (Meta l Inert Gas) welding is a proc ess in which a power wire elec trod eis fed continuously into the weld poo l a t a controlled , constant ra te.

The wire is c onnec ted to the positive side of a rec tified voltage supp ly. Theworkp iec e is connec ted to the neg ative side o f the supp ly.

When the w ire is fed , it comes into c onta c t with the workp iec e a nd an arc

is struck. The arc melts the wire a nd the ma teria l, fusing it togethe r.The w ire, which is fed by the w ire feed motor is fed into the weld p ool,burning itself off at a ra te d ep endent upon the selec ted wire feed speed .

To p rotec t the we ld poo l from oxida tion and imp urities during the we ld ingprocess, a shield ing gas flows over and a round the weld pool. This gas flowmust be suffic ient to p rotec t the we ld , but not w asteful.

NOTE: Poor gas coverage will result in poor welding. Excessive gascoverage is wasteful and expensive.

BENEFITS OF MIG WELDING

1. 50% faster welding time.

2. Ope rator training time kept to a minimum.

3. There is no slag rem ova l, thus elimina ting a lmo st a ll post-we ld ingc lea ning op era tions.

4. Minimum w aste of w elding c onsumab les.

5. Overall, a faster more effic ient wa y of getting the job done.

6. Less heat - less d istortion.

7. Ability to weld thin ma terial.

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ELECTRICAL CONNECTIONS

WARNING: THIS MACHINE MUST BE EARTHED.

This welder must b e c onnec ted to a 230 volt (50Hz) supp ly, having a ra ted

c apa c ity of grea ter than 13 amp s.

A 13 Amp (BS1363) plug is not suitable for this device.

Connec t the three c ore ma ins lea d to a suitab ly fused supp ly throug h anisolator or heavy duty p lug .

IMPORTANT: The wires in the mains lead a re coloured in accordance withthe following colour code:

Green & Yellow - Earth

Blue - NeutralBrown - Live

Connec t GREEN & YELLOW c oloured c ord to p lug terminal marked

with a le t ter E or Earth symbo l .

Connect BROWN c oloured c ord to p lug terminal ma rked let ter L

Connect BLUE c oloured c ord to plug terminal ma rked let ter N

We strong ly rec om me nd tha t this ma c hine is c onnec ted to the m a inssup p ly throug h a Resid ua l Curren t Dev ic e .

IMPORTANT: If in doubt, consult a qualified e lectrician. Do not attempt

any electrica l repa irs yourself.

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Fig.1

ASSEMBLY

Remove c onte nts from c a rton a nd c hec k a ll c om ponents as follow s:

The side panel is hinged a t its rea r edg e: Op en by pulling the sec uring c a tc hsideways, lay out a ll components c onta ined within, and c hec k to ensure tha t they

a re a ll c orrec t ac c ording to the list be low .

A - 2 Wheels

B - 1 Axle

C - 2 Wheel reta ining wa shers

D - 2 Wheels

E - 1 Hand le

G - 2 Fixing sc rews

LOOSE ITEMS

1x Mask with f ixing sc rews & washers

1x Ma sk hand le

2x Hand le reta ining sc rew s

1x Transparent g lass

1x Dark glass

1x 0.6mm we ld ing tip1x 0.8mm we ld ing tip

1x Ga s reg ula to r

1x welding torch and lea d (Torch and hose a ssem bly is fac tory fitted )

SHOULD ANY PART BE MISSING OR DAMAGED, CONTACT YOUR LOCAL DEALER FORREPLACEMENT.

A. Handle a nd Wheels

1. Slot the a xle (B) throug h the holes at the rear of the mac hine a nd slide awhe el (A) on to eac h end follow ed by the reta ining w ashers.

2. Screw the two c asters (D) to the ma chine.

3. Attac h the hand le to the top of the ma c hine, line upthe holes with those inthe c asing , and sec ure using the sc rew s p rovided .

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B. FACE SHIELD

To a ssem ble the welding shield, insert the c lea r g lass panel first, followed by thedark glass panel into the rec ess in the shield, i.e. the c lear glass MUST be on theoutside o f the shield . Sec uring them w ith the p lastic sc rew s provided .

Slot the two piec es together as shown, and

enter the threaded end of the handle throughthe holes provided. Thread on the plastic nutand tighten.

Always maintain the welding mask in goodcondition. If the clear glass protection lensbecomes badly pitted , suffic ient to interferewith vision, or cracked, have it replacedimmediately. Replacement c lear and da rklenses are available from your Clarke dea ler

- see Parts Lists for deta ils. NEVER use any darkfilter lens other than tha t provided by CLARKE

International, or one with the same certified Optical class (degree of p rotection).

The shield should a lwa ys be c leaned with a c lea n soft c loth after use, ensuring the lensesare c lean. Remove any dust that may have accumulated and store it in a safe placewhere it cannot be damaged . NEVER use a shield that isnot in perfec t condition.

The c lea r g lass panel should be rep lac ed when it b ec omes bad ly p itted .

WARNING:

NEVER look at an electric a rc without eye protection as this can injure the eyesperma nently. ALWAYS use a protection mask or welding helm

C. GAS SUPPLY

It is nec essary to p rocure a cylinder of gas, suitab le fo r the job in hand .

Loc ate the g as c ylinder on the p la tform a t the rear of the unit, and sec ure usingthe c hain p rovide d.

A reg ula tor is p rovided, co mp lete with outlet p ressure gauge fo r use with argon or

argon mix gas bottles. Should you req uire to use Ca rbon Dioxide, it will be nec essaryfor you to p urchase an ap prop ria te reg ulator with a fema le c onnec tor. Your Clarkedea ler will be ha ppy to a dvise in this reg ard .

Ensure the outlet of the gas bottle is clean, then screw on the regulator andtighten.

Alwa ys use the approp ria te g as for the ma teria l being welded. If you a re unsure,consult a qua lified tradesma n, or a suitab le refe renc e b oo k.

Atta c h the nut and ta il to the gas hose, using the wo rm d rive c lip p rovided , thensc rew the nut on to the reg ula tor outlet a nd tighten.

Open the g as valve a nd sc rew in the regulator knob a llow gas into the system tochec k for gas lea ks. If any are a pparent, they must be rec tified before p roc eeding.Turn off the gas when satisfied the system is leak free.

Fig.2

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A. Insta lling the Weld ing Wire

NOTE: These machines are designed to accept either the Clarke 5kg or 15kg wire

spools of mild steel, stainless steel or aluminium according to the type of metal youwish to weld.Wire spools must be purchased separately. See your Clarke dealer forfull details.

1. IMPORTANT: Ensure that the gas and electrical supplies are disconnected.

PREPARATION FOR USE

2. REF: FIG 4To fit the wire spool,firstly op en the sidec omp artment by

pulling the recessedc atc h b ac kwards.

Fig.6

3. Turn the p lastic knob with ca m (7,) to theposition shown in Fig. 5, so tha t the latch isunloc ked, and pull off the c olla r (4).

4. Slide the spoo l on to the shaft, ensuringtha t the Peg A loc a tes snugly in loc a tinghole B , ensuring the d irec tion o f feed of

the wire is in the d irec tion of the a rrow.Rep lac e the c ollar - 4, (5kg spool ONLY),and turn the Plastic knob with cam (7) tothe position shown in Fig .6 the reby loc kingthe spoo l on the shaft.

NOTE: The Plastic knob, item 7 Fig.4 is also usedto apply slight tension to the wire spool. Thisprevents the spool from running freely, whichcould cause the wire to unspool, creating a

birds nest tangle within the side compartment.Adjust by hand and test the tension.

1. Pressure plate

2. Mounting Shaft3. Wire Spool4. Collar5. Flat Washer6. Spring

7. Plastic Nut

Fig.5

Fig.4

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5. Unsc rew the pressure rollerb rac ket sec uring knob (A, Fig7), suffic ient fo r it to be pulledout of its ho lder. This relea sesthe pressure roller b rac ket (B)whic h, ma y then b e p ulled upto e xpose the we ld ing wire.

IMPORTANT!

Before fitting ANY wire, ensure the correct groove on the roller is in place.(see page 20)

Fig.9

6. Pull out the end of the wirefrom the rim of the spoo l,ta king c are NOT to relea se it.The spool is wound firmly andshould rem ain th is way.

Ensuring the wire is stra ight a ndnot kinked in any wa y, c lip off

the end with a sharp p a ir ofsnips ensuring the re a re noburrs or sha rp edges.

Proc eed to feed it through theguide tube (C , Fig .8), over thegroo ve on the roller (D), andinto the wire liner, by about 10- 15 cm .

7. Rep osition the pressure roller brac ket a nd sec uring knob (A) and tighten

slightly.Tightening the knob (A) too tightly will crush the wire and da ma ge thewire feed motor, too loose will not allow the wire to be pulled by the roller.

8. (Ref. Fig 9)Remove the to rc h shroud bytw isting it anti c loc kwise andpulling it o ff, then unsc rew thec ontact t ip.

Should any w ire p rotrude from thetip ....pull it out c om plete ly anddiscard.

19

Fig.7

Fig.8

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OPERATION1. These ma chines have 6 welding

positions (see the ta b le w hic hfollow s) in which to regulate c urrentfor various c ond itions, ob ta inab lethrough a c omb ination of one 2 -position (Min-Max) switch (A, Fig11)and one-3 position switc h (B, Fig11).

2. The selec tion of a welding p ositionis dete rmined by the thicknessof theme ta l to b e welded. The thicker itis, the higher the c urrent must b e.

3. Acc ording to the thickness to bewelded , the amo unt of ga s

reg ula ted to the work a lso va riesand must b e ad justed accord ingly.

4. For weld ing a djustments, refer tothe Wire Spec ifica tion Cha rt whichfollows.

WARNING(i) Ma ke sure a ll flammable materials are removed from the work area .

(ii) Never look direc tly at the welding a rc, it ca n seriously damage youreyes. Always use an approved we lding ma sk or helmet.

(iii) Wear protective c lothing so that all skin areas are covered.

(iv) Kee p a fire extinguisher handy.

Tuning The WelderThe tuning o f a Mig welding ma c hine req uires some p rac tic e, due to the fac tthat - contrary to the arc welding procedure - two parameters must be

ac c omm od ated to a c hieve a pe rfect w eld. These a re:

(A) Wire Feed Speed, and (B) Welding Voltage.

It is imp ortant to a rrive a t the c orrec t c omb ina tion to suit the type and thic knessof ma teria l to b e w elded . The c urrent ne cessa ry for we ld ing is d irec tly de pend entupon the wire feed speed. Wire speed is adjusted by turning the adjuster C,Fig11.

If the wire feed speed is increased, the current is also increased, but the arcleng th is dec rea sed . Conversely, if the wire feed speed is dec rea sed , and c urrent

is therefo re d ec rea sed , the leng th o f arc is inc rea sed .Increase of the welding voltage leads to a longer arc (without substantiallyaffecting the current). Conversely, a decreased welding voltage results in ashorter a rc , (the c urrent a ga in is not sub sta ntially changed ).

Fig.11

M

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A c hange in wire d iame ter results in c hanged pa rame ters. A sma ller diamete rwire req uires an inc rea se in wire feed spee d to rea c h the same c urrent . If certa inlimits a re e xc eeded , a sa tisfac tory weld c annot b e o b ta ined . These a re:

A) A too high wire feed spe ed (too high with reg ard to the we lding voltag e)results in p ulsing within the to rch. This is bec ause the wire elec trod e d ips intothe pud dle and c annot b e me lted off fast enough.

B) If the welding voltag e is set too high, large d rop s c an b e seen a t the end ofthe w ire e lec trod e. These d rop s are o ften d ep osited beside the we ld ing sea m.

The c orrec t ra te o f wire feed spee d (c urrent ) and we ld ing voltage, results in verylittle spa tte r and a c ontinuous, intensive hissing c an be he a rd from the a rc .

1. Always weld clean, dry and well prepa red material.

2. Hold gun at a 45angle to the workpiece with nozzle about 6mm from the surface.

3. Move the gun smoothly and stead ily as you weld.

4. Avoid welding in very draughty areas. A weak pitted and porous weld w ill result due to airblowing a way the protec tive we lding ga s.

5. Keep wire a nd wire liner clean. Do not use rusted wire.

6. Sharp bends or kinks on the welding hose should be avoided.

7. Try to avoid getting partic les of metal inside the machine since they could cause short circuits.

8. If ava ilable, use compressed air to period ically clean the hose liner when chang ing w ire spools.

IMPORTANT: Disconnect from power source when carrying out this operation.

9. Oc casiona lly blow dust from the inside welder (LOW PRESSURE AIR). This keeps machine runningcooler. Note: DO NOTblow air over the printed c ircuit board a nd elec tronic components.

10. The wire feed roller will eventually wea r during norma l use. With the correc t tension the pressureroller must feed the wire without slipping. If the pressure roller and the wire feed roller make

contact (when the wire is in place between them), the wire feed roller must be replac ed .

11. Check all cables period ically. They must be in good condition and not c rac ked.

1

2

3

Min

MaxSwitches

SWITCH

POSITIONS

Steel wirediameter

(mm)

Wire Speedadjustment

1 - MIN

1 - MAX

2 - MIN

3 - MIN

2 - MAX

3 - MAX

0.6

0.6

0.6 - 0.8

0.6 - 0.8

0.8

0.8

LOW

LOW

MED.

MED.

MED. - HIGH

HIGH

WIRE SIZE SPECIFICATION CHART

WELDING TIPS AND MAINTENANCE

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a) insuffic ient feed roller

pressureb) Burr on end of wirec) Liner blocked/damaged

d) Inferior wire

TROUBLE SHOOTING

1. No life fromwelder

2. No wire feed

Check fuses and mains lead a) Replace fuses as necessary.If problem persists. return welder

to your local dea ler.b) Check fuse size.

Return welder to your loc al dea ler.Motor malfunction

a) Increase roller pressure

b) Re-cut wire squarec) Clear with compressed a ir or

rep lace liner.d) Use only good d ean wire

a) Unscrew tip c ut wire and fit new

tip. Increa se wire speed beforeoperating again.

b) Change tip size.

a) As ab ove plus reduce feed rollerpressure so if bloc kage occurswire sleeps on roller. i.e. no feed

b) Renew wire liner.

Tighten drum b rake DO NOTOVERTIGHTEN

3. Feed motor

operates but wirew ill not fee d

4. Wire w elds itself to

tip

a) Wire welded to tip.b ) Wire liner damaged

preventing smoothoperation.

a) Wirefeed speed too low

b) Wrong size tip

5. Wire feed s intobirds nest tangle.

6. Ta ngled c oils ofwire around drum

7. Erra tic wire fee d

8. Poor quality welds

9. Wire jam s in tipwhen weldingaluminium

Drum b rake too slack.

a) Drum brake too lightb) Feed roller wornc) Insuffic ient p ressure on

feed rollerd) Wire d irty, rusty, damp or

bente) Liner pa rtially blocked

a) Loosen drum brake slightlyb) Check and replace if necessaryc) Increase p ressure on feed roller

DO NOTOVER TIGHTENd) Re-cut wire and ensure it is c lean

e) Clear with compressed air

a) Check gas is not being blownaway by draughts, if so, move toa sheltered area. If no draught,increase gas supply.

b) Consult Mig Welding manual

c) Ensure wkpiece is c lean a nd d ryd) Ensure wire is c lean and drye) Check ground clamp/ wkpiece

connection.

Use slightly oversize tip i.e. for 0.8mmwire use 1mm tip (Applies toaluminium only)

Allow welder to cool for 10-30min

before continuing. Note: If duty cycleis continually exceeded, damage towelder may result and welder outputis probably too small for application,

a) lnsuffic ient gas at weldarea

b) Incorrect gas/w irecombination

c) Rusty, pa inted, da mp. oily

or grea sy work pieced) Rusty, dirty work.e) Poor ea rth c onta c t

Tip too small

Duty Cyc le excee de d (auto

cut-out operates)

10. Welder cuts out

whilst in use

PROBLEM PROBABLE CAUSE REMEDY

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PARTS DIAGRAM

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No. Desc rip tion Qty Part No.

01 P.C Boa rd 1 EM22710043

02 Ha nd le 1 EM21600042

03 Motor 1 EM04600145

04 Rec tifier 1 EM22400038

05 Thermosta t 1 EM04600113

06 Comp lete Fa n 1 EM04600055

07 Torc h Connec tion Cover 1 EM21690268

08 Kno b 1 EM04600268

09 Upp er Frame Sp ac er 1 EM21690232

10 Potentiometer Knob 1 EM21690309

11 Current Switc h 16A 250V 1 EM22200006

12 Zinc Cha in 1 EM04600205

13 Up p er Pa ne l 1 EM33705448

14 Divid ing Pa nel 1 EM3372008915 To o lMa t 1 EM30905022

16 Pla stic Wire Feed er 1 EM44400021

17 Wire Feed Roll 1 EM33805001

17 Wire Feed Roll 1 EM33805027

18 Left Wire Feed er 1 EM21690231

19 Inp ut Ca b le 1 EM20220014

20 Ca b le Cla mp 2 EM04600233

21 Right Sid e Pa nel 1 EM33705362

22 Yellow Pilot-light Switc h 1 EM22200022

23 Right Wire Feed er 1 EM21690230

24 Front Pa nel 1 EM33710305

25 Sw itc h 1 EM22205001

26 Cho ke 1 EM44135018

27 Tra nsformer 1 EM44120114

28 Thermosta t 1 EM22210016

29 Ba c k Pa ne l 1 EM33715092

30 Wheels-a xle 1 EM55200005

31 Torc h 1 EM23000061

32 Lower Fra me Spa c er 1 EM2169023333 Ea rth Ca b le 1 EM43210119

34 Ea rth Cla mp 1 EM22110005

35 Wheel 2 EM21625041

36 Sp ool Hold er 1 EM04600001

37 Lower Pa nel 1 EM33700162

38 Left Sid e Panel 1 EM33705390

39 Wheel 2 EM21625039

40 Slid e Clip 1 EM21690226

41 Pla stic Ma sk W/ Ha nd le 1 EM21905018

42 Tra nsp a rent G la ss 1 EM21905020

43 Da rk Gla ss 1 EM21905021

44 Red uc er W/ Ga ug e 1 EM22905043

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1 21690339 Comp lete Torc h Hand le 12 21690340 Torc h Trigger 13 23005009 Torc h Gas Va lve 14 23005077 Torc h Nec k 15 23005091 Threa d Guid e Wire Liner 1

6 23005090 Torc h Nec k Insula tor 16a 23005093 Hea d Insula tor Torc h 1

7 23005096 Ga s Diffuser 17a 23005095 Reta iner Sp ring 18 23005018 0,6mm Conta c t Tip 1

8 23005019 0,8mm Conta c t Tip 18 23005020 1,0mm Conta c t Tip 19 23005021 Torc h Ga s Nozzle 19a 23005022 Sp ot Weld ing Nozzle 110 30900019 Rub ber Outer Sleeve 1

11 30900008 Torc h Ga s Hose 112 30900001 Blac k Wire Liner 113 22910001 Fast Coup ling Connec tor 2

14 33810090 Pin For Torc h Trigger 115 33800009 No-ga s Torc h Contac t Sp ring 1

16 21020081 Self Ta p p ing Sc rew 517 23005075 Gas Va lve W/ Torc h Nec k 1

No. Part No. Desc rip tion Qty

TORCH ASSEMBLY

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WIRING DIAGRAM