Related Manuals for Clarke MIG160-S MULTI
Summary of Contents for Clarke MIG160-S MULTI
- Page 1 MIG/MMA/TIG INVERTER WELDER MODEL NO: MIG160-S MULTI PART NO: 6015616 OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC01/25...
- Page 2 INTRODUCTION Thank you for purchasing this CLARKE Welder. The MIG160-S Multi is a machine that automatically sets the welding parameters according to the wire type and diameter and the shielding gas. This is achieved by selecting either the amperage, wire feed speed or plate thickness required with a single knob.
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Page 3: 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 4: Specifications
1-4 mm (TIG) 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 5 THE MACHINE RATING PLATE Name/address of manufacturer Rated No-load Voltage Model Number Conventional Load Voltage Part number Insulation grade Welding Power Source Rated Supply Voltage British Standards applied Rated Maximum Supply Current Welding Process symbol Rated welding current value Degree of Protection Rated Max input current Welding Current symbol Electrode symbol...
- Page 6 SAFETY PRECAUTIONS FOR ALL 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 7 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 2.
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Page 8: Preparation Of The Working Area
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. -
Page 9: Shock Prevention
EYE AND HEAD PROTECTION Protect eyes from exposure to arc. NEVER look at an electric arc without protection. Always use a welding helmet or shield containing an appropriate filter plate (Please refer to the section ‘Welding Shield on page 18). Place over face before striking arc. Protect filter plate with a clear cover plate. - Page 10 Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases, workpieces, etc. NEVER touch the electrode and any metal object unless the welding power source is off. When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building earth.
- Page 11 6. NEVER attempt any electrical or mechanical repair unless your are a qualified technician. If you have a problem with the machine contact your local CLARKE dealer. 7. ALWAYS keep a fire extinguisher handy (Dry Powder, C0 or BCF, NOT Water).
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Page 12: 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 13: Electrical Connection
ELECTRICAL CONNECTION WARNING: READ THESE SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE WELDER 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 14 OVERVIEW The MIG160-S Multi-welder has the following features: Handle Gas selection Current display Wire dimension selection Voltage display Negative pole Operating knob Positive pole Fly joint Power switch Euro connector Power cable VRD/A/V operate MIG/MMA/LIFT-TIG selection Gas connector Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
- Page 15 1 x Wrench (for changing torch tips) • 1 x Face shield assembly c/w spare lenses When unpacking, any damage or deficiency should be reported to your CLARKE dealer immediately. PREPARING THE WELDER FOR USE WARNING: NEVER OPERATE THIS MACHINE WITH THE SIDE PANELS PARTIALLY OPENED OR REMOVED.
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Page 16: Mounting The Welding Wire Spool
Spools of welding wire are available from your CLARKE dealer. 1. Open the side panel and remove the locking nut and retaining spring from the spindle. -
Page 17: Threading The Wire
THREADING THE WIRE WARNING: NEVER OPERATE THIS MACHINE WITH THE SIDE PANELS PARTIALLY OPENED OR REMOVED. IMPORTANT: Do not release the tension on the wire as it will unravel causing feeding problems later. 1. Pull out the end of the wire from the spool, taking care not to release the tension. •... -
Page 18: 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 19 CONFIGURING THE ATTACHMENTS Making sure that the ON/OFF switch, located on the rear panel is in the OFF position, connect the welding leads and gas bottle. To prepare the machine for welding it is important that you follow the configuration applicable to the type of welding being performed as shown below.
- Page 20 The earth clamp is used to clamp the work piece. 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. WIRE ROD WORKPIECE THICKNESS DIAMETER 0.6 mm...
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Page 21: Preparing The Workpiece
Attach the earth clamp to the workpiece as close as possible to the area being welded. Clean with a wire brush where necessary to ensure the connection is as clean as possible. PREPARING THE WORKPIECE The area being welded should be perfectly clean. Any coating, plating or corrosion must be removed, otherwise a good weld will be impossible to achieve. - Page 22 SYNERGIC CONTROL SETTINGS WELDING WITH NO GAS - FLUX CORED WELDING Select “MIG” and Choose “FLUX”, and select welding wire which diameter you need 0.6, 0.8 / 0.9, 1.0. Adjust the output current potentiometer using the third button. Adjust current/ Voltage by pressing the third button.
- Page 23 MMA WELDING STEPS Select the MMA function. If the VRD function is needed, select VRD and the LED will illuminate. LIFT TIG WELDING STEPS Select LIFT TIG and the correct torch connection. Use Argon gas start welding work. Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
- Page 24 USING 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 25: Lift Tig Welding
LIFT TIG WELDING Before TIG welding, you must obtain the correct torch and a gas cylinder of 100% pure Argon. (see page 37) To prepare the machine for TIG welding and adopt the following procedure. 1. Plug the work clamp lead in to the positive terminal, and secure the work clamp to the workpiece. - Page 26 Notes: • To avoid a visible strike mark on the surface of the workpiece it is advisable to strike the arc in the joint where the mark will be concealed by the weld. • Thin sheet and stainless steel may be welded with or without filler, similar to gas welding.
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Page 27: Welding Technique
USING THE WELDER (MIG) CAUTION: THE DUTY CYCLE MUST BE ADHERED TO IN ORDER TO PREVENT THE THERMAL OVERLOAD PROTECTION FROM ACTIVATING 1. Switch on the welder and follow the MIG settings. 2. Cover your face with a suitable welding mask. 3. - Page 28 USING THE WELDER (MMA) 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 WELDING SETTINGS TABLES L-SHAPED BUTT WELDING Metal Wire Root gap Welding Welding Welding Gas Flow Number 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 30: Welding Defects
WELDING DEFECTS 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 31: 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 32 DEFECT CAUSES SUGGESTIONS Profile defects Welding parameters are Follow basic and general incorrect. welding principles. Pass rate is not related to the operating parameter requirements. Electrode not inclined constantly while welding. High Sprays Electrode is too inclined. Make appropriate corrections. Arc is unstable Insufficient current.
- Page 33 DEFECT CAUSES SUGGESTIONS Loose coils of wire Locking knob too slack. Tighten the locking knob tangle around wire slightly. Do not over-tighten. drum inside machine. Erratic wire feed. Tensioning knob too tight. Loosen the tensioning knob slightly. Tension roller worn. Check and replace if necessary.
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Page 34: 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 35: Component Parts
COMPONENT PARTS Handle Torch ring Machine cover Torch position base Fan cover Insulation board Torch connector Power switch Main board Wire feeder Solenoid valve Output bar 1 Display PCB cover Socket Output bar 2 Side panel Power cable Wind shield Door lock Industrial plug Front panel... -
Page 36: Mig Torch Components
MIG TORCH COMPONENTS Cylindrical nozzle 16mm Trigger Conical nozzle 12mm Connecting terminal Tapered nozzle 9.5mm Protective spring Contact tip Torch sleeve Nozzle spring Protective spring Diffuser Connector body Swan neck Screw cap Neck end EU connector Neck connector End connector Screw cap Torch liner Handle... - Page 37 WELDING CONSUMABLES/ACCESSORIES The following are some of the accessories available from your CLARKE dealer including Gas Regulator, Anti-spatter Spray, Swan Necks, Torch Shrouds & Torch Liners. Please quote the part numbers shown below: Part Description Part No Comment Welding Wire...
- Page 38 DECLARATIONS OF CONFORMITY - UK Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
- Page 39 DECLARATIONS OF CONFORMITY - CE Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
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