Clarke MIG85ENC Installation and operation manual

NO GAS MIG WELDER
OPERATING & MAINTENANCE
INSTRUCTIONS
MIG85ENC
0606
NO GAS MIG WELDER
Part No. 6014001

31
Thank you for purchasing this CLARKE NO-GAS 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.
2
CLARKE 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.
TEL: [phone]
or e-mail
[e-mail]
For Service, please contact the following:
When disposing of this machine, ensure it is disposed of according to all local ordinances. DO NOT
dispose of with general household waste.
The full technical specification for your welder is to be found printed in a table on the rear
panel of the machine.
The meaning of the markings and symbols shown in the table are explained as follows.
ELECTRICAL SYMBOLS EXPLAINED
Symbol for the mains supply and No. of phases
Symbol for manual arc welding and covered electrodes
Symbol for dropping characteristic
Duty Cycle, expressed as a % in a 10 min period
No. Electrodes that can be burned per hour from the cold state
HCode letter for degree of insulation
IP_ _ Degree of protection (e.g. IP21)
1Symbol, rated value and dimension of the max. supply current
Imax_ _A
Size of the necessary main fuse
A
_ _
Rated value of the supply voltage
U1V
_ _ _
Symbol and dimension for the welding current
I2A
Symbol and dimension for the diameter of reference electrodes
mm
Min. and Max. rated value of the welding current
_ _ _ _ AI2
50Hz Rated frequency for alternating current
Min. and Max. rated no load voltage1~
U0_ _ _ _ V
Single Phase Transformer
1~
Symbol for the No. reference electrodes being melted with the
welding power source at the hot state, without operation of
the thermal cut-out.
nh
Symbol for the number of reference electrodes capable of
being melted with the welding power source, starting from the
cold state without operation of the thermal cut-out
nc
X
E/h

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30
CONTENTS PAGE
Guarantee .............................................................................................. 2
Electromagnetic Interference (EMC) ................................................. 4
Safety Precautions ................................................................................. 6
Additional Safety Precautions for MIG Welding ...............................11
Principles of Operation ....................................................................... 13
Electrical Connections ....................................................................... 14
Unpacking and Parts Identification ................................................... 15
Assembly ....................... Installing Welding Wire .............................. 16
Welding Shield ........................................... 18
Preparation for Use Preparing the Work ................................... 19
Setting the Controls ................................... 19
Attaching the Earth Clamp ....................... 20
Control Settings Reference Tables ........... 20
MIG Welding Operation ......................................................................21
Thermal Overload ................................................................................ 21
Welding Tips .......................................................................................... 22
Maintenance ....................................................................................... 22
Troubleshooting ................................................................................... 23
Parts Lists ............................................................................................... 24
Wiring Diagrams ................................................................................... 28
Parts & Service Contacts ....................................................................28
Welder Specifications ......................................................................... 29
Accessories .......................................................................................... 29
Electrical Symbols Explained ............................................................. 31
3

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 welder 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
429
SPECIFICATIONS
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
* Duty Cycle: Determines the machine ‘down time’.
eg. Operating at MIN setting and welding thin material, the Duty Cycle is 100%. i.e. the
welder may be used continuously.
At MAX setting, welding thick material (4mm), the Duty Cycle is 12%. This means that in ANY
10 minute period, the machine may be used for a total of 1.2 minutes and must have a
down time of 8.8 minutes.
Always bear in mind that the welding current will be influenced by the thickness and
characteristics of the workpiece....the thicker the workpiece, the greater the current.
Power Supply ................................................................ 230V, 50Hz 1Ph
Fuse Rating .................................................................... 13Amps
Current Range ............................................................... 27 - 85Amps
Max. Metal Thickness ................................................... 4mm
Welding Wire Sizes ......................................................... 0.9mm Flux Cored
Duty Cycle*
MIN (27A) .................................................... 100%
MAX (85A) .................................................. 12%
Dimensions ..................................................................... 380x175x350mm
Weight (net) ................................................................... 20.4kg
Part No. .......................................................................... 6010109
ACCESSORIES
The following accessories are available from your Clarke dealer. Please quote the
part numbers shown below:
Welding Wire Spool Part No.
Mini - 0.9mm (FLUX Core) 6000664

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.
WIRING DIAGRAM
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: [e-mail]
SERVICE: [e-mail]
PARTS & SERVICE CONTACTS
28

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 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 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.
6
PARTS LIST - TORCH
No. Description Part No.
01 Black Torch Handle EM21690300
02 Red Trigger EM21690301
03 Rubber Sleeve D.18 EM21690387
04 Gas Valve W/Torch Neck EM23005321
05 Torch Neck Insulator EM23005002
06 1.0mm Contact Tip PWB142710
07 Torch Gas Nozzle Hole D.10 PWB1430P
08 Pin For Torch Trigger D.4x16 ZN EM33810090
09 Fast -ON Contact 6,3x0,8 EM21200010
10 No Gas Torch Contact Spring EM33800032
11 TCC Self Tapping 4x16 Black EM21020081
12 Steel Wire Liner 1,4x4 Blue L=2100 EM23005324
13 Rubber Outer Sleeve D.17,5 + Hoses EM30900019
27

7
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.
PARTS DIAGRAM - TORCH
26

8
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.
PARTS LIST
No. Description Part No.
01 Input Cable EM20220068
02 Handle EM21600036
03 Plastic Wire Feeder EM44400018
04 Wire Feed Roll EM33805074
05 Side Panel EM33705326
06 Torch Grommet EM21690001
07 Welding Current Switch EM22200038
08 Potentiometer Knob EM21690309
09 Yellow Pilot-light Switch EM22200022
10 Right Upper Panel EM33705324
11 Motor Control PC Board EM22710047
12 Dividing Panel EM33720108
13 Slow Motor EM04600144
14 Rectifier EM22400094
15 Complete Thermostat EM04600126
16 Flux-cored Wire Spool 6000664
17 Kit Spool Holder EM04600108
18 Left Side Panel EM33705325
19 Cable Clamp EM04600233
20 Torch EM23000098
21 Earth Cable EM43210021
22 Earth Clamp EM22110005
23 Choke EM44135097
24 Rear Panel EM33700174
25 Transformer EM44120130
26 Plastic Mask EM21905018
27 Transparent Glass EM21905020
28 Dark Glass EM21905021
29 Hammer/Brush EM21905039
25

9
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
connectionsmay overheat orflashand cause a fire. Neverstrikean arconacylinder
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 SUPP’T DEVICES (PACEMAKERS)
Magneticfieldsfrom highcurrentscanaffectpacemakeroperation.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.
PARTS DIAGRAM
24

10
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.
23
PROBLEM CAUSE REMEDY
1. No “life” from welder Check fuses and mains lead a) Replace fuses as necessary If
problem persists return welder to
your local dealer
b) Check fuse size
2. No wire feed Motormalfunction Return welder to your local dealer
3. Feed motor operates a) Insufficient Feed Roller Pressure a) Increase roller pressure
but wire will not feed b) Burr on end of wire b) Re-cut wire square with no burr
c) Liner blocked or damaged c) Clean with compressed air or
replace liner.
d) Inferior wire d) Use only good “clean” wire
e) Roller worn out e) Replace roller
4. Wire welds itself to tip a) Wire feed speed too low a) Unscrew tip, cut wire and fit new tip
Increase wire speed before
operating again
b) Wrong size tip b) Fit correct size tip
5. Wire feeds into ‘birds a) Wire welded to tip a) As above plus reduce feed roller
nest’ tangle pressure so that if blockage occurs
wire slips on roller i.e. no feed
b) Wire liner damaged preventing
smooth operation b) Renew wire liner
6. Loose coils of wire Drum brake too slack Tighten drum brake
tangle around wire Caution: Do not over-tighten
drum inside machine
7. Erratic wire feed a) Drum brake too tight a) Loosen drum brake slightly
b) Feed roller worn b) Check and replace if necessary
c) Insufficient pressure on feed roller c) Increase pressure on feed roller
Caution: Do not over-tighten
d) Wire dirty, rusty, damp or bent d) Re-cut wire and ensure it is clean
e) Liner partially blocked e) Clean with compressed air
8. Poor quality welds a) Insufficient gas at weld area a) Check that gas is not being blown
away by draughts and if so move
to more sheltered weld area. If not
increase gas supply
b) Rusty, painted, damp, oil or b) Ensure workpiece is clean and dry
greasy workpiece
c) Rusty/dirty wire c) Ensure wire is clean and dry
d) Poor earth contact d) Check earth clamp/workpiece conn
9. Welder cuts out Duty cycle exceeded Allow welder to cool before
whilst in use (auto cut-out operates) continuing(Untilamber light goesout)
Note: If duty cycle is continually
exceeded, damage to the welder
may result, and welder output is
probably too small for application
If you have any problems which cannot be resolved by reference to the above, or if you
require spare parts for your welder please contact your local Clarke dealer.
TROUBLESHOOTING
Your Clarke Mig Welder has been designed to give long and trouble free service. If,
however, having followed the instructions in this booklet carefully, you still encounter
problems, the following points should help identify and resolve them.

11
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 inspect the hose before use to ensure it is in good condition.
✔ALWAYS keep the free length of hose outside the work area.
✔ALWAYS remove all flammable materials from the welding area.
✔ALWAYS Keep fire extinguisher handy....’Dry Powder, C02 or BCF,
NOT Water
✗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.
✗NEVER attempt any electrical or mechanical repair unless your are a qualified
technician. If you have a problem with the machine contact your CLARKE dealer.
✗NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN.
✗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.
22
MAINTENANCE
Frequency of maintenance operations depends on the operating conditions, how
intensively the welder is used, and how clean or dirty the welding site is (aggressive
atmospheres, etc).
Always inspect the cables, both earth and torch cable, before use to ensure they
are in perfect condition.
Ensure the earth clamp is clean and secured correctly to the cable.
Check the hose for security and serviceability.
As a general rule the covers should br removed and the transformer, and other
components, should be inspected at least annually. Consult your CLARKE dealer
for advice if necessary.
WELDING SHIELD
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.
WELDING TIPS
1. Try to maintain the tip of the nozzle at an angle of approx. 45Oand at a constant
distance of approx 5-7mm from the workpiece.
2. Try to maintain a constant speed of movement with the torch.
3. Do not weld in windy conditions or in an area where ventilation is a problem,
or where air flow fluctuates.
4. ALWAYS keep the wire and nozzle clean...NEVER use rusted wire.
5. Avoid sharp bends or kinks in the welding hose.
6. Whenever possible, clean out the wire liner with compressed air when
replacing the wire spool.
7. Periodically remove the dust, using LOW PRESSURE compressed air, within the
casing. Adequate heat dissipation is essential during the welders operation.

21
OPERATION
Plug the machine into the mains supply or switch on at the isolator, and, ensuring all
precautions have been taken and with the machine set up correctly, lower the
torch to the workpiece with one hand, whilst holding the welding mask in the other.
Approach the work with the tip at an angle of approx. 45O. and pull the torch trigger
fully.
As the electrode touches the workpiece, an arc will be struck....BUT, before it is
struck, COVER THE FACE WITH THE FACE MASK.
Simultaneously gas will be generated, via the flux core in the wire, as the wire is
fed into the molten pool.
Maintain a gap of approx. 5 - 7mm from the workpiece to the tip.
The speed of weld will depend upon the wire speed and welding current.
NOTES:
As MIG welding is an aquired skill, it is strongly advised that, if you are not fully
familiar with this type of welding, you practise on a piece of material with the
same characteristics as that of your workpiece, until you are satisfied with the
result, and you have fine tuned your welder to produce a satisfactory weld.
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.
The Wire Feed control is for fine tuning the wire speed. The speed of wire delivery
will increase automatically as the current is increased from MIN to MAX, and vice
versa. Therefore, once the ideal speed is achieved, by fine tuning,it should not be
necessary to adjust this control when the welding current is changed.
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
Should your welder cut out for no apparent reason, it is probable that the THERMAL
OVERLOAD has intervened. This is a safety device which shuts off the welder when
the duty cycle has been exceeded. This is to prevent damage to the machine
caused by overheating.
When this occurs, the ON/OFF switch will glow (amber). Allow the welder to cool,
until the amber light extinguishes before resuming.
For details of the duty cycle...i.e. the length of time the machine may be used
continuously, refer to the data and notes on page 27.
12
DANGER - ELECTRIC SHOCK CAN BE FATAL.
Aperson 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.
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.

SAFETY EQUIPMENT
A comprehensive range of CLARKE safety equipment for use when
welding is available from your local dealer.
NO-GAS 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 negative side of a rectified voltage supply.
The workpiece is connected to the positive 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
is provided by a flux core within the welding wire electrode. The flux melts
due to the heat produced, giving off a gas. This gas prevents oxygen, in
the surrounding air, from coming into contact with the molten pool at a
critical time. Solidification takes place, creating a much stronger, cleaner
weld, free of impurities.
BENEFITS OF NO-GAS MIG WELDING
1. No need for cumbersome or short life gas bottles
2. Better outdoor use as wind has less chance of disturbing the gas shroud.
3. 50% faster welding time.
4. Operator training time kept to a minimum.
5. There is no slag removal, thus eliminating almost all post-welding
cleaning operations.
6. Minimum waste of welding consumables.
7. Overall, a faster more efficient way of getting the job done.
8. Less heat - less distortion.
9. Ability to weld thin material.
13
20
D. Trim the Welding Wire
Trim the welding wire so that it protrudes no more than 5mm from the end of the
contact tip.
E. Attach the Earth Clamp
Attach the earth clamp to the workpiece, as close to the point of weld as possible,
without it being intrusive.
Again, as with the ‘welding point of contact’, the earth clamp MUST be attached
to CLEAN BARE METAL. Any coating, plating or corrosion MUST be removed,
otherwise a good weld will be impossible to achieve.
Your welder is now fully prepared for welding.
The 10-position wire speed control should be set to 6 to begin with, then adjusted as
required. (See notes under ‘Operation).
Workpiece Thickness Current Setting Wire Feed
(mm)
0 - 2.0 MIN 6
2.0 - 4.0 MAX 6
WARNING!
ELECTRICITY CAN KILL
NEVER TOUCH LIVE ELECTRICAL COMPONENTS
DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS AND
MAINTENANCE OPERATIONS
BEWARE HOT SURFACES.....ALWAYS LET THE POWER SUPPLY COOL DOWN
BEFORE ACCESSING INTERNAL COMPONENTS.

ELECTRICAL CONNECTIONS
WARNING! THIS APPLIANCE MUST BE EARTHED.
The welder is fitted with a standard 13 amp BS 1363 plug, fitted with a 13 amp fuse.
Connect to a 230 volt (50Hz) domestic electrical supply andwe strongly recommend
that this be done via a Residual Current Device (RCD).
IMPORTANT: The wires in the mains lead are coloured in accordance with the
following code:
Green & Yellow .......... Earth
Blue .......... Neutral
Brown .......... Live
As the colours of the flexible cord of this appliance may not correspond with the
coloured markings identifying terminals in your plug, proceed as follows:
•Connect GREEN & YELLOW cord to plug terminal marked with a letter “E” or
Earth symbol “ ”, or coloured GREEN or GREEN & YELLOW.
•Connect BROWN cord to plug terminal marked letter “L” or coloured RED.
•Connect BLUE cord to plug terminal marked letter “N” or coloured BLACK.
IMPORTANT: If the welder is fitted with a plug which is moulded onto the electric
cable (i.e. non- re-wirable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a danger of
electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code). Replacement fusecovers
can be obtained from your local dealer or most electrical stockists.
Fuse Rating
The fuse in the plug must be replaced with one of the same rating (13 amps) and
this replacement must be ASTA approved to BS1362.
Extension Cable
If an extension cable is fitted, ensure the minimum cross section of the conductor
is 1.5mm2for up to 15 metres in length, and 2.5mm2for up to 25 metres.
14
!
19
PREPARATION FOR USE
A. PREPARE THE WORK
MOST IMPORTANT!
It is VITAL that the workpiece is perfectly clean at the point of weld. Any coating,
plating or corrosion MUST be removed, otherwise a good weld will be impossible
to achieve.
B. SET THE CONTROLS
Three switches are provided....(1) ON/OFF, (2) MAX/MIN and (3) WIRE FEED.
The ON/OFF switch is self explanatory, but serves a secondary function. You will
note that it is coloured amber. The switch doubles as a lamp, which will illuminate
if the Thermal Overload intervenes. Please see the notes on page 21.
The MAX/MIN switch controls the welding current....and the ‘WIRE FEED’ rotary
knob controls the speed of the wire feed to the nozzle.
In order to determine the correct settings for the job in hand....the following table
serves as a useful reference.

18
It is important to pay attention to the notes on welding shield maintenance, given
on page 22. When replacing the glass panels, use ONLY those parts supplied by
Clarke International. The dark panel is a certified, specific optical class, and should
not be exchanged for any other type.
The clear glass panel should be replaced when it becomes badly pitted.
WARNING:
NEVER look at an electric arc without eye protection as this can injure the
eyes permanently. ALWAYS use a protection mask or welding helmet.
To assemble the welding shield, (Fig.2),
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.
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.
B. ASSEMBLING THE WELDING SHIELD
Fig.2
15
UNPACKING & PARTS IDENTIFICATION
Unpack and lay out the components, checking against the following list. Any
damage or deficiency should be reported to your CLARKE dealer immediately.
Some of the components are stored within
the side compartment. To open the
compartment, pull the side panel up, as
indicated in Fig.1.
The cover may be quite tight when new, so
ease off gently.
1. Welder complete with Torch and Hose,
Earth Cable with Clamp and Power cable.
2. 2-Piece Welding Mask
3. Welding Mask handle, complete with
plastic nut and 2xPlastic screws.
4. Package containing 1xClear Glass
and Dark Glass Lens
5. Wire Spool, fitted to the Spool Holder
6. Spare welding tip
Fig.1

ASSEMBLY & INSTALLATION
A. INSTALLING THE WELDING WIRE
NOTE: This machine is supplied with a Clarke ‘Mini’ spool of 0.9mm, mild steel, flux
cored welding wire. Replaceable spools available from your Clarke dealer. See
‘Accessories’ for full details.
1. IMPORTANT: Ensure that the electrical supply is disconnected.
2. Firstly remove the side cover, on the left hand side of the unit, by pulling it sharply
upwards.
(1) Removing/Replacing the Wire Spool
Re: Fig. 3
If the wire spool is mounted on the spool
holder, it needs to be removed in order
to remove the plastic wrapper. To do this,
proceed as follows:
Pull out the centre retainer, arrowed in
Fig.3, then squeeze the retaining lugs
together (on the spindle), so that the
spool may be withdrawn.
Remove the wrapper and replace the
spool, pushing home fully, and ensuring
the centre retainer is properly located.
Fig.3
16
Fig.4
(2) Installing the Wire
Re: Fig.4
1. Loosen theplastic knob (A)byturningit
anticlockwise, (this device maintains
pressure on the wire).
2. Pull, on the plastic knob, so that
the screw rod hinges out of its slot.
This releases the pivoted pressure
roller bracket (C). Raise the bracket,
in the direction of the arrow, and pull
out any wire that has been left in the
wire liner (D), pulling it from the
nozzle end of the hose.
17
Pull out the end of the wire
from the rim of the spool,
taking care NOT to release it.
The spool is wound firmly and
should remain this way.
Ensuring the wire is straight
and not kinked in any way,
clip off the end cleanly,
ensuring there are no burrs or
sharp edges.
Proceed to feed it through
the guide tube (E), over the
groove on the roller (B), and
into the wire liner (D), by
about 10 - 15 cm.
Fig.5
4. Reposition the pressure roller bracket (C, FIG.4) and plastic knob (A, Fig.4) and
tighten slightly.
CAUTION:
Tightening the knob (A) too tightly will crush the wire and damage the
wire feed motor, too loose will not allow the wire to be pulled by the roller.
3. Re: Fig.5
5. (Ref. Fig 6)
Unscrew and remove the torch
shroud by twisting it anti clockwise,
then unscrew the contact tip.
6. Close the side panel of the machine,
plug into a 230V, 50HZ outlet (or switch
on isolator).
Set the ‘WIRE FEED ‘ rotary switch, on
the front panel, to position 7OR 8,
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 disconnect the machine from
the mains supply. 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 fed through to the wire liner and contact tip.
Fig.6