Clarke 250TE Specifications

Model Nos.
215TE, 250TE & 260TE
OPERATING & MAINTENANCE
INSTRUCTIONS
1
0100
Thank you for purchasing this CLARKE Mig welder.
Before attempting to operate this machine, please read this leaflet thor-oughly
and follow the instructions carefully, in doing so you will ensure the safety of
yourself and that of others around you, and so that it will provide you with long
and troublefree service.
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.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission. This guarantee does not effect
your statutory rights.
CONTENTS:
Safety
Electromagnetic Interference (EMC)
Safety Precautions
Preparation of Working Area
Safety Equipment
Mig Welding - How it Works
Benefits of Mig welding
Welder Specifications
Electrical Connections
Assembly
Torch Lead Assembly Instructions
Face Mask
Attaching Gas Bottle and Regulator
Loading Wire
Preparation for Welding
Operation
Wire Size Specification Chart
Tuning the Welder
Welding Hints and Maintenance
Troubleshooting Chart
Types of Joints
Parts Drawing and Lists & Wiring Diagrams
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4
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7
12
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13
14
15
16
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17
18
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19
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23-30
SAFETY
1. ASSESSMENT OF AREA
Special care is taken during all stages of manufacture to ensure that your Clarke Mig
Welder arrives with you in good condition.
Before using the machine it is in your own interest to read this manual thoroughly,
paying particular attention to the following rules, and the EMC Regulations:
1
Do not open or remove side panels from the machine unless the mains plugs
disconnected.
2
Do not use the machine with any of the panels open or removed.
3
Do not try to attempt any electrical or mechanical repair unless you are a
qualified technician. If you have a problem with your machine contact your
local dealer or CLARKE International Service Dep’t on 020 8988 7400.
4
Remove any flammable materials from the welding area.
5
Do not expose gas cylinder to high temperature, and do not strike an arc near
or on the gas cylinder.
Caution: Gas cylinders are pressurised containers. Do not pierce or burn, even when
empty. Protect from direct sunlight.
6
Make sure you have good ventilation in the welding area since toxic gases are
released during the MIG welding process.
7
Ultra-violet radiation is released by the MIG welding process and it is of the
utmost importance that the operator, and any spectators, protect themselves
by using welding face-shields or helmets with suitable filter lenses. The wearing
of gloves and proper working clothes is also strongly recommended.
8
Never use in a wet or damp environment.
9
If welding outdoors, screens MUST BE USED around the weld site, to protect
the general public from the glare of the arc.
Before installing welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. Avoid using your welder in the
vicinity of:
a) Other supply cables, control cables, signalling and telephone cables; above, below
and adjacent to the welding equipment;
b) Radio and television transmitters and receivers;
c) Computer and other control equipment;
d) Safety critical equipment, e.g. guarding of industrial equipment;
e) Pacemakers and hearing aids etc;
f) Equipment used for calibration or measurement;
g) Other equipment in the environment. The user shall ensure that other equipment
being used in the environment is compatible. This may require additional protection
measures;
ELECTROMAGNETIC INTERFERENCE (EMC)
Welding equipment should be connected to the mains supply according to the
manufacturers recommendations. If interference occurs, it may be necessary to 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.
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’. In other cases it
could involveconstructing an electromagnetic screen enclosing the power source
and the work complete with associated input filters. In all cases electromagnetic
disturbances must be reduced to the point where they are no longer troublesome.
NOTE: The welding circuit may not be earthed for safety reasons. Changing the
earthing arrangements should only be authorised by a person who is competant to
assess whether changes will increase the risk of injury, e.g. by allowing parallel
welding current return paths which may damage the earthing circuits of other
equipment.
It may be possible to avoid the above by changing the time of day that welding or
other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
2. METHODS OF REDUCING EMISSIONS
2.1Mains supply
2.2Maintenance of the welding equipment
The welding equipment should be routinely maintained according to the manufacturers
recommendations. All access and service doors and covers should be closed and
properly fastened when the welding equipment is in operation. The welding equipment
should not be modified in any way except for those changes and adjustments covered
in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturers
recommendations.
5
2.3Welding cables
The welding cables should be kept as short as possible and should be positioned
close together, running at or close to the floor level.
2.4Equi-potential bonding
Bonding of all metallic components in the welding installation and adjacent to it
should be considered. However, metallic components bonded to the work piece will
increase the risk that the operator could receive a shock by touching these metallic
components and the electrodes at the same time. The operator should be insulated
from all such bonded metallic components.
2.5 Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to
earth because of its size and position, e.g. ships hull orn building steelwork, a
connection bonding the workpiece to earth may reduce emissions in some, but not
all instances. Care should be taken to prevent the earthing of the workpiece increasing
the risk of injury to users, or damage to other electrical equipment. Where necessary,
the connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected according
to national regulations.
2.6 Screening and shielding
Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of
the entire welding installation may be considered for special applications.
SAFETY PRECAUTIONS
1.0 Introduction
Read and understand these safe practices before attempting to install, operate, or
service the equipment. Comply with these procedures as applicable to the particular
equipment used and their instruction manuals, for personal safety and for the safety
of others. Failure to observe these safe practices may cause serious injury or death.
When safety becomes a habit, the equipment can be used with confidence.
2.0 General precautions
2-A Burn prevention
Wear protective clothing - gauntlet gloves designed for use in welding, hat, and protective
shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag. Wear helmet with safety goggles or glasses with side shields underneath,
appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes from radiant energy and flying
metal. Replace cover glass when broken, pitted, or spattered. Avoid oily greasy clothing.
A spark may ignite them. Hot metal such as electrode stubs and workpieces should
never be handled without gloves. First aid facilities and a qualified first aid person should
be available for each shift unless medical facilities are close by for immediate treatment
of flash burns of the eyes and skin burns. Ear plugs should be worn when working
overhead or in a confined space. A hard hat should be worn when others work overhead.
Flammable hair preparations should not be used by persons intending to weld or cut.
2-B Toxic fume prevention
Severe discomfort, illness or death can result from fumes, vapours, heat, or oxygen
enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate
ventilation. NEVER ventilate with oxygen. Lead-, cadmium-, zinc-, mercury- and beryllium, bearing materials, when welded (or cut) may produce harmful concentrations of toxic
fumes. Adequate local exhaust ventilation must be used, or each person in the area as
well as the operator must wear an air- supplied respirator. For beryllium, both must be
used. Metals coated with or containing materials that emit toxic fumes should not be
heated unless coating is removed from the work surface, the area is well ventilated, or
the operator wears an air-supplied respirator. Work in a confined space only while it is
being ventilated and, if necessary, while wearing an air-supplied respirator. Vapours
from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form
PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet
(radiant) energy of the arc can also decompose trichloroethylene and perchlorethylene
vapours to form phosgene. DO NOT WELD or cut where solvent vapours can be drawn
into the welding or cutting atmosphere or where the radiant energy can penetrate to
atmospheres containing even minute amounts of trichloroethylene or perchlorethylene.
7
2-C Fire and explosion prevention
Causes of fire and explosion are: combustibles reached by the arc, flame, flying
sparks, hot slag or heated material; misuse of compressed gases and cylinders;
and 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. To prevent fires and
explosion: keep equipment clean and operable, free of oil, grease, and (in electrical
parts) of metallic particles that can cause short circuits. If combustibles are in area,
do NOT weld or cut. Move the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be
moved, move combustibles at least 10m. away out of reach of sparks and heat; or
protect against ignition with suitable and snug fitting, fire- resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on (or cut).
Walls, ceilings, and floor near work should be protected by heat resistant covers or
shields. Fire watcher must be standing by with suitable fire extinguishing equipment
during and for some time after welding or cutting if:
a) appreciable combustibles (including building construction) are within 10m.
b) appreciable combustibles are further than 10m but can be ignited by sparks.
c) openings (concealed or visible) in floors or walls within 10m can expose
combustibles to sparks.
d) combustibles adjacent to walls, ceilings, roofs or metal partitions can be ignited
by radiant or conducted heat.
After work is done, check that area is free of sparks, glowing embers, and flames. An
empty container that held combustibles, or that can produce flammable or toxic
vapours when heated, must never be welded on or cut, unless container has first
been cleaned. This includes: a thorough steam or caustic cleaning (or a solvent or
water washing, depending on the combustible’s solubility) followed by purging and
inerting with nitrogen or carbon dioxide, and using protective equipment. Water filling
just below working level may substitute for inerting. A container with unknown contents
should be cleaned (see paragraph above), do NOT depend on sense of smell or sight
to determine if it is safe to weld or cut. Hollow castings or containers must be vented
before welding or cutting -they can explode. In explosive atmospheres, never weld or
cut where the air may contain flammable dust, gas, or liquid vapours (such as gasoline).
3.0 Electric arc (Mig, Tig) welding
Comply with precautions in 1, 2 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.
3-A Burn protection
Comply with precautions in 2. The welding arc is intense and visibly bright. Its radiation
can damage eyes, penetrate lightweight clothing, reflect from light coloured surfaces,
and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas shielded arcs are more severe and painful.
DON’T GET BURNED! COMPLY WITH PRECAUTIONS!
(I) Protective clothing
Wear long sleeved clothing (particularly for gas shielded arc) in addition to gloves,
hat and shoes (2-A). As necessary, use additional protective clothing such as
leather jacket or sleeves, flameproof apron, and fire-resistant leggings. Avoid outer
garments of untreated cotton. Protect bare skin. Wear dark substantial clothing.
Button collar to protect chest and neck and button pockets to prevent entry of
sparks.
(II) Eye and head protection
Protect eyes from exposure to arc. NEVER look at an electric arc without
protection. Welding helmet or shield containing a filter plate shade no. 12
or denser must be used when welding. Place over face before striking arc.
Protect filter plate with a clear cover plate. Cracked or broken helmet or
shield should NOT be worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced IMMEDIATELY.
Replace clear cover plate when broken, pitted, or spattered. WE
SUGGEST to wear flash goggles with side shields under the helmet, to give
some protection to the eyes should the helmet not be lowered over the
face before an arc is struck. Looking at an arc momentarily with
unprotected eyes (particularly a 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.
(III) Protection of Nearby Personnel
For production welding, a separate room or enclosed bay is best. In open
areas, surround the operation with low reflective, non-combustible
screens or panels. Allow for free air circulation, particularly at floor level.
Provide face shields for all persons who will be looking directly at the weld.
Others working in the area should wear flash goggles. Before starting to
weld, make sure that screen or bay doors are closed.
3-B Toxic Fume Prevention
Comply with precautions in 2-B. Generator engine exhaust must be
vented to the outside air. Carbon monoxide can kill.
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3-C Fire and Explosion Prevention
Comply with precautions in 2-C. 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.
3-D Shock Prevention
Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded,
electrically-HOT equipment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when
welding, without suitable protection.
3-E Protection for Wearers of Electronic Life Support Devices
(Pacemakers).
Magnetic fields from high currents can affect pacemaker operation. Persons wearing
electronic life support equipment (pacemaker) should consult with their doctor before
going near arc welding, gouging, or spot welding operations.
3-F To Protect Against Shock:
Keep body and clothing dry. Never work in damp area without adequate insulation
against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or
sweat can not be avoided. Sweat, sea water, or moisture between body and an
electrically HOT part - or grounded metal - reduces the body surface electrical
resistance, enabling dangerous and possibly lethal currents to flow through the body.
(I) Grounding the equipment
When arc welding equipment is grounded according to the National Electrical
Code, and the work is grounded, a voltage may exist between the electrode and
any conducting object. 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 ground. Conductors must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may shock, possibly fatally.
Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a
flammable liquid such as oil or fuel.
(III) Connectors
Fully insulated lock-type connectors should be used to join welding cable lengths.
(IV) 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.
(V) Terminals and other exposed parts
Terminals and other exposed parts of electrical units should have insulating covers
secured before operation.
(VI) Electrode
a) Equipment with output on/off control (contactor) Welding power sources for
use with the gas metal arc welding, gas tungsten arc welding and similar
processes normally are equipped with devices that permit on/off control of the
welding power output. When so equipped the electrode wire becomes
electrically HOT when the power source switch is ON and welding gun switch
is closed. Never touch the electrode wire or any conducting object in contact
with the electrode circuit unless the welding power source is off.
b) Equipment without output on/off control (no contactor) Welding power sources
used with shielded metal arc welding and similar processes may not be equipped
with welding power output on/off control devices. With such equipment the
electrode is electrically HOT when the power switch is turned ON. Never touch
the electrode unless the welding power source is off.
(VII) Safety devices
Safety devices such as interlocks and circuit breakers should not be disconnected
or shunted out. Before installation, inspection, or service of equipment, SHUT
OFF all power and remove line fuses (or lock or red-tag switches) to prevent
accidental turning ON of power. Do not open power circuit or change polarity
while welding. If, in an emergency, it must be disconnected, guard against shock
burns, or flash from switch arcing. Always shut OFF and disconnect all power to
equipment. Power disconnect switch must be available near the welding power
source.
(II) Electrode holders
Fully insulated electrode holders should be used. Do NOT use holders with
protruding screws or with any form of damage.
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PREPARATION OF THE WORKING AREA
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. Least of all,
do not weld upon tanks which may contain inflammable residuals.
SAFETY EQUIPMENT
A comprehensive range of CLARKE safety equipment for use when welding is available
from your local dealer.
MIG WELDING - HOW IT WORKS
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. When the wire is fed, it comes into contact with the
workpiece and an arc is struck. The arc melts the wire and the material, fusing it
together. The wire, which is fed by the wire feed motor is fed into the weld pool,
burning itself off at a rate dependent upon the selected wire feed speed. To protect
the weld pool from oxidation and impurities during the welding process, a shielding
gas flows over and around the weld pool. This gas flow must be sufficient to protect
the weld, but not wasteful.
NOTE: Poor gas coverage will result in poor welding. Excessive gas coverage is
wasteful and expensive.
BENEFITS OF MIG WELDING
1. 50% faster welding time.
2. Operator training time kept to a minimum.
3. There is no slag removal, thus eliminating almost all post-welding cleaning
operations.
4. Minimum waste of welding consumables.
5. Overall, a faster more efficient way of getting the job done.
6. Less heat - less distortion.
7. Ability to weld thin material.
WELDER SPECIFICATIONS
PRIMARY or INPUT POWER DATA
MIG215TE
MIG250TE
MIG260TE
Primary Volts
Primary Amps
230V/1PH
29 Amps
230V/1PH
36 Amps
Frequency
50 HZ
50 HZ
230/400V/3Ph
23 Amps (230V)
13.3Amps(400V)
50Hz
SECONDARY or OUTPUT POWER DATA
Sec. Volts
Max. Sec. Amps
Current Range
21-43 V
21-48 V
17-38 V
200 Amps 250 Amps 260 Amps
30-200 Amps30-250 Amps30-260 Amps
DUTY CYCLES
100%
60%
35%
25%
95 Amps
123 Amps
-190 Amps
115 Amps
150 Amps
-230 Amps
80 Amps
103 Amps
230 Amps
--
NOTE: Duty Cycles are rated over a 10 minute period.
Example: If welding with a MIG 215TE at 100amps, a 25% duty cycle applies. This means
that over a 10 minute period, the welding time is 2.5 minutes, the down time is 7.5 minutes.
USABLE WIRE SIZES
Mild Steel Wire
Stainless Steel Wire
Aluminium Wire
0.6-1.0mm
0.8-1.0mm
0.8-1.0mm
0.6-1.0mm
0.8-1.0mm
0.8-1.0mm
0.6-1.0mm
0.8-1.0mm
0.8-1.0mm
USABLE GASES MAIN USES
75% Argon 25% CO2
100% Argon
100% CO2
-
Thin Sheet Metal, Mild Steel
Welding Aluminium, Stainless Steel
Mild Steel
The details and specifications contained herein, are correct at the time of going to print. However, CLARKE
International reserve the right to change specifications at any time without prior notice. Consult machines data plate.
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ELECTRICAL CONNECTIONS
WARNING: THESE MACHINES MUST BE EARTHED.
MIG 215TE & 230TE
This welder must be connected to the correct receptacle, 1Ph 230 volt (50Hz). A 13
Amp plug is not suitable for this device. Connect the three core mains lead to a
suitably fused supply through an isolator or heavy duty plug.
IMPORTANT: The wires in the mains lead are coloured in accordance with
the following colour code:
Green & Yellow - Earth
Blue - Neutral
Brown - Live
Connect GREEN & YELLOW coloured cord to plug terminal marked with a letter “E”
or Earth symbol ‘W’.
Connect BROWN coloured cord to plug terminal marked letter “L”
Connect BLUE coloured cord to plug terminal marked letter “N”
ASSEMBLY
1
The side panel is hinged at its rear edge: Open by pulling sideways at the front
edge, lay out all components contained within, and check to ensure that they
are all correct according to the list below.
FIG.1
A
2 Wheels
B
1 Axle
C
2 Wheel retaining washers
D
2 Castors
E
1 Handle
F
2 Brackets
G
4 Fixing screws
1 Mask with fixing screws & washers
1 Transparent glass
1 Dark glass
We strongly recommend that this machine is connected to the mains supply through
a Residual Current Device.
1 Gas regulator
1 Worm drive clips for gas hose
MIG 260TE
These machines are normally supplied connected to at 400V three-phase. For safety
double check the sticker placed at the end of the input cable.
Should it became necessary to use an input current at 230V three-phase follow
these simple instructions:
1
Bring on the “OFF” position the ON/OFF
switch, disconnect the mains switch and the
input voltage plug from the mains.
2
Open the right side panel (facing the welder)
undoing the screws holding it to the frame.
3
Change the connection by following the
instructions displayed on the here attached
drawing.
4
Make sure that the nuts holding the bridges
are securely tightened.
5
Re-assemble the side panel.
connections
1 Welding torch and lead
1 Cover for hose support bracket
2 Self tapping screws for cover
1 Earth Cable
1 0.6mm welding tip
1 0.8mm welding tip
1 1.0mm welding tip
SHOULD ANY PART BE MISSING OR DAMAGED, CONTACT YOUR LOCAL
DEALER FOR REPLACEMENT.
2
Attach the handle (E) to the welder unit by sliding the brackets (F) on the front of
the machine, lining up the holes with those in the casing and securing the four
screws (G) provided.
DO NOT WORK WITH THE SIDE PANLES PARTIALLY OPENED OR COMPLETELY
REMOVED FROM THE POWER SOURCE IN ORDER TO AVOID CONTACTS WITH
WIRE OR PARTS.
3
Fix the wheels (A) to the back of the unit and the castors (D) to the front.
4
Connect the earth return lead to the negative (-) socket on the fornt panel of the
welder unit.
IMPORTANT: If in doubt, consult a qualified electrician. Do not attempt any
electrical repairs yourself.
5
Ensure that the side panels are securely closed before using the welder.
6
Connect the torch lead assembly to the welder, following the appropriate instructions.
15
TORCH LEAD ASSEMBLY INSTRUCTIONS
Plug the troch hose into the socket on the front of the welder and secure by hand
screwing in the threaded connection.
FIG.2
LOADING WIRE
NOTE: These machines are designed to accept either 5Kg or 15Kg wire spools of
mild steel, stainless steel or aluminium according to the type of metal you wish to
weld. Wire spools ARE NOT supplied with the unit and must be purchased separately.
1 Ensure the gas and electrical supplies are disconnected;
2 (Ref. Fig. 3) Turn the plastic knob (23F), 180°.
3 Take off the plastic cover of the wire spool;
FIG.3
4 To fit the wire spool (23H)
into the hub (23A) push the
button (23I), insert the wire
spool, followed by the collar
(23C)(it must be used only
with 5Kg wire spools) .
5 Turn the plastic knob (23F)
by 180° again.
FACE MASK
To assemble the face mask, first place the dark glass window and the clear glass
window together in the recessed window area of the body.
IMPORTANT: the clear glass window should be placed on the outside of the
mask.
Secure in place using the screws and nuts provided. Bend the sides of the mask into
shape and fix together using the screws and nuts provided, and finally, fit the handle
to the shield body also using the screws and nuts provided.
ATTACHING THE GAS BOTTLE AND REGULATOR
1.
2.
3.
4.
5.
The bottle (not supplied) should be located at the rear of the welder,
securely held in position by the chain provided.
For safety, and economy, ensure that the regulator is fully closed, (turned
anti-clockwise) when not welding and when fitting or removing the gas cylinder.
Connect the gas hose to the regulator securing with clip/nut provided.
Screw the gas regulator fully down on the gas bottle valve, and fully tighten.
Turn the power on, open the cylinder valve, then set the gas flow to approx. 8l/
min. on the regulator. Operate the torch trigger to ensure that the gas is flowing
through the torch.
6 Loosen the plastic knob by
turning it anti-clockwise,
(this maintains pressure on
the wire via the roller). Pull,
on the plastic knob, so that
the screw rod comes out
of its slot, thereby
releasing the pivoted roller
bracket. Raise the bracket
together with the pressure
roller, and pullout any wire
that has been left in the
hose.
7 If you are changing the size of wire, you must also select the appropriate groove
on the feed roller. To change to the other groove, undo the Hex. Socket Screw and
remove the roller from its shaft. Turn it through 180°, replace it on the shaft, and
adjust so that the groove is directly in line with the Wire Liner. Firmly secure it in
that position with the Hex. Socket Screw.
8 Clip the end of the wire, on the spool, cleanly, ensuring there are no burrs or sharp
edges, and, ensuring it is straight, feed it through the guide tube , over the channel
on the roller and into the wire liner, by approx. 10 - 15cm.
17
9 Reposition the pressure roller and plastic knob and tighten slightly.
WIRE SIZE SPECIFICATION CHART
IMPORTANT: Too tight will crush the wire and damage the wire feed motor,
too loose will not allow the wire to be pulled by the roller.
SWITCH
1
3
10 Pull off the torch shroud by twisting it clockwise, and unscrew the contact tip.
Close the side panel of the machine, plug into a 230V, 50HZ outlet (or switch on
isolator), switch on the machine and press the trigger. The wire will feed through
the hose and when it appears at the torch end, release the trigger, switch off the
machine and replace the contact tip and the torch shroud.
IMPORTANT: Ensure the hose is kept straight during this operation, to assist
the wire as it is feed through to the nozzle.
PREPARATION FOR WELDING
1
Attach the earth clamp to the bare metal to be welded, making sure of good
contact.
2 Make sure that the wire-roller groove in the roller corresponds to the diameter of
the welding wire being used. Refer to “Loading wire” above.
3 Plug the machine into a 230V AC 50Hz outlet.
4 Open the gas valve on the gas cylinder regulator, (turn knob clockwise)and adjust
the gas regulator to the proper setting position. NOTE: this varies with different
metals, thicknesses and currents. Refer to a MIG welding manual for
instructions.
OPERATION
1 These machines have 7 welding positions (see the table below) in which to
regulate current for various conditions.
2 The selection of a welding position is determined by the thicknessof the metal
to be welded. The thicker it is, the higher the current must be.
3 According to the thickness to be welded, the amount of gas regulated to the
work also varies and must be adjusted accordingly.
4 For welding adjustments, refer to the table below.
WARNING
(i) Make sure all flammable materials are removed from the work area.
(ii) Never look directly at the welding arc, it can seriously damage your eyes.
Always use an approved welding mask or helmet.
(iii) Wear protective clothing so that all skin areas are covered.
(iv) Keep a fire extinguisher handy.
2
6
SWITCH
POSITIONS
5
STEEL WIRE
DIAMETER
(mm)
WIRE SPEED
ADJUSTMENT
4
0.6
0.6
0.6 - 0.8
0.6 - 0.8
0.8
0.8
1.0
1
2
3
4
5
6
7
LOW
LOW
MEDIUM
MEDIUM
MEDIUM - HIGH
HIGH
HIGH
TUNING THE WELDER
The tuning of a Mig welding machine requires some practice, due to the fact that contrary to the arc welding procedure - two parameters must be accommodated to
achieve a perfect weld. These are:
(A) Wire Feed Speed, and (B) Welding Voltage.
It is important to arrive at the correct combination to suit the type and thickness of
material to be welded. The current necessary for welding is directly dependent
upon the wire feed speed.
If the wire feed speed is increased, the current is also increased, but the arc length
is decreased. Conversely, if the wire feed speed is decreased, and current is therefore
decreased, the length of arc is increased.
Increase of the welding voltage leads to a longer arc (without substantially affecting
the current). Conversely, a decreased welding voltage results in a shorter arc, (the
current again is not substantially changed).
A change in wire diameter results in changed parameters. A smaller diameter wire
requires an increase in wire feed speed to reach the same current. If certain limits
are exceeded, a satisfactory weld cannot be obtained. These are:
A) A too high wire feed speed (too high with regard to the welding voltage) results
in pulsing within the torch. This is because the wire electrode dips into the puddle
and cannot be melted off fast enough.
B) If the welding voltage is set too high, large drops can be seen at the end of the
wire electrode. These drops are often deposited beside the welding seam.
The correct rate of wire feed speed (current) and welding voltage, results in very little
spatter and a continuous, intensive hissing can be heard from the arc.
19
TROUBLE SHOOTING
WELDING HINTS AND MAINTENANCE
1
2
Always weld clean, dry and well prepared material.
Hold gun at a 45° angle to the workpiece with nozzle about 6mm from the
surface.
3
Move the gun smoothly and steadily as you weld.
4
Avoid welding in very draughty areas. A weak pitted and porous weld will
result due to air blowing away the protective welding gas.
5
Keep wire and wire liner clean. Do not use rusted wire.
6
Sharp bends or kinks on the welding hose should be avoided.
7
Always try to avoid getting particles of metal inside the machine since they
could cause short circuits.
8
If available, use compressed air to periodically clean the hose liner when
changing wire spools
IMPORTANT: Disconnect from power source when carrying out this operation.
9
Using low pressure air (20-30 PSI), occasionally blow the dust from the inside
of the welder. This keeps the machine running cooler. Note: do not blow air
over the printed circuit board and electronic components.
10
The wire feed roller will eventually wear during normal use. With the correct
tension the pressure roller must feed the wire without slipping. If the pressure
roller and the wire feed roller make contact (when the wire is in place between
them), the wire feed roller must be replaced.
11
Check all cables periodically. They must be in good condition and not cracked.
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
1. No "life" from the welder
2. No wire feed
3. Feed motor operates but wire
will not feed
4. Wire welds itself to tip
PROBABLE CAUSE
a) Replace fuses as necessary. If
problem persists, return welder to
your local dealer.
b) Check fuse size.
Motor malfunction
Return welder to your local dealer.
a ) i n s u f f i c i e n t f e e d r o l l e r a) Increase roller pressure
pressure
b) Burr on end of wire
b) Re-cut wire square
c) Linerblocked or damaged c) Clear with compressed air or
replace liner.
d) Inferior wire
d) Use only good clean wire
a) Wire feed speed too low
b) Wrong size tip
5. Wire feeds into "bird's" nest
tangle.
6. Loose coils of wire
tanglearound wire druminside
machine
7. Erratic wire feed
POSSIBLE SOLUTION
Check fuses and mains lead.
a) Unscrew tip, cut wire and
fitnew tip. Increase wire speed
before operating again.
b) Change tip size.
a) Wire welded to tip.
a) As above plus reduce feedroller
pressure so that if blockage occurs
wire sleeps on roller. i.e. no feed
b ) W i r e l i n e r d a m a g e d b) Renew wire liner.
preventing smooth operation.
Tighten drum brake - DO NOT
Drum brake too slack.
OVERTIGHTEN
a) Drum brake too tight
b) Feed roller worn
c) Insufficient pressure on
feed roller
d) Wire dirty, rusty, damp or
bent
d) Liner partilly blocked
a) Insufficient gas at weld area
a) Loosen drum brake slightly
b) Checkand replace if necessary
c) Increase pressur eon feed roller
DO NOT OVERTIGHTEN
d ) Re-cut wire and ensure it i s
clean
e) Clear with compressed air
8. Poor quality welds
a ) Check that gas is not being
b lown a w a y b y draughts, i f s o ,
m o ve to a sheltered area. If no
draught, incrtease gas supply.
b ) I n c o r r e c t g a s / w i r e b ) C o nsult your Mig Welding
combination
manual
c) Rusty, painted, damp, oily or c) Ensure workpiece is clean and
greasy workpiece
dry
d) Rusty, dirty wire.
d) Ensure wire is clean and dry
e) Poor earth contact
e) Check ground clamp/workpiece
connection.
9. Wire jams in tip when welding Tip too small
Use slightlyoversize tip i.e. fo r
aluminium
0.8mm wire use 1mm tip (Applies
to aluminium only)
10.Welder cuts out whilst in use
Duty cycle exceeded (auto
Allow welder to cool for 15-30min.
cut-out operates)
before continuing. Note if duty
cycle is continually e x c e e d e d ,
damage to the welder may result
and welder output is probably too
small for application.
21
TYPES OF JOINTS
OPEN SQUARE BUTT JOINT
CORNER JOINT
Gap varies from 1.6mm to 4.8mm depending
on plate thickness
SINGLE VEE BUTT JOINT
NOT LESS THAN 70°
SINGLE FILLET LAP JOINT
1 .6m m
DOUBLE VEE BUTT JOINT
NOT LESS THAN 70°
DOUBLE FILLET LAP JOINT
PARTS DRAWINGS AND LISTS
&
1 .6m m
SINGLE STRAP JOINT
WIRING DIAGRAMS
SINGLE BEVEL JOINT
DOUBLE STRAP JOINT
DOUBLE BEVEL JOINT
DOUBLE FILLET TEE JOINT
SINGLE FILLET TEE JOINT
23
PARTS DRAWING - MIG 215TE (Part No.6015215)
& MIG 250TE (Part No. 6010250)
PARTS LIST - MIG 215TE (Part No. 6015215)
ITEM PART NO.
DESCRIPTION
QTY.
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
25
25
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
CLIP+COUPLING FOR PANEL
COMPLETE SPOOL HOLDER D.50
HANDLE
HOLDER MAT
3X270X640
ON/OFF SWITCH
16A-250V
SWITCH KNOB D.34
POTENTIOMETER KNOB 1945/B GREEN
ORANGE PILOT LAMP
220V L=500
BINZEL CONNECTION TORCH GROMMET
COUPLE OF INCLINED-OVAL HANDLES 15X30
DISTANCE PIECE FOR INCLINED HANDLE
P.C.BOARD
E0788 220V
WIRE FEEDING MOTOR 42V D.62
UPPER PANEL
RECTIFIER’S THERMOSTAT 100ø 16A
RECTIFIER
PMS 20/4/2 F 1/MOV
DIVIDING PANEL
FAN
C20 240V VENT ASP.154 ALL
BACK PANEL
CABLE CLAMP
FOR HOLE D.20
BLACK GAS HOSE
D.5X10,5 L=2150
PVC INPUT CABLE 3X2,5 M.2,5
DINSE PLUG
25SQMM TSKM25 CX20
SIDE PANEL
WIRE FEED ROLL 0,6-0,8MM AL.MOTOR 2R
WIRE FEED ROLL 1,0-1,2MM AL.MOTOR 2R
WIRE FEED ROLL 0,8-1MM NYLON AL.MOTOR 2R
WIRE FEED ROLL 1,2-1,6MM NYLON MOT.AL.2R
RUBBER PIVOTING WHEEL D.80
FRONT PANEL
BALL BEARING
D10X30 SP.9
AL. WIRE FEEDER D62 42V 2ROLLS 06-08
DINSE PLUG
25SQMM TBEM25 CX30
WHEELS-AXLE D.20 L=488
RIGHT-SIDE PANEL
BINZEL TORCH ADAPTOR
L=40 AT109
SWITCH
20 A CM 17
CHOKE 50X60CU
RESISTANCE 3 OHM D.16 L=90
LOWER PANEL
AUXILIARY CONTACT BL/X 2NC
CONTACTOR 220V 16A CN-16 (LX1)
GAS SOLENOID VALVE 4W 220V 50HZ 1/8"FF
CAPACITOR
22000 MF 63V 63X105
TRANSFORMER
230V 64X90 CU
WHEEL D.175 RUBBER HOLE D.20
EARTH CABLE 25 SQMM MT.3 W/C.261/DN25
EARTH CLAMP ART.261 - OK 150
TORCH PLUS 14 M.3 BZ CONN L,B14 MAM411
REDUCER MAXI ARG/UK 1/GAUGE
CARTON MASK 82X108
TRANSPARENT GLASS 82X108 ART.470
DARK GLASS
82X108 ART.471 BS DIN13
FUSE
5X20 T 2A 250V
FUSE HOLDER
PTF/35 6,3A 250V
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
EM04600025
EM04600001
EM33725047
EM30905001
EM22200002
EM21690015
EM21690058
EM22610013
EM21690003
EM21600012
EM21690129
EM22710010
EM22810006
EM33705162
EM22210601
EM22400013
EM33720013
EM22800013
EM33715054
EM21605010
E M30900026
EM20220020
EM22100001
EM33705164
EM33805003
EM33805005
EM33805021
EM33805022
EM21625002
EM33710134
EM21500004
EM44410017
EM22100002
EM55200001
EM33705163
EM23005048
EM22205033
EM44135007
EM22305004
EM33700111
EM22225018
EM22225008
EM22900001
EM22315003
EM44120018
EM21625009
EM43210036
EM22110007
EM23000322
EM22905017
EM21905019
EM21905020
EM21905024
EM22220004
EM22220016
25
1
1
1
1
1
1
3
1
2
1
1
1
1
1
1
1
1
1
PARTS LIST - MIG 250TE (Part No. 6010250)
ITEM PART NO.
DESCRIPTION
QTY.
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
25
25
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
COMPLETE SPOOL HOLDER D.50
COMPLETE SPOOL HOLDER D.50
HANDLE
HOLDER MAT
3X270X640
ON/OFF SWITCH
16A-250V
SWITCH KNOB D.34
POTENTIOMETER KNOB 1945/B GREEN
ORANGE PILOT LAMP
220V L=500
BINZEL CONNECTION TORCH GROMMET
COUPLE OF INCLINED-OVAL HANDLES 15X30
DISTANCE PIECE FOR INCLINED HANDLE
P.C.BOARD
E0788 220V
WIRE FEEDING MOTOR 42V D.62
UPPER PANEL
RECTIFIER’S THERMOSTAT 100ø 16A
RECTIFIER
PMS 24/4/2 F 1/MOV
DIVIDING PANEL
FAN
C20 240V VENT ASP.154 ALL
BACK PANEL
CABLE CLAMP
FOR HOLE D.20
BLACK GAS HOSE
D.5X10,5 L=2150
INPUT CABLE 3X4 2,5MT.
DINSE PLUG
25SQMM TSKM25 CX20
SIDE PANEL
WIRE FEED ROLL 0,6-0,8MM AL.MOTOR 2R
WIRE FEED ROLL 1,0-1,2MM AL.MOTOR 2R
WIRE FEED ROLL 0,8-1MM NYLON AL.MOTOR 2R
WIRE FEED ROLL 1,2-1,6MM NYLON MOT.AL.2R
RUBBER PIVOTING WHEEL D.80
FRONT PANEL
BALL BEARING
D10X30 SP.9
AL. WIRE FEEDER D62 42V 2ROLLS 06-08
DINSE PLUG
25SQMM TBEM25 CX30
WHEELS-AXLE D.20 L=488
RIGHT-SIDE PANEL
BINZEL TORCH ADAPTOR
L=40 AT109
SWITCH
20 A CM 17
CHOKE
50X60 CU
RESISTANCE 3 OHM D.16 L=90
LOWER PANEL
AUXILIARY CONTACT BL/X 2NC
CONTACTOR 220V 16A CN-16 (LX1)
GAS SOLENOID VALVE 4W 220V 50HZ 1/8"FF
CAPACITOR
22000 MF 63V 63X105
TRANSFORMER
230V 60X100 CU
WHEEL D.175 RUBBER HOLE D.20
EARTH CABLE 25 SQMM M3 W/C.411/DN25
EARTH CLAMP ART.411
TORCH ERGOPLUS 15 MT.3 EURO CON. MA7007
REDUCER MAXI ARG/UK 1/GAUGE
CARTON MASK 82X108
TRANSPARENT GLASS 82X108 ART.470
DARK GLASS
82X108 ART.471 BS DIN13
FUSE
5X20 T 2A 250V
FUSE HOLDER
PTF/35 6,3A 250V
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
2
1
1
1
1
1
1
1
1
1
EM04600001
EM04600001
EM33725047
EM30905001
EM22200002
EM21690015
EM21690058
EM22610013
EM21690003
EM21600012
EM21690129
EM22710010
EM22810006
EM33705162
EM22210601
EM22400016
EM33720013
EM22800013
EM33715054
EM21605010
EM30900026
EM20220044
EM22100001
EM33705164
EM33805003
EM33805005
EM33805021
EM33805022
EM21625002
EM33710134
EM21500004
EM44410017
EM22100002
EM55200001
EM33705163
EM23005048
EM22205033
EM44135008
EM22305004
EM33700111
EM22225018
EM22225008
EM22900001
EM22315003
EM44120082
EM21625009
EM43210013
EM22110009
EM23000349
EM22905017
EM21905019
EM21905020
EM21905024
EM22220004
EM22220016
PARTS DRAWING - MIG 260TE (Part No. 6010390)
27
WIRING DIAGRAM - MIG 215TE (Part No.6015215) &
MIG 250TE(Part No. 6010250)
PARTS LIST- MIG 260TE (Part No. 6010390)
ITEM PART NO.
DESCRIPTION
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
23
23
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
COUPLE OF INCLINED-OVAL HANDLES 15X30
P.C.BOARD
E0788WI
GAS SOLENOID VALVE 4W 24V 50HZ 1/8"FF
RECTIFIER
PTS 180 F 1/MOV
RECTIFIER’S THERMOSTAT 100ø 16A
FAN
C30 220-240 VENT.ASP.154 ALL
CABLE CLAMP
FOR HOLE D.20
BLACK GAS HOSE
D.5X10,5 L=2150
INPUT CABLE 4X2,5 M.3,3
CLIP+COUPLING FOR PANEL
SIDE PANEL
BINZEL CONNECTION TORCH GROMMET
HANDLE
GREEN PILOT-LIGHT SWITCH 10A-380V
POTENTIOMETER KNOB 1945/B GREEN
RIGHT-SIDE PANEL
ORANGE PILOT-LAMP
24V L=600
SWITCH KNOB D.34
SWITCH
16 A SCH 6411
UPPER PANEL
AL WIRE FEEDER
D.62 42V 2ROLLS
WIRE FEEDING MOTOR 42V D.62
WIRE FEED ROLL 0,6-0,8MM AL.MOTOR 2R
WIRE FEED ROLL 1,0-1,2MM AL.MOTOR 2R
WIRE FEED ROLL 0,8-1MM NYLON AL.MOTOR 2R
WIRE FEED ROLL 1,2-1,6MM NYLON MOT.AL.2R
CONTACTOR
24V 16A CN-16 (LX1)
DINSE PLUG
25SQMM TBEM25 CX30
VOLTAGE CHANGE BOARD 9/HOLES 80X130
LOWER PANEL
TRANSFORMER
LATERAL WINDING
230V 50X70X150 AL
BINZEL TORCH ADAPTOR
L=40 AT109
RUBBER PIVOTING WHEEL D.80
WHEELS-AXLE D.20 L=488
WHEEL D.175 RUBBER HOLE D.20
BACK PANEL
COMPLETE SPOOL HOLDER D.50
DIVIDING PANEL
FRONT PANEL
DINSE PLUG
25SQMM TSKM25 CX20
EARTH CABLE 25 SQMM M3 W/C.411/DN25
EARTH CLAMP ART.411
TORCH ERGOPLUS 15 MT.3 EURO CON. MA7007
REDUCER MAXI ARG/UK 2/GAUGES
CARTON MASK 82X108
TRANSPARENT GLASS 82X108 ART.470
DARK GLASS
82X108 ART.471 BS DIN13
HOLDER MAT
3X270X640
FUSE HOLDER
PTF/35 6,3A 250V
FUSE
5X20 T 2A 250V
AUXILIARY TRANSFORMER
28X42CU
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
EM21600012
EM22710027
EM22900002
EM22400029
EM22210601
EM22800005
EM21605010
EM30900026
EM20220030
EM04600025
EM33705164
EM21690003
EM33725047
EM22200005
EM21690058
EM33705163
EM22610011
EM21690015
EM22205030
EM33705162
EM44410017
EM22810006
EM33805003
EM33805005
EM33805021
EM33805022
EM22225007
EM22100002
EM21890001
EM33700111
EM44125038
EM44025084
EM23005048
EM21625002
EM55200001
EM21625009
EM33715054
EM04600001
EM33720013
EM33710134
EM22100001
EM43210013
EM22110009
EM23000349
EM22905018
EM21905019
EM21905020
EM21905024
EM30905001
EM22220016
EM22220004
EM44140036
29
WIRING DIAGRAM - MIG 260TE (Part No. 6010390)
31