MIG 220TE • MIG255TE • MIG 270TE OPERATING & MAINTENANCE INSTRUCTIONS 0803
CONTENTS PAGE DECLARATION OF CONFORMITY We declare that this product complies with thie following standards/directives Guarantee .............................................................................................. 3 • • • • • • Parts & Service Contacts ....................................................................... 3 Electromagnetic Interference (EMC) .................................................. 4 Safety Precautions ...............................................................
TROUBLESHOOTING Your Clarke Mig 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. PROBLEM CAUSE 1. No “life” from welder Check fuses and mains lead 2. No wire feed 3.
ELECTROMAGNETIC INTERFERENCE (EMC) PARTS DIAGRAM - MIG270TE 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’.
PARTS LIST - MIG 270TE No. Description Part No. No. Description Part No. 2.2 Maintenance of the welding equipment 01 Wire Feeding Motor EM22810006 29 Black Gas Hose EM30900026 02 P.C. Board EM22710051 30 Wheel Axle EM55200029 03 Gab Solenoid Valve EM22900002 31 Casteor EM21625003 04 Compl.
SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING PARTS DIAGRAM - MIG255TE 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 PARTS LIST - MIG 255TE Causes of fire and explosion are: No. Description Part No. No. Description Part No. 01 Wire Feed Motor 42V EM22810006 30 Resistance EM22305004 02 P.C.
3. ELECTRIC ARC (MIG, TIG) WELDING PARTS DIAGRAM - MIG220TE 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.
3B) TOXIC FUME PREVENTION PARTS LIST - MIG 220TE Part No. No. Description 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 40 41 41 41 42 43 44 45 46 47 48 50 51 52 Motor + Pinion ........................................................................................ Motor Control ......................................................................................... Gas Solenoid Valve ....................................................
2) Torch Fully insulated torch should be used. Do NOT use a torch 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.
ADDITIONAL SAFETY PRECAUTIONS for MIG WELDING ensure that there is full free air circulating around the outer casing of ✔ ALWAYS the machine, and that the louvres are unobstructed. arc can seriously damage your eyes. Both operator and spectators ✔ Welding must ALWAYS use a proper welding face shield or helmet, with suitable filter lenses. Proper gloves and working clothes should be worn at all times. check that the pressure regulator and gauges (where fitted), are ✔ ALWAYS working correctly.
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.
WIRING DIAGRAMS ELECTRICAL CONNECTIONS WARNING! THIS APPLIANCE MUST BE EARTHED. MIG 220TE & 255TE Connect the mains lead, through a suitably fused isolator switch, to a 230 Volt (50Hz) electrical supply, having a fuse rating in accordance with that given in the specification chart on page 2. A standard 13 Amp plug MUST NOT be used with this machine.
UNPACKING & PARTS IDENTIFICATION Unpack and lay out the components, checking against the following list. Any damage or deficiency should be reported to your CLARKE dealer immediately. Some components are stored within the side compartment. To open the compartment, slide the recessed handle backwards. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Welder complete with power cable and gas hose.
GENERAL LAYOUT SPECIFICATIONS Power Supply 220TE 250TE 270TE 230V 50Hz 3Ph 230V 50Hz 3Ph 400V 50Hz 3Ph Main Fuse Rating 25Amps 40Amps 16Amps Current Range 40-200A 30-250A 30-260A 3-4mm 4-5mm 6mm 0.6-1.2mm 0.6-1.2mm 0.6-1.2mm Max. Metal Thickness (m/s) Welding Wire Sizes Duty Cycle* 20% 200A - - 30% - 250 - 35% - - 260A 60% 125A 180A 170A 100% Dimensions (no handle) mm 95A 140A 135A 685x820x500 685x820x500 685x820x500 6015220 6015235 6015240 Fig.
ASSEMBLY & INSTALLATION MAINTENANCE WARNING! A. Wheels & Casters ELECTRICITY CAN KILL....NEVER TOUCH LIVE ELECTRICAL COMPONENTS DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS AND MAINTENANCE OPERATIONS Raise the machine, thread the axle into its housing and attach the wheels, securing with the circlips provided. Thread the casters into their mountings and tighten the bolts. B. Handle Attach the handle to the top front of the machine using the two hex. socket head screws provided. C.
E. The Welding Shield GENERAL INFORMATION A. Spot Timer Control Fig.3 This control may be used for spot (plug) welding, or stitch welding. The control is set so that the duration of weld lasts for a predetermined time. For plug welding, a special nozzle is required, (see your CLARKE dealer) which is pressed hard against the two pieces of material to be welded, as the trigger is pressed.
F. Attach the Earth Clamp PREPARATION FOR USE Attach the earth clamp to the workpiece as close to the point of weld as possible, without it being intrusive. A. Installing the Welding 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.
(i) WELDING CURRENT CONTROL Fig.7 Select the welding current according to the type of metal and thickness to be welded. The control has 7 positions as indicated in the chart below. Experience will determine the optimum setting for the job in hand, but the chart gives general settings from which to work. 1 7 6 Switch Positions 2 Steel Wire Diameter (mm) Wire Speed Adjustment 1 0.6 LOW 2 0.6 LOW 3 0.6 - 0.8 MEDIUM 4 0.6 - 0.8 MEDIUM 5 0.8 MEDIUM _ HIGH 6 0.8 HIGH 7 1.
OPERATION 9. Close the side panel of the machine, and switch on at the mains or isolator. 10. Set the Wire Feed rotary switch, on the front panel, to position 6 OR 7, switch on the machine and press the trigger. The wire will feed through the hose and when it appears at the torch end, release the trigger, switch off the machine and disconnect from the mains supply. Replace the contact tip and the torch shroud.
