MIG 160TM Part No: 6015530 OPERATING & MAINTENANCE INSTRUCTIONS 0108
WELDER SPECIFICATIONS PRIMARY or INPUT POWER DATA Primary Volts 230V / 1PH Primary Amps 16 Amps Frequency 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 Stainless Steel Wire 0.8mm Aluminium Wire 0.
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.
ASSEMBLY Remove contents from carton and check all components as follows: The side panel is hinged at its rear edge: Open by pulling the securing catch sideways, lay out all components contained within, and check to ensure that they are all correct according to the list below. A - Fig.
B. FACE SHIELD To assemble the welding shield, insert the clear glass panel first, followed by the dark glass panel into the recess in the shield, i.e. the clear glass MUST be on the outside of the shield. Securing them with the plastic screws provided. Slot the two pieces together as shown, and Fig.2 enter the threaded end of the handle through the holes provided. Thread on the plastic nut and tighten. Always maintain the welding mask in good condition.
PREPARATION FOR USE 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. IMPORTANT: Ensure that the gas and electrical supplies are disconnected. 2. REF: FIG 4 To fit the wire spool, firstly open the side compartment by pulling the recessed catch backwards. Fig.
Fig.7 5. Unscrew the pressure roller bracket securing knob (A, Fig 7), sufficient for it to be pulled out of its holder. This releases the pressure roller bracket (B) which, may then be pulled up to expose the welding wire. IMPORTANT! Before fitting ANY wire, ensure the correct groove on the roller is in place. (see page 20) 6. Pull out the end of the wire from the rim of the spool, taking care NOT to release it. The spool is wound firmly and should remain this way. Fig.
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.
OPERATION 1. These machines have 6 welding Fig.11 positions (see the table which follows) in which to regulate current for various conditions, obtainable through a combination of one 2 position (Min-Max) switch (A, Fig11) and one-3 position switch (B, Fig11). 2. The selection of a welding position is determined by the thicknessof the metal to be welded. The thicker it is, the higher the current must be. 3.
A change in wire diameter results in changed parameters. A smaller diameter wire requires an increase in wire feed speed to reach the same current. If certain limits are exceeded, a satisfactory weld cannot be obtained. These are: A) A too high wire feed speed (too high with regard to the welding voltage) results in pulsing within the torch. This is because the wire electrode dips into the puddle and cannot be melted off fast enough.
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 DIAGRAM 24
No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 17 18 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 Description Qty P.
TORCH ASSEMBLY No. 1 2 3 4 5 6 6a 7 7a 8 8 8 9 9a 10 11 12 13 14 15 16 17 Part No.
WIRING DIAGRAM 27
