Clarke Weld 215TE Installation and operation manual

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Model Nos.
215TE, 250TE & 260TE
OPERATING & MAINTENANCE
INSTRUCTIONS
0100

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Thank you for purchasing this CLARKE Mig welder.
Beforeattemptingtooperatethismachine,pleasereadthisleafletthor-oughly
and follow the instructions carefully, in doing so you will ensure the safety of
yourselfand that of others around you, andso that it will provide you withlong
andtroublefreeservice.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period
of12 months from thedate of purchase. Please keep your receipt as proof of
purchase.Thisguaranteeisinvalidiftheproductisfoundtohavebeenabused
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.
CONTENTS:
Safety 4
ElectromagneticInterference(EMC) 4
Safety Precautions 7
PreparationofWorking Area 12
Safety Equipment 12
Mig Welding - How it Works 12
Benefits of Mig welding 12
Welder Specifications 13
Electrical Connections 14
Assembly 15
Torch Lead Assembly Instructions 16
Face Mask 16
Attaching Gas Bottle and Regulator 16
LoadingWire 17
PreparationforWelding 18
Operation 18
Wire Size Specification Chart 19
TuningtheWelder 19
WeldingHints and Maintenance 20
TroubleshootingChart 21
Typesof Joints 22
Parts Drawing and Lists & Wiring Diagrams 23-30

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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) Othersupplycables,controlcables,signallingandtelephonecables;above,below
and adjacent to the welding equipment;
b) Radioand television transmitters and receivers;
c) Computerand other control equipment;
d) Safety critical equipment, e.g. guarding of industrial equipment;
e) Pacemakers and hearing aids etc;
f) Equipmentused 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.
Thesize of the surrounding area tobe considered will depend on thestructure 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
2.1Mains supply
Welding equipment should be connected to the mains supply according to the
manufacturersrecommendations.Ifinterferenceoccurs, it may be necessary to take
additionalprecautions such as filtering of themains supply. Consideration should be
given to shielding the supply cable of permanently installed welding equipment, in
metallicconduitor 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.
2.2Maintenance of the welding equipment
Theweldingequipmentshouldberoutinelymaintainedaccording to the manufacturers
recommendations. All access and service doors and covers should be closed and
properlyfastened when the welding equipment isinoperation.Thewelding equipment
shouldnotbemodifiedinanywayexceptforthosechangesand adjustments covered
in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizingdevices should be adjusted and maintained according to the manufacturers
recommendations.
SAFETY
Specialcareis taken during all stages of manufacturetoensure that your Clarke Mig
Welder arrives with you in good condition.
Before using the machine it is in your own interest to read this manual thoroughly,
paying particular attention to the following rules, and the EMC Regulations:
1Do not open or remove side panels from the machine unless the mains plugs
disconnected.
2Do not use the machine with any of the panels open or removed.
3Do not try to attempt any electrical or mechanical repair unless you are a
qualified technician. If you have a problem with your machine contact your
localdealer or CLARKE International Service Dep’t on 020 8988 7400.
4Removeany flammable materials from thewelding area.
5Donot expose gas cylinder tohigh temperature, and do not strike an arc near
or on the gas cylinder.
Caution:Gascylinders are pressurised containers. Do not pierceorburn, even when
empty. Protect from direct sunlight.
6Makesure you have good ventilationin the welding area sincetoxic gases are
released during the MIG welding process.
7Ultra-violet radiation is released by the MIG welding process and it is of the
utmost importance that the operator, and any spectators, protect themselves
byusing welding face-shields or helmets with suitable filter lenses. The wearing
of gloves and proper working clothes is also strongly recommended.
8Neveruse in a wet ordamp environment.
9Ifweldingoutdoors, screens MUST BE USED around theweldsite, to protect
the general public from the glare of the arc.
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 involveconstructing 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 not be earthed for safety reasons. Changing the
earthing arrangements should only be authorised by a person who is competant to
assess whether changes will increase the risk of injury, e.g. by allowing parallel
welding current return paths which may damage the earthing circuits of other
equipment.

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SAFETY PRECAUTIONS
1.0 Introduction
Read and understand these safe practices before attempting to install, operate, or
servicethe equipment. Comply with theseprocedures as applicable to the particular
equipmentused and their instructionmanuals, for personal safety and for the safety
ofothers. Failure to observethese safe practices maycause serious injury ordeath.
When safety becomes a habit, the equipment can be used with confidence.
2.0 General precautions
2-A Burn prevention
Wearprotectiveclothing-gauntletgloves designedfor useinwelding,hat,and protective
shoes.Button shirt collar andpocket flaps, and wear cuffless trousers to avoid entry of
sparksandslag.Wearhelmetwithsafetygogglesorglasseswithsideshields 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 flying
metal.Replacecoverglass whenbroken,pitted, orspattered.Avoidoilygreasy clothing.
A spark may ignite them. Hot metal such as electrode stubs and workpieces should
neverbehandledwithout gloves.Firstaid facilitiesandaqualifiedfirst aidpersonshould
beavailable for eachshiftunlessmedical facilities are closebyforimmediate treatment
of flash burns of the eyes and skin burns. Ear plugs should be worn when working
overheadorina confinedspace. Ahardhat shouldbe wornwhenothersworkoverhead.
Flammable hair preparations should not be used by persons intending to weld or cut.
2-B Toxic fume prevention
Severe discomfort, illness or death can result from fumes, vapours, heat, or oxygen
enrichmentordepletionthatwelding(orcutting)mayproduce.Preventthemwithadequate
ventilation.NEVERventilatewithoxygen.Lead-,cadmium-,zinc-,mercury- andberyllium-
,bearing materials, when welded (or cut) may produce harmful concentrations of toxic
fumes.Adequate local exhaust ventilation must beused,oreachperson 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,ahighlytoxicgas,andotherlung andeye irritatingproducts. Theultraviolet
(radiant)energy of thearccanalso decompose trichloroethyleneandperchlorethylene
vapoursto formphosgene.DO NOTWELDor cut wheresolventvapours canbedrawn
into the welding or cutting atmosphere or where the radiant energy can penetrate to
atmospherescontainingevenminute amountsoftrichloroethylene orperchlorethylene.
2.3Welding 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.
2.4Equi-potential 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 orn building steelwork, a
connection bonding the workpiece to earth may reduce emissions in some, but not
allinstances. Care should be taken to prevent the earthingoftheworkpieceincreasing
theriskof injury to users, or damage to other electricalequipment.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 shouldbeachievedby suitable capacitance,selectedaccording
to national regulations.
2.6 Screening and shielding
Selective screening and shielding of other cables and equipment in the
surroundingareamayalleviateproblems of interference. Screening of
the entire welding installation may be considered for special applications.

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3-A Burn protection
Complywith precautions in 2. The welding arcisintenseandvisiblybright. Its radiation
candamageeyes,penetratelightweightclothing,reflectfromlightcolouredsurfaces,
and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas -
shieldedarcs are more severe andpainful.
DON’T GET BURNED! COMPLY WITH PRECAUTIONS!
(I) Protective clothing
Wearlongsleevedclothing(particularlyforgas shielded arc) in addition to gloves,
hat and shoes (2-A). As necessary, use additional protective clothing such as
leatherjacket or sleeves, flameproof apron, and fire-resistantleggings.Avoidouter
garments of untreated cotton. Protectbare skin. Wear dark substantial clothing.
Button collar to protect chest and neck and button pockets to prevent entry of
sparks.
(II) 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 to 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.
(III) 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.
3-B Toxic Fume Prevention
Comply with precautions in 2-B. Generator engine exhaust must be
vented to the outside air. Carbon monoxide can kill.
2-C Fire and explosion prevention
Causes of fire and explosion are: combustibles reached by the arc, flame, flying
sparks, hot slag or heated material; misuse of compressed gases and cylinders;
and 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,
outofsightofthegoggledoperator.Sparksandslagcanfly 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
protectagainstignition with suitable and snug fitting, fire- resistant coversorshields.
Walls touching combustibles on opposite sides should not be welded on (or cut).
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.
Afterworkisdone, check that area is free of sparks, glowing embers, andflames.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
inertingwithnitrogenor carbon dioxide, and using protective equipment. Water filling
justbelow working level maysubstitutefor inerting. A containerwithunknowncontents
shouldbecleaned(seeparagraphabove),doNOTdependon sense of smell or sight
todetermine if it issafe to weld orcut. Hollow castings or containers must be vented
beforeweldingorcutting-they can explode. In explosive atmospheres, never weld or
cutwhere theairmay containflammabledust, gas,orliquid vapours (suchasgasoline).
3.0 Electric arc (Mig, Tig) welding
Comply with precautions in 1, 2 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.

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(III) Connectors
Fullyinsulatedlock-typeconnectorsshouldbeusedto join welding cable lengths.
(IV) Cables
Frequentlyinspect cables forwear,cracks and damage.IMMEDIATELYREPLACE
thosewith excessively worn or damaged insulation to avoid possiblylethal shock
from bared cable. Cables with damaged areas may be taped to give resistance
equivalentto original cable. Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
(V) Terminals and other exposed parts
Terminalsand other exposed parts of electrical units should have insulating covers
securedbeforeoperation.
(VI) Electrode
a) Equipmentwith output on/off control (contactor) Weldingpower sources for
use with the gas metal arc welding, gas tungsten arc welding and similar
processesnormally are equipped with devices that permit on/off control of the
welding power output. When so equipped the electrode wire becomes
electricallyHOT when the powersource 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) Equipmentwithoutoutputon/off control(nocontactor) Weldingpowersources
usedwith shieldedmetalarc weldingandsimilar processesmaynot beequipped
with welding power output on/off control devices. With such equipment the
electrodeiselectricallyHOTwhen the power switch is turned ON. Never touch
the electrode unless the welding power source is off.
(VII) Safety devices
Safetydevicessuchas 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
whilewelding. 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.
3-C Fire and Explosion Prevention
Comply with precautions in 2-C. Equipment’s rated capacity. Do not overload arc
weldingequipment.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
sucha rupture later under roughhandling.
3-D Shock Prevention
Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded,
electrically-HOT 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.
3-E Protection for Wearers of Electronic Life Support Devices
(Pacemakers).
Magneticfieldsfromhighcurrents can affect pacemaker operation. Persons wearing
electroniclifesupport equipment (pacemaker) should consult with their doctor before
goingnear arc welding, gouging, or spot welding operations.
3-F To Protect Against Shock:
Keep body and clothing dry. Never work in damp area without adequate insulation
againstelectrical shock. Stay on a dry duckboard, or rubbermat when dampness or
sweat can not be avoided. Sweat, sea water, or moisture between body and an
electrically HOT part - or grounded metal - reduces the body surface electrical
resistance,enablingdangerous and possibly lethal currents to flow through thebody.
(I) Grounding the equipment
When arc welding equipment is grounded according to the National Electrical
Code, and the work is grounded, a voltage may exist between the electrode and
anyconductingobject.Examples of conducting objects include, but are not limited
to, buildings, electrical tools, work benches, welding power source cases,
workpieces,etc. Never touchtheelectrodeand any metalobjectunless 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 ground. Conductors must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may shock, possibly fatally.
Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a
flammable liquid such as oil or fuel.
(II) Electrode holders
Fully insulated electrode holders should be used. Do NOT use holders with
protruding screws or with any form of damage.

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WELDER SPECIFICATIONS
PRIMARY or INPUT POWER DATA MIG215TE MIG250TE MIG260TE
Primary Volts 230V/1PH 230V/1PH 230/400V/3Ph
Primary Amps 29 Amps 36 Amps 23Amps (230V)
13.3Amps(400V)
Frequency 50HZ 50HZ 50Hz
SECONDARY or OUTPUT POWER DATA
Sec. Volts 21-43 V21-48 V17-38 V
Max. Sec. Amps 200 Amps 250 Amps 260 Amps
CurrentRange 30-200 Amps30-250 Amps30-260 Amps
DUTY CYCLES
100% 95 Amps 115 Amps 80 Amps
60% 123 Amps 150 Amps 103 Amps
35% -- -- 230 Amps
25% 190 Amps 230 Amps --
NOTE: Duty Cycles are rated over a 10 minute period.
Example: If welding with a MIG 215TE at 100amps, a 25% duty cycle applies. This means
thatover a 10 minute period,the welding time is 2.5minutes, the down time is 7.5 minutes.
USABLE WIRE SIZES
Mild Steel Wire 0.6-1.0mm 0.6-1.0mm 0.6-1.0mm
StainlessSteel Wire 0.8-1.0mm 0.8-1.0mm 0.8-1.0mm
Aluminium Wire 0.8-1.0mm 0.8-1.0mm 0.8-1.0mm
USABLE GASES MAIN USES
75%Argon 25% CO2 -Thin Sheet Metal, Mild Steel
100%Argon -Welding Aluminium, Stainless Steel
100%CO2 -MildSteel
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. Consult machines data plate.
PREPARATION OF THE WORKING AREA
Theworking area must besufficiently spacious, not humid, and well-ventilated as to
avoidany fumes which develop from the welding process and fromincidentalmaterial
adheringtothepieces to be welded (oils, paints, tars...) which may cause annoyance
tothe operator.
Avoid welding by contact with humid parts nearby combustible liquids. Least of all,
do not weld upon tanks which may contain inflammable residuals.
SAFETY EQUIPMENT
Acomprehensiverangeof CLARKEsafetyequipment forusewhenweldingis available
from your local dealer.
MIG WELDING - HOW IT WORKS
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 positive side of a rectified voltage supply. The workpiece is connected to the
negative 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 must be sufficient to protect
the weld, but not wasteful.
NOTE: Poor gas coverage will result in poor welding. Excessive gas coverage is
wastefulandexpensive.
BENEFITS OF MIG WELDING
1. 50% faster welding time.
2. Operator training time kept to a minimum.
3. There is no slag removal, thus eliminating almost all post-welding cleaning
operations.
4. Minimum waste of welding consumables.
5. Overall, a faster more efficient way of getting the job done.
6. Less heat - less distortion.
7. Ability to weld thin material.

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1The side panel is hinged at its rear edge: Open by pulling sideways at the front
edge, lay out all components contained within, and check to ensure that they
are all correct according to the list below. FIG.1
A2 Wheels
B1 Axle
C2 Wheel retaining washers
D2 Castors
E1 Handle
F2 Brackets
G4 Fixing screws
1 Mask with fixing screws & washers
1Transparent glass
1 Dark glass
1Gas regulator
1 Worm drive clips for gas hose
connections
1 Welding torch and lead
1Cover for hose support bracket
2Self tapping screws for cover
1 Earth Cable
1 0.6mm welding tip
1 0.8mm welding tip
1 1.0mm welding tip
SHOULD ANY PART BE MISSING OR DAMAGED, CONTACT YOUR LOCAL
DEALER FOR REPLACEMENT.
2Attachthe handle (E) to the welder unit by slidingthe brackets (F) on the front of
the machine, lining up the holes with those in the casing and securing the four
screws(G) provided.
3Fix the wheels (A) to the back of the unit and the castors (D) to the front.
4Connect the earth return lead to the negative (-) socket on the fornt panel of the
welder unit.
5Ensure that the side panels are securely closed before using the welder.
6Connectthetorchleadassemblytothewelder,followingtheappropriateinstructions.
ASSEMBLY
ELECTRICAL CONNECTIONS
WARNING: THESE MACHINES MUST BE EARTHED.
MIG 215TE & 230TE
Thiswelder must be connected to thecorrect receptacle, 1Ph 230 volt (50Hz). A13
Amp plug is not suitable for this device. Connect the three core mains lead to a
suitably fused supply through an isolator or heavy duty plug.
IMPORTANT: The wires in the mains lead are coloured in accordance with
the following colour code:Green & Yellow - Earth
Blue - Neutral
Brown - Live
ConnectGREEN & YELLOW coloured cordto plug terminal marked witha letter “E”
or Earth symbol ‘W’.
Connect BROWN coloured cord to plug terminal marked letter “L”
Connect BLUE coloured cord to plug terminal marked letter “N”
Westrongly recommend that this machine is connectedto the mains supply through
aResidual Current Device.
MIG 260TE
Thesemachinesare normally supplied connected to at 400Vthree-phase. For safety
double check the sticker placed at the end of the input cable.
Should it became necessary to use an input current at 230V three-phase follow
these simple instructions:
1Bring on the “OFF” position the ON/OFF
switch, disconnect the mains switch and the
inputvoltage plug from the mains.
2Openthe right sidepanel(facing thewelder)
undoing the screws holding it to the frame.
3Change the connection by following the
instructions displayed on the here attached
drawing.
4Make sure that the nuts holding the bridges
are securely tightened.
5Re-assemble the side panel.
DO NOT WORK WITH THE SIDE PANLES PARTIALLY OPENED OR COMPLETELY
REMOVED FROM THE POWER SOURCE IN ORDER TO AVOID CONTACTS WITH
WIRE OR PARTS.
IMPORTANT: If in doubt, consult a qualified electrician. Do not attempt any
electrical repairs yourself.

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LOADING WIRE
NOTE: These machines are designed to accept either 5Kg or 15Kg wire spools of
mild steel, stainless steel or aluminium according to the type of metal you wish to
weld.Wire spools ARE NOT supplied with the unit and must be purchased separately.
1Ensure the gas and electrical supplies are disconnected;
2(Ref. Fig. 3) Turn the plastic knob (23F), 180°.
3Take off the plastic cover of the wire spool; FIG.3
4To fit the wire spool (23H)
intothehub (23A) push the
button (23I),insertthe wire
spool,followed by thecollar
(23C)(itmust be used only
with 5Kg wire spools) .
5Turn theplastic knob (23F)
by 180° again.
6Loosenthe plasticknob by
turning it anti-clockwise,
(thismaintains pressure on
thewireviatheroller).Pull,
ontheplastic knob, so that
the screw rod comes out
of its slot, thereby
releasingthe pivoted roller
bracket. Raise the bracket
together with the pressure
roller, and pullout any wire
that has been left in the
hose.
7 If you are changing the size of wire, you must also select the appropriate groove
onthefeed roller. To change to the other groove,undotheHex.SocketScrewand
remove the roller from its shaft. Turn it through 180°, replace it on the shaft, and
adjust so that the groove is directly in line with the Wire Liner. Firmly secure it in
that position with the Hex. Socket Screw.
8 Cliptheend of the wire, on the spool,cleanly,ensuring there are no burrs or sharp
edges,and,ensuringitis straight, feed it through the guide tube , over the channel
on the roller and into the wire liner, by approx. 10 - 15cm.
FACE MASK
To assemble the face mask, first place the dark glass window and the clear glass
window together in the recessed window area of the body.
IMPORTANT: the clear glass window should be placed on the outside of the
mask.
Securein place using the screwsand nuts provided. Bend the sides of the mask into
shapeand fix together usingthe screws and nutsprovided, and finally, fit the handle
to the shield body also using the screws and nuts provided.
ATTACHING THE GAS BOTTLE AND REGULATOR
1. The bottle (not supplied) should be located at the rear of the welder,
securely held in position by the chain provided.
2. For safety, and economy, ensure that the regulator is fully closed, (turned
anti-clockwise)when not welding and when fitting orremoving thegascylinder.
3. Connect the gas hose to the regulator securing with clip/nut provided.
4. Screw the gas regulator fully down on the gas bottle valve, and fully tighten.
5. Turnthepower on, open the cylinder valve, thensetthe gas flow to approx. 8l/
min.on the regulator. Operate the torch trigger to ensure that the gas is flowing
through the torch.
TORCH LEAD ASSEMBLY INSTRUCTIONS
Plug the troch hose into the socket on the front of the welder and secure by hand
screwing in the threaded connection. FIG.2

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WIRE SIZE SPECIFICATION CHART
TUNING THE WELDER
The tuning of a Mig welding machine requires some practice, due to the fact that -
contrary to the arc welding procedure - two parameters must be accommodated to
achievea perfect weld. These are:
(A) Wire Feed Speed, and (B) Welding Voltage.
It is important to arrive at the correct combination to suit the type and thickness of
material to be welded. The current necessary for welding is directly dependent
upon the wire feed speed.
If the wire feed speed is increased, the current is also increased, but the arc length
isdecreased. Conversely, if the wire feed speed is decreased, and current is therefore
decreased, the length of arc is increased.
Increase of the weldingvoltage leads to alonger arc (without substantiallyaffecting
the current). Conversely, a decreased welding voltage results in a shorter arc, (the
current again is not substantially changed).
A change in wire diameter results in changed parameters. A smaller diameter wire
requires an increase in wire feed speed to reach the same current. If certain limits
are exceeded, a satisfactory weld cannot be obtained. These are:
A)Atoo high wire feed speed (too highwithregard to the welding voltage) results
inpulsing within the torch. This isbecause the wire electrode dips intothe puddle
and cannot be melted off fast enough.
B)If the welding voltageis set too high,large drops can be seen at the end of the
wire electrode. These drops are often deposited beside the welding seam.
Thecorrectrate of wire feed speed (current) and welding voltage,resultsin very little
spatter and a continuous, intensive hissing can be heard from the arc.
1 2
3
45
6
SWITCH STEEL WIRE
DIAMETER
(mm)
WIRE SPEED
ADJUSTMENT
SWITCH
POSITIONS
1
2
3
4
5
6
7
0.6
0.6
0.6 - 0.8
0.6 - 0.8
0.8
0.8
1.0
LOW
LOW
MEDIUM
MEDIUM
MEDIUM - HIGH
HIGH
HIGH
9 Reposition the pressure roller and plastic knob and tighten slightly.
IMPORTANT: Too tight will crush the wire and damage the wire feed motor,
too loose will not allow the wire to be pulled by the roller.
10 Pull off the torch shroud by twisting it clockwise, and unscrew the contact tip.
Close the side panel of the machine, plug into a 230V, 50HZ outlet (or switch on
isolator), 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 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 feed through to the nozzle.
PREPARATION FOR WELDING
1 Attach the earth clamp to the bare metal to be welded, making sure of good
contact.
2 Make sure that the wire-roller groove in the roller corresponds to the diameter of
thewelding wire being used. Refer to“Loading wire” above.
3 Plug the machine into a 230V AC 50Hz outlet.
4 Openthe gas valve on the gascylinder regulator, (turn knob clockwise)and adjust
the gas regulatorto the proper settingposition. NOTE: this varies with different
metals, thicknesses and currents. Refer to a MIG welding manual for
instructions.
OPERATION
1 These machines have 7 welding positions (see the table below) in which to
regulatecurrent for various conditions.
2 The selection of a welding position is determined by the thicknessof the metal
to be welded. The thicker it is, the higher the current must be.
3 According to the thickness to be welded, the amount of gas regulated to the
work also varies and must be adjusted accordingly.
4 For welding adjustments, refer to the table below.
WARNING
(i) Make sure all flammable materials are removed from the work area.
(ii) Never look directly at the welding arc, it can seriously damage your eyes.
Always use an approved welding mask or helmet.
(iii) Wear protective clothing so that all skin areas are covered.
(iv) Keep a fire extinguisher handy.

21
TROUBLE SHOOTING
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.
PROBLEM PROBABLE CAUSE POSSIBLE SOLUTION
1. No "life" from the 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 Motor malfunction Return welder to your local dealer.
3. Feed motor operates but wire
will not feed
a) insufficient feed roller
pressure
b) Burr on end of wire
c) Linerblocked or damaged
d) Inferior wire
a) Increase roller pressure
b) Re-cut wire square
c) Clear with compressed air or
replace liner.
d) Use only good clean wire
4. Wire welds itself to tip a) Wire feed speed too low
b) Wrong size tip
a) Unscrew tip, cut wire and
fitnew tip. Increase wire speed
before operating again.
b) Change tip size.
5. Wire feeds into "bird's" nest
tangle. a) Wire welded to tip.
b) Wire liner damaged
preventing smooth operation.
a) As above plus reduce feedroller
pressure so that if blockage occurs
wire sleeps on roller. i.e. no feed
b) Renew wire liner.
6. Loose coils of wire
tanglearound wire druminside
machine
Drum brake too slack. Tighten drum brake - DO NOT
OVERTIGHTEN
7. Erratic wire feed a) Drum brake too tight
b) Feed roller worn
c) Insufficient pressure on
feed roller
d) Wire dirty, rusty, damp or
bent
d) Liner partilly blocked
a) Loosen drum brake slightly
b) Checkand replace if necessary
c) Increase pressur eon feed roller
DO NOT OVERTIGHTEN
d) Re-cut wire and ensure it is
clean
e) Clear with compressed air
8. Poor quality welds a) Insufficient gas at weld area
b) Incorrect gas/wire
combination
c) Rusty, painted, damp, oily or
greasy workpiece
d) Rusty, dirty wire.
e) Poor earth contact
a) Check that gas is not being
blown away by draughts, if so,
move to a sheltered area. If no
draught, incrtease gas supply.
b) Consult your Mig Welding
manual
c) Ensure workpiece is clean and
dry
d) Ensure wire is clean and dry
e) Check ground clamp/workpiece
connection.
9. Wire jams in tip when welding
aluminium Tip too small Use slightlyoversize tip i.e. for 0.8mm wire use 1mm tip (Applies
to aluminium only)
10.Welder cuts out whilst in use Duty cycle exceeded (auto
cut-out operates) Allow welder to cool for 15-30min. before continuing. Note if duty
cycle is continually exceeded,
damage to the welder may result
and welder output is probably too
small for application.
WELDING HINTS AND MAINTENANCE
1Always weld clean, dry and well prepared material.
2Hold gun at a 45° angle to the workpiece with nozzle about 6mm from the
surface.
3Move the gun smoothly and steadily as you weld.
4Avoid welding in very draughty areas. A weak pitted and porous weld will
result due to air blowing away the protective welding gas.
5Keep wire and wire liner clean. Do not use rusted wire.
6Sharp bends or kinks on the welding hose should be avoided.
7Always try to avoid getting particles of metal inside the machine since they
could cause short circuits.
8If available, use compressed air to periodically clean the hose liner when
changingwire spools
IMPORTANT: Disconnect from power source when carrying out this operation.
9Usinglowpressure air (20-30 PSI), occasionally blow thedustfrom the inside
of the welder. This keeps the machine running cooler. Note: do not blow air
over the printed circuit board and electronic components.
10 The wire feed roller will eventually wear during normal use. With the correct
tensionthe pressure roller must feed the wire without slipping. If the pressure
rollerandthe wire feed roller make contact (when the wireisin place between
them), the wire feed roller must be replaced.
11 Checkall cables periodically. They must be ingoodcondition and not cracked.

23
PARTS DRAWINGS AND LISTS
&
WIRING DIAGRAMS
TYPES OF JOINTS
OPEN SQUARE BUTT JOINT
1.6mm
SINGLE VEE BUTT JOINT
1.6mm
DOUBLE VEE BUTT JOINT
NOT LESS THAN 70°
NOT LESS THAN 70°
SINGLE BEVEL JOINT
DOUBLE BEVEL JOINT
CORNER JOINT
SINGLE FILLET LAP JOINT
DOUBLE FILLET LAP JOINT
SINGLE STRAP JOINT
DOUBLE STRAP JOINT
DOUBLE FILLET TEE JOINT SINGLE FILLET TEE JOINT
Gap varies from 1.6mm to 4.8mm depending
on plate thickness

25
PARTS LIST - MIG 215TE (Part No. 6015215)
ITEM PARTNO. DESCRIPTION QTY.
01 EM04600025 CLIP+COUPLINGFORPANEL 1
02 EM04600001 COMPLETESPOOL HOLDER D.50 1
03 EM33725047 HANDLE 1
04 EM30905001 HOLDER MAT 3X270X640 1
05 EM22200002 ON/OFF SWITCH 16A-250V 1
06 EM21690015 SWITCHKNOB D.34 1
07 EM21690058 POTENTIOMETERKNOB 1945/BGREEN 2
08 EM22610013 ORANGE PILOT LAMP 220V L=500 1
09 EM21690003 BINZELCONNECTIONTORCH GROMMET 1
10 EM21600012 COUPLEOFINCLINED-OVALHANDLES 15X30 1
11 EM21690129 DISTANCEPIECEFORINCLINEDHANDLE 1
12 EM22710010 P.C.BOARD E0788 220V 1
13 EM22810006 WIREFEEDING MOTOR42VD.62 1
14 EM33705162 UPPERPANEL 1
15 EM22210601 RECTIFIER’STHERMOSTAT 100ø16A 1
16 EM22400013 RECTIFIER PMS 20/4/2 F 1/MOV 1
17 EM33720013 DIVIDINGPANEL 1
18 EM22800013 FAN C20 240V VENT ASP.154 ALL 1
19 EM33715054 BACKPANEL 1
20 EM21605010 CABLE CLAMP FOR HOLE D.20 2
21 E M30900026 BLACK GAS HOSE D.5X10,5 L=2150 1
22 EM20220020 PVCINPUTCABLE 3X2,5 M.2,5 1
23 EM22100001 DINSE PLUG 25SQMM TSKM25 CX20 1
24 EM33705164 SIDEPANEL 1
25 EM33805003 WIREFEEDROLL 0,6-0,8MMAL.MOTOR2R 1
25 EM33805005 WIREFEEDROLL 1,0-1,2MMAL.MOTOR2R 1
25 EM33805021 WIREFEED ROLL 0,8-1MMNYLONAL.MOTOR2R 1
25 EM33805022 WIREFEEDROLL 1,2-1,6MM NYLON MOT.AL.2R 1
26 EM21625002 RUBBERPIVOTING WHEELD.80 2
27 EM33710134 FRONTPANEL 1
28 EM21500004 BALL BEARING D10X30 SP.9 1
29 EM44410017 AL.WIRE FEEDER D62 42V 2ROLLS 06-08 1
30 EM22100002 DINSE PLUG 25SQMM TBEM25 CX30 1
31 EM55200001 WHEELS-AXLE D.20L=488 1
32 EM33705163 RIGHT-SIDEPANEL 1
33 EM23005048 BINZEL TORCH ADAPTOR L=40 AT109 1
34 EM22205033 SWITCH 20 A CM 17 1
35 EM44135007 CHOKE 50X60CU 1
36 EM22305004 RESISTANCE 3OHM D.16 L=90 1
37 EM33700111 LOWERPANEL 1
38 EM22225018 AUXILIARY CONTACT BL/X 2NC 1
39 EM22225008 CONTACTOR 220V 16A CN-16 (LX1) 1
40 EM22900001 GAS SOLENOID VALVE 4W 220V 50HZ 1/8"FF 1
41 EM22315003 CAPACITOR 22000 MF 63V 63X105 3
42 EM44120018 TRANSFORMER 230V 64X90 CU 1
43 EM21625009 WHEELD.175 RUBBER HOLED.20 2
44 EM43210036 EARTHCABLE 25SQMM MT.3 W/C.261/DN25 1
45 EM22110007 EARTH CLAMP ART.261 - OK 150 1
46 EM23000322 TORCH PLUS14 M.3 BZ CONN L,B14 MAM411 1
47 EM22905017 REDUCER MAXIARG/UK 1/GAUGE 1
48 EM21905019 CARTONMASK82X108 1
49 EM21905020 TRANSPARENTGLASS82X108 ART.470 1
50 EM21905024 DARK GLASS 82X108 ART.471 BS DIN13 1
51 EM22220004 FUSE 5X20 T 2A 250V 1
52 EM22220016 FUSE HOLDER PTF/35 6,3A 250V 1
PARTS DRAWING - MIG 215TE (Part No.6015215)
& MIG 250TE (Part No. 6010250)

27
PARTS DRAWING - MIG 260TE (Part No. 6010390)PARTS LIST - MIG 250TE (Part No. 6010250)
ITEM PARTNO. DESCRIPTION QTY.
01 EM04600001 COMPLETESPOOL HOLDER D.50 1
02 EM04600001 COMPLETESPOOL HOLDER D.50 1
03 EM33725047 HANDLE 1
04 EM30905001 HOLDER MAT 3X270X640 1
05 EM22200002 ON/OFF SWITCH 16A-250V 1
06 EM21690015 SWITCHKNOB D.34 1
07 EM21690058 POTENTIOMETERKNOB 1945/BGREEN 2
08 EM22610013 ORANGE PILOT LAMP 220V L=500 1
09 EM21690003 BINZELCONNECTIONTORCH GROMMET 1
10 EM21600012 COUPLEOFINCLINED-OVALHANDLES 15X30 1
11 EM21690129 DISTANCEPIECEFORINCLINEDHANDLE 1
12 EM22710010 P.C.BOARD E0788 220V 1
13 EM22810006 WIREFEEDING MOTOR42VD.62 1
14 EM33705162 UPPERPANEL 1
15 EM22210601 RECTIFIER’STHERMOSTAT 100ø16A 1
16 EM22400016 RECTIFIER PMS 24/4/2 F 1/MOV 1
17 EM33720013 DIVIDINGPANEL 1
18 EM22800013 FAN C20 240V VENT ASP.154 ALL 1
19 EM33715054 BACKPANEL 1
20 EM21605010 CABLE CLAMP FOR HOLE D.20 2
21 EM30900026 BLACK GAS HOSE D.5X10,5 L=2150 1
22 EM20220044 INPUTCABLE3X42,5MT. 1
23 EM22100001 DINSE PLUG 25SQMM TSKM25 CX20 1
24 EM33705164 SIDEPANEL 1
25 EM33805003 WIREFEEDROLL 0,6-0,8MMAL.MOTOR2R 1
25 EM33805005 WIREFEEDROLL 1,0-1,2MMAL.MOTOR2R 1
25 EM33805021 WIREFEED ROLL 0,8-1MMNYLONAL.MOTOR2R 1
25 EM33805022 WIREFEEDROLL 1,2-1,6MM NYLON MOT.AL.2R 1
26 EM21625002 RUBBERPIVOTING WHEELD.80 2
27 EM33710134 FRONTPANEL 1
28 EM21500004 BALL BEARING D10X30 SP.9 1
29 EM44410017 AL.WIRE FEEDER D62 42V 2ROLLS 06-08 1
30 EM22100002 DINSE PLUG 25SQMM TBEM25 CX30 1
31 EM55200001 WHEELS-AXLE D.20L=488 1
32 EM33705163 RIGHT-SIDEPANEL 1
33 EM23005048 BINZEL TORCH ADAPTOR L=40 AT109 1
34 EM22205033 SWITCH 20 A CM 17 1
35 EM44135008 CHOKE 50X60 CU 1
36 EM22305004 RESISTANCE 3OHM D.16 L=90 1
37 EM33700111 LOWERPANEL 1
38 EM22225018 AUXILIARY CONTACT BL/X 2NC 1
39 EM22225008 CONTACTOR 220V 16A CN-16 (LX1) 1
40 EM22900001 GAS SOLENOID VALVE 4W 220V 50HZ 1/8"FF 1
41 EM22315003 CAPACITOR 22000 MF 63V 63X105 4
42 EM44120082 TRANSFORMER 230V 60X100 CU 1
43 EM21625009 WHEELD.175 RUBBER HOLED.20 2
44 EM43210013 EARTHCABLE 25SQMMM3 W/C.411/DN25 1
45 EM22110009 EARTH CLAMP ART.411 1
46 EM23000349 TORCH ERGOPLUS15MT.3EUROCON.MA7007 1
47 EM22905017 REDUCER MAXIARG/UK 1/GAUGE 1
48 EM21905019 CARTONMASK82X108 1
49 EM21905020 TRANSPARENTGLASS82X108 ART.470 1
50 EM21905024 DARK GLASS 82X108 ART.471 BS DIN13 1
51 EM22220004 FUSE 5X20 T 2A 250V 1
52 EM22220016 FUSE HOLDER PTF/35 6,3A 250V 1

29
WIRING DIAGRAM - MIG 215TE (Part No.6015215) &
MIG 250TE(Part No. 6010250)
PARTS LIST- MIG 260TE (Part No. 6010390)
ITEM PARTNO. DESCRIPTION QTY.
1EM21600012 COUPLEOFINCLINED-OVALHANDLES 15X30 1
2EM22710027 P.C.BOARD E0788WI 1
3EM22900002 GAS SOLENOID VALVE 4W 24V 50HZ 1/8"FF 1
4EM22400029 RECTIFIER PTS 180 F 1/MOV 1
5EM22210601 RECTIFIER’STHERMOSTAT 100ø16A 1
6EM22800005 FAN C30 220-240 VENT.ASP.154 ALL 1
7EM21605010 CABLE CLAMP FOR HOLE D.20 2
8EM30900026 BLACK GAS HOSE D.5X10,5 L=2150 1
9EM20220030 INPUTCABLE4X2,5 M.3,3 1
10 EM04600025 CLIP+COUPLINGFORPANEL 1
11 EM33705164 SIDEPANEL 1
12 EM21690003 BINZELCONNECTIONTORCH GROMMET 1
13 EM33725047 HANDLE 1
14 EM22200005 GREENPILOT-LIGHTSWITCH 10A-380V 1
15 EM21690058 POTENTIOMETERKNOB 1945/BGREEN 1
16 EM33705163 RIGHT-SIDEPANEL 1
17 EM22610011 ORANGE PILOT-LAMP 24V L=600 1
18 EM21690015 SWITCHKNOB D.34 2
19 EM22205030 SWITCH 16 A SCH 6411 1
20 EM33705162 UPPERPANEL 1
21 EM44410017 AL WIRE FEEDER D.62 42V 2ROLLS 1
22 EM22810006 WIREFEEDING MOTOR42VD.62 1
23 EM33805003 WIREFEEDROLL 0,6-0,8MMAL.MOTOR2R 1
23 EM33805005 WIREFEEDROLL 1,0-1,2MMAL.MOTOR2R 1
23 EM33805021 WIREFEED ROLL 0,8-1MMNYLONAL.MOTOR2R 1
23 EM33805022 WIREFEEDROLL 1,2-1,6MM NYLON MOT.AL.2R 1
24 EM22225007 CONTACTOR 24V 16A CN-16 (LX1) 1
25 EM22100002 DINSE PLUG 25SQMM TBEM25 CX30 1
26 EM21890001 VOLTAGE CHANGE BOARD 9/HOLES 80X130 1
27 EM33700111 LOWERPANEL 1
28 EM44125038 TRANSFORMER 1
29 EM44025084 LATERAL WINDING 230V 50X70X150 AL 3
30 EM23005048 BINZEL TORCH ADAPTOR L=40 AT109 1
31 EM21625002 RUBBERPIVOTING WHEELD.80 2
32 EM55200001 WHEELS-AXLE D.20L=488 1
33 EM21625009 WHEELD.175 RUBBER HOLED.20 2
34 EM33715054 BACKPANEL 1
35 EM04600001 COMPLETESPOOL HOLDER D.50 1
36 EM33720013 DIVIDINGPANEL 1
37 EM33710134 FRONTPANEL 1
38 EM22100001 DINSE PLUG 25SQMM TSKM25 CX20 1
39 EM43210013 EARTHCABLE 25SQMMM3 W/C.411/DN25 1
40 EM22110009 EARTH CLAMP ART.411 1
41 EM23000349 TORCH ERGOPLUS15MT.3EUROCON.MA7007 1
42 EM22905018 REDUCER MAXIARG/UK 2/GAUGES 1
43 EM21905019 CARTONMASK82X108 1
44 EM21905020 TRANSPARENTGLASS82X108 ART.470 1
45 EM21905024 DARK GLASS 82X108 ART.471 BS DIN13 1
46 EM30905001 HOLDER MAT 3X270X640 1
47 EM22220016 FUSE HOLDER PTF/35 6,3A 250V 1
48 EM22220004 FUSE 5X20 T 2A 250V 1
49 EM44140036 AUXILIARY TRANSFORMER 28X42CU 1

31
WIRING DIAGRAM - MIG 260TE (Part No. 6010390)