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Summary of Contents for Clarke MIG150 MULTI
- Page 1 MIG/MMA/TIG INVERTER WELDER MODEL NO: MIG150 MULTI PART NO: 6015603 OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC02/24...
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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 MIG150 Multi is an inverter type welding machine, suitable to carry out Gas and No Gas CO welding, MMA, TIG and MIG. 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 40.
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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 A POWER SUPPLY. THE INSTALLATION OF THIS APPLIANCE SHOULD BE CARRIED OUT BY A COMPETENT ELECTRICIAN AND BE IN ACCORDANCE WITH CURRENT IEE WIRING REGULATIONS (BS4343). This welder MUST be connected to a 230 Volt, 1 phase 50Hz supply through a suitably rated isolator switch. - Page 13 OVERVIEW The MIG150 Multi- welder is fitted with the following features: Digital Current meter (A) Welding voltage selector knob Digital voltage display meter(V) MIG torch connector Power-On LED Negative socket Overheating LED Positive socket 2T/4T weld feed selector switch On/off Switch (at rear)
- Page 14 THE CONTROL FUNCTIONS 1. Digital Current display meter (A) • Displays amperage being drawn by the machine. 2. Digital voltage display meter(V) • Displays voltage being drawn by the machine. 3. Power-On LED • When the power is switched on at the back of the machine the switch will be illuminated, as will the green ‘Power On’...
- Page 15 LOOSE ITEMS SUPPLIED INCLUDE THE FOLLOWING: • 1 x MIG welding torch with hose (0.8mm tip) • 1 x Torch Cable/Electrode Holder • 1 x Earth Cable/Clamp • 1 x Gas Hose • 1 x Chipping Hammer/Wire brush • 1 x Face shield c/w handle, lenses & locking nuts •...
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Page 16: 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 17 Spools of welding wire are available from your CLARKE dealer. 1. Open the side panel and remove the locking nut and retaining spring. The retaining locknut nut has a left-hand thread.
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Page 18: Setting The Drive Roller Size
2. Place a spool of welding wire over the spindle. • DO NOT release the tension on the wire, as it will unravel causing feeding problems later. • The wire will feed off the spool anticlockwise from the bottom of the reel. •... - Page 19 • We recommend you cut off and discard the first 10 cm of wire from the spool to avoid any burrs and then straighten the next few centimetres of wire to help with feeding. 2. Loosen the tensioning knob and pivot it towards you. 3.
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Page 20: Connecting The Gas Cylinder
CONNECTING THE GAS CYLINDER The welder can be configured to weld, with or without a gas supply according to the type of welding wire being used. • Mild steel solid core (with gas) • Flux cored (no gas) 1. Connect a bottled gas cylinder to the connector at the back of the welder. - Page 21 CONFIGURING THE MACHINE ATTACHMENTS To prepare the machine for welding it is important that you follow the following procedure. Making sure that the ON/OFF switch, located on the rear panel is in the OFF position, connect the welding leads and gas bottle as follows and set the selector switch to the position shown.
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Page 22: Lift-Tig Welding
MMA ELECTRODE WELDING Connect the earth clamp to the positive terminal and the electrode holder to the negative as shown. Set the selector switch to the Electrode symbol. LIFT-TIG WELDING Welding rod holder lead to the (+) Positive terminal. Set the selector switch to the TIG torch symbol. -
Page 23: Preparing The Workpiece
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 wire 0.8 mm wire 1-5 mm 0.9 mm wire... -
Page 24: Control Settings
CONTROL SETTINGS Refer to page 14 for control panel functions. MIG WELDING WITH GAS 1. Turn on the gas regulator of the gas cylinder. The gas pressure is shown by the gauge. 2. Turn the gas regulator anticlockwise. Loosen the wire roller while depressing on the torch switch and adjusting the gas flow as required. - Page 25 2. Set the Welding Current Selector knob (10) according to the size of the weld being performed. 3. Set the Mode Selector knob (8) to left or right according to the shape of the weld (either deep/narrow or wide/shallow. 4. Confirm the electrode and cables are configured as shown on page 21. 5.
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Page 26: 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 27: Thermal Overload
THERMAL OVERLOAD The ‘Thermal Overload’ shuts off the welder when it becomes too hot, due to the duty cycle being exceeded. This is to prevent any damage to the machine. When this occurs, the warning lamp shown will light up. Allow the welder to cool until the amber light extinguishes before resuming work. - Page 28 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 29 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 30: Tig Welding
TIG WELDING Before TIG welding, you must obtain the correct torch and a gas cylinder of 100% pure Argon. (see page 40) To prepare the machine 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 31 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 32 WELDING SETTINGS TABLES L-SHAPED BUTT WELDING Metal Wire Root gap Welding Welding Welding Gas Flow thickness diameter current (A) voltage (V) 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 33: 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 34: 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 35 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 36 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 37: 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 38: Component Parts
COMPONENT PARTS Plastic front plate Cable gland Potentiometer Quick socket Power cable/ plug Shunt Quick socket holder 15 Rocker switch Potentiometer knob Front panel Rear panel Holster mtg plate Base panel Rectifier board MIG torch Vertical panel Support panel Door lock Wire feed holder Input filter board Flip cover... - Page 39 THE MACHINE RATING PLATE Name/address of manufacturer Energy Supply symbol Model Number Range of Output Part number Rated No-load Voltage Welding Power Source Conventional Load Voltage Standards applied Insulation grade Welding Process symbols Rated Supply Voltage Degree of Ingress Protection Rated Maximum Supply Current Welding Current symbol Max Effective Supply Current...
- Page 40 6000910 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 41: 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 42 DECLARATION OF CONFORMITY -UK Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
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Page 43: 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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