Related Manuals for Clarke MIG120 MULTI
Summary of Contents for Clarke MIG120 MULTI
- Page 1 MIG/MMA/TIG INVERTER WELDER MODEL NO: MIG120 MULTI PART NO: 6015601 OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC0722...
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Page 2: Specifications
INTRODUCTION Thank you for purchasing this CLARKE 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. - Page 3 PRINCIPLES OF THE MACHINE The MIG120 Multi is an inverter type welding machine, suitable to carry out Gas and No Gas CO welding, MMA, TIG and MIG (MAG -USA welding). The welder is mainly used for CO gas protected welding which has the advantages of high energy efficiency, strong arc penetration and small welding deformation.
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Page 4: Environmental Recycling Policy
SUITABILITY OF DIFFERENT METHODS MMA/Arc Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron. MIG Welding Carbon Steel, Mild Steel, Stainless Steel TIG Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron, Titanium, Copper + Brass. Metal Being Welded Suitable Gas Part number Mild Steel... -
Page 5: General Precautions
SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING 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. -
Page 6: Fire And Explosion Prevention
vapours can be drawn into the welding atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene. FIRE AND EXPLOSION PREVENTION Causes of fire and explosion are: 1. Combustibles reached by the arc, flying sparks, hot slag or heated material;... -
Page 7: Electric Arc Welding
weld or cut. Hollow castings or containers must be vented before welding as they can explode. In explosive atmospheres, NEVER weld or cut where the air may contain flammable dust, gas, or liquid vapours. DO NOT overload arc welding equipment. It may overheat cables and cause a fire. -
Page 8: Shock Prevention
an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision. Before welding whilst wearing contact lenses, seek advice from your optician. PROTECTION OF NEARBY PERSONNEL For production welding, a separate, well vented room or enclosed bay is best. -
Page 9: Preparation Of The Working Area
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. - Page 10 9. NEVER allow the earth cable or torch to become wrapped around the operator or any person in the vicinity. A comprehensive range of CLARKE safety equipment for use when welding is available from your local dealer. See page 37.
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Page 11: Safety Symbols
SAFETY SYMBOLS The following symbols may be displayed on the machine or its packaging. Read this instruction Do not expose to rain. booklet carefully before use. Wear welding mask Recycle unwanted materials under WEEE Directive Wear protective gloves General Hazard Wear a dust mask Warning;- Magnetic field created (... -
Page 12: Electrical Connection
ELECTRICAL CONNECTION WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY. Before switching the product on, make sure that the voltage of your electricity supply is the same as that indicated on the rating plate. This product is designed to operate on 230VAC 50Hz. - Page 13 OVERVIEW & INVENTORY The MIG120 Multi- welder is fitted with: 1. On/off Switch (at rear) 2. Gas cylinder connecting port (at rear) 3. Wire thickness selector switch 4. MIG/MMA/LIFT TIG function selector switch 5. Current selector knob 6. Positive terminal 7.
- Page 14 Loose items supplied include the following: 13. 1 x Hammer/brush 14. 1 x Face shield 15. 1x Spool of 0.6mm mild steel welding wire 16. 1x Spool of 0.9 mild steel welding wire 17. 1 x 0.6mm welding torch tip 18.
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Page 15: Assembling The Welding Shield
• The clear glass panel should be replaced when it becomes badly pitted. 4. When replacing the glass panels, only use parts supplied by CLARKE International. The dark panel is a certified, optical glass and should not be exchanged for any other type. -
Page 16: Preparation For Use
PREPARATION FOR USE FITTING THE GAS BOTTLE HOLDER WARNING: NEVER OPERATE THIS MACHINE WITH THE SIDE PANELS PARTIALLY OPENED OR REMOVED. IMPORTANT: Ensure that the welder is not connected to the mains supply before opening. 1. Open the side panel by pushing the latch down and allowing the side panel to drop down. -
Page 17: Mounting The Welding Wire Spool
Spools of welding wire are available from your CLARKE dealer. 1. Open the side panel by pushing the latches down and allowing the side panel to open. -
Page 18: Threading The Wire
6. Replace the drive roller cover back onto the drive spindle with the opening facing right. 7. Ensure that the flanges at the base of the drive roller cover, seat fully into the circular recess in the main moulding and then rotate the drive roller cover through 90°... -
Page 19: Connecting The Gas Cylinder
10. Release the trigger and switch off the welder and disconnect the machine from the mains supply. 11. Refit the appropriate size contact tip (the 0.9 mm tip, for no gas welding is supplied fitted) to suit your wire and replace the shroud. •... -
Page 20: Lift-Tig Welding
MIG WELDING WITH GAS If using 0.9mm flux cored wire, connect the earth clamp to the negative terminal as shown. FLUX WELDING WITH NO GAS If using 0.9mm flux cored wire, connect the earth clamp to the positive terminal as shown. MMA ELECTRODE WELDING Connect the earth clamp to the positive terminal and the... - Page 21 3. For Flux or MMA welding, select the appropriate welding rod and fit it into the welding rod holder. The following sizes can be used and are available from your CLARKE dealer. ROD DIAMETER WORKPIECE THICKNESS 0.6 mm 0.8 mm...
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Page 22: Control Settings
CONTROL SETTINGS 1. Set the rocker switch (1) to either welding mode. 2. Select the welding wire thickness using the left rocker switch (2). • Set the welding voltage (Settings 1-10) using the selector knob (3). • With practice you will gain a feel for the correct current setting for different welding rod thicknesses. -
Page 23: Welding Technique
OPERATING THE WELDER (MIG) CAUTION: THE DUTY CYCLE MUST BE ADHERED IN ORDER TO PREVENT THE THERMAL OVERLOAD PROTECTION FROM ACTIVATING 1. With the welding current set and the wire trimmed, set the wire feed control to an intermediate setting. 2. - Page 24 OPERATING THE WELDER (MMA/ARC) WARNING: WHEN WELDING ALWAYS ENSURE THERE IS ADEQUATE VENTILATION IN THE WORK AREA DUE TO TOXIC FUMES. WARNING: DO NOT STRIKE THE ELECTRODE ON THE WORKPIECE, AS THIS MAY DAMAGE THE ELECTRODE. WARNING: WELDING ARCS PRODUCE HARMFUL UV/IR LIGHT WHICH CAN SERIOUSLY DAMAGE YOUR EYES.
- Page 25 OPERATING THE WELDER (TIG WELDING) TIG welding is primarily for very thin materials. It uses a non-consumable tungsten (or tungsten alloy) electrode, held in a torch. A shielding gas (100% Argon), is fed through the torch to protect: • The electrode •...
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Page 26: Tig Welding
TIG WELDING Before TIG welding, you must obtain the correct torch and a gas cylinder of 100% pure Argon. (see page 36) To prepare the unit for TIG welding, adopt the following procedure. 1. Plug the work clamp lead in to the +ve terminal, and secure the work clamp to the workpiece. - Page 27 9. Cover your face with the head shield, bring the torch to within 3-4mm of the work, and at an angle of 40-60 , so that the ceramic nozzle gently touches the work surface. 10. Scratch the tip of the electrode against the piece to be welded, as soon as the welding arc starts, remove the electrode to a distance of 3-4 mm, and continue the weld.
- Page 28 WELDING SETTINGS TABLES L-SHAPED BUTT WELDING Metal Wire Root gap Welding Welding Welding Gas Flow Number thickness diameter current voltage speed (L/min) (mm) (mm) 0.8 - 0.9 60-70 16-16.5 50-60 0.8 - 0.9 75-85 17-17.5 50-60 10-15 0.8 - 0.9 80-90 17-18 50-60...
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Page 29: Welding Pitfalls
WELDING PITFALLS The arc welding technique is an acquired skill and requires considerable practice before perfect results are obtained. The diagrams below will help to explain the pitfalls in your technique and how to overcome them. ARC TOO SHORT This causes irregular masses of weld to be deposited, with slag contamination on an uneven surface. -
Page 30: Troubleshooting
TROUBLESHOOTING Your CLARKE 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. DEFECT CAUSES SUGGESTIONS Spark will not start Bad clamp connection. - Page 31 DEFECT CAUSES SUGGESTIONS Profile defects Welding parameters are Follow basic and general incorrect. welding principles. Pass rate is not related to operating parameter requirements. Electrode not inclined constantly while welding. High Sprays Electrode is too inclined. Make appropriate corrections. Arc is unstable Insufficient current.
- Page 32 DEFECT CAUSES SUGGESTIONS Wire feeds into Wire welded to tip. As previous plus reduce ‘birds nest’ tangle. feed roller pressure. Wire liner damaged Renew wire liner. preventing smooth operation. Loose coils of wire Locking knob too slack. Tighten Locking Knob tangle around slightly.
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Page 33: Care And Maintenance
To keep the contact tip free from spatter, we recommend the use of anti- spatter spray (6000715) available from your CLARKE dealer. Torch shroud: The torch shroud must also be kept clean and free from spatter. Build-up of spatter inside the gas cup can cause a short circuit at the contact tip which will result in expensive machine repairs. -
Page 34: Component Parts
COMPONENT PARTS NO DESCRIPTION NO DESCRIPTION Handle Base panel Cover panel Potentiometer Main PCB Insulation board 1 3-gear switch Insulation board 2 Coupling device Dam board Torch cable gland 10 dia Centre panel Torch cable gland 12 dia Power switch Wire feeder Entry port Feeding door... - Page 35 THE MACHINE RATING PLATE Name/address of manufacturer Energy Supply symbol Model Number / Part Number Range of Output Serial / Batch number Rated No-load Voltage Welding Power Source Conventional Load Voltage symbol British Standards applied Insulation grade Welding Process symbol Rated Supply Voltage Degree of Protection Rated Maximum Supply Current...
- Page 36 Argon Gas Regulator 8134140 A Gas Regulator, Arc Activated Headshields, Anti-spatter Spray, Swan Necks, Torch Shrouds and Torch Liner are also available from your CLARKE dealer or our parts division. Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
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Page 37: Arc Activated Headshields
HSF1 6000705 GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase. This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended. - Page 38 DECLARATION OF CONFORMITY -UK Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
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Page 39: Declaration Of Conformity (Ce)
DECLARATION OF CONFORMITY - CE Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
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