Clarke MIG102NG Specifications

WARNING: Read these instructions before using the machine
NO GAS MIG WELDER
MODEL NO: MIG102NG
PART NO: 6015600
OPERATION & MAINTENANCE
INSTRUCTIONS
LS0214
INTRODUCTION
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.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
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CONTENTS
INTRODUCTION ............................................................... 2
GUARANTEE .................................................................... 2
ENVIRONMENTAL RECYCLING POLICY ......................... 2
CONTENTS ....................................................................... 3
GENERAL SAFETY INSTRUCTIONS ................................... 4
SAFETY SYMBOLS ............................................................ 7
THE WELDING SHIELD ...................................................... 7
ELECTRICAL CONNECTIONS .......................................... 8
UNPACKING ................................................................... 9
Opening The Cover.............................................................. 9
OVERVIEW ....................................................................... 10
THE CONTROL PANEL ...................................................... 11
PREPARATION FOR USE .................................................. 12
Mounting The Welding Wire Spool...................................... 12
Setting The Drive Roller Size ................................................. 12
Threading The Wire ............................................................... 13
MIG WELDING PRINCIPLES ............................................. 15
OPERATING THE WELDER ................................................ 15
Preparing The Workpiece .................................................... 15
Operation .............................................................................. 15
Thermal Overload................................................................. 16
Duty Cycle ............................................................................. 17
ACCESSORIES ................................................................. 17
MAINTENANCE ............................................................... 18
RATING PLATE ................................................................. 19
TROUBLESHOOTING ........................................................ 20
SPECIFICATIONS ............................................................. 22
DECLARATION OF CONFORMITY ................................... 23
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GENERAL SAFETY INSTRUCTIONS
WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY
WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO
OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.
ELECTRIC SHOCK
insulated for safety. - Keep all
equipment well maintained.
• Remove the plug from the socket
and wait 5 minutes to allow the
capacitors to discharge before
carrying out any servicing or
maintenance on this welder.
• The operator shall prevent any gas
cylinders in the vicinity of the work
piece from becoming part of the
welding circuit.
• Do not touch live electrical parts.
FUMES & GASES
• Never use electrode holders or
cables which are damaged.
• The welding process generates
hazardous fumes as a by-product.
Inhalation of these fumes is
hazardous to health.
• Keep working environment,
equipment, cables and clothing
free from grease, oil, moisture and
dirt.
• Keep your head away from the
weld to avoid breathing the fumes.
• Ensure welding machine has been
correctly earthed.
• If welding in confined spaces
ensure adequate ventilation and
use a fume extractor.
• The operator must be insulated
from the floor and work bench
using a dry insulation mat.
• By-products of welding can react
to create a toxic/explosive
environment.
• Always ensure a second person is
present in case of accident.
FIRE OR EXPLOSION
• Never change electrodes with
bare hands or damp gloves.
Welding can cause fire and
explosions. Precautions should be
taken to prevent these hazards.
• Keep welding cables away from
power cables.
• Before starting work ensure the
area is clear of flammable
materials.
• Regularly inspect the condition of
the cables for signs of damage.
• Remove plug from the mains
socket when not in use, do not
leave the machine unattended.
• Move any combustible materials to
a safe distance, especially
substances likely to generate a
dangerous vapour.
• Ensure earth clamp is secured to
bare metal adjacent to weld
seam, and when not in use is
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• The welding arc can cause serious
burns. Avoid contact with skin.
one is looking before striking an
arc.
• Sparks and molten metal are
ejected during welding. Take
precautions to prevent fire.
• Wear hearing protection if
required.
• Allow the weld to cool. Hot metal
should never be handled without
gloves.
• Sparks and molten metal can pass
through gaps. Be aware that fire
can start out of sight.
• Take care when adjusting or
maintaining the torch, that it has
had time to cool sufficiently and
the welder is disconnected from
the mains supply.
• Do not weld pressurised containers.
or containers containing
flammable vapours e.g. fuel tanks.
• Always have appropriate fire
fighting equipment to hand
suitable for use in electrical
environments.
• 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.
• Avoid carrying any fuels with you
e.g. cigarette lighters or matches.
PERSONAL PROTECTION
• A hard hat should be worn when
others are working overhead.
• The body should be protected by
suitable clothing.
• Flammable hair sprays/gels should
not be used by persons intending
to weld or cut.
• The use of neck protection may be
necessary against reflected
radiation.
PROTECTIVE CLOTHING
• Arc machines generate a
magnetic field which is detrimental
to pacemakers. Consult your
doctor before going near active
welding equipment/operations.
• Wear gauntlet gloves designed for
use in welding.
• Wear an apron, and protective
shoes.
• The UV and IR radiation generated
by welding is highly damaging to
the eye, causing burns. This can
also affect the skin.
• Wear cuffless trousers (not turned
up) to avoid catching sparks and
slag.
• Always use suitable welding shields
equipped with appropriate
protection filters.
• Protective head and shoulder
coverings should be worn when
overhead welding.
• Where there are pedestrians and
traffic ensure a protective screen is
used to avoid accidental arc glare.
• 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
• Avoid oily greasy clothing.
• Do not weld in the vicinity of
children or animals and ensure no
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from radiant energy and spatter.
Replace cover glass when broken,
pitted, or spattered.
• Never touch the MIG torch nozzle
until the welder is switched OFF and
the nozzle has been allowed to
cool off.
NOTE: ALL protective wear inc. masks
& head shields MUST comply with PPE
Directive 89/686/EEC
• NEVER allow the earth cable or
hose to become wrapped around
the operator or any person in the
vicinity.
ADDITIONAL SAFETY PRECAUTIONS
FOR MIG WELDING
• ALWAYS ensure that there is ample
free air circulating around the
outer casing of the machine, and
that the louvres are unobstructed.
• ALWAYS inspect the 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 a fire extinguisher
handy;-Dry Powder, C02 or BCF,
NOT Water.
• NEVER remove any of the panels
unless the machine is
disconnected from the power
supply, AND never use the
machine with any of the panels
removed.
• NEVER attempt any electrical or
mechanical repair unless you are a
qualified technician. If you have a
problem with the machine contact
your local CLARKE dealer.
• Never use or store in a wet/damp
environment.
• 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.
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SAFETY SYMBOLS
General Warning, indicates that failing to follow these instructions
could result in injury or damage to the machine.
Recycle unwanted materials instead of disposing of them as
waste. All tools, accessories and packaging should be sorted,
taken to a recycling centre and disposed of in a manner which is
compatible with the environment.
Read Instruction Manual before use.
THE WELDING SHIELD
1. Push the two halves of the shield
together as shown, making sure
the hooks and pins on the side
engage correctly.
2. Place the handle into position
and secure using the plastic nut
provided.
3. Working from the inside of the
shield, insert the clear glass panel
into the recess in the shield,
followed by the dark glass panel.
• The clear glass must be inserted
first.
4. Insert the two plastic screws to
clamp the glass panels from the
inside of the mask.
When replacing the glass panels,
only use 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.
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ELECTRICAL CONNECTIONS
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
Before switching the product on, make sure that the voltage of your electricity
supply is the same as that indicated on the rating plate. This product is designed to
operate on 230VAC 50Hz. Connecting it to any other power source may cause
damage.
This product may be fitted with a non-rewireable plug. If it is necessary to change
the fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost
or damaged, the plug must not be used until a suitable replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring
instructions shown below. The old plug must be disposed of safely, as insertion into
a mains socket could cause an electrical hazard.
WARNING! THE WIRES IN THE POWER CABLE OF THIS PRODUCT
ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH
• The wire which is coloured Blue must be connected to the terminal
which is marked N or coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked L or coloured Red.
• The wire which is coloured Yellow and Green must be connected to the
terminal which is marked E or
or coloured Green.
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Earth
(Green and Yellow)
Live
Neutral
(Brown)
(Blue)
Ensure that the outer sheath of the cable is firmly held by the clamp
WE STRONGLY RECOMMEND THAT THIS MACHINE IS CONNECTED TO THE MAINS SUPPLY
VIA A RESIDUAL CURRENT DEVICE (RCD)
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.
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UNPACKING
Any damage or deficiency should be reported to your CLARKE dealer
immediately.
The components include the following:
• 1 x Gasless MIG Welder (torch and earth clamp attached)
• 2 x 0.9 mm Torch Tips (one installed in the torch)
• 1 x Spool Of Flux Cored Wire
• 1 x Combination Wire Brush / Hammer
• 1 x Split Welding Mask
• 1 x Instruction Manual
WARNING: NEVER OPERATE THIS MACHINE WITH THE COVER OPENED
OPENING THE COVER
IMPORTANT: Ensure that the welder is not connected to the mains supply.
1. Open the cover, by sliding the top
back ,and then lift the cover open
as shown.
2. Remove any loose items that
have been transported inside.
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OVERVIEW
NO
DESCRIPTION
NO DESCRIPTION
1
Handle
4
Hammer/Brush Tool
2
Control Panel
5
Torch
3
Earth Clamp
6
Torch Hose
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THE CONTROL PANEL
1. Thermal overload light. If the duty cycle is exceeded as a result of welding
too long with a high current, the amber overload light will illuminate and the
welder will turn off. When the welder has cooled down (approx. 5 to 10
minutes), the light will go out, the power will be restored and welding can
recommence.
2. Power ON/OFF switch. When the power is ON, the green switch will be
illuminated. When the welder is no longer required, the Power On/Off switch
should be switched to the OFF position and the plug should be disconnected
from the mains supply.
3. Current setting switches MIN-MAX & 1-2. Used together these two switches
provide 4 increasing power levels as follows:
• MIN-1
• MIN-2
• MAX-1
• MAX-2.
4. Wire speed control knob. As a general rule, a higher current requires a
higher wire speed.
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PREPARATION FOR USE
MOUNTING THE WELDING WIRE SPOOL
Warning: Ensure that the welder is not connected to the mains supply.
NOTE: Spools of welding wire are available from your Clarke Dealer.
1. Open the cover, by sliding the top
back ,and then lift the cover open
as shown on page 9.
2. Remove the locking knob and
retaining disc.
3. Place the spool of welding wire
(supplied) over the spindle so that
it sits on the spring.
• Do not release the tension on
the wire as it will unravel causing feeding problems later.
• The wire will feed off the spool anticlockwise from the bottom of the
reel.
• The spool must be fitted with the correct orientation otherwise it will
not feed correctly.
SETTING THE DRIVE ROLLER SIZE
1. Loosen the tensioning knob and
pivot it towards you.
2. Lift up the arm.
3. Take hold of the triangular knob
on the drive roller cover and
rotate it 90°anticlockwise to
release it.
4. Pull the roller retainer off the drive
spindle to reveal the roller.
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5. Pull the roller off the drive spindle.
• The groove size is stamped on
the corresponding side of the
roller. Select the groove size
according to the size of the
wire you are using and put the
roller back on the spindle with
your chosen side facing you.
6. Replace the drive roller cover
back onto the drive spindle with
the opening facing right.
7. Ensure that the flanges at the base of the drive roller cover, seat fully into
the circular recess in the main moulding and then rotate the drive roller
cover through 90° to lock it in place.
THREADING THE WIRE
IMPORTANT: Do not release the tension on the wire as it will unravel causing
feeding problems later.
1. Pull out the end of the wire from the spool, taking care not to release the
tension.
• We recommend you cut off and discard the first 10 cm of wire from
the spool to avoid burrs and then straighten the next 15 cm of wire
to help with feeding.
2. Loosen the tensioning knob and pivot it towards you.
3. Lift up the arm.
4. Pass the wire through the guide,
over the drive roller and into the
torch liner.
• Push about 10-15 cm into the
torch liner.
5. Lower the arm and replace the
tensioning knob.
• Tighten the tensioning knob
sufficiently to hold firmly, but do
not fully tighten.
NOTE: Correct tension will allow the wire to feed into the torch liner
smoothly, but will allow the drive roller to slip in the event of a
blockage.
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6. Lower the cover and slide it
forward to close.
7. Pull off the torch shroud with a
twisting movement, then unscrew
the contact tip.
8. Connect the welder to the power
supply and switch ON.
9. Set the ‘WIRE FEED’ rotary control
on the front panel to position 7 or
8 and squeeze the trigger on the
torch body.
• The wire will feed through the
hose until it appears at the
torch tip.
• Ensuring the hose is free from
kinks during this process will
assist the wire in its passage
through the hose liner.
10. Release the trigger and switch off the welder and disconnect the machine
from the mains supply.
11. Refit the contact tip (0.9 mm is supplied fitted) to suit your wire. then
replace the shroud.
12. Trim the welding wire so that it protrudes no more than 5 mm from the end
of the contact tip.
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MIG WELDING PRINCIPLES
MIG (Metal Inert Gas) welding allows you to fuse together two similar metals
without altering the properties of the metal.
A consumable wire electrode is continuously fed through the welding torch
that is fitted with a concentric gas nozzle. the wire is connected to a high
voltage supply which creates an electric arc between the electrode (the
wire) and the workpiece. The arc is used to create the required heat to turn
the metal into a molten state. The wire is used as both the electrode and as a
filler.
When using a gasless welder the shielding gas is created from the flux within
the welding wire.
When using the welder outside, you may need to erect a wind break.
OPERATING THE WELDER
PREPARING THE WORKPIECE
The area being welded should be perfectly clean. Any coating, plating or
corrosion must be removed, otherwise a good weld will be impossible to
achieve.
Attach the earth clamp to the workpiece as close to the point of weld as
possible, without it being intrusive.
OPERATION
CAUTION: TO PREVENT THE THERMAL OVERLOAD PROTECTION FROM
ACTIVATING, THE DUTY CYCLE MUST BE NOT BE EXCEEDED.
1. With the welding current set and the wire trimmed, set the wire feed
control to 6.
2. Plug the machine into the mains supply and switch ON the machine.
3. Cover your face with a welding mask or welding helmet.
• This is essential.
4. Lower the torch to the workpiece with one hand and approach the work
with the torch tip at an angle of about 35o and pull the torch trigger fully.
• As the wire touches the workpiece, an arc will be struck.
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5. In order to produce a satisfactory weld, the controls may be fine tuned as
required. This will come with practice.
NOTE: MIG welding is an acquired skill, it is strongly advised that, if you
are not fully familiar with this type of welding, you practice on a
piece of material with the same characteristics as your
workpiece, until you are satisfied with the result, and you have
fine tuned your welder to produce a satisfactory weld.
NOTE: 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.
NOTE: The Wire Feed control is for fine tuning the wire speed. The speed
of wire delivery will increase automatically as the current is
increased. 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.
NOTE: 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.
THERMAL OVERLOAD
The ‘Thermal Overload’ shuts off the
welder when it becomes too hot,
due to the duty cycle being
exceeded. This is to prevent any
damage to the machine.
When this occurs, the warning lamp
shown will glow (amber). Allow the
welder to cool, until the amber light
extinguishes before resuming work.
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DUTY CYCLE
These welders are covered by
regulations EN 60974-1 and EN
60974-10, where the duty cycle is
expressed as a percentage of time
the machine may be used in a
given period for a specified welding
current.
Using the example shown, which is
an illustration of the data plate;e.g. when welding at 35 amps the
machine may be used for 6 minutes
(60%) in any 10 minute period.
ACCESSORIES
The following are some of the accessories available from your CLARKE dealer.
Please quote the part numbers shown below:
PART
DESCRIPTION
Welding Wire Spools
Mini - 0.9mm flux-cored
PART NUMBER
Arc Activated Headshields
CWH6
6000671
CWH7 (Flame)
6000672
8132110
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MAINTENANCE
WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL
COMPONENTS.
WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS
AND MAINTENANCE OPERATIONS. BEWARE HOT SURFACES.
WARNING: ALWAYS LET THE WELDER 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 environments etc).
Always inspect the earth cable and torch hose before use, to ensure they are
in perfect condition and that the earth clamp is clean and secured correctly
to the cable.
Check the hose for security and damage.
As a general rule the power supply should be inspected at least annually.
Consult your CLARKE dealer for advice if necessary.
Wire feed unit:
The feed roller wire guide plays an important part in obtaining consistent
results. Clean the rollers weekly, especially the feed roller groove, removing all
dust deposits.
Torch:
Protect the torch hose assembly from mechanical wear. Clean the liner from
the machine forwards by using compressed air. If the liner is blocked it must be
replaced.
Contact tip:
The contact tip is a consumable item and must be replaced when the bore
becomes enlarged or oval. The contact tip MUST be kept free from spatter to
ensure an unimpeded flow of gas.
To keep the contact tip free from spatter, we recommend the use of antispatter spray (Part number: 6000715) available from your CLARKE dealer.
Torch shroud:
The torch shroud must also be kept clean and free from spatter. Build-up of
spatter inside the gas cup can cause a short circuit at the contact tip which
will result in expensive machine repairs.
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RATING PLATE
1
Name and address of manufacturer
13
Load Voltage symbol
2
Model number, part number
14
Energy Input symbol
3
Batch number
15
Rated supply voltage
4
Single phase transformer-rectifier
16
Rated maximum supply current
5
British Standards applied
17
Maximum effective supply current
6
Welding process
18
N/A
7
This symbol indicates that the unit is
suitable for carrying out welding
operations in an environment which
has an increased risk of electric
shock.
19
N/A
8
Welding Current symbol - direct current.
20
N/A
9
Rated no-load voltage
21
N/A
10
Min+max welding current and corresponding load voltages
22
Degree of protection
11
Duty Cycle symbol
23
N/A
12
Rated Welding Current symbol
24
N/A
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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
SOLUTION
No response from Check fuses and mains
welder
lead
Replace fuses as necessary, If problem
persists return welder to your local dealer
Check fuse size
Welder does not
feed wire
Feed motor has malfunc- Return welder to your local dealer
tioned.
Feed motor running but no wire
being fed from
welder tip
Insufficient Feed Roller
pressure
Increase roller pressure
Burr on end of wire
Re-cut wire square with no burr
Liner blocked or damaged
Clean with compressed air or replace
liner.
Inferior wire
Use only good “clean” wire
Roller worn out
Replace roller
Wire feed speed too low
Unscrew tip, cut wire and fit new tip
Increase wire speed before operating
again
Wrong size tip
Fit correct size tip
Wire welded to tip
As above plus reduce feed roller pressure
Wire liner damaged preventing smooth operation
Renew wire liner
Wire welds itself
to tip
Wire feeds into
‘birds nest’ tangle
Loose coils of
Locking knob too slack
wire tangle
around wire drum
inside machine
Tighten Locking Knob slightly. Do not
over-tighten
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PROBLEM
CAUSE
SOLUTION
Erratic wire feed
Locking Knob too tight
Loosen Locking Knob slightly
Feed roller worn
Check and replace if necessary
Insufficient pressure on
feed roller
Increase pressure on feed roller
Caution: Do not over-tighten
Wire dirty, rusty, damp or
bent
Re-cut wire and ensure it is clean
Liner partially blocked
Clean with compressed air
Poor earth contact
Check earth clamp/workpiece connection
Rusty, painted, damp, oil
or greasy workpiece
Ensure workpiece is clean and dry
Rusty/dirty wire
Ensure wire is clean and dry
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
Poor quality
welds
Welder cuts out
whilst in use
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.
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SPECIFICATIONS
Model
MIG102NG
Part No
6015600
Weight
16.65 kg
Dimensions (l x w x h) mm
420 X 192 X 362
Power Supply
230 V @ 50Hz
IP Rating
IP21S
Output Min/Max Amps
35 / 90 A
Open Circuit Voltage
20-30 V DC
Rated Max Input Current
16 A
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.
DUTY CYCLE
The duty cycle determines the machine ‘down time’. i.e 10% means 1 minutes operation
followed by 9 minutes of rest. The duty cycle must not be exceeded to to prevent the
thermal cutout protection from activating.
Duty Cycle (%)
10
60
Rated Welding Current (A)
90
35
18.5
15.7
Conventional Load Voltage (V)
Do not exceed the stated duty cycle for this machine. Failure to heed
this warning may invalidate your warranty.
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Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com
DECLARATION OF CONFORMITY
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Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com