Clarke 250TE Specifications

MIG 220TE • MIG255TE • MIG 270TE
OPERATING & MAINTENANCE
INSTRUCTIONS
0803
CONTENTS
PAGE
DECLARATION OF CONFORMITY
We declare that this product complies with thie following standards/directives
Guarantee .............................................................................................. 3
•
•
•
•
•
•
Parts & Service Contacts ....................................................................... 3
Electromagnetic Interference (EMC) .................................................. 4
Safety Precautions ................................................................................. 6
Additional Safety Precautions for MIG Welding ............................... 11
Principles of Operation ........................................................................ 12
Electrical Connections ........................................................................ 13
93/68 EEC
89/336 EEC
73/23 EEC
98/37 EC
EN50 119
EN 60 974-1
Unpacking and Parts Identification ................................................... 14
General Layout .................................................................................... 15
Assembly & Installation..Loose Components ................................... 16
signed
Connecting the Gas Supply ..................... 16
Welding Shield ........................................... 17
Preparation for Use ....... Installing the Welding Wire ........................ 18
Selecting Drive Roller ................................. 20
ACCESSORIES
Operation ............................................................................................. 21
Setting the Controls .................................... 21
A full range of accessories is available from your Clarke dealer.
General Information ............................................................................ 24
Spot Timer Control ...................................... 24
Thermal Overload ...................................... 24
Welding Tips ................................................ 24
Maintenance ................. Welding Shield ............................................ 25
PARTS AND SERVICE CONTACTS
Renewing the Wire Liner ............................ 25
Welder Specifications .......................................................................... 26
Wiring Diagrams ................................................................................... 27
Parts Lists and Diagrams ..................................................................... 31
Troubleshooting .................................................................................... 38
Declaration of Conformity .................................................................. 39
Parts & Service Contacts .................................................................... 39
2
For Spare Parts and Service, please contact your nearest dealer,
or CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: 020 8988 7400
PARTS & SERVICE FAX: 020 8558 3622
or e-mail as follows:
PARTS: Parts@clarkeinternational.com
SERVICE: Service@clarkeinternational.com
39
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. Feed motor operates
but wire will not feed
REMEDY
Motor malfunction
Return welder to your local dealer
a) Insufficient Feed Roller Pressure
b) Burr on end of wire
c) Liner blocked or damaged
d) Inferior wire
e) Roller worn out
4. Wire welds itself to tip
a) Wire feed speed too low
b) Wrong size tip
5. Wire feeds into ‘birds
nest’ tangle
a) Wire welded to tip
7. Erratic wire feed
Drum brake too slack
a) Drum brake too tight
b) Feed roller worn
c) Insufficient pressure on feed roller
d) Wire dirty, rusty, damp or bent
e) Liner partially blocked
8. Poor quality welds
a) Increase roller pressure
b) Re-cut wire square with no burr
c) Clean with compressed air or
replace liner.
d) Use only good “clean” wire
e) Replace roller
a) Unscrew tip, cut wire and fit new tip
Increase wire speed before
operating again
b) Fit correct size tip
a) As above plus reduce feed roller
pressure so that if blockage occurs
wire slips on roller i.e. no feed
b) Wire liner damaged preventing
smooth operation
6. Loose coils of wire
tangle around wire
drum inside machine
a) Replace fuses as necessary If
problem persists return welder to
your local dealer
b) Check fuse size
a) Insufficient gas at weld area
b) Incorrect gas/wire combination
c) Rusty, painted, damp, oil or
greasy workpiece
d) Rusty/dirty wire
e) Poor earth contact
b) Renew wire liner
Tighten drum brake
Caution: Do not over-tighten
a) Loosen drum brake slightly
b) Check and replace if necessary
c) Increase pressure on feed roller
Caution: Do not over-tighten
d) Re-cut wire and ensure it is clean
e) Clean with compressed air
a) Check that gas is not being blown
away by draughts and if so move
to more sheltered weld area. If not
increase gas supply
b) Consult your MIG welding manual
for correct set-up
c) Ensure workpiece is clean and dry
d) Ensure wire is clean and dry
e) Check earth clamp/workpiece conn
9. Wire jams in tip when
welding aluminium
Tip too small
Use slightly oversize tip ie., for 0.8mm
wire use 1mm tip. (Note: Applies to
aluminium only)
10. Welder cuts out
whilst in use
Duty cycle exceeded
(auto cut-out operates)
Allow welder to cool 15-30 mins
before continuing
Note: If duty cycle is continually
exceeded, damage to the welder
may result, and welder output is
probably too small for application
If you have any problems which cannot be resolved by reference to the above, or if you
require spare parts for your welder please contact your local Clarke dealer.
38
Thank you for purchasing this CLARKE MIG 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.
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.
PARTS AND SERVICE CONTACTS
For Spare Parts and Service, please contact your nearest dealer,
or CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: 020 8988 7400
PARTS & SERVICE FAX: 020 8558 3622
or e-mail as follows:
PARTS: Parts@clarkeinternational.com
SERVICE: Service@clarkeinternational.com
3
ELECTROMAGNETIC INTERFERENCE (EMC)
PARTS DIAGRAM - MIG270TE
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 involve constructing 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 or may not be earthed for safety reasons. Changing
the earthing arrangements should only be authorised by a person who is
competent to assess whether the changes will increase the risk of injury, e.g. by
allowing parallel welding current return paths which may damage the earth circuits
of other equipment.
1.ASSESSMENT OF AREA
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;
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
2.1 Mains supply
Welding equipment should be connected to the mains supply according to the
manufacturers recommendations. If interference occurs, it may be necessary to
4
37
PARTS LIST - MIG 270TE
No. Description
Part No.
No. Description
Part No.
2.2 Maintenance of the welding equipment
01
Wire Feeding Motor
EM22810006
29
Black Gas Hose
EM30900026
02
P.C. Board
EM22710051
30
Wheel Axle
EM55200029
03
Gab Solenoid Valve
EM22900002
31
Casteor
EM21625003
04
Compl. Thermostat
EM04600113
32
Switch Knob
EM21690312
05
Rectifier
EM22400029
33
Switch
EM22205030
06
Fan
EM22800005
34
Orange Pilot-lamp
EM22610011
07
Front Panel
EM33710295
35
Female Plug
EM22100002
08
Plastic Front Frame
EM21690285
36
Rear Wheel
EM21625011
09
Torch Adaptor
EM23005048
37
Cable Clamp
EM21605010
10
Green Pilot-light
EM22200005
38
Lower Panel
EM33700172
11
Fuse
EM22220002
39
Compl. Spool Holder
EM04600001
12
Fuse Holder
EM22220016
40
Left Access
EM33705371
13
Potentiometer Knob
EM21690309
41
Al. Wire Feeder
EM44410017
14
Right Side Panel
EM33705320
42
Wire Feed Roll 0,6-0,8mm EM33805003
15
Chain
EM10990010
42
Wire Feed Roll 1,0-1,2mm EM33805005
16
Rear Panel
EM33715096
42
Wire Feed Roll 0,8-2mm
17
Dividing Panel
EM33720099
42
Wire Feed Roll 1,2-1,6mm EM33805022
18
Mat For Tools
EM30905023
43
Wire Block Roll
EM33805007
19
Cover Panel
EM33705319
44
Slide Clip
EM21690226
20
Handle Bases
EM21690235
45
Earth Clamp
EM22110009
21
Handle
EM21600030
46
Earth Cable
EM43210013
22
Torch Conn. Cover
EM21690267
47
Dinsel Plug
EM22100001
23
Contactor
EM22225007
48
Torch
EM23000349
24
Auxiliary Transformer
EM44140036
49
Reducer + 2/Gauges
EM22905018
26
Transformer
EM44125038
51 Face Mask
EM21905019
27
Side
EM44025084
52 Transparent Glass
EM21905020
28
Input Cable
EM20220030
53 Dark Glass
EM21905024
36
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.
EM33805021
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.
2.3 Welding 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.
2.4 Equipotential 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 or 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.
5
SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING
PARTS DIAGRAM - MIG255TE
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. GENERAL PRECAUTIONS
A) Burn prevention
Wear protective clothing - gauntlet gloves designed for use in welding, apron, 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 glass). This
is a MUST for welding (and chipping) to protect the eyes from radiant energy and
spatter. Replace cover glass when broken, pitted, or spattered. Avoid oily greasy
clothing. A spark may ignite them. Hot metal should never be handled without gloves.
First aid facilities and a qualified first aid person should be available 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.
NOTE: ALL protective wear incl. masks & head shields MUST comply with PPE
Directive 89/686/EEC
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-, mercuryand 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 forcs 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 perchloroethylene 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 perchloroethylene.
6
35
C) Fire and explosion prevention
PARTS LIST - MIG 255TE
Causes of fire and explosion are:
No. Description
Part No.
No. Description
Part No.
01
Wire Feed Motor 42V
EM22810006
30
Resistance
EM22305004
02
P.C. Board
EM22710051
31
Transformer
EM44120084
03
Gas Solenoid Valve
EM22900002
32
Complete Fan
EM22800021
04
Complete Thermostat
EM04600113
33
Wheels Axle
EM55200029
05
Rectifier
EM22400086
34
Castor
EM21625003
06
Fan
EM22800002
35
Swicth Knob
EM21690312
07
Front Panel
EM33710295
36
Switch
EM22205033
08
Plastic Front
EM21690285
37
Orange Pilot-lamp
EM22610011
09
Binzel Torch Adaptor
EM23005048
38
Female Plug
EM22100002
10
On/Off Switch
EM22200002
39
Rear Wheel
EM21625011
11
Fuse
EM22220002
40
Cable Clamp
EM21605010
12
Fuse Holder
EM22220016
41
Lower Panel
EM33700172
13
Potentiometer Knob
EM21690309
42
Compl. Spool Holder
EM04600001
14
Right Side Panel
EM33705320
43
Left Access Panel
EM33705371
15
Chain
EM10990010
44
Al .wire Feeder
EM44410017
16
Rear Panel
EM33715096
45
Feed Roll 0.6-0.8mm
EM33805003
17
Dividing Panel
EM33720099
45
Feed Roll 1.0-1.2mm
EM33805005
18
Mat For Tools
EM30905023
45
Feed Roll 0.8-1.0mm nylon EM33805021
19
Cover Panel
EM33705319
45
Feed Roll 1.2-1.6mm nylon EM33805022
20
Handlebases
EM21690235
46
Block Roll
EM33805007
21
Handle
EM21600030
47
Slide Clip
EM21690226
22
Torch Conn. Cover
EM21690267
48
Earth Clamp
EM22110009
23
Capacitor
EM22315003
49
Earth Cable
EM43210013
24
Input Cable
EM20220044
50 Dinse Plug
EM22100001
25
Black Gas Hose
EM30900026
51 Torch
EM23000349
26
Contactor
EM22225007
52 Reducer
EM22905017
27
Auxiliary Contacts
EM22225018
53 Face Mask
EM21905019
28
Choke
EM44135073
54 Transparent Glass
EM21905020
29
Auxiliary Transformer
EM44140036
55 Dark Glass
EM21905024
34
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.
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. 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, 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.
7
3. ELECTRIC ARC (MIG, TIG) WELDING
PARTS DIAGRAM - MIG220TE
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. 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!
1) Protective clothing
Wear long sleeved clothing (particularly for gas shielded arc) in addition to
gloves, apron and shoes (2A). As necessary, use additional protective clothing
such as leather jacket or sleeves, flameproof apron, and fire-resistant leggings.
Avoid outer garments of untreated cotton. Bare skin protection: Wear dark
substantial clothing, Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2) Eye and head protection
Protect eyes from exposure to arc. NEVER look at an electric arc without
protection. Welding helmet or shield containing an appropriate filter plate
(Please refer to the section ‘Welding Shield). 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
you 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.
3) Protection of nearby personnel
For production welding, a separate, well vented room or enclosed bay is
best. In open areas, surround the operation with low reflective, noncombustible 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.
8
33
3B) TOXIC FUME PREVENTION
PARTS LIST - MIG 220TE
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
34
35
36
37
38
39
40
41
41
41
42
43
44
45
46
47
48
50
51
52
Motor + Pinion ........................................................................................
Motor Control .........................................................................................
Gas Solenoid Valve ...............................................................................
Compl. Thermostat ................................................................................
Rectifier ....................................................................................................
Fan ...........................................................................................................
Front Panel ..............................................................................................
Plastic Front Frame ................................................................................
Torch Adaptor ........................................................................................
On/Off Switch .........................................................................................
Fuse ..........................................................................................................
Fuse Holder .............................................................................................
Potentiometer Knob ..............................................................................
Right Side Panel .....................................................................................
Chain .......................................................................................................
Rear Panel ..............................................................................................
Dividing Panel ........................................................................................
Tool Mat ...................................................................................................
Cover Panel ............................................................................................
Pair Of Handles ......................................................................................
Handle .....................................................................................................
Torch Conn. Cover ................................................................................
Switch ......................................................................................................
Contactor ...............................................................................................
Choke ......................................................................................................
Auxiliary Transformer ..............................................................................
Transformer Mig ......................................................................................
Input Cable .............................................................................................
Rear Wheel .............................................................................................
Wheels Axle ............................................................................................
Castor ......................................................................................................
Switch Knob ............................................................................................
Female Dinsel Plug ................................................................................
Black Gas Hose ......................................................................................
Cable Clamp ..........................................................................................
Loner Panel .............................................................................................
Compl. Spool Holder .............................................................................
Left Access Panel ..................................................................................
Alum. Wire Fender .................................................................................
Wire Feed Roll 0.6-0.8mm ....................................................................
Wire Feed Roll 1.0-1.2mm ....................................................................
Wire Feed Roll 0.6-0.8mm nylon .........................................................
Wire Block Roll ........................................................................................
Slide Clip ..................................................................................................
Earth Clamp ............................................................................................
Earth Cable .............................................................................................
Dinsel Plug ...............................................................................................
Torch ........................................................................................................
Reducer ...................................................................................................
Mask .........................................................................................................
Transparent Glass ...................................................................................
Dark Glass ...............................................................................................
32
EM04600147
EM22710050
EM22900002
EM04600113
EM22400085
EM22800002
EM33710295
EM21690285
EM23005048
EM22200002
EM22220002
EM22220016
EM21690309
EM33705320
EM10990010
EM33715096
EM33720099
EM30905023
EM33705319
EM21690235
EM21600030
EM21690267
EM22205033
EM22225007
EM44135082
EM44140036
EM44120109
EM20220020
EM21625011
EM55200029
EM21625003
EM21690312
EM22100002
EM30900026
EM21605010
EM33700172
EM04600001
EM33705371
EM44410021
EM33805003
EM33805005
EM33805021
EM33805007
EM21690226
EM22110025
EM43210105
EM22100001
EM23000349
EM22905017
EM21905019
EM21905020
EM21905024
Comply with precautions in 2B.
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.
3D) SHOCK PREVENTION
Exposed live conductors or other bare metal in the welding circuit, or in
unearthed, electrically-LIVE 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.
3E) PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPP’T 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.
3F) 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 LIVE part - or earthed metal - reduces the
body surface electrical resistance, enabling dangerous and possibly lethal
currents to flow through the body.
1) Earthing the equipment
When arc welding equipment is earthed according to the National
Electrical Code, and the workpiece is earthed, 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 earth.
Conductors must be adequate to carry earth currents safely. Equipment
made electrically LIVE by stray current may shock, possibly fatally. Do NOT
EARTH to electrical conduit, or to a pipe carrying ANY gas or a flammable
liquid such as oil or fuel.
9
2) Torch
Fully insulated torch should be used. Do NOT use a torch with protruding
screws or with any form of damage.
3) Connectors
Fully insulated lock-type connectors should be used to join welding cable.
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.
6) 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.
PARTS LISTS AND DIAGRAMS
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
danger to the operator.
Avoid welding tanks which may contain flammable residuals.
DANGER - ELECTRIC SHOCK CAN BE FATAL.
A person qualified in first aid should always be present in the working area.
If person is unconscious and electric shock is suspected, do not touch the person if
he or she is in contact with the welder or cables. Disconnect the welder from the
power source and then use First Aid. Dry wood, or other insulating material can be
used to move cables, if necessary, away from the person.
10
31
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.
check that the pressure regulator and gauges (where fitted), are
✔ ALWAYS
working correctly. DO NOT lubricate the regulator.
use the correct regulator. Regulators are designed to be used with
✔ ALWAYS
a specific gases.
✔ ALWAYS inspect the torch hose before use to ensure it is in good condition.
✔ ALWAYS keep the free length of torch hose outside the work area.
✔ ALWAYS remove all flammable materials from the welding area.
✔ ALWAYS keep fire extinguisher handy....’Dry Powder, C0 or BCF, NOT Water
NEVER remove any of the panels unless the machine is disconnected from
✗
the supply, AND never use the machine with any of the panels removed.
attempt any electrical or mechanical repair unless your are a qualified
✗ NEVER
technician. If you have a problem with the machine contact your local
MIG 270TE
2
CLARKE dealer.
✗
✗
✗
✗
✗
✗
✗
✗
30
NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN.
The MIG welding process uses an INERT gas to protect the weld pool. It is
important to ensure the appropriate gas is being used. NEVER use gas from
a cylinder, the content of which is unknown.
NEVER
a.
Use a damaged cylinder.
b.
Lift the cylinder by the valve.
c.
Expose the cylinder to a heat source or sparks.
NEVER continue to weld, if, at any time, you feel even the smallest electric shock.
Stop welding IMMEDIATELY, and DO NOT attempt to use the machine until the fault
is diagnosed and corrected.
NEVER point the MIG torch at any person or animal.
NEVER touch the MIG torch nozzle until the welder is switched OFF and the
nozzle has been allowed to cool off.
NEVER connect, disconnect, or attempt to service the MIG torch, until the machine
is switched OFF and disconnected from the mains supply.
NEVER allow the earth cable or torch hose to become wrapped around the
operator or any person in the vicinity.
11
SAFETY EQUIPMENT
A comprehensive range of CLARKE safety equipment for use when
welding is available from your local dealer.
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.
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.
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.
MIG 250TE
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.
BENEFITS OF MIG WELDING
•
50% faster welding time.
•
Operator training time kept to a minimum.
•
There is no slag removal, thus eliminating almost all post-welding
cleaning operations.
•
Minimum waste of welding consumables.
•
Overall, a faster more efficient way of getting the job done.
•
Less heat - less distortion.
•
Ability to weld thin material.
12
29
WIRING DIAGRAMS
ELECTRICAL CONNECTIONS
WARNING! THIS APPLIANCE MUST BE EARTHED.
MIG 220TE & 255TE
Connect the mains lead, through a suitably fused isolator switch, to a 230 Volt (50Hz)
electrical supply, having a fuse rating in accordance with that given in the specification
chart on page 2. A standard 13 Amp plug MUST NOT be used with this machine.
IMPORTANT: The wires in the mains lead are coloured in accordance with the following
code:
Green & Yellow
- Earth
Blue
-
Neutral
Brown
-
Live
As the colours of the flexible lead of this appliance may not correspond with the
coloured markings identifying terminals in your electrical supply, proceed as follows:
MIG 220TE
• Connect GREEN & YELLOW coloured cord to terminal marked with a letter
“E” or Earth symbol “ ” or coloured GREEN or GREEN & YELLOW.
•
Connect BROWN cord to terminal marked with a letter “L” or coloured RED.
•
Connect BLUE cord to terminal marked with a letter “N” or coloured BLACK.
MIG 270TE
This model is designed for use with a 400V three-phase supply, and should be
connected through a suitably fused isolator switch.
The GREEN or GREEN & YELLOW wire should be connected to the EARTH terminal
or terminal marked with “ ” symbol. The other two wires are for connection to the
phase wires.
Cable Extensions:
IMPORTANT:
For extensions up to 10M, the size of the conductors MUST be at least the same size
as that used on the machine - 2.5mm2. It is NOT advised to use extensions greater
than this, but if it is absolutely necessary, the conductor size must be 4mm2 up to a
maximum of 25M in length.
DANGER
NEVER OPERATE THIS MACHINE WITH THE SIDE PANELS PARTIALLY
OPENED OR COMPLETELY REMOVED
28
13
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.
Some components are stored within the side compartment. To open the
compartment, slide the recessed handle backwards.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Welder complete with power cable and gas hose.
2xWheels
2x Casters
1xTubular axle
1xHandle
1x Welding Mask
1xWelding Mask handle
1xPackage containing 1x Clear Glass and 1x Dark Glass Lens
1xPackage containing 6 screws and nuts for welding mask
1xGas Regulator with nut and tail connector.
1xPackage containing:
a. 2xcirclips for wheel axle (wheel retainers)
b. 2xHex. socket head screws for securing the handle.
c. Worm drive hose clip for gas hose to regulator
d. 3xspare welding tips...0.6mm, 0.8mm and 1.0mm
WIRING DIAGRAMS
NOTE: A 0.6mm tip is also fitted to the torch
12. Torch & Hose assembly
13. Earth Lead Assembly
Fig.1
14
27
GENERAL LAYOUT
SPECIFICATIONS
Power Supply
220TE
250TE
270TE
230V 50Hz 3Ph
230V 50Hz 3Ph
400V 50Hz 3Ph
Main Fuse Rating
25Amps
40Amps
16Amps
Current Range
40-200A
30-250A
30-260A
3-4mm
4-5mm
6mm
0.6-1.2mm
0.6-1.2mm
0.6-1.2mm
Max. Metal Thickness (m/s)
Welding Wire Sizes
Duty Cycle*
20%
200A
-
-
30%
-
250
-
35%
-
-
260A
60%
125A
180A
170A
100%
Dimensions (no handle) mm
95A
140A
135A
685x820x500
685x820x500
685x820x500
6015220
6015235
6015240
Fig.2
Weight
Part No.
* Duty Cycle: Determines the machine ‘down time’.
DUTY CYCLE
These models are covered by regulations EN 60974-1 and EN 50199, where the Duty Cycle
(X) is expressed as a percentage of time the machine may be used in a given period for a
specified welding current.
i.e. using the example below, which is an illustration of the 270TE data plate.....
When welding at 170 Amps the machine may be used for 6 minutes (60%) in any 10 minute
period..........
............or, the machine may be used continuously, (100%) when welding at 135 Amps
Please note that 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. ALWAYS CONSULT THE MACHINE’S DATA PLATE
26
15
ASSEMBLY & INSTALLATION
MAINTENANCE
WARNING!
A. Wheels & Casters
ELECTRICITY CAN KILL....NEVER TOUCH LIVE ELECTRICAL COMPONENTS
DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS AND
MAINTENANCE OPERATIONS
Raise the machine, thread the axle into its housing and attach the wheels, securing
with the circlips provided.
Thread the casters into their mountings and tighten the bolts.
B. Handle
Attach the handle to the top front of the machine using the two hex. socket head
screws provided.
C. Hose & Earth Cable
Simply screw the Torch Hose connector into the adapter on the front panel (see Fig
4.), taking care to ensure the pins are correctly aligned. DO NOT force it into place.
BEWARE HOT SURFACES.....ALWAYS LET THE POWER SUPPLY COOL DOWN
BEFORE ACCESSING INTERNAL COMPONENTS.
Frequency of maintenance operations depends on the operating conditions, how
intensively the welder is used, and how clean or dirty the welding site is (aggressive
atmospheres, etc.).
Always inspect the earth return and torch hose, before use to ensure they are in perfect
condition and earth clamp is clean and secured correctly to the cable.
Check the gas hose and Pressure Regulator for security and serviceability, and
ensure there is sufficient gas to complete the job in hand.
As a general rule the power supply should be inspected internally at least annually.
Consult your CLARKE dealer
Tighten the large plastic round nut.
The earth cable plug is inserted into its receptacle on the lower front panel, ensuring
the key lines up with the keyway, and then rotated through 90 degrees to lock
into place.
D. Gas Supply
It is necessary to procure a cylinder of gas, suitable for the job in hand.
Locate the gas cylinder on the platform at the rear of the unit, and secure using
the chain provided.
A regulator is provided, complete with outlet pressure gauge for use with argon or
argon mix gas bottles. Should you require to use Carbon Dioxide, it will be necessary
for you to purchase an appropriate regulator with a female connector. Your Clarke
dealer will be happy to advise in this regard.
Ensure the outlet of the gas bottle is clean, then screw on the regulator and nip
up... do not overtighten.
THE WELDING SHIELD
Always maintain the welding mask in good condition. If the clear glass protection lens
becomes badly pitted, sufficient to interfere with vision, or cracked, have it replaced
immediately. Replacement clear and dark lenses are available from your Clarke dealer
- see Parts Lists for details. NEVER use any dark filter lens other than that provided by
CLARKE International, or one with the same certified ‘Optical class’ (degree of protection).
The shield should always be cleaned with a clean soft cloth after use, ensuring the lenses
are clean. Remove any dust that may have accumulated and store it in a safe place
where it cannot be damaged. NEVER use a shield that is not in perfect condition.
RENEWING THE WIRE LINER
If the liner becomes damaged or kinked, it will be
necessary to replace it.
1.
Always use the appropriate gas for the material being welded. If you are unsure,
consult a qualified tradesman, or a suitable reference book.
Attach the nut and tail to the gas hose, using the worm drive clip provided, then
screw the nut on to the regulator outlet and tighten.
2.
3.
Open the gas valve and screw in the regulator knob allow gas into the system to
check for gas leaks. If any are apparent, they must be rectified before proceeding.
Turn off the gas when satisfied the system is leak free.
4.
16
Fig.11
Remove the welding wire from the hose and
torch assembly, either by cutting it at the wire
spool and pulling through from the nozzle end,
or rewinding it back on to the spool.
Disconnect the hose from the machine.
Unscrew the end nut shown in Fig. 11 using
a 12mm spanner, and, having
straightened the hose assembly, pull
the liner completely out of the hose.
Thread the new liner into the hose fully, then
screw the end nut back into place.
25
E. The Welding Shield
GENERAL INFORMATION
A. Spot Timer Control
Fig.3
This control may be used for spot (plug) welding, or stitch welding. The control is
set so that the duration of weld lasts for a predetermined time.
For plug welding, a special nozzle is required, (see your CLARKE dealer) which is
pressed hard against the two pieces of material to be welded, as the trigger is
pressed. The arc will last for a predetermined time, depending upon the control
setting, melting the metal and fusing the two parts together.
Allow a short period with parts held together before withdrawing the nozzle.
1.
Remove the shield, handle and screws bag from the packaging
2.
Carefully bend the side and upper panels ‘inwards’ so that the holes in the
upper panel and top of the side panels coincide(A). Secure together with
screws and nuts provided.
3.
Prise back the window flap and insert the clear glass first, followed by the
dark glass, ensuring they fit snugly in the recesses, then secure the flap with
two screws with nuts provided.
IMPORTANT: The clear glass MUST installed BEFORE the dark glass
B. Thermal Overload
The ‘Thermal Overload’ is a safety device which shuts off the welder when the
duty cycle has been exceeded. This is to prevent damage to the machine caused
by overheating.
When this occurs, the warning lamp will glow (amber). Allow the welder to cool,
until the amber light extinguishes before resuming.
For details of the duty cycle...i.e. the length of time the machine may be used at
a particular welding current, refer to the data and notes on page 28.
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.
•
Whenever possible, clean out the wire liner with compressed air when
replacing the wire spool.
•
Periodically remove the dust, using LOW PRESSURE compressed air, within the
casing. Adequate heat dissipation is essential during the welders operation.
24
It is important to pay attention to the notes on welding shield maintenance, given
on page 27. When replacing the glass panels, use ONLY those parts supplied by
Clarke International. The dark panel is a certified, specific optical class, and should
not be exchanged for any other type.
The clear glass panel should be replaced when it becomes badly pitted.
WARNING:
NEVER look at an electric arc without eye protection as this can injure the
eyes permanently. ALWAYS use a protection mask or welding helmet.
NOTE: The correct shade of glass should be used in accordance with the following
chart:
All components are now correctly assembled, and the welder
may now be prepared for use as follows:
17
F. Attach the Earth Clamp
PREPARATION FOR USE
Attach the earth clamp to the workpiece as close to the point of weld as possible,
without it being intrusive.
A. Installing the Welding Wire
NOTE: These machines are designed to accept either the Clarke 5kg or 15kg wire
spools of mild steel, stainless steel or aluminium according to the type of metal you
wish to weld.Wire spools must be purchased separately. See your Clarke dealer for
full details.
1.
IMPORTANT: Ensure that the gas and electrical supplies are disconnected.
2.
REF: FIG 4
To fit the wire spool,
firstly open the side
compartment by
pulling the recessed
catch backwards.
Fig.4
Open the gas valve on the gas cylinder. Regulate the pressure by turning the
regulator knob clockwise (to increase pressure), and adjust to the desired setting.
NOTE: this varies with different metals, thicknesses and currents. Refer to a MIG
welding manual for instructions.
With the welding current set, and welding wire trimmed, set the wire feed control
to 6, (8 for Aluminium).
Pressure plate
Mounting Shaft
Wire Spool
Collar
Flat Washer
Spring
Plastic Nut
Fig.5
4.
G. Open the gas valve
Your welder is now fully prepared for welding as follows:
1.
2.
3.
4.
5.
6.
7.
3.
Ensure there is good contact, if necessary, clean the area with a wire brush
beforehand....Remember, the contact MUST be on bare metal - thoroughly clean.
18
As the wire touches the workpiece, an arc will be struck......BEFORE it is struck,
cover the face with the face mask.
The speed of weld will depend upon the wire speed and welding current.
Slide the spool on to the shaft, ensuring
that the Peg ‘A’ locates snugly in locating
hole ‘B’, ensuring the direction of feed of
the wire is in the direction of the arrow.
NOTE: The Plastic knob, item 7 Fig.4 is also used
to apply slight tension to the wire spool. This
prevents the spool from running freely, which
could cause the wire to unspool, creating a
‘birds nest’ tangle within the side compartment.
Adjust by hand and test the tension.
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 and gas will be issued.
Maintain a gap of approx. 5 - 7mm from the workpiece to the tip, and feed the
wire into the molten pool at a steady rate, along the line of the proposed weld.
Turn the plastic knob with cam (7,) to the
position shown in Fig. 5, so that the latch is
unlocked, and pull off the collar (6).
Replace the collar - 4, (5kg spool ONLY),
and turn the Plastic knob with cam (7) to
the position shown in Fig.6 thereby locking
the spool on the shaft.
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, switch
ON the machine, and lower the torch to the workpiece with one hand, whilst
holding the welding mask in the other.
NOTES:
As MIG welding is an acquired skill, it is strongly advised that, if you are not fully
familiar with this type of welding, you practise on a piece of material with the
same characteristics as that of your workpiece, until you are satisfied with the
result, and you have fine tuned your welder to produce a satisfactory weld.
Fig.6
One of the problems experienced with novice welders, is the welding wire sticking to the
contact tip. This is as a result of the wire feed speed being too slow. It is always better
therefore to start with too high a speed, and back off slightly, to avoid the possibility of the
wire welding itself to the tip. This is the reason position 6 is recommended for start up.
The Wire Feed control is for fine tuning the wire speed. The speed of wire delivery
will increase automatically as the current is increased from MIN to MAX, and vice
versa. Therefore, once the ideal speed is achieved, by fine tuning, it should not be
necessary to adjust this control when the welding current is changed.
Listen to the sound made. An irregular crackling sound denotes too high a wire
speed. Decrease the speed until a regular, strong buzzing sound is heard.
23
(i) WELDING CURRENT CONTROL
Fig.7
Select the welding current according to the type of metal and thickness to be
welded. The control has 7 positions as indicated in the chart below.
Experience will determine the optimum setting for the job in hand, but the chart
gives general settings from which to work.
1
7
6
Switch
Positions
2
Steel Wire
Diameter
(mm)
Wire Speed
Adjustment
1
0.6
LOW
2
0.6
LOW
3
0.6 - 0.8
MEDIUM
4
0.6 - 0.8
MEDIUM
5
0.8
MEDIUM _ HIGH
6
0.8
HIGH
7
1.0
HIGH
5
3
4
5.
IMPORTANT!
Before fitting ANY wire, ensure the correct groove on the roller is in place.
(see page 20)
6.
PLEASE NOTE: If the current and hence the wire speed is increased, the volume of
gas at the nozzle must also be increased. Turn the regulator knob accordingly.
The WIRE FEED Rotary Control Knob, with graduations from 0 to 10, is used to fine
tune the wire speed feed to the nozzle.
7.
8.
E. Trim the Welding Wire
Trim the welding wire so that it protrudes no more than 5mm from the end of the
shroud.
22
Reposition the pressure roller bracket and securing knob (A) and tighten
slightly.
Tightening the knob (A) too tightly will crush the wire and damage the
wire feed motor, too loose will not allow the wire to be pulled by the roller.
It is always better to start with too high a speed, and back off slightly, to avoid the
possibility of the wire welding itself to the tip.
This is explained in more detail on page 24. For all normal welding operations, set
this control to zero
Fig.8
Proceed to feed it through the
guide tube (C, Fig.8), over the
groove on the roller (D), and
into the wire liner, by about 10
- 15 cm.
The knob should be set to position 6 to begin with for welding steel, and 8 for welding
aluminium, then adjusted as required.
D. Timer Control
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 with a sharp pair of
snips ensuring there are no
burrs or sharp edges.
(ii)WIRE FEED SPEED CONTROL.
Note: This control is for fine tuning the wire speed. The speed of wire delivery will
increase automatically as the current is increased and vice versa. Therefore, once
the ideal speed is achieved by fine tuning, it should not be necessary to adjust
this control when the welding current is changed.
Unscrew the pressure roller
bracket securing knob (A, Fig
7), whilst holding down the
pressure roller bracket (B),
against spring pressure, so that
the screw rod hinges out of its
slot. This releases the pressure
roller bracket which, when
released, will pivot upwards
under spring pressure.
Fig.9
(Ref. Fig 9)
Remove the torch shroud by
twisting it anti clockwise and
pulling it off, then unscrew the
contact tip.
Should any wire protrude from the
tip....pull it out completely and
discard.
19
OPERATION
9.
Close the side panel of the machine, and switch on at the mains or isolator.
10. Set the Wire Feed rotary switch, on the front panel, to position 6 OR 7, 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 disconnect from the mains
supply. 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 fed through to the wire liner and torch.
Each time you use the machine, it will be necessary to perform the following
operations:
A. Check The Welding Wire
Check to ensure the correct type of welding wire is installed for the job in hand,
and is correctly adjusted.
B. 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.
D. 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 rollers are provided, one with 0.6
and 0.88mm grooves, and one with 1.0 and 1.2mm grooves.
The welder is factory set with the 0.8mm groove in position.
Fig.10
To change grooves, proceed as follows:
1.
With the pressure roller bracket
raised, and the old wire removed,
remove the roller securing knob
(arrowed), by turning it fully
anticlockwise, then pull the roller
from the shaft.
C. Set The Controls
In order to produce a satisfactory weld, the controls must be fine tuned whenever
there is a material change in weld characteristics. This is generally referred to as
‘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:
(1) Welding Current, and (2) Wire Feed Speed,
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 related to the wire feed speed.
As the current is increased, the wire feed speed is also increased.
2.
Ensure the appropriate groove is
facing inwards, before sliding
the roller on to the shaft.
Conversely, if current is decreased the wire feed speed is decreased.
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.
Screw on the securing knob, to
lock the roller securely in place.
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 current)
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 current 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 and welding current, results in very little
spatter and a continuous, intensive hissing can be heard from the arc.
20
21