Clarke Weld MIG103NG Bedienungsanleitung

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC06/23

NO GAS MIG WELDER

MODEL NO: MIG103NG

PART NO: 6015615

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.

When unpacking, any damage or deficiency should be reported to your

CLARKE dealer immediately. Some of the components are stored within the

machine side compartment.

MIG WELDING PRINCIPLES

MIG (Metal Inert Gas) welding allows you to fuse together two similar metals

without altering the properties of the metal.

A consumable wire electrode is continuously fed through the welding torch

that is fitted with a concentric gas nozzle. the wire is connected to a high

voltage supply which creates an electric arc between the electrode (the

wire) and the workpiece. The arc is used to create the required heat to turn

the metal into a molten state. The wire is used as both the electrode and as a

filler.

When using a gasless welder the shielding gas is created from the flux within

the welding wire.

When using the welder outside, you may need to erect a wind break.

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.

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

SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING

FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY.

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 glass). This is a MUST for welding (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 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.

NOTE: ALL protective wear inc. masks & head shields MUST comply with

PPE Directive 89/686/EEC

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 force 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

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.

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

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.

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 the area, do NOT weld. Move the work if

practicable, to an area free of combustibles.

Avoid working in paint spray rooms, dip tanks, storage areas, ventilators. If the

work cannot be moved, move combustibles away from sparks and heat; or

protect against ignition with suitable 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:

1. Appreciable combustibles (including building construction) are within 10m.

2. Appreciable combustibles are further than 10m, but can be ignited by

sparks.

3. Openings (concealed or visible) in floors or walls can expose combustibles

to sparks.

4. Combustibles adjacent to walls, ceilings, roofs or metal partitions can be

ignited by radiant or conducted heat.

After work, 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 the

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 the working level may substitute for inerting.

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

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 as they can explode.

In explosive atmospheres, never weld or cut where the air may contain

flammable dust, gas, or liquid vapours.

ELECTRIC ARC (MIG, TIG) WELDING

Comply with precautions in 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 and work pieces

are hot. The wise operator avoids unnecessary risks and protects himself and

others from accidents.

A) BURN PROTECTION

The welding arc is intense and visibly bright. It’s 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! FOLLOW ALL SAFETY PRECAUTIONS!

PROTECTIVE CLOTHING

Wear long sleeved clothing (particularly for gas shielded arc) in addition to

gloves, apron and strong shoes. 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 collars closed to protect the chest and

neck and button any pockets to prevent entry of sparks.

EYE AND HEAD PROTECTION

Protect eyes from exposure to arc. NEVER look at an electric arc without

protection. Welding helmet or shield containing an appropriate filter plate

(Please refer to the section ‘Welding Shield). 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 high intensity gas-shielded arc) can cause a retinal burn that may

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

leave a permanent dark area in the field of vision. Before welding whilst

wearing contact lenses, seek advice from your optician.

PROTECTION OF NEARBY PERSONNEL

For production welding, a separate, well vented 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.

B) TOXIC FUME PREVENTION

Comply with all precautions in 1B.

C) FIRE AND EXPLOSION PREVENTION

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.

D) 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.

PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT DEVICES

(PACEMAKERS).

Magnetic fields from high currents can affect pacemaker operation. Persons

wearing pacemakers should consult with their doctor before going near arc

welding or spot welding operations.

E) PROTECTION AGAINST SHOCK

Keep body and clothing dry. Never work in damp area without adequate

insulation against electric 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.

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

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) TORCH

A fully insulated torch should be used without protruding screws or other

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) 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. A power disconnect switch

must be available near the welding power source.

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

PREPARATION OF THE WORKING AREA

The working area must be sufficiently spacious, not humid, and well-ventilated

as to avoid any fumes which develop from the welding process and from

incidental material adhering to the pieces to be welded (oils, paints, tars...)

which may cause danger to the operator.

Avoid welding tanks which may contain flammable residuals.

ADDITIONAL PRECAUTIONS FOR MIG WELDING

1. ALWAYS ensure that there is full free air circulating around the outer casing

of the machine and that the louvres are unobstructed.

2. Welding arc can seriously damage your eyes. Both operator and

spectators must ALWAYS use a proper welding face shield or helmet with

suitable filter lenses. Proper gloves and working clothes should be worn at

all times.

3. ALWAYS check that the pressure regulator and gauges (where fitted), are

working correctly. DO NOT lubricate the regulator.

4. ALWAYS inspect the torch hose before use to ensure it is in good condition.

5. ALWAYS keep the free length of torch hose outside the work area.

6. ALWAYS remove all flammable materials from the welding area.

7. NEVER remove any of the panels unless the machine is disconnected from

the supply and never use the machine with any of the panels removed.

8. The MIG welding process uses an INERT gas to protect the weld pool. It is

important to ensure the appropriate gas is being used. NEVER use gas from

a cylinder, the content of which is unknown.

9. NEVER use or store in a damp environment. DO NOT EXPOSE TO RAIN.

10. NEVER attempt any electrical or mechanical repair unless your are a

qualified technician. If you have a problem with the machine contact your

local CLARKE dealer.

WARNING: ELECTRIC SHOCK CAN BE FATAL. A PERSON QUALIFIED IN FIRST

AID SHOULD ALWAYS BE PRESENT IN THE WORKING AREA. IF PERSON IS

UNCONSCIOUS AND ELECTRIC SHOCK IS SUSPECTED, DO NOT TOUCH

THE PERSON IF HE OR SHE IS IN CONTACT WITH THE WELDER OR CABLES.

DISCONNECT THE WELDER FROM THE POWER SOURCE AND THEN USE FIRST

AID. DRY WOOD, OR OTHER INSULATING MATERIAL CAN BE USED TO

MOVE CABLES, IF NECESSARY, AWAY FROM THE PERSON.

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

11. ALWAYS keep fire extinguisher handy....’Dry Powder, C02 or BCF, NOT Water

12. 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.

13. NEVER point the MIG torch at any person or animal.

14. NEVER touch the MIG torch nozzle until the welder is switched OFF and the

nozzle has been allowed to cool.

15. NEVER connect, disconnect, or attempt to service the welding torch, until

the machine is switched OFF and disconnected from the mains supply.

16. NEVER allow the earth cable or torch hose to become wrapped around

the operator or any person in the vicinity.

A comprehensive range of CLARKE safety equipment for use when welding, is

available from your local dealer.

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.

The welding equipment should be routinely maintained according to the

manufacturer’s 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 manufacturer’s

instructions. In particular, the spark gaps of arc striking and stabilizing devices

should be adjusted and maintained according to the manufacturers

recommendations.

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

ELECTRICAL CONNECTIONS

This product is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug,

for connection to a standard, domestic electrical supply. Should the plug

need changing, make sure that a plug of identical specification is used.

If the colours of the wires in

the power cable do not

correspond with the

markings on the terminals of

your plug, proceed as

follows.

• Connect the blue wire

to the terminal which

is marked N.

• Connect the brown

wire to the terminal

which is marked L.

• Connect the Yellow and Green wire to the terminal which is marked

E or .

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

Residual Current Device (RCD)

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

yourself.

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS FULLY

BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY.

WARNING: THE WIRES IN THE CABLE ARE COLOURED AS FOLLOWS:

BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

Plug must be BS1363/A approved.

Always fit

make sure that the outer sheath of

Neutral

(Blue)

Live

(Brown)

a 13 Amp

the cable is firmly held by the clamp

fuse.

Earth

(Green and

Yellow)

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