MIG WELDER Model Nos.
WELDER SPECIFICATIONS PRIMARY or INPUT POWER DATA Primary Volts Primary Amps Frequency MIG195TE MIG205TE MIG230TE 230V/1PH 24 Amps 50 HZ 230V/1PH 24 Amps 50 HZ 230V/1Ph 28 Amps 50Hz 23-44 V 185 30-185 23-30 V 185 30-185 23-46 V 210 30-210 80 Amps 103 Amps 170 Amps --- 60 Amps 80 Amps --65 Amps 80 Amps 103 Amps -200 Amps -- SECONDARY or OUTPUT POWER DATA Sec. Volts Max. Sec. Amps Current Range DUTY CYCLES 100% 60% 20% 16% 12% NOTE: Duty Cycles are rated over a 10 minute period.
CONTENTS PAGE Welder Specifications ............................................................................ 2 Parts & Service Contacts ....................................................................... 3 Guarantee .............................................................................................. 4 Electromagnetic Interference (EMC) .................................................. 5 Safety Precautions .................................................................................
Thank you for purchasing this CLARKE MIG Welder, designed to operate using a gas cylinder with plain metal welding wire ONLY. This is explained in greater detail within the manual. 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.
ELECTROMAGNETIC INTERFERENCE (EMC) Whilst this unit complies with EMC regulations, the user is responsible for installing and using the welding equipment according to the manufacturers instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation. In some cases this remedial action may be as simple as earthing the welding circuit, see ‘Note’.
take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure. 2.
SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING 1. 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. FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY 2.
C) Fire and explosion prevention Causes of fire and explosion are: 1) combustibles reached by the arc, flame, flying sparks, hot slag or heated material; 2) misuse of compressed gases and cylinders; 3) short circuits. BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks and slag can fly 10M.
3. ELECTRIC ARC (MIG, TIG) WELDING Comply with precautions in 1 above, and this section. Arc welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot. The wise operator avoids unnecessary risks and protects himself and others from accidents. 3A) BURN PROTECTION Comply with precautions in 2.
3B) TOXIC FUME PREVENTION Comply with precautions in 2B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. 3C) FIRE AND EXPLOSION PREVENTION Comply with precautions in 2C. Equipment’s rated capacity. 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.
2) Electrode holders Fully insulated electrode holders should be used. Do NOT use holders with protruding screws or with any form of damage. 3) Connectors Fully insulated lock-type connectors should be used to join welding cable. 4) Cables Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable.
PREPARATION OF THE WORKING AREA The working area must be sufficiently spacious, not humid, and well-ventilated as to avoid any fumes which develop from the welding process and from incidental material adhering to the pieces to be welded (oils, paints, tars...) which may cause annoyance to the operator. Avoid welding by contact with humid parts nearby combustible liquids. Least of all, do not weld upon tanks which may contain flammable residuals.
✗ ✗ PREPARATION OF THE WORKING AREA NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN. The MIG welding process uses an INERT gas to protect the weld pool. It is important to ensure the appropriate gas is being used. NEVER use gas from a cylinder, the content of which is unknown. ✗ ✗ NEVER a. Use a damaged cylinder. b. Lift the cylinder by the valve. c. Expose the cylinder to a heat source or sparks.
SAFETY EQUIPMENT A comprehensive range of CLARKE safety equipment for use when welding is available from your local dealer. MIG WELDING - PRINCIPLES OF OPERATION MIG (Metal Inert Gas) welding is a process in which a power wire electrode is fed continuously into the weld pool at a controlled, constant rate. The wire is connected to the positive side of a rectified voltage supply. The workpiece is connected to the negative side of the supply.
ELECTRICAL CONNECTIONS WARNING: THIS MACHINE MUST BE EARTHED. This welder must be connected to a 230 volt (50Hz) supply, having a rated capacity of greater than 13 amps. A 13 Amp (BS1363) plug is not suitable for this device. Connect the three core mains lead to a suitably fused supply through an isolator or heavy duty plug.
UNPACKING & PARTS IDENTIFICATION 1. The side panel is hinged at its rear edge: Open by pulling sideways at the front edge, lay out all components contained within, and check to ensure that they are all correct according to the list below. A 2 Wheels B 1 Axle C 2 Wheel retaining washers D 2 Casters E 1 Handle F 2 Brackets G 4 Fixing screws Fig.
ASSEMBLY A. Attaching the Torch Fig.2 Mig 195TE - Mig 205TE A. It is necessary to fit the torch hose assembly (7) to the machine, but before doing so you must first measure the length of protrusion of the liner (9) from the brass nut (10). IMPORTANT: This measurement should be a maximum of 18mm and should be carefully trimmed to this length using a good pair of side cutters, or similar, ensuring there are no burrs or sharp edges which may impede the progress of the wire when fitted. B.
Mig 230TE Fig.3 Plug the torch hose into the socket on the front of the welder and secure by hand screwing in the threaded connection. B. Loading the 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 you wish to weld.Wire spools must be purchased separately. See your Clarke dealer for full details. 1. IMPORTANT: Ensure that the gas and electrical supplies are disconnected. 2.
Fig.6 NOTE: The Plastic knob, item 7 is also used to apply slight tension to the wire spool. This prevents the spool from running freely, which could cause the wire to unspool, creating a ‘birds nest’ tangle within the side compartment. Adjust by hand and test the tension. It Is now necessary to load the wire into the Torch...as follows: 5. Loosen the plastic knob (17, Fig.2) by turning it anticlockwise, (this maintains pressure on the wire via the roller).
C. Gas Supply It is necessary to procure a cylinder of gas, suitable for the job in hand. Locate the gas cylinder on the platform at the rear of the unit, and secure using the chain provided. A regulator is provided, complete with outlet pressure gauge for use with argon or argon mix gas bottles. Should you require to use Carbon Dioxide, it will be necessary for you to purchase an appropriate regulator with a female connector. Your Clarke dealer will be happy to advise in this regard.
PREPARATION FOR WELDING 1. Attach the earth clamp to the bare metal to be welded. Ensure contact is good . 2. Make sure that the wire-roller groove in the roller corresponds to the diameter of the welding wire being used. Refer to “Loading wire” above. 3. Plug the machine into a 230V AC 50Hz outlet. 4. Open the gas valve on the gas cylinder regulator, (turn knob clockwise)and adjust the gas regulator to the proper setting position. NOTE: this varies with different metals, thicknesses and currents.
WARNING (i) (ii) Make sure all flammable materials are removed from the work area. Never look directly at the welding arc, it can seriously damage your eyes. Always use an approved welding mask or helmet. (iii) Wear protective clothing so that all skin areas are covered. (iv) Keep a fire extinguisher handy. WIRE SIZE SPECIFICATION CHART SWITCH SWITCH POSITIONS 1 2 3 4 5 6 STEEL WIRE DIAMETER (mm) WIRE SPEED ADJUSTMENT 0.6 0.6 0.6 - 0.8 0.6 - 0.8 0.8 0.
TROUBLE SHOOTING PROBLEM 1. No life from welder 2. No wire feed 3. Feed motor operates but wire will not feed PROBABLE CAUSE Check fuses and mains lead Motor malfunction a) insufficient feed roller pressure b) Burr on end of wire c) Liner blocked/damaged d) Inferior wire REMEDY a) Replace fuses as necessary. If problem persists. return welder to your local dealer. b) Check fuse size. Return welder to your local dealer.
PARTS DRAWING - MIG 195TE 24
PARTS LIST - MIG 195TE No. Part No. Item Qty 01 02 03 04 05 06 07 08 09 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 P.C. Board 0698 220/240V Wire Feeding Motor 24V D.48 MP Gas Solenoid Valve 4W 220V 50hz Complete Thermostat 100° 16A Rectifier PMS 16/4/2 F Resistance 3 Ohm D.16 L=90 Fan C20 240V Torch Grommet Direct Connection Handle Fuse 5x20 1A 250V On/Off Switch 16A-250V Fuse Holder 6,3A 250V Black Hose D.
PARTS DRAWING - MIG 205TE 26
PARTS LIST - MIG 205TE No. 01 02 03 04 05 06 07 08 09 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Part No.
PARTS DRAWING - MIG 230TE 28
PARTS LIST - MIG 230TE No. Part No.
WIRING DIAGRAM - MIG 195TE & MIG 230TE 30
WIRING DIAGRAM - MIG 205TE 31
