Clarke MIG 160TM Installation and operation manual

MIG 160TM
OPERATING & MAINTENANCE
INSTRUCTIONS 0108
Part No: 6015530

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WELDER SPECIFICATIONS
PRIMARY or INPUT POWER DATA
Primary Volts 230V / 1PH
Primary Amps 16 Amps
Frequency 50Hz
SECONDARY or OUTPUT POWER DATA
Sec. Volts 18 - 28 V
Max. Sec. Amps 150 Amps
USABLE WIRE SIZES
Mild Steel Wire 0.6-0.8mm
Stainless Steel Wire 0.8mm
Aluminium Wire 0.8mm
USABLE GASES MAIN USES
75% Argon 25% CO2 - Thin Sheet Metal, Mild Steel
100% Argon - Welding Aluminium, Stainless Steel
100% CO2 - Mild Steel
This model is 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. When welding at 75
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 55
Amps
Interpolate for other
welding currents
DUTY CYCLE
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

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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
For Spare Parts and Service, please contact your nearest dealer,
or CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [e-mail]
PARTS AND SERVICE CONTACTS

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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.
Beforeattempting to operate the machine, it is essential that you readthismanual
thoroughly and carefully follow all instructions given. In doing so you will ensure
thesafetyofyourselfand that of others aroundyou, and you canalsolookforward
to the welder giving you long and satisfactory service.
GUARANTEE
ThisCLARKEproductisguaranteedagainstfaulty 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.
When disposing of this product, do not dispose of with general waste. It must be disposed of according to the laws
governing Waste Electrical and Electronic equipment, at a recognised disposal facility.

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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
Beforeinstalling welding equipment the user shall make anassessmentofpotential
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

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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
continuousthroughout itslength.Theshieldingshouldbeconnectedtothe welding
powersourceso that good electricalcontactis 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
manufacturersrecommendations. 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
changesandadjustments coveredinthe manufacturersinstructions.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
Selectivescreeningandshieldingofothercables andequipmentinthesurrounding
area may alleviate problems of interference. Screening of the entire welding
installation may be considered for special applications.

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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
radiantenergy andspatter.Replace cover glass whenbroken, pitted, or spattered.
Avoid oily greasy clothing. A spark may ignite them. Hot metal such as electrode
stubsand workpiecesshouldnever behandledwithout gloves.Firstaidfacilitiesand
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
wornwhen othersworkoverhead.Flammablehairpreparationsshouldnotbeused
by persons intending to weld or cut.
B) Toxic fume prevention
Severediscomfort,illnessor death can result from fumes,vapours,heat,or oxygen
enrichment or depletion that welding (or cutting) may produce. Prevent them
with adequate ventilation. NEVER ventilate with oxygen. Lead-, cadmium-, zinc-,
mercury- and beryllium-, bearing materials, when welded (or cut) may produce
harmful concentrations of toxic fumes. Adequate local exhaust ventilation must
be used, or each person in the area as well as the operator must wear an air-
supplied respirator. For beryllium, both must be used. Metals coated with or
containing materials that emit toxic fumes should not be heated unless coating is
removed from the work surface, the area is well ventilated, or the operator wears
anair-suppliedrespirator.Work in a confined spaceonlywhileitisbeing ventilated
and,if necessary,whilewearinganair-suppliedrespirator.Vapoursfromchlorinated
solventscanbedecomposed by the heat ofthearc (or flame)toformPHOSGENE,
a highly toxic gas, and other lung and eye irritating products. The ultraviolet
(radiant) energy of the arc can also decompose trichloroethylene and
perchloroethylenevapours toform phosgene. DONOTWELDorcut where solvent
vapourscanbedrawnintothewelding orcuttingatmosphereor wheretheradiant
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) appreciablecombustibles(includingbuildingconstruction)arewithin10m.
b) appreciablecombustiblesarefurtherthan10mbutcanbeignitedbysparks.
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.
Inexplosiveatmospheres,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
Complywithprecautionsin1above,andthissection.Arcwelding,properlydone,
is a safe process, but a careless operator invites trouble. The equipment carries
highcurrentsat significantvoltages.Thearcisverybrightandhot.Sparksfly,fumes
rise,ultravioletandinfraredenergyradiates,weldmentsarehot.Thewiseoperator
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
colouredsurfaces, and burntheskinandeyes.Skinburnsresembleacutesunburn,
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,apronand shoes (2A). As necessary,useadditionalprotectiveclothing
suchasleather jacket orsleeves,flameproofapron,and fire-resistantleggings.
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
densermust beusedwhenwelding.Placeoverface beforestrikingarc.Protect
filterplatewithaclear cover plate. Cracked or broken helmet or shield should
NOT be worn; radiation can pass through to cause burns. Cracked, broken,
orloosefilterplatesmustbereplacedIMMEDIATELY.Replaceclearcoverplate
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
screensorpanels.Allowforfreeair circulation,particularlyatfloor 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
Complywith precautions in 2B.Generator engine exhaustmust 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
connectionsmayoverheatorflashandcauseafire.Neverstrikeanarconacylinder
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-LIVEequipmentcanfatallyshocka personwhosebody
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)
Magneticfieldsfromhighcurrentscanaffectpacemakeroperation.Personswearing
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.