Clarke WE6480 MIG 95 Installation and operation manual

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OPERATING & MAINTENANCE
INSTRUCTIONS

Congratulations of the the purchase of your new |_|iill_EOMig Welder. Before atlempting to operate
this machine, please read this instructions manual thoroughly and follow all directions carefully. By
doing so you will ensure the safety of both yourself and others around you, and at the same time, you
should look forward to long and trouble free service from your €|iiM_Ul Mig Welder.
Safely Precautions ..................................................................................... 3
Welder Specifications ................................................................................ zl
Wiring ........................................................................................................ 4
Assembly ................................................................................................... 4
Connecting the welding wire .................................................................... 5
MIG Welding ............................................................................................. 6
NO GAS Welding ....................................................................................... 6
PreparMon for Welding ............................................................................... 6
Advantages of NO GAS Welding .............................................................. 6
Welding procedures .................................................................................. 6
Wire Size Specification Chart ..................................................................... 6
Replacement of The Wire Spool ............................................................... 7
Welding Tips .............................................................................................. 7
Adjustment of The Welder ......................................................................... 7
Welding Problems and Solutions ............................................................... 7
Spare Paris List........................................................................................... 8
Parts Drawing ............................................................................................. 8
wiring Diagram ......................................................................................... 9
Torch Spare Parts List................................................................................ 10
Torch Spare Parts Drawing ....................................................................... 10
Types of Joints ......................................................................................... 11
2

1.1 General Instructions
Make sure this manual is carefully read and understood by the welder.
1.2 Location
Welding orocesses of any kind can be dangerous not only to the ooerator but to an't oersoq siluated
near the eauiement, if safely and ooerafing rules are not strictN observed.
These are the main precautionary measures to observe:
Operators should protect their body by wearing closed, non-fiammab_ protective ck3thing,
without pockets or turned up trousers.
The operators should wear a non-flammable welding helmet des;gned so as to shield the neck
and the face, also on the sides, it is necessary to keep the protective lens atwoCs ctean and to repk_e
it when broken or cracked, itis advisable to put a transparent glass belween the lens and the wela_-_3
area. Welding should be done in a closed area ti%fl does not open into other working areas.
The operators slnould never look at the welc_ng arc without the correct protection for the eyes.
They should alv_ys wear safely glasses with side shields to protect from flying pariicles.
The welding process must be performed on metal coatings thoroughly cleaned from layers
of rust or paint, to avoid production of harmful fumes. The parts degreased with a solvent must be
dried before welding.
Welding should never be done on metals or coated metals containing zinc, mercury, chro-
mium, graphite, lead, cadmium or beryllium unless the operator and the people standing in the
same area use an air-supplied respirator.
1.3 Safe_ Instructions
For your safely, before plugging in the welder, closely follow these instructions:
When working in a confined space, the welder must be kept outside the welding area and
the ground cable should be fixed to the work piece. Never work in a damp or wet area, in these
conditions.
Do not use damaged power cards or welding cables;
The welding torch should never be pointed at the operator's or al other persons' pr:x_;
The welder must never be operated without its panels as this could cause serious injuryto
the operator and could damage the equipment.
1,4 Fire Prevention
Make sure that opp_opfiate fife pre'eenlion de_=es are available ne_ 1o the welding area;
All combustible material must be removed from the welding area.
1.5 ShieldingGas
Use the correctshieldinggas fortheweldingprocess.Make surethattheregulatormounted on
cylinderisworkingwell.Remember tokeep thecylinderaway fromany sourceofheat.
1.6 ElectricShock
DANGER -ELECTRICSHOCK CAN BE FATAL.
Ifa personisfoundunconsciousand electricshockissuspected,do nottouchthepersoniftheyare
incontactwithany electricalwires.Disconnectpower fromthemachine and thenuse FirstAid.DW
wood, and otherinsulatingmaterialcan be used tomove electricalcables,ifnecessary,away from
the person.
...

Primary Or Input Power Data
MIG 95
Primary Volts 120 Volts
Primary Amps 13 Amps
Frequency 60 Hz
Secondary Or Output Power Data
Max. Sec, Volts 27 Volts
Peak Sec. Amps 95 Amps
DLriyCycle 60 Amps at 20%
Duty Cycle
Mig 95 isratedata 20% du_/cycle.Ibismeans forexample,thatwhen weldingwiththismachine
ata currentoutputof60 Amps overa periodof10 minutes,thetotalweldingtimeis2 minutes,
and the rest time is8 minutes.
The wire in the power cord of this machine (A) in Fig.l, is coloured in accordance with the following
code: F120 V.
GREEN WIRE Ground
WHITE WIRE Neutral
BLACK WIRE Live
n/
•i
°1
In order to assemble the plastic handle follow the instructions in figure 1.
In order to assemble the handshield; insert the plasfic protection shield in the special opening
fixing it with the two screws. Place the handle fixing it in the slit of the protection mask, push it and
rotate it by 90° until it enters into the hole inside the protection mask.
CAUTION: Never look at an electric arc without eye protection, the arc rays can injure the eyes
permanently. Use always the protection shield supplied with the welder or any other protection mask
or welding helmet.

Thewelderissuppliedwithaweldingwirespool.Inordertoinstallthiswireintothefeedingsystem,
followtheinstructionsandrefertoFigure2.
1,Removethespoolholder[R}lockingknob[I},pressthelwoclicks{J]andextractthewirespool.
2.Removetheplaslicfl_nfrcr'nthewirespool[K)andref:k:_ceifonthespodhok:Jer[f_).Replacethespool
holaerlackingknob(1)[thesp_ing and the washer fccn the bro_t,ir'g swtem of lt_e wire spool speed].
3. Loosen and lower the plastic knob [L). release the upper roll of the feeder (N} and exlTact the
shipping wire from the torch liner.
4. When the wire on the spool is loosened, hold it with pliers so that it cannot uncoil from the spool,
and s#aighten it before inserting it in the wire input guide [O}. Insert the wire on the lower roll (M)
and in the torch liner.
WARNING: The torch must 13e kept stralaJnt When feeding a new wi_e through the finer, make sure
the wire is cut cleanly (no burrs or angles) and at least l0 inches of the end is straight {no curves}.
Failure to foflaw these instructions could lead to the wire damaging the liner,
5, Lower the upper roll {N} and the knob [L} and tighten slightly {ifthere is too much pressure the wire
gets lacked and the motor could get damaged, if tea loose the wire will not be fed by the rolls}.
6, Plug the power cord into the 120',/60Hz plug and _ on the switch, then press _ torch switch. 1he
wire fed by the wire feecJng motor at variable speed must slide througiq the liner; when it exits from the
torch neck release the torch switch turn off the machine and install the contact rip and the nozzle.
WARNING: 1he roils, when
in movement, may crush the
fingers. Periodically check the
rolls and replace them when
they are worn.
WARNING: The torch is the part
of the welder that needs the
most maintenance. We recom-
mend to periodical checking
of the contact tips and the noz-
zle, These parts must be clean
and not worn-out, The torch
liner must be replaced when
the wire does not feed
smoothly.

!_l[e_I_Vl__l_j
In MIG welding [Metal Inert Gas) a continuously fed metal electrode is melted into a welding pool at
constant and controlled speed.
The wire is connected to a constant voltage pole while the work piece is connected to the other
pole. When the wire is fed and touches the work piece, an electric arc is produced,
The arc melts the wire that is deposited on the work piece.
In "NO GAS welding =the torch is connected to the negative pole and the ground cable to the
positive pole, With gas welding the shielding gas is used to protect the weld pool from oxidation and
porosly. By NO GAS welding this protection is given by a special wire called "flux cored wire", this
technique simplifies the use of these machines compared to the machines with standard wire, on
which the gas flow must be adjusted separately.
1. Connect the welding machine to the 120V 60Hz line;
2. Connect the ground cable to the work piece and make sure that the contact is good;
3. Make sure that the wire-feeding roll is correctly positioned [groove matching the wire diameter].
Note that each rell has two grooves one marked ,035 the other marked .030.
1, There is no need for gas cylinders.
2, Welding outdoom iseasier because there are fewer chances that wind blows away the shielding gas.
3. Welding time is about 50% less compared to the normal electrode welding.
4. The learning time for the operator is very short.
5. Minimum waste of welding material.
6. Most important, this process allows the welding to be completed more quickly and efficiently.
7. Less heat, less distorlJon.
8. Possibility to weld thin materials.
1. Your _ haslwo pe_a'_sfor conlTdioftheweldnganqperage.
2, Thechoice of the position for the welding isdetermined by the
thickness of the matedal to weld,
3. Forthea_nt of the welderrefer to the _aphs on thispage.
SOFT STEEL
FOR NO GAS
B C
1/64- 1/32 MIN LOW
1/32- 1/16 MIN MEDIUM
1/16 - 3/32 MAX MEDIUM
3/32 - 1/8 MAX HIGH
,/f
6

Your welder is supplied with a mini wire spool of about 0.5 pounds of .035" diameter wire. When the
wire spool is finished it can be replaced with a 2 pound wire spool.
the wire is pushed by a roll which is moved by a series of mechanisms, the roll has two grooves of_e
marked by ,035" and the ether marked by .030", It is veq/important to use the correct groove. Ctherwise
the wire will r_t be fed regularly or Itwill be crushed. Make sure that the torch tip matches with the wire
diameter. Your welder issupplied with a torch complete of tip for the wire included with the welder.
Refer to figure 2 and Follow the procedure described at page 5 "Connecting the welding wire" for
the replacement of the wire spool.
CAUTION : ONLY 2 POUND SPOOLS OF .035 FLUX CORED WIRE
" Lrar j UI"
1. Keep the torch handle at an angle of 45° with respect to the work pece and maintain the nozzJe
about 6ram from the surface.
2. Move the torch handle with a steady motion.
3. Avoid welding in areas with too much wind. The wind blows away the shielding gas from the
weld pool causing porosity in the weld.
4. Keep the wire and its cover clean. Do not use rusted wire.
5. Avoid sharp bends and kinks on the welding hose.
6. If possible, clean the wire liner with compressed air when replacing the wire spool.
7, Periodically remove the dust, using low pressure (20-30 PSI)from the inside of the welder, to assure
adequate heat dissipation from welder during operation.
Set the voltage: use the correct "stick out". The wire "stick out" isthe distance between the contact tip
and the work piece. The wire "Stick out" (sometimes Improperly called arc length) should remain in
the range 3/16" + 6/16" in order to obtain best welding performances.
t. Position the voltage switch in the desired position. Select lower position for lower thickness and
higher settings for higher thickness.
2.Adr,Jstthe wire speed. Sta# usng a tridi rnetal sheet thoroughly cleaned from layers of rustc_ paint. Conneat
the ground cable to fne work piece. Adjust the wire speed at high setting, pless Ihe torch switch (note: the
torch switch must be pressed lhorodghly in order to perform itstwo funclto_, wire _ _ _ c_,
Startwelting and decrease the wire speed gradudiiy. Continue to decrease line wife speed and listento lhe
sound. 1he sound Wltlcha'_e from a ciackling nase to a reguk_- and _ong buz_ (si'n/,a-to the sound of
f_ng bacon], 1hisbu_ng sound indicates the correct wire speed f_ the walk p_ce beingwelded.When
the welting amperage is changed set the wire speed again. ,Nways start tram a _ wire speed. INs
operation prevents damage to the contact tip during welting.
1. Defect:
Cause:
2, Defect:
Cause:
3. Defect:
Cause:
4. Defect:
Cause:
1he wire pushes the torch back from the work piece.
Excessive wire speed.
The wire sticks on the contact tip.
Low wire feeding,
Excessive welding spatters
Erratic wire feeding, improper torch position (too inclined)
Arc is unstable
Low voltage, erratic wire feeding.
5. Defect: Inadequate penetration,
Cause: Welding current too low, excessive travel speed, torch travel direction should be reversed.
6. Defect: Cracking
Cause: Base material dirty,,welting CLJTenttoo low, exces&,ve welding voltage, ruston the electrode wire.

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SitCable 3x4wgl 4 m 2,5+American Plug
Handle
Plastic Wire Feeder D.28 Rolls 06-08
Wire Feed Roll D.7x25 0,6x0,8
Side Panel
Torch Grommet On Front Panel
Wel_ng Cuffent Switch 16A 250V
Patentiometer Knob
On/Off Switch 16A-250V
Right Upper Panel
Rc. Board E0585.1 220V
Internal Panel
Wire Feed Motor 12V D.28
Rectifier Pms 30b F/1 Type
Complete 111en-nostat100°+ Support
O,9mm 0,225 Kg. Flux-cored Wire Spool
KitSpool Holder For 016 Spools - Complete
Left Side Panel
Cable Clamp
E3 8ram 2 m 2 No_as Torch
Earth Cable lOmm 2m 1,6 C.120/Conn
Earth Clamp 120A
Choke 40x25 AI
Rear Panel
Transfon_ner60Hz 115V 50x70 AI
Plastic Mask 75x98
Adiactinic Glass 75x98 Art.471 Din 11
Hammer-brush
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Complete Torch Handle
Trigger
Torch Gas Valve For No Gas T 1.0 Torch
Torch Neck For Twl Torch
Thread Guide Wire Liner X T Neck 1.4
Torch Neck Insulator 1.4 Torch E3
Gas Diffuser For Torch Twt Me-99
1,0mm Contact Tip For Torch T 1.4-1.6
Torch Gas Nozzle For Torch Twl Mc-31
Outer Sleeve D. 15,5 L= 1700
Steel Wire Liner 1,4x4 81ue L 1950
Pin For Torch Trigger D.4x16
No-gas Torch Contact Spring Sp.0,5
Self Tapping Screw
Gas Valve No Gas W/Neck
Outside Liner
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L............. ! ........ J , /
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OPEN SQUARE BUTT JOINT
G_p varies ft_m l.emm to 4 8ram @eperdirg
on pl3te th_kr_ss
hCORNER JOINT
SINGLE VEE BUT[ JOINT
-_ - .7/ NOT LESS THAN 70"
"\ /•
\
1.6ram >
DOUBLE VEE BUTT JOINT
_%_ _ _/_ NOT LESS THAN 70"
\, /
1.6ram
SINGLE BEVEL JOINT
/I
/
SINGLE FILLET LAP JOINT
h
DOUBLE FILLET LAP JOINT
11 fill J
SINGLE STRAP JOINT
d . II
DOUBLE BEVEL JOINT
DOUBLE STRAP JOINT
ml -ll
I F
DOUBLE FILLET TEE JOINT SINGLE FILLET TEE JOINT
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WE6480 MIG 95 (_,
OPERATING MANUAL
COD.77610490