Clarke 195TE Specifications

MIG WELDER
Model Nos.
195TE • 205TE • 230TE
OPERATING & MAINTENANCE
INSTRUCTIONS
1104
WELDER SPECIFICATIONS
PRIMARY or INPUT POWER DATA
Primary Volts
Primary Amps
Frequency
MIG195TE
MIG205TE
MIG230TE
230V/1PH
24 Amps
50 HZ
230V/1PH
24 Amps
50 HZ
230V/1Ph
28 Amps
50Hz
23-44 V
185
30-185
23-30 V
185
30-185
23-46 V
210
30-210
80 Amps
103 Amps
170 Amps
---
60 Amps
80 Amps
--65 Amps
80 Amps
103 Amps
-200 Amps
--
SECONDARY or OUTPUT POWER DATA
Sec. Volts
Max. Sec. Amps
Current Range
DUTY CYCLES
100%
60%
20%
16%
12%
NOTE: Duty Cycles are rated over a 10 minute period.
Example: If welding with a MIG 205TE at 80amps, a 60% duty cycle applies. This
means that over a 10 minute period, the welding time is 6 minutes, the down time
is 4 minutes.
USABLE WIRE SIZES
Mild Steel Wire
Stainless Steel Wire
Aluminium Wire
0.6-0.8mm
0.8mm
0.8mm
0.6-0.8mm
0.8mm
0.8mm
0.6-0.8mm
0.8mm
0.8mm
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.
2
CONTENTS
PAGE
Welder Specifications ............................................................................ 2
Parts & Service Contacts ....................................................................... 3
Guarantee .............................................................................................. 4
Electromagnetic Interference (EMC) .................................................. 5
Safety Precautions ................................................................................. 7
Additional Safety Precautions for MIG Welding ............................... 12
Principles of Operation ........................................................................ 14
Electrical Connections ........................................................................ 15
Unpacking and Parts Identification ................................................... 16
Assembly ....................... Attaching the Torch ................................... 17
Installing the Welding Wire ....................... 18
Connecting the Gas Supply ..................... 20
Welding Shield ........................................... 20
Preparation for Use ....... Tuning the Welder ....................................... 21
MIG Welding Operation ...................................................................... 21
Wire Specification Chart ..................................................................... 22
Welding Tips & Maintenance .............................................................. 22
Troubleshooting .................................................................................... 23
Parts Lists and Diagrams ............................................................. 24 - 29
Wiring Diagrams ........................................................................... 30 - 31
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
Thank you for purchasing this CLARKE MIG Welder, designed to operate using a
gas cylinder with plain metal welding wire ONLY. This is explained in greater detail
within the manual.
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.
4
ELECTROMAGNETIC INTERFERENCE (EMC)
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 inverter 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
5
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.
2.2 Maintenance 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.
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.
6
SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING
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 cover
glass). This is a MUST for welding or cutting, (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 such as electrode
stubs and workpieces 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.
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 airsupplied 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
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.
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C) Fire and explosion prevention
Causes of fire and explosion are:
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 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, 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.
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3. ELECTRIC ARC (MIG, TIG) WELDING
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 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 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 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.
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3B) TOXIC FUME PREVENTION
Comply with precautions in 2B. Generator engine exhaust must be vented to
the outside air. Carbon monoxide can kill.
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 SUPPT 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.
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2) Electrode holders
Fully insulated electrode holders should be used. Do NOT use holders 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) 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 LIVE 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 LIVE
when the power switch is turned ON. Never touch the electrode unless
the welding power source is off.
7) 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.
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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 flammable residuals.
ADDITIONAL SAFETY PRECAUTIONS for MIG WELDING
✔ ALWAYS ensure that there is full free air circulating around the outer casing of
the machine, and that the louvres are unobstructed.
✔ Welding arc can seriously damage your eyes. Both operator and spectators
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.
✔ ALWAYS check that the pressure regulator and gauges (where fitted), are
working correctly. DO NOT lubricate the regulator.
✔ ALWAYS use the correct regulator. Regulators are designed to be used with
a specific gases.
✔ ALWAYS inspect the hose before use to ensure it is in good condition.
✔ ALWAYS keep the free length of gas 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
2
the supply, AND never use the machine with any of the panels removed.
✗
NEVER attempt any electrical or mechanical repair unless your are a qualified
technician. If you have a problem with the machine contact your local
CLARKE dealer.
12
✗
✗
PREPARATION OF THE WORKING AREA
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 cables to become wrapped around the operator or any
person in the vicinity.
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.
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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.
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.
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ELECTRICAL CONNECTIONS
WARNING: THIS MACHINE MUST BE EARTHED.
This welder must be connected to a 230 volt (50Hz) supply, having a rated capacity of greater than 13 amps.
A 13 Amp (BS1363) 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 ‘
’.
• Connect BROWN coloured cord to plug terminal marked letter “L”
• Connect BLUE coloured cord to plug terminal marked letter “N”
We strongly recommend that this machine is connected to the mains supply
through a Residual Current Device.
IMPORTANT: If in doubt, consult a qualified electrician. Do not attempt any electrical repairs yourself.
15
UNPACKING & PARTS IDENTIFICATION
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.
A
2 Wheels
B
1 Axle
C
2 Wheel retaining washers
D
2 Casters
E
1 Handle
F
2 Brackets
G
4 Fixing screws
Fig.1
Loose Items - not shown
1 x Mask with fixing screws and washers
1 x Mask handle
2 x Handle retaining screws
1 x Transparent glass
1 x Dark glass
1 x 0.6mm welding tip
1 x 0.8mm welding tip
1 x 1.0mm welding tip
1 x Gas regulator
2 x Worm drive clips for gas hose connections (1 only for MIG 230TE)
1 x Welding torch and lead
1 x Plastic cover for hose support bracket (MIG195TE & 205TE only)
2 x Self tapping screws for cover (MIG195TE & 205TE only)
SHOULD ANY PART BE MISSING OR DAMAGED, CONTACT YOUR LOCAL
DEALER FOR REPLACEMENT.
2.
Slot the axle (B) through the holes at the rear of the machine and slide a
wheel (A) on to each end followed by the retaining washers.
3.
Screw the two casters (D) to the machine.
4.
Slide handle (E) and the two brackets (F) into the top of the machine, line up
the holes with those in the casing, and secure using the 4 screws provided.
16
ASSEMBLY
A. Attaching the Torch
Fig.2
Mig 195TE - Mig 205TE
A. It is necessary to fit the torch hose
assembly (7) to the machine, but
before doing so you must first
measure the length of protrusion of
the liner (9) from the brass nut (10).
IMPORTANT:
This measurement should be a
maximum of 18mm and should
be carefully trimmed to this
length using a good pair of side
cutters, or similar, ensuring there
are no burrs or sharp edges which
may impede the progress of the
wire when fitted.
B.
Having checked the protrusion of
the liner, and trimmed where
necessary remove the nut (1) and
the washer (2) from the end of the torch assembly (7). Carefully feed the hose
assembly through the hole in the front face of the welder (16), taking care to
feed the electrical connectors (11-14) through at the same time. Continue to
feed the hose assembly through the brass collar (5) in the bracket assembly
(4).
C. You will notice a large ring terminal (3) roughly in position to be threaded on
the end of the hose assembly, as it appears through the brass collar (5) in the
bracket assembly (4). Thread the terminal on the hose assembly, followed by
the washer (2) and screw on the nut (1) which should then be carefully
tightened.
Note: when correctly assembled, the wire liner (9) must not be in contact with the
wire feed roller (8).
D. Fit the plastic cover (15) over the complete assembly, securing with the two
self-tapping screws provided.
E.
Connect the gas hose (12) to the gas hose nipple (6) securing with the worm
drive clip (13) provided.
F.
Make the electrical connections by joining connectors (11-14)
Note: The connectors are one-way fit, and simply clip together - do not use
excessive force.
17
Mig 230TE
Fig.3
Plug the torch hose into
the socket on the front of
the welder and secure
by hand screwing in the
threaded connection.
B. Loading the 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.
To fit the wire spool, firstly open the side
compartment by pulling the recessed
catch backwards.
3.
Turn the plastic knob with cam (7) to the
position shown in Fig. 4, i.e. with the flat
uppermost, so that the latch is unlocked,
and pull off the collar (6).
4.
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.
Fig.5
Replace the collar - 4, (5kg
spool ONLY), and turn the
Plastic knob with cam (7)
through 180 degrees, to the
position shown in Fig.6 thereby
locking the spool on the shaft.
1.
2.
3.
4.
5.
6.
7.
Pressure plate
Mounting Shaft
Wire Spool
Collar
Flat Washer
Spring
Plastic Nut
18
Fig.4
Fig.6
NOTE: The Plastic knob, item 7 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.
It Is now necessary to load the wire into the Torch...as follows:
5.
Loosen the plastic knob (17, Fig.2) by turning it anticlockwise, (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. Check to ensure there is no wire
in the liner, if there is...pull it out and discard.
6.
Ensure the Wire roller is set so that the appropriate groove - 6mm or 8mm, is in
place, i.e. in line with the wire liner.
To change to the other groove, undo the Hex. socket securing 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.
7. 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.
8. Reposition the pressure roller and plastic knob and tighten slightly.
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.
9.
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.
19
C. 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 tighten.
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.
Open the gas valve and screw in the regulator knob to 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.
D. Face Shield
To assemble the welding shield, insert the
clear glass panel first, followed by the dark
glass panel into the recess in the shield,
i.e. the clear glass MUST be on the outside
of the shield. Securing them with the
plastic screws provided.
Fig.7
Slot the two pieces together as shown, and
enter the threaded end of the handle
through the holes provided. Thread on the
plastic nut and tighten.
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.
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 helm
20
PREPARATION FOR WELDING
1.
Attach the earth clamp to the bare metal to be welded. Ensure contact is good .
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.
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.
OPERATION
1.
These machines have 6 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.
21
WARNING
(i)
(ii)
Make sure all flammable materials are removed from the work area.
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.
WIRE SIZE SPECIFICATION CHART
SWITCH
SWITCH
POSITIONS
1
2
3
4
5
6
STEEL WIRE
DIAMETER
(mm)
WIRE SPEED
ADJUSTMENT
0.6
0.6
0.6 - 0.8
0.6 - 0.8
0.8
0.8
LOW
LOW
MEDIUM
MEDIUM
MEDIUM - HIGH
HIGH
WELDING TIPS AND MAINTENANCE
1.
2.
3.
4.
Always weld clean, dry and well prepared material.
Hold gun at a 45° angle to the workpiece with nozzle about 6mm from the surface.
Move the gun smoothly and steadily as you weld.
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.
22
TROUBLE SHOOTING
PROBLEM
1. No life from
welder
2. No wire feed
3. Feed motor
operates but wire
will not feed
PROBABLE CAUSE
Check fuses and mains lead
Motor malfunction
a) insufficient feed roller
pressure
b) Burr on end of wire
c) Liner blocked/damaged
d) Inferior wire
REMEDY
a) Replace fuses as necessary.
If problem persists. return welder
to your local dealer.
b) Check fuse size.
Return welder to your local dealer.
a) Increase roller pressure
b) Re-cut wire square
c) Clear with compressed air or
replace liner.
d) Use only good dean wire
b) Wrong size tip
a) Unscrew tip cut wire and fit new
tip. Increase wire speed before
operating again.
b) Change tip size.
5. Wire feeds into
birds nest tangle.
a) Wire welded to tip.
b ) Wire liner damaged
preventing smooth
operation.
a) As above plus reduce feed roller
pressure so if blockage occurs
wire sleeps on roller. i.e. no feed
b) Renew wire liner.
6. Tangled coils of
wire around drum
Drum brake too slack.
Tighten drum brake DO NOT
OVERTIGHTEN
7. Erratic wire feed
a) Drum brake too light
b) Feed roller worn
c) Insufficient pressure on
feed roller
d) Wire dirty, rusty, damp or
bent
e) Liner partially blocked
a) Loosen drum brake slightly
b) Check and replace if necessary
c) Increase pressure on feed roller
DO NOT OVER TIGHTEN
d) Re-cut wire and ensure it is clean
4. Wire welds itself to
tip
a) Wirefeed speed too low
8. Poor quality welds a) lnsufficient gas at weld
area
b) Incorrect gas/wire
combination
c) Rusty, painted, damp. oily
or greasy work piece
d) Rusty, dirty work.
e) Poor earth contact
e) Clear with compressed air
a) Check gas is not being blown
away by draughts, if so, move to
a sheltered area. If no draught,
increase gas supply.
b) Consult Mig Welding manual
c) Ensure wkpiece is clean and dry
d) Ensure wire is clean and dry
e) Check ground clamp/ wkpiece
connection.
9. Wire jams in tip
when welding
aluminium
Tip too small
10. Welder cuts out
whilst in use
Duty Cycle exceeded (auto Allow welder to cool for 10-30min
before continuing. Note: If duty cycle
cut-out operates)
is continually exceeded, damage to
welder may result and welder output
is probably too small for application,
Use slightly oversize tip i.e. for 0.8mm
wire use 1mm tip (Applies to
aluminium only)
23
PARTS DRAWING - MIG 195TE
24
PARTS LIST - MIG 195TE
No. Part No.
Item
Qty
01
02
03
04
05
06
07
08
09
11
12
13
14
15
16
17
18
19
19
20
21
22
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
50
51
52
P.C. Board 0698 220/240V
Wire Feeding Motor 24V D.48 MP
Gas Solenoid Valve 4W 220V 50hz
Complete Thermostat 100° 16A
Rectifier PMS 16/4/2 F
Resistance 3 Ohm D.16 L=90
Fan C20 240V
Torch Grommet Direct Connection
Handle
Fuse 5x20 1A 250V
On/Off Switch 16A-250V
Fuse Holder 6,3A 250V
Black Hose D.5x10,5 L=2500
Tool Mat
Dividing Panel
Upper Panel
Plastic Wire Feeder D.48
Wire Feed Roll D.9x30 0,6-0,8mm Knurled
Wire Feed Roll 0,8-1 Nylon
Handle Bases (pair)
Plastic Front Frame
Chain
Potentiometer Knob
Right Panel
Contactor 220V 10A
Choke 40x50 Cu
Auxiliary Contact
Thermostat 16A
Transformer 230v 45x90 Cu
Capacitor 12000 MF 63V 50x80
Cable Clamp For Hole D.20
PVC Input Cable 3x2,5 M.2,
Front Panel
Switch 6A
Switch Knob D.38
DinseL Plug 25mm2
Wheel D.175 Rubber Hole D.20
Wheels-axle D.20 L=462
Rear Panel
Complete Spool Holder D.50
Lower Panel
Side Panel
Caster D.80
Side Panel Clip
Earth Clamp
Earth Cable 16mm2
Dinse Plug 25mm2
Torch Plus 14 M3 Direct Conn.
Reducer Mini Arg/UK w/Gauge
Welding Mask 82x108
Transparent Glass 82x108
Dark Glass 82x108 BS Din11
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0,76
2
1
1
1
1
1
1
4
2
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
EM22710035
EM22810015
EM22900001
EM04600113
EM22400009
EM22305004
EM22800013
EM21690268
EM21600030
EM22220002
EM22200002
EM22220016
EM30900027
EM30905021
EM33720088
EM33705291
EM44400003
EM33805023
EM33805027
EM21690235
EM21690234
EM10990010
EM21690309
EM33705292
EM22225006
EM44135017
EM22225018
EM22210016
EM44120016
EM22315002
EM21605010
EM20220020
EM33710306
EM22205016
EM21690312
EM22100002
EM21625009
EM55200030
EM33715091
EM04600001
EM33700161
EM33705391
EM21625002
EM21690226
EM22110007
EM43210009
EM22100001
EM23000324
EM22905004
EM21905019
EM21905020
EM21905021
25
PARTS DRAWING - MIG 205TE
26
PARTS LIST - MIG 205TE
No.
01
02
03
04
05
06
07
08
09
11
12
13
14
15
16
17
18
19
19
20
21
22
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
Part No.
EM22710035
EM22810015
EM22900001
EM04600113
EM22400009
EM22800013
EM10990010
EM21690268
EM21600030
EM22220002
EM22200002
EM22220016
EM33705292
EM30905021
EM33720088
EM33705291
EM44400003
EM33805023
EM33805027
EM21690235
EM21690234
EM21690309
EM22225006
EM44135017
EM22210016
EM44120093
EM33715091
EM21605010
EM20220020
EM30900027
EM33710306
EM22205016
EM21690312
EM22100002
EM21625009
EM55200030
EM04600001
EM33700161
EM33705391
EM21690177
EM21625002
EM22110007
EM43210009
EM22100001
EM23000324
EM22905004
EM21905019
EM21905020
EM21905021
Item
Qty
P.C.board 220/240V
Wire Feeding Motor 24V
Gas Solenoid Valve 4W 220V 50Hz
Complete Thermostat 100° 16A
Rectifier PMS 16/4/2 F
Fan C20 240V
Chain
Torch Grommet Direct Connection
Handle
Fuse 5x20 1A 250V
On/Off Switch 16A-250V
Fuse Holder 6,3A 250V
Right Panel
Tool Mat
Dividing Panel
Upper Panel
Plastic Wire Feeder D.48
Wire Feed Roll D.9x30 0,6-0,8mm Knurled
Wire Feed Roll 0,8-1 Nylon
HandleBase (pair)
Plastic Front Frame
Potentiometer Knob
Contactor 220V 10A
Choke 40x50
Thermostat 16A
Transformer 230V 45x90
Rear Panel
Cable Clamp D.20
PVC Input Cable 3x2,5 M.2,5
Black Hose D.5x10,5 L=2500
Front Panel
Switch 16 A
Switch Knob D.38
Dinsel Plug 25mm2
Wheel D.175 Rubber. D.20 Hole
Wheels-Axle D.20
Complete Spool Holder D.50
Lower Panel
Side Panel
Side Panel Clip
Caster D.80
Earth Clamp
Earth Cable 16 mm²
Dinsel Plug 25mm²
Torch Plus 14 M3 Direct Conn.
Reducer Mini Arg/UK W/Gauge
Carton Mask 82x108
Transparent Glass 82x108
Dark Glass 82x108 Din11
27
1
1
1
1
1
1
0,76
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
PARTS DRAWING - MIG 230TE
28
PARTS LIST - MIG 230TE
No.
Part No.
Item
Qty
01
02
03
04
05
06
07
08
10
11
12
13
14
15
16
17
18
18
19
20
21
23
24
25
26
27
28
29
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
EM22710035
EM22810015
EM22900001
EM04600113
EM22305004
EM22400009
EM22800013
EM21600030
EM22220016
EM22200002
EM22220002
EM10990010
EM33705291
EM33720088
EM30905021
EM44400003
EM33805023
EM33805027
EM21690235
EM23005048
EM21690267
EM30900027
EM33705292
EM21690309
EM22205016
EM21690312
EM22225006
EM44135017
EM22210016
EM44120016
EM22315002
EM21605010
EM20220020
EM33710306
EM21690234
EM22100002
EM21625009
EM55200030
EM33715091
EM04600001
EM33700161
EM33705391
EM21690226
EM21625002
EM22110007
EM43210009
EM22100001
EM23000322
EM22905004
EM21905019
EM21905020
EM21905021
P.C.Board 220/240V
Wire Feeding Motor 24V D.48
Gas Solenoid Valve 4W 220V 50hz
Complete Thermostat 100° 16A
Resistance 3 Ohm D.16 L=90
Rectifier PMS 16/4/2 F
Fan C20 240V Vent
Handle
Fuse Holder 6,3A 250V
On/Off Switch 16A-250V
Fuse 5x20 1A 250V
Chain
Upper Panel
Dividing Panel
Tool Mat
Plastic Wire Feeder D.48
Wire Feed Roll D.9x30 0,6-0,8mm Knurled
Wire Feed Roll 0,8-1 Nylon
Handle base (pair)
Dinzel Torch Adaptor L=40
Binzel Connection Torch Grommet
Black Hose D.5x10,5 L=2500
Right Panel
Potentiometer Knob
Switch 16 A
Switch Knob D.38
Contactor 220V 10A
Choke 40x50
Thermostat16A
Transformer 230v 45x90
Capacitor 12000 mF 63V 50x80
Cable Clamp For Hole D.20
Input Cable 3x2,5 M.2,5
Front Panel
Plastic Front Frame
DinseL Plug 25sqmm Cx30
Wheel D.175 Rubber Hole D.20
Wheels-axle D.20 L=462
Rear Panel
Complete Spool Holder D.50
Lower Panel
Side Panel
Side Panel Clip
Caster D.80
Earth Clamp
Earth Cable 16mm2
DinseL Plug 25mm2
Torch Plus 14 M.3 BZ Conn
Reducer Mini Arg/UK w/Gauge
Carton Mask 82x108
Transparent Glass 82x108
Dark Glass 82x108 BS Din11
1
1
1
1
1
1
1
1
1
1
1
0,76
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
4
2
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
29
WIRING DIAGRAM - MIG 195TE & MIG 230TE
30
WIRING DIAGRAM - MIG 205TE
31