Clarke MIG 240 Bedienungsanleitung

WARNING: Read these instructions before using the machine

The welder is supplied set up for no gas welding

OPERATION & MAINTENANCE

INSTRUCTIONS

LS1118 - ISS 1

GAS/NO GAS MIG WELDER

MODEL NO: MIG 240

PART NO: 6014200

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

INTRODUCTION

Thank you for purchasing this CLARKE MIG Welder.

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

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

will ensure the safety of yourself and that of others around you, and you can

also look forward to the welder giving you long and satisfactory service.

GUARANTEE

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

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

purchase.

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

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

intended.

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

be returned to us without prior permission.

This guarantee does not effect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the

obligation to deal with the WEEE in accordance with the WEEE

regulations in relation to the treatment, recycling & recovery and

environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with general

household waste. It must be disposed of according to the laws governing

Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal

facility.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

CONSUMABLE

The following are some of the consumables available from your CLARKE

dealer. Please quote the part numbers shown below:

Welding tips / Gas Regulators / Arc Activated Headshields / Anti-spatter Spray

/ Swan Necks / Torch Shrouds and Torch Liners are also available from your

CLARKE dealer or our parts division.

PART DESCRIPTIO N PART

NUMBER

COMMENT

Welding Wire

Spools

Flux cored mild steel (4.5kg)

0.9mm

6000666 Use for no gas welding

Mild steel - 0.6mm (5 kg) 6000476 Use for gas welding

Mild steel - 0.8mm (5 kg) 6000475 Use for gas welding

Mild steel - 0.8mm (15 kg) 3050522 Use for gas welding

Stainless Steel 0.8mm (mini spool) 8132090 Use for gas welding

Welding Gas CO2 (250g) 6000642 For welding mild steel

CO2 (600g) 6000643 For welding mild steel

Argon 6000661 For welding stainless

steel / aluminium

CO2/Argon Mix 6000660 For welding stainless/

thin sheet mild steel

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

CONTENTS

INTRODUCTION ............................................................... 2

GUARANTEE .................................................................... 2

ENVIRONMENTAL RECYCLING POLICY ......................... 2

CONSUMABLE ................................................................. 3

CONTENTS ....................................................................... 4

GENERAL SAFETY INSTRUCTIONS ................................... 5

ELECTRICAL CONNECTIONS .......................................... 8

OVERVIEW ....................................................................... 9

The Control panel ................................................................. 10

OPENING THE SIDE PANEL .............................................. 11

UNPACKING ................................................................... 11

ASSEMBLY ....................................................................... 12

Fitting the Gas bottle bRACKET........................................... 12

Connect the torch................................................................ 12

Connect the earth lead ...................................................... 12

THE WELDING SHIELD ...................................................... 13

PREPARATION FOR USE .................................................. 14

Mounting The Welding Wire Spool...................................... 14

Setting The Drive Roller Size ................................................. 14

Threading The Wire ............................................................... 15

MIG WELDING PRINCIPLES ............................................. 17

GAS/NO-GAS SELECTION .............................................. 17

Welding Without Gas ........................................................... 18

Welding With Gas ................................................................. 18

OPERATING THE WELDER ................................................ 19

Prepare The Workpiece ....................................................... 19

Operation .............................................................................. 19

Thermal Overload................................................................. 20

Duty Cycle............................................................................. 20

MAINTENANCE ............................................................... 21

RATING PLATE ................................................................. 22

SPECIFICATIONS ............................................................. 23

ARC ACTIVATED HEADSHIELDS ...................................... 24

TROUBLESHOOTING ........................................................ 25

DECLARATION OF CONFORMITY ................................... 27

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

GENERAL SAFETY INSTRUCTIONS

ELECTRIC SHOCK

• Remove the plug from the socket

and wait 5 minutes to allow the

capacitors to discharge before

carrying out any servicing or

maintenance on this welder.

• Do not touch live electrical parts.

• Never use electrode holders or

cables which are damaged.

• Keep working environment,

equipment, cables and clothing

free from grease, oil, moisture and

dirt.

• Ensure welding machine has been

correctly earthed.

• The operator must be insulated

from the floor and work bench

using a dry insulation mat.

• Always ensure a second person is

present in case of accident.

• Never change electrodes with

bare hands or damp gloves.

• Keep welding cables away from

power cables.

• Regularly inspect the condition of

the cables for signs of damage.

• Remove the plug from the mains

socket when not in use, do not

leave the machine unattended.

• Make sure that the earth clamp is

secured to bare metal adjacent to

the weld seam and when not in use

is insulated for safety.

• Keep all equipment well

maintained.

• The operator shall prevent gas

cylinders in the vicinity of the work

piece from becoming part of the

welding circuit.

FUMES & GASES

• The welding process generates

hazardous fumes as a by-product.

Inhalation of these fumes is

hazardous to health.

• Keep your head away from the

weld to avoid breathing the fumes.

• If welding in confined spaces

ensure adequate ventilation and

use a fume extractor.

• By-products of welding can react

to create a toxic/explosive

environment.

FIRE OR EXPLOSION

Welding can cause fires and

explosions. Precautions should be

taken to prevent these hazards.

• Before starting work ensure the

area is clear of flammable

materials.

• Move any combustible materials to

a safe distance, especially

WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY

PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF

FIRE, ELECTRIC SHOCK AND PERSONAL INJURY

WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO

OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

substances likely to generate a

dangerous vapour.

• The welding arc can cause serious

burns. Avoid contact with skin.

• Sparks and molten metal are

ejected during welding. Take

precautions to prevent fire.

• Sparks and molten metal can pass

through gaps. Be aware that fire

can start out of sight.

• Do not weld pressurised containers.

or containers containing

flammable vapours e.g. fuel tanks.

• Always have appropriate fire

fighting equipment to hand

suitable for use in electrical

environments.

• Avoid carrying any fuels with you

e.g. cigarette lighters or matches.

PERSONAL PROTECTION

• The body should be protected by

suitable clothing.

• The use of neck protection may be

necessary against reflected

radiation.

• Arc machines generate a

magnetic field which is detrimental

to pacemakers. Consult your

doctor before going near active

welding equipment/operations.

• The UV and IR radiation generated

by welding is highly damaging to

the eye, causing burns. This can

also affect the skin.

• Always use suitable welding shields

equipped with appropriate

protection filters.

• Where there are pedestrians and

traffic ensure a protective screen is

used to avoid accidental arc glare.

• Do not weld in the vicinity of

children or animals and ensure no

one is looking before striking an

arc.

• Wear hearing protection if

required.

• Allow the weld time to cool. Hot

metal should never be handled

without gloves.

• Take care when adjusting or

maintaining the torch, that it has

had time to cool sufficiently and

the welder is disconnected from

the mains supply.

• 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.

• A hard hat should be worn when

others are working overhead.

• Flammable hair sprays/gels should

not be used by persons intending

to weld or cut.

PROTECTIVE CLOTHING

• Wear gauntlet gloves designed for

use in welding.

• Wear an apron, and protective

shoes.

• Wear cuffless trousers to avoid

entry of sparks and slag.

• Avoid oily greasy clothing.

• Protective head and shoulder

coverings should be worn when

overhead welding.

• Wear helmet with safety goggles or

glasses with side shields

underneath, appropriate filter

lenses or plates (protected by clear

glass). This is a MUST for welding

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

(and chipping) to protect the eyes

from radiant energy and spatter.

Replace cover glass when broken,

pitted or spattered.

NOTE: ALL protective wear inc. masks

& head shields MUST comply with PPE

Directive 89/686/EEC

GAS CYLINDERS:

• Gas cylinders should be located or

secured so that they cannot be

knocked over.

• Shield gas containers can explode

if damaged. Take care when

handling.

• Ensure gas cylinders are shut-off

when not in use and between

operations.

• Take care that a build-up of gas is

not permitted to form in confined

areas.

• Cylinders must be in an upright

position at all times during use and

storage.

• The gas cylinder must never come

in to contact with the electrode.

• Follow the manufacturer's

instructions for handling, storing

and using the gas bottle correctly

and safely.

• Use the correct equipment to

connect the gas bottle to the

welding torch.

ADDITIONAL SAFETY PRECAUTIONS

FOR MIG WELDING

• ALWAYS ensure that there is ample

free air circulating around the

outer casing of the machine, and

that the louvres are unobstructed.

• ALWAYS inspect the hose before

use to ensure it is in good condition.

• ALWAYS keep the free length of

torch hose outside the work area.

• ALWAYS remove all flammable

materials from the welding area.

• ALWAYS keep a fire extinguisher

handy;-Dry Powder, C02 or BCF,

NOT Water.

• NEVER remove any of the panels

unless the machine is

disconnected from the power

supply, AND never use the

machine with any of the panels

removed.

• NEVER attempt any electrical or

mechanical repair unless you are a

qualified technician. If you have a

problem with the machine contact

your local CLARKE dealer.

• NEVER use or store in a wet/damp

environment.

• 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 allow the earth cable or

hose to become wrapped around

the operator or any person in the

vicinity.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

ELECTRICAL CONNECTIONS

A STANDARD 13AMP PLUG MUST NOT BE USED WITH THIS

UNIT.

The unit must be connected to a 230V socket cabable of supplying 32 Amps,

We recommend that you consult a qualified electrician and connect the

mains lead, through a suitably fused isolator switch

Before switching the product on, make sure that the voltage of your electricity

supply is the same as that indicated on the rating plate. This product is

designed to operate on 230VAC 50Hz. Connecting it to any other power

source may cause damage.

If the colours of the wires in the power cable of this product do not correspond

with the markings on the terminals of your plug, proceed as follows.

• The wire which is coloured Blue must be connected to the terminal

which is marked Nor coloured Black.

• The wire which is coloured Brown must be connected to the terminal

which is marked Lor coloured Red.

• The wire which is coloured Yellow and Green must be connected to

the terminal which is marked E or or coloured Green.

We strongly recommend that this machine is connected to the mains supply via

a Residual Current Device (RCD)

If in any doubt, consult a qualified electrician. DO NOT attempt any repairs

yourself.

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS

THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS

SUPPLY.

WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE

COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:

BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

OVERVIEW

NO DESCRIPTION NO DESCRIPTION

1 Handle 4 Torch

2 Gas Connection Point 5 Torch Hose

3 Control Panel 6 Earth Clamp

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

THE CONTROL PANEL

1. Wire speed control knob. As a general rule, a higher current requires a

higher wire speed.

2. Current setting dial. Provides 6 increasing power levels.

3. Power ON/OFF switch. When the power is ON the green switch will be

illuminated. When the welder is no longer required, the Power On/Off switch

should be switched to the OFF position and the welder should be

disconnected from the power supply.

4. Thermal overload light. If the duty cycle is exceeded as a result of welding

for too long with a high current, the overload light will illuminate and the

welder will turn off. When the welder has cooled down (approx. 5 to 10

minutes), the power will be restored and welding can recommence.

Dial Setting Welding Current in Amps

150A

275A

3100A

4130A

5180A

6240A

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