Clarke MIG196 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1121 - rev 11
NO GAS/GAS MIG WELDER
MODEL NO: MIG196
PART NO: 6015200

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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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SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING
FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY
GENERAL PRECAUTIONS
A) BURN PREVENTION
Wear protective clothing - gauntlet gloves designed for use in welding, apron,
and protective shoes. Button shirt collar and pocket flaps, and wear cuffless
trousers to avoid entry of sparks and slag. Wear helmet with safety goggles or
glasses with side shields underneath, appropriate filter lenses or plates
(protected by clear glass). This is a MUST for welding (and chipping) to protect
the eyes from radiant energy and spatter. Replace cover glass when broken,
pitted, or spattered. Avoid oily greasy clothing. A spark may ignite them. Hot
metal should never be handled without gloves. First aid facilities and a
qualified first aid person should be available unless medical facilities are close
by for immediate treatment of flash burns of the eyes and skin burns. Ear plugs
should be worn when working overhead or in a confined space. A hard hat
should be worn when others work overhead. Flammable hair preparations
should not be used by persons intending to weld or cut.
NOTE: ALL protective wear incl. masks & head shields MUST comply with
PPE Directive 89/686/EEC
B) TOXIC FUME PREVENTION
Severe discomfort, illness or death can result from fumes, vapours, heat, or
oxygen enrichment or depletion that welding (or cutting) may produce.
Prevent them with adequate ventilation. NEVER ventilate with oxygen. Lead-,
cadmium-, zinc-, 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 an air-supplied respirator. Work in a
confined space only while it is being force 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
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.

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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.
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.
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 the area, do NOT weld. Move the work if
practicable, to an area free of combustibles.
Avoid working in paint spray rooms, dip tanks, storage areas, ventilators. If the
work cannot be moved, move combustibles away from sparks and heat; or
protect against ignition with suitable 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:
1. appreciable combustibles (including building construction) are within 10m.
2. appreciable combustibles are further than 10m, but can be ignited by
sparks.
3. openings (concealed or visible) in floors or walls can expose combustibles
to sparks.
4. combustibles adjacent to walls, ceilings, roofs or metal partitions can be
ignited by radiant or conducted heat.
After work, 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 the
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 the working level may substitute for inerting.

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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 as they can explode.
In explosive atmospheres, never weld or cut where the air may contain
flammable dust, gas, or liquid vapours.
ELECTRIC ARC (MIG, TIG) WELDING
Comply with precautions in 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 and work pieces
are hot. The wise operator avoids unnecessary risks and protects himself and
others from accidents.
A) BURN PROTECTION
The welding arc is intense and visibly bright. It’s 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! FOLLOW ALL SAFETY PRECAUTIONS!
PROTECTIVE CLOTHING
Wear long sleeved clothing (particularly for gas shielded arc) in addition to
gloves, apron and strong shoes. 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 collars closed to protect the chest and
neck and button any pockets to prevent entry of sparks.
EYE AND HEAD PROTECTION
Protect eyes from exposure to arc. NEVER look at an electric arc without
protection. Welding helmet or shield containing an appropriate filter plate
(Please refer to the section ‘Welding Shield). Place over face before striking
arc. Protect filter plate with a clear cover plate. Cracked or broken helmet or
shield should NOT be worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced IMMEDIATELY.Replace
clear cover plate when broken, pitted, or spattered. WE SUGGEST you wear
flash goggles with side shields under the helmet, to give some protection to
the eyes should the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected eyes (particularly high

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intensity gas-shielded arc) can cause a retinal burn thatmay leave a
permanent dark area in the field of vision. Before welding whilst wearing
contact lenses, seek advice from your optician.
PROTECTION OF NEARBY PERSONNEL
For production welding, a separate, well vented room or enclosed bay is best.
In open areas,surround the operation with low reflective, 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.
B) TOXIC FUME PREVENTION
Comply with all precautions in 1B.
C) FIRE AND EXPLOSION PREVENTION
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.
D) 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.
PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT DEVICES
(PACEMAKERS).
Magnetic fields from high currents can affect pacemaker operation. Persons
wearing pacemakers should consult with their doctor before going near arc
welding or spot welding operations.
E) PROTECTION AGAINST SHOCK
Keep body and clothing dry. Never work in damp area without adequate
insulation against electric 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.

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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.
2) TORCH
A fully insulated torch should be used without protruding screws or other
damage.
3) CONNECTORS
Fully insulated lock-type connectors should be used to join welding cable.
4) CABLES
Frequently inspect cables for wear, cracks and damage. IMMEDIATELY
REPLACE those with excessively worn or damaged insulation to avoid possibly
lethal shock from bared cable. Cables with damaged areas may be taped to
give resistance equivalent to original cable. Keep cable dry, free of oil and
grease and protected from hot metal and sparks.
5) TERMINALS AND OTHER EXPOSED PARTS
Terminals and other exposed parts of electrical units should have insulating
covers secured before operation.
6) SAFETY DEVICES
Safety devices such as interlocks and circuit breakers should not be
disconnected or shunted out. Before installation, inspection, or service of
equipment, shut OFF all power and remove line fuses (or lock or red-tag
switches) to prevent accidental turning ON of power. Do not open power
circuit or change polarity while welding. If, in an emergency, it must be
disconnected, guard against shock burns, or flash from switch arcing. Always
shut OFF and disconnect all power to equipment. A 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 danger to the operator.
Avoid welding tanks which may contain flammable residuals.
ADDITIONAL PRECAUTIONS FOR MIG WELDING
1. ALWAYS ensure that there is full free air circulating around the outer casing
of the machine, and that the louvres are unobstructed.
2. 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.
3. ALWAYS check that the pressure regulator and gauges (where fitted), are
working correctly. DO NOT lubricate the regulator.
4. ALWAYS use the correct regulator. Regulators are designed to be used with
a specific gases.
5. ALWAYS inspect the torch hose before use to ensure it is in good condition.
6. ALWAYS keep the free length of torch hose outside the work area.
7. ALWAYS remove all flammable materials from the welding area.
8. NEVER remove any of the panels unless the machine is disconnected from
the supply, AND never use the machine with any of the panels removed.
WARNING: 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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9. The MIG welding process uses an INERT gas to protect the weld pool. It
isimportant 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.
10. NEVER use or store in a damp environment. DO NOT EXPOSE TO RAIN.
11. ALWAYS keep fire extinguisher handy....’Dry Powder, C02 or BCF, NOT Water
12. 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.
13. 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.
14. NEVER point the MIG torch at any person or animal.
15. NEVER touch the MIG torch nozzle until the welder is switched OFF and the
nozzle has been allowed to cool.
16. NEVER connect, disconnect, or attempt to service the welding torch, until
the machine is switched OFF and disconnected from the mains supply.
17. NEVER allow the earth cable or torch hose to become wrapped around
the operator or any person in the vicinity.
A comprehensive range of CLARKE safety equipment for use when welding is
available from your local dealer.
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.
The welding equipment should be routinely maintained according to the
manufacturer’s 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 manufacturer’s
instructions. In particular, the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the manufacturers
recommendations.

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ELECTRICAL CONNECTIONS
This product is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug,
for connection to a standard, domestic electrical supply. Should the plug
need changing, make sure that a plug of identical specification is used.
If the colours of the wires in the power cable do not correspond with the
markings on the terminals of your plug, proceed as follows.
• Connect the blue
wire to the
terminal which is
marked N.
• Connect the
brown wire to the
terminal which is
marked L.
• Connect the
Yellow and Green
wire to the
terminal which is
marked E or .
We recommend that this machine is connected to the mains supply via a
Residual Current Device (RCD)
If in doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS FULLY
BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY.
WARNING: THE WIRES IN THE CABLE ARE COLOURED AS FOLLOWS:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH
Plug must be BS1363/A approved.
Always fit
make sure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
a 13 Amp
the cable is firmly held by the clamp
fuse.
Earth
(Green and
Yellow)