PRO-90 MIG MIG 100E MIG 150TE OPERATING & MAINTENANCE INSTRUCTIONS 0402
CONTENTS ACCESSORIES PAGE Guarantee .............................................................................................. 3 Parts & Service Contacts ....................................................................... 3 Electromagnetic Interference (EMC) .................................................. 4 Safety Precautions ................................................................................. 6 The following accessories are available from your Clarke dealer.
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 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 No.
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. WIRING DIAGRAMS MIG 110E FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY 2.
C) Fire and explosion prevention SPECIFICATIONS Causes of fire and explosion are: PRO-90 Supply 100E 150TE Power 230V 50Hz 1Ph 230V 50Hz 1Ph 230V 50Hz 1Ph Fuse Rating 13Amps 13Amps 20Amps Current Range 24-90A 30-100A 30-150A Max. Metal Thickness (m/s) 3-4mm 4-5mm 6mm Welding Wire Sizes 0.6-0.8mm 0.6-0.8mm 0.6-0.8mm 8% 80A 100A 130A 60% 30A 40A 75A 100% 24A 30A 55A 430X250X370 430X250X370 700X320X580 Weight 24KG 25kg 32kg Part No.
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 CONTROL SETTINGS - REFERENCE TABLES Comply with precautions in 2B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. B. MIG 100E STEEL 0.6 mm Gas Welding Wire Workpiece Thickness (mm) Welding Wire Speed Welding Wire Speed Position Adjustment Position Adjustment A B C D 0.5 - 0.6 I 2/3 MIN 5 0.6 - 0.8 I 2/3 MAX 0.8 - 1.0 A 2 1.0 - 1.2 A 1.2 - 2.0 2.0 - 3.
2) Electrode holders Fully insulated electrode holders should be used. Do NOT use holders with protruding screws or with any form of damage. CONTROL SETTINGS - REFERENCE TABLES A. MIG PRO-90 3) Connectors Fully insulated lock-type connectors should be used to join welding cable. STEEL 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.
RENEWING THE WIRE LINER PREPARATION OF THE WORKING AREA Fig.12 If the liner becomes damaged or kinked, it will be necessary to replace it. 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.
✗ ✗ NEVER a. Use a damaged cylinder. b. Lift the cylinder by the valve. c. Expose the cylinder to a heat source or sparks. 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. ✗ ✗ ✗ ✗ MAINTENANCE WARNING! ELECTRICITY CAN KILL....
Thermal Overload SAFETY EQUIPMENT A thermal overload is a safety device which shuts off the welder when the duty cycle has been exceeded. This is to prevent damage to the machine caused by overheating. A comprehensive range of CLARKE safety equipment for use when welding is available from your local dealer. When this occurs, the ON/OFF switch will glow (amber). Allow the welder to cool, until the amber light extinguishes before resuming. For details of the duty cycle...i.e.
ELECTRICAL CONNECTIONS WARNING! THIS APPLIANCE MUST BE EARTHED. A. MIG’s PRO-90 and 100E ONLY D. Trim the Welding Wire Trim the welding wire so that it protrudes no more than 5mm from the end of the shroud. E. Attach the Earth Lead These welders are 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).
1. MIG PRO-90 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. Two, 2-pole switches are marked 1- 2 and MAX - MIN respectively, Most of the components are stored within the side compartment. To open the compartment, slide the side cover upwards. Set these switches according to the charts on pages 27-29. PRO MIG-90 & MIG100E MIG150TE 1.
ASSEMBLY & INSTALLATION PREPARATION FOR USE A. Loose Components A. PREPARE THE WORK PRO-90 & MIG 110E Lie the welder gently on its side and attach the four feet using the screws and flat washers provided. Fig.1 MIG 150TE Insert the axle through the holes in the rear base of the machine, then attach the wheels, securing them by pushing the star locking washers provided, on to the axle, using a piece of tube or an old socket, ensuring the centre tines of the washer face outwards.
Replace the collar, spring and plastic knob, tightening the knob sufficiently to allow the spool to rotate smoothly but with a slight amount of braking friction. Do not over tighten as this will exert undue pressure on the wire drive motor and may cause serious damage. B. ASSEMBLING THE WELDING SHIELD Fig.8 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.
8. Fig.5 (Ref. Fig 5) Unscrew and remove the torch shroud by twisting it anti clockwise, then unscrew the contact tip. A mini gas bottle complete with gas regulator is provided. Should you prefer to use larger gas cylinders, the appropriate gas regulator and fittings need to be acquired. Your Clarke dealer will be happy to advise in this regard. Should any wire protrude from the tip....pull it out completely and discard. 9. C. The Gas Supply Fig.
