GAS/NO-GAS MIG WELDER Models 90EN, 100EN, 105EN & 151EN OPERATING & MAINTENANCE INSTRUCTIONS 0502
Thank you for purchasing this CLARKE MIG Welder, designed to operate with or without gas....so-called GAS/NO-GAS welders. 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.
CONTENTS PAGE Guarantee .............................................................................................. 3 Parts & Service Contacts ....................................................................... 3 Electromagnetic Interference (EMC) .................................................. 4 Safety Precautions ................................................................................. 6 Additional Safety Precautions for MIG Welding ...............................
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.
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. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling.
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. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. 5) Terminals and other exposed parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation.
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. ✔ ALWAYS inspect the hose before use to ensure it is in good condition.
SAFETY EQUIPMENT A comprehensive range of CLARKE safety equipment for use when welding is available from your local dealer. NO-GAS 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 (NO-GAS Welding).
ELECTRICAL CONNECTIONS WARNING! THIS APPLIANCE MUST BE EARTHED. 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). IMPORTANT: If the welder is fitted with a plug which is moulded onto the electric cable (i.e. non- re-wirable) please note: 1. The plug must be thrown away if it is cut from the electric cable.
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. Most of the components are stored within the side compartment. To open the compartment, pull the side panel up sharply. The cover may be quite tight when new, so exercise a little care. MIG151EN MIG 90EN,105EN & 110EN 1. Rubber Feet with washers and screws (4 pcs) 2. 2-Piece Welding Mask 3.
ASSEMBLY & INSTALLATION A. LOOSE COMPONENTS MIG’s, 90EN, 100EN & 105EN Lay the welder gently on its side and attach the four feet using the screws and flat washers provided. MIG 151EN only 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.
C. INSTALLING THE WELDING WIRE NOTE: These machines are supplied with a Clarke ‘Mini’ spool of mild steel flux cored welding wire. A 5kg spool is available from your Clarke dealer. See ‘Accessories’ for full details. 1. IMPORTANT: Ensure that theelectrical supply is disconnected. 2. Firstly remove the side cover, on the left hand side of the unit, by pulling it sharply upwards.
IMPORTANT! If you are changing the size of wire, you must also select the appropriate groove on the feed roller. See p. 19 3. Fig.5 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. Ensuring the wire is straight and not kinked in any way, clip off the end cleanly, ensuring there are no burrs or sharp edges.
(3) Selecting the Correct Drive Roller Groove As previously mentioned, it is important that the correct groove in the drive roller is selected for the particular wire being used. Two grooves, 7mm and 9mm are provided. The 7mm groove should be used with 6mm dia. wire and the 9mm groove for all 8mm wire and 9mm flux cored wire. The welder s factory set with the 9mm groove in position. To change to the other groove, proceed as follows: 1. Fig.
Always use the appropriate gas for the material being welded. Three types are provided by Clarke International, as follows: Carbon Dioxide (CO2) ......... For Mild Steel .................... Part No. 6000642 Argon .................................... For Aluminium ................... Part No. 6000661 CO2/Argon Mix .................... For Thin Sheet metal Mild Steel/ Stainless ......... Part No. 6000660 Additionally a larger CO2 bottle is available ............... Part No.
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 Fig.10 In order to produce a satisfactory weld, the controls must be fine tuned whenever there is a material change in weld characteristics. Three sets of controls are provided....
Models 90EN, 1010EN and 105EN are provided with two, 2-position switches marked 1- 2 and MAX - MIN respectively, as shown in Fig 10. Model 150EN is provided with three 2-position switches, marked A-1, 2-3 and MAX-MIN. These controls areused to control the welding current according to the type and thickness ofmaterial to be welded, and in accordance with the charts shown in the‘Reference Tables’ on pages 26-28.
OPERATION With the welding current set, and welding wire trimmed, set the wire feed control to 6 , (8 for Aluminium). 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. A welding current is now available at the tip.
WELDING TIPS • • • • • • 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. Try to maintain a constant speed of movement with the torch. Do not weld in windy conditions or in an area where ventilation is a problem, or where air flow fluctuates. ALWAYS keep the wire and nozzle clean...NEVER use rusted wire. Avoid sharp bends or kinks in the welding hose.
RENEWING THE WIRE LINER Fig.12 If the liner becomes damaged or kinked, it will be necessary to replace it. Before commencing work, ensure the gas and electrical supplies are disconnected. 1. Open the side cover, and remove the welding wire from the hose and torch assembly. (Refer to ‘Installing Welding Wire’ on page 16). 2. Slacken the three screws (W), securing the Hose Support Bracket Cover, slightly...do not remove. Remove the Roller (D) 3. Fig.10 Fig.13 4.
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.
CONTROL SETTINGS - REFERENCE TABLES A. MIG 90EN STEEL 0.6 mm Gas Welding Wire Workpiece Thickness (mm) 0.6 - 0.8 0.8 mm Gas Welding Wire Welding Wire Speed Welding Wire Speed Position Adjustment Position Adjustment A B C A B C 1 MIN 5 1 MIN 5 0.8 - 1.0 2 MIN 6 2 MIN 6 1.0 - 2.0 1 MAX 6 2 MAX 6 2.0 - 3.0 2 MAX 7-8 2 MAX 7-8 ALUMINIUM Workpiece Thickness (mm) 0.8 mm Gas Welding Wire Welding Wire Speed Position Adjustment A B C 0.8 1 MIN 7-8 1.0 -2.
CONTROL SETTINGS - REFERENCE TABLES B. MIGs 100EN & 105EN STEEL Workpiece Thickness (mm) 0.6 mm Gas Welding Wire 0.8 mm Gas Welding Wire Welding Wire Speed Welding Wire Speed Position Adjustment Position Adjustment A B C A B C 0.6 - 0.8 1 MIN 5 1 MIN 5 0.8 - 1.0 1 MIN 6 2 MIN 6 6 1.0 - 2.0 2 MIN 6 2 MAX 2.0 - 3.0 2 MAX 7 2 MAX 7 >3.0 2 MAX 7-8 2 MAX 7-8 ALUMINIUM Workpiece Thickness (mm) 0.8 1.0 - 2.0 2.0 - 3.0 0.
CONTROL SETTINGS - REFERENCE TABLES B. MIGs 151EN STEEL 0.6 mm Gas Welding Wire Workpiece Thickness (mm) Welding Position 0.8 mm Gas Welding Wire Wire Speed Welding Wire Speed Adjustment Position Adjustment A B C D A B C 0.5 - 0.6 1 2/3 MIN 5 0.6 - 0.8 A 2 MIN 5 A 0.8- -1.0 1 2/3 MAX 6 1 2/3 MAX D 2 MIN 6 2/3 MAX 6 1.0 - 1.2 A 3 MIN 6 1 1.2 - 2.0 A 2 MAX 6 A 2 MAX 6 2.0 - 3.0 A 3 MAX 7 A 3 MAX 7/8 3.0 - 6.
WIRING DIAGRAMS MIG 100EN & 105EN 30
PARTS DIAGRAM - MIG 100EN & 105EN 34
PARTS LIST - MIG100EN & 105EN 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 33 34 35 P.C.
ACCESSORIES The following accessories are available from your Clarke dealer. Please quote the part numbers shown below: 1. Welding Wire Spools Mild Steel Stainless Steel Aluminium 6000641 6000481 6000664 6000476 6000475 6000666 6000498 - 6000483 - CO2 (250g) 6000642 For welding Mild Steel CO2 (600g) Argon CO2/Argon Mix 6000643 6000661 6000660 For welding Mild Steel For welding Aluminium For welding Stainless/Thin Sheet MS Mini - 0.6mm Mini - 0.8mm Mini - 9mm (FLUX Core) 5kg - 0.6mm 5kg - 0.
SPECIFICATIONS Power Supply 90EN 100EN 105EN 151TE 230V 50Hz 1Ph 230V 50Hz 1Ph 230V 50Hz 1Ph 230V 50Hz 1Ph Fuse Rating 13Amps 13Amps 13Amps 13Amps Current Range 30-90A 30-100A 30-100A 30-150A Max. Metal Thickness 3-4mm 4-5mm 4-5mm 5-6mm 0.6-0.9mm 0.6-0.9mm 0.6-0.9mm 0.6-0.
