Clarke MIG 150TE Installations- und Betriebshandbuch

OPERATING & MAINTENANCE

INSTRUCTIONS

0904

MIG PRO-90 • MIG 100E • MIG 150TE

CONTENTS PAGE

Guarantee .............................................................................................. 3

Parts & Service Contacts ....................................................................... 3

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 ....................... Loose Components .................................... 16

Installing the Welding Wire ....................... 16

Selecting the Drive Roller Groove ............ 18

Connecting the Gas Supply ..................... 19

Welding Shield ........................................... 20

Preparation for Use ....... Preparing the Work .................................... 21

Setting the Controls .................................... 21

Welding Wire Preparation .......................... 23

Attaching the Earth Clamp ....................... 23

MIG Welding Operation 23

Thermal Overload ...................................... 24

Welding Tips .......................................................................................... 24

Maintenance ........................................................................................ 25

Renewing the Wire Liner ............................ 26

Control Settings Reference Tables ............................................... 27-29

Welder Specifications .......................................................................... 30

Wiring Diagrams ............................................................................. 30-31

Parts Lists and Diagrams32-33

Troubleshooting .................................................................................... 34

Accessories .......................................................................................... 35

Parts & Service Contacts ..................................................................... 35

Thank you for purchasing this CLARKE MIG Welder.

Before attempting to operate the machine, it is essential that you read this manual

thoroughly and carefully follow all instructions given. In doing so you will ensure

the safety of yourself and that of others around you, and you can also look forward

to the welder giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12

months from the date of purchase. Please keep your receipt as proof of purchase.

This guarantee is invalid if the product is found to have been abused or tampered

with in any way, or not used for the purpose for which it was intended.

Faulty goods should be returned to their place of purchase, no product can be

returned to us without prior permission.

This guarantee does not effect your statutory rights.

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: Parts@clarkeinternational.com

SERVICE: [email protected]

PARTS AND SERVICE CONTACTS

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

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.

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.

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.

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.

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

connections may overheat or flash and cause a fire. Never strike an arc on a cylinder

or other pressure vessel. It creates a brittle area that can cause a violent rupture or

lead to such a rupture later under rough handling.

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)

Magnetic fields from high currents can affect pacemaker operation. Persons wearing

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.

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.

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