NO GAS MIG WELDER MIG85ENB Part No.
Thank you for purchasing this CLARKE NO-GAS MIG 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. CLARKE GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase.
CONTENTS PAGE Guarantee .............................................................................................. 2 Electromagnetic Interference (EMC) .................................................. 4 Safety Precautions ................................................................................. 6 Additional Safety Precautions for MIG Welding ............................... 11 Principles of Operation ........................................................................
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.
✗ ✗ NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN. NEVER continue to weld, if, at any time, you feel even the smallest electric shock. Stop welding IMMEDIATELY, and DO NOT attempt to use the machine until the fault is diagnosed and corrected. ✗ ✗ NEVER point the MIG torch at any person or animal. NEVER touch the MIG torch nozzle until the welder is switched OFF and the nozzle has been allowed to cool off.
SAFETY EQUIPMENT A comprehensive range of CLARKE safety equipment for use when welding is available from your local dealer. NO-GAS 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 negative side of a rectified voltage supply. The workpiece is connected to the positive side of the supply.
ELECTRICAL CONNECTIONS ! WARNING! THIS APPLIANCE MUST BE EARTHED. The welder is fitted with a standard 13 amp BS 1363 plug, fitted with a 13 amp fuse. Connect to a 230 volt (50Hz) domestic electrical supply and we strongly recommend that this be done via a Residual Current Device (RCD). IMPORTANT: The wires in the mains lead are coloured in accordance with the following code: Green & Yellow .......... Earth Blue .......... Neutral Brown ..........
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 of the components are stored within the side compartment. To open the compartment, pull the side panel up, as indicated in Fig.1. The cover may be quite tight when new, so ease off gently. 1. Welder complete with Torch and Hose, Earth Cable with Clamp and Power cable. 2. 2-Piece Welding Mask 3.
ASSEMBLY & INSTALLATION A. INSTALLING THE WELDING WIRE NOTE: This machine is supplied with a Clarke ‘Mini’ spool of 0.9mm, mild steel, flux cored welding wire. Replaceable spools available from your Clarke dealer. See ‘Accessories’ for full details. 1. IMPORTANT: Ensure that the electrical supply is disconnected. 2. Firstly remove the side cover, on the left hand side of the unit, by pulling it sharply upwards. (1) Removing/Replacing the Wire Spool Fig.3 Re: Fig.
3. Re: Fig.5 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.5 Ensuring the wire is straight and not kinked in any way, clip off the end cleanly, ensuring there are no burrs or sharp edges. Proceed to feed it through the guide tube (E), over the groove on the roller (B), and into the wire liner (D), by about 10 - 15 cm. 4. Reposition the pressure roller bracket (C, FIG.4) and plastic knob (A, Fig.
B. ASSEMBLING THE WELDING SHIELD Fig.2 To assemble the welding shield, (Fig.2), 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 enter the threaded end of the handle through the holes provided. Thread on the plastic nut and tighten.
PREPARATION FOR USE A. PREPARE THE WORK MOST IMPORTANT! It is VITAL that the workpiece is perfectly clean at the point of weld. Any coating, plating or corrosion MUST be removed, otherwise a good weld will be impossible to achieve. B. SET THE CONTROLS Three switches are provided....(1) ON/OFF, (2) MAX/MIN and (3) WIRE FEED. The ON/OFF switch is self explanatory, but serves a secondary function. You will note that it is coloured amber.
Workpiece Thickness (mm) Current Setting Wire Feed 0 - 2.0 2.0 - 4.0 MIN MAX 6 6 The 10-position wire speed control should be set to 6 to begin with, then adjusted as required. (See notes under ‘Operation). D. Trim the Welding Wire Trim the welding wire so that it protrudes no more than 5mm from the end of the contact tip. E. Attach the Earth Clamp Attach the earth clamp to the workpiece, as close to the point of weld as possible, without it being intrusive.
OPERATION Plug the machine into the mains supply or switch on at the isolator, and, ensuring all precautions have been taken and with the machine set up correctly, lower the torch to the workpiece with one hand, whilst holding the welding mask in the other. Approach the work with the tip at an angle of approx. 45O. and pull the torch trigger fully. As the electrode touches the workpiece, an arc will be struck....BUT, before it is struck, COVER THE FACE WITH THE FACE MASK.
WELDING TIPS 1. Try to maintain the tip of the nozzle at an angle of approx. 45O and at a constant distance of approx 5-7mm from the workpiece. 2. Try to maintain a constant speed of movement with the torch. 3. Do not weld in windy conditions or in an area where ventilation is a problem, or where air flow fluctuates. 4. ALWAYS keep the wire and nozzle clean...NEVER use rusted wire. 5. Avoid sharp bends or kinks in the welding hose. 6.
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.
PARTS DIAGRAM 24
PARTS LIST No. Description Part No.
WIRING DIAGRAM PARTS & SERVICE CONTACTS 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.com SERVICE: Service@clarkeinternational.
SPECIFICATIONS Power Supply ................................................................. 230V, 50Hz 1Ph Fuse Rating ..................................................................... 13Amps Current Range ............................................................... 27 - 85Amps Max. Metal Thickness ................................................... 4mm Welding Wire Sizes ......................................................... 0.9mm Flux Cored Duty Cycle* MIN (27A) ...............................
