Clarke MIG 240 Instruction Manual

WARNING: Read these instructions before using the machine
The welder is supplied set up for no gas welding
OPERATION & MAINTENANCE
INSTRUCTIONS
LS1118 - ISS 1
GAS/NO GAS MIG WELDER
MODEL NO: MIG 240
PART NO: 6014200

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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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CONSUMABLE
The following are some of the consumables available from your CLARKE
dealer. Please quote the part numbers shown below:
Welding tips / Gas Regulators / Arc Activated Headshields / Anti-spatter Spray
/ Swan Necks / Torch Shrouds and Torch Liners are also available from your
CLARKE dealer or our parts division.
PART DESCRIPTIO N PART
NUMBER
COMMENT
Welding Wire
Spools
Flux cored mild steel (4.5kg)
0.9mm
6000666 Use for no gas welding
Mild steel - 0.6mm (5 kg) 6000476 Use for gas welding
Mild steel - 0.8mm (5 kg) 6000475 Use for gas welding
Mild steel - 0.8mm (15 kg) 3050522 Use for gas welding
Stainless Steel 0.8mm (mini spool) 8132090 Use for gas welding
Welding Gas CO2 (250g) 6000642 For welding mild steel
CO2 (600g) 6000643 For welding mild steel
Argon 6000661 For welding stainless
steel / aluminium
CO2/Argon Mix 6000660 For welding stainless/
thin sheet mild steel

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CONTENTS
INTRODUCTION ............................................................... 2
GUARANTEE .................................................................... 2
ENVIRONMENTAL RECYCLING POLICY ......................... 2
CONSUMABLE ................................................................. 3
CONTENTS ....................................................................... 4
GENERAL SAFETY INSTRUCTIONS ................................... 5
ELECTRICAL CONNECTIONS .......................................... 8
OVERVIEW ....................................................................... 9
The Control panel ................................................................. 10
OPENING THE SIDE PANEL .............................................. 11
UNPACKING ................................................................... 11
ASSEMBLY ....................................................................... 12
Fitting the Gas bottle bRACKET........................................... 12
Connect the torch................................................................ 12
Connect the earth lead ...................................................... 12
THE WELDING SHIELD ...................................................... 13
PREPARATION FOR USE .................................................. 14
Mounting The Welding Wire Spool...................................... 14
Setting The Drive Roller Size ................................................. 14
Threading The Wire ............................................................... 15
MIG WELDING PRINCIPLES ............................................. 17
GAS/NO-GAS SELECTION .............................................. 17
Welding Without Gas ........................................................... 18
Welding With Gas ................................................................. 18
OPERATING THE WELDER ................................................ 19
Prepare The Workpiece ....................................................... 19
Operation .............................................................................. 19
Thermal Overload................................................................. 20
Duty Cycle............................................................................. 20
MAINTENANCE ............................................................... 21
RATING PLATE ................................................................. 22
SPECIFICATIONS ............................................................. 23
ARC ACTIVATED HEADSHIELDS ...................................... 24
TROUBLESHOOTING ........................................................ 25
DECLARATION OF CONFORMITY ................................... 27

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GENERAL SAFETY INSTRUCTIONS
ELECTRIC SHOCK
• 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.
• Do not touch live electrical parts.
• Never use electrode holders or
cables which are damaged.
• Keep working environment,
equipment, cables and clothing
free from grease, oil, moisture and
dirt.
• Ensure welding machine has been
correctly earthed.
• The operator must be insulated
from the floor and work bench
using a dry insulation mat.
• Always ensure a second person is
present in case of accident.
• Never change electrodes with
bare hands or damp gloves.
• Keep welding cables away from
power cables.
• Regularly inspect the condition of
the cables for signs of damage.
• Remove the plug from the mains
socket when not in use, do not
leave the machine unattended.
• Make sure that the earth clamp is
secured to bare metal adjacent to
the weld seam and when not in use
is insulated for safety.
• Keep all equipment well
maintained.
• The operator shall prevent gas
cylinders in the vicinity of the work
piece from becoming part of the
welding circuit.
FUMES & GASES
• The welding process generates
hazardous fumes as a by-product.
Inhalation of these fumes is
hazardous to health.
• Keep your head away from the
weld to avoid breathing the fumes.
• If welding in confined spaces
ensure adequate ventilation and
use a fume extractor.
• By-products of welding can react
to create a toxic/explosive
environment.
FIRE OR EXPLOSION
Welding can cause fires and
explosions. Precautions should be
taken to prevent these hazards.
• Before starting work ensure the
area is clear of flammable
materials.
• Move any combustible materials to
a safe distance, especially
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.

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substances likely to generate a
dangerous vapour.
• The welding arc can cause serious
burns. Avoid contact with skin.
• Sparks and molten metal are
ejected during welding. Take
precautions to prevent fire.
• Sparks and molten metal can pass
through gaps. Be aware that fire
can start out of sight.
• 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.
• Avoid carrying any fuels with you
e.g. cigarette lighters or matches.
PERSONAL PROTECTION
• The body should be protected by
suitable clothing.
• The use of neck protection may be
necessary against reflected
radiation.
• Arc machines generate a
magnetic field which is detrimental
to pacemakers. Consult your
doctor before going near active
welding equipment/operations.
• The UV and IR radiation generated
by welding is highly damaging to
the eye, causing burns. This can
also affect the skin.
• Always use suitable welding shields
equipped with appropriate
protection filters.
• Where there are pedestrians and
traffic ensure a protective screen is
used to avoid accidental arc glare.
• Do not weld in the vicinity of
children or animals and ensure no
one is looking before striking an
arc.
• Wear hearing protection if
required.
• Allow the weld time to cool. Hot
metal should never be handled
without gloves.
• 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.
• 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.
• A hard hat should be worn when
others are working overhead.
• Flammable hair sprays/gels should
not be used by persons intending
to weld or cut.
PROTECTIVE CLOTHING
• Wear gauntlet gloves designed for
use in welding.
• Wear an apron, and protective
shoes.
• Wear cuffless trousers to avoid
entry of sparks and slag.
• Avoid oily greasy clothing.
• Protective head and shoulder
coverings should be worn when
overhead welding.
• 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

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(and chipping) to protect the eyes
from radiant energy and spatter.
Replace cover glass when broken,
pitted or spattered.
NOTE: ALL protective wear inc. masks
& head shields MUST comply with PPE
Directive 89/686/EEC
GAS CYLINDERS:
• Gas cylinders should be located or
secured so that they cannot be
knocked over.
• Shield gas containers can explode
if damaged. Take care when
handling.
• Ensure gas cylinders are shut-off
when not in use and between
operations.
• Take care that a build-up of gas is
not permitted to form in confined
areas.
• Cylinders must be in an upright
position at all times during use and
storage.
• The gas cylinder must never come
in to contact with the electrode.
• Follow the manufacturer's
instructions for handling, storing
and using the gas bottle correctly
and safely.
• Use the correct equipment to
connect the gas bottle to the
welding torch.
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.
• Never touch the MIG torch nozzle
until the welder is switched OFF and
the nozzle has been allowed to
cool off.
• NEVER allow the earth cable or
hose to become wrapped around
the operator or any person in the
vicinity.

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ELECTRICAL CONNECTIONS
A STANDARD 13AMP PLUG MUST NOT BE USED WITH THIS
UNIT.
The unit must be connected to a 230V socket cabable of supplying 32 Amps,
We recommend that you consult a qualified electrician and connect the
mains lead, through a suitably fused isolator switch
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.
If the colours of the wires in the power cable of this product do not correspond
with the markings on the terminals of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal
which is marked Nor coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked Lor coloured Red.
• The wire which is coloured Yellow and Green must be connected to
the terminal which is marked E or or coloured Green.
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.
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.
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

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OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Handle 4 Torch
2 Gas Connection Point 5 Torch Hose
3 Control Panel 6 Earth Clamp
12
3
4
5
6

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THE CONTROL PANEL
1. Wire speed control knob. As a general rule, a higher current requires a
higher wire speed.
2. Current setting dial. Provides 6 increasing power levels.
3. 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 welder should be
disconnected from the power supply.
4. Thermal overload light. If the duty cycle is exceeded as a result of welding
for too long with a high current, the overload light will illuminate and the
welder will turn off. When the welder has cooled down (approx. 5 to 10
minutes), the power will be restored and welding can recommence.
Dial Setting Welding Current in Amps
150A
275A
3100A
4130A
5180A
6240A

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OPENING THE SIDE PANEL
IMPORTANT: Make sure that the
welder is not connected to the mains
supply.
1. Push the latches down and let the
side panel drop down.
2. Remove loose items that have
been transported inside.
UNPACKING
Any damage or deficiency should be reported to your CLARKE dealer
immediately. Some of the components are stored within the machine side
compartment.
The components include the following:
WARNING: DO NOT OPERATE THIS MACHINE WITH THE SIDE PANEL
OPENED OR REMOVED.
1 x MIG TORCH Euro connection Torch (Quick release)
1 x 0.8mm tip for no gas welding in the torch
1 x 0.9mm tip (loose) 1 x hammer brush
1 x 0.6mm tip (loose) 1 x torch neck
1 x 0.8mm tip (loose) 1 x torch shroud
1 x 1.0mm tip (loose) 1 x gas bottle bracket
1 x welding shield 1 x chain

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ASSEMBLY
FITTING THE GAS BOTTLE BRACKET
1. Place the bottle bracket into
position and secure in place using
the screws provided.
CONNECT THE TORCH
Connect the plug on the end of the
torch hose to the socket shown on
the welder.
CONNECT THE EARTH LEAD
Insert the earth lead plug as shown.

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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. Insert the clear glass panel into
the recess inside 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 shield.
5. Replace the clear glass panel when it becomes badly pitted.
CAUTION: 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.

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PREPARATION FOR USE
MOUNTING THE WELDING WIRE SPOOL
NOTE: Spools of welding wire are available from your Clarke dealer.
1. Open the side panel by pushing
the latch down and allowing the
side panel to open.
2. Remove the locking screw and
retaining spring.
3. Place the spool of welding wire
(not supplied) over the spindle.
• Do not release the tension on
the wire as it will unravel,
causing feeding problems later.
• The wire will feed off the spool clockwise from the top of the reel.
• The spool must be fitted with the correct orientation otherwise it will
not feed correctly.
4. Replace the retaining spring and locking screw.
SETTING THE DRIVE ROLLER SIZE
1. Loosen the tensioning knob and
pivot it towards you.
2. Lift up the arm.
3. Remove the drive roller
thumbscrew.
4. Pull the roller retainer off the drive
spindle to reveal the roller.
WARNING: MAKE SURE THAT THE WELDER IS NOT CONNECTED TO THE
MAINS SUPPLY.

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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
thumbscrew.
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. Feed 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 refit the
tensioning knob.
• Tighten the tensioning knob
sufficiently to hold in position,
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. Close the side panel of the
welder.
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 appropriate size contact tip to suit your wire. then replace the
shroud.
• Spare tips or various sizes are supplied loose and should be used
when appropriate.
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.
The gas is used to prevent oxidation and to shield the arc and the weld from
atmospheric contamination. The choice of gas is dependent upon the
material being welded
When using the welder in a gasless configuration 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 to make
sure the shielding gas is not blown away, thereby leaving a poor quality weld.
GAS/NO-GAS SELECTION
The welder can be configured to
weld, with or without a gas supply
according to the type of welding
wire being used.
• Mild Steel solid core (With Gas),
• Flux Cored (No Gas)
Metal Being Welded Suitable Gas Part number
Mild Steel Carbon Dioxide (CO2) 6000643
Stainless Steel Argon 6000661
Aluminium
Thin Sheet Metal/Mild Steel Carbon Dioxide (CO2)/Argon Mix 6000660

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WELDING WITHOUT GAS
1. If you use 0.9mm flux cored wire,
connect the terminal as shown.
• The earth cable must be
connected to the positive
(upper) terminal.
• The cable from torch must be
connected to the Negative
(lower) terminal.
WELDING WITH GAS
1. If you use solid cored wire 0.6/
0.8mm mild steel, connect the
terminal as shown.
• The earth cable must be
connected to the negative
(lower) terminal.
• The cable from torch must be
connected to the positive
(upper) terminal.
CONNECT THE GAS SUPPLY
2. Place the gas bottle
(maximum10kg) on the platform
and secure it using the chains
provided.
3. Connect the gas supply hose
(included) to the connection at
the rear of the welder. (hose clips
have been provided).
4. Connect the other end of the gas
supply hose to a suitable gas
bottle.

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OPERATING THE WELDER
PREPARE THE WORKPIECE
The welded area must be clean. Coatings, plating or corrosion must be
removed. If not, you will not be able to achieve a good quality weld.
Attach the earth clamp to the workpiece as near to the point of weld as
possible.
OPERATION
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.
3. Cover your face with a welding mask or welding shield.
• 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 35oand pull the trigger fully.
• As the wire touches the workpiece an arc will be struck.
5. In order to produce a good quality weld, the controls can 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
CAUTION: THE DUTY CYCLE MUST BE FOLLOWED TO PREVENT THE
THERMAL OVERLOAD PROTECTION FROM OPERATING.

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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.
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 be followed to prevent the thermal
cutout protection from activating
These welders are covered by
regulations EN 60974-1 and EN 50199,
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 illustration of the data plate
shown;-
e.g. when welding at 98 amps the
machine may be used for 6 minutes
(60%) in any 10 minute period.
Do not exceed the stated duty cycle for this machine. Failure to heed
this warning may invalidate your warranty.
Duty Cycle (%) 10 60 100
Rated Welding Current (A) 240 98 75
Conventional Load Voltage (V) 26 19.5 17.7