8132100

6015603 CLARKE | Alldatasheet

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OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS DL01/26 -Rev 3 MIG/MMA/TIG INVERTER WELDER MODEL NO: MIG150 MULTI PART NO: 6015603

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INTRODUCTION Thank you for purchasing this CLARKE 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. SPECIFICATIONS NOTE: 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. Model MIG150 Multi Unpacked Weight (kg) 14.3 Dimensions (L x W x H) (mm) 555 x 203 x 300 Power Supply 230V~ 50Hz Connecting plugs (32A) Peak Input Power 5500 W Max Input Current II Max/II eff 24A/13.1A Output Welding Current MIG 30A-140A MMA 30A-120A TIG 30A-120A IP Rating IP21S Insulation Grade Class 1 - Grade H Suitable electrode size MMA: 1.6 - 3.2mm TIG 1.6 - 2.4mm Welding Wire size 0.6mm, 0.8mm, 0.9mm & 1.0mm Welding Capacity (Mild Steel) 1-6 mm (MIG) 1-6 mm (MMA) 1-4mm (TIG)

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PRINCIPLES OF THE MACHINE The MIG150 Multi is an inverter type welding machine, suitable to carry out Gas and No Gas CO2 welding, MMA, TIG and MIG. The welder is mainly used for CO2 gas protected welding which has the advantages of high energy efficiency, strong arc penetration and small welding deformation. Weldable materials include low carbon steel, low alloy steel, high strength steel, stainless steel and aluminium alloy. Methods include full position spot welding, butt welding, fillet welding and lap welding. The stable welding process can be obtained by using pure CO2, CO2+Ar, CO2+ O2 and other protective gases. The torch is suitable for wire diameters of 0.6-1.0mm. Manual Metal Arc (MMA) welding uses a coated consumable electrode (stick) to lay the weld, therefore an additional welding torch kit is not used. The arc melts the core of the electrode to produce drops of molten metal (weld pool) that cool to create the welded joint. Because of the versatility and simplicity of MMA welding, it requires less skill and is used primarily to weld iron and steel (including stainless steel. but nickel and copper can also be welded using this method.) 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 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. The gas is used to prevent oxidation and to shield the arc and the weld from atmospheric contamination. The choice of gas is dependent upon the material being welded. This machine is designed to be used for both metal ARC (MMA) and TIG welding. A TIG torch kit is not supplied with the machine. These are readily available from your CLARKE dealer (Part number 6012232/6012239). A wide selection of accessories and consumables are available from your CLARKE dealer (see page 40).

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SUITABILITY OF DIFFERENT METHODS When using the welder in a gasless configuration 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 to make sure the shielding gas is not blown away, thereby leaving a poor quality weld. 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. If disposing of this product or any damaged components, do not dispose of with general waste. This product contains valuable raw materials. Metal products should be taken to your local civic amenity site for recycling of metal products. MMA/Arc Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron. MIG Welding Carbon Steel, Mild Steel, Stainless Steel TIG Welding Carbon Steel, Low Alloy Steel, Stainless Steel, Cast Iron, Titanium, Copper + Brass. Metal Being Welded Suitable Gas Part number Mild Steel Carbon Dioxide (CO 2) 6000642 Stainless Steel Argon 6000663 Aluminium Thin Sheet Metal/Mild Steel Carbon Dioxide (CO2)/Argon Mix 6000662

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY. GENERAL PRECAUTIONS 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 or 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. 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 incl. masks & head shields MUST comply with PPE Regulation (EU) 2016/425. 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 when 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 by-products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapours to form phosgene. DO NOT WELD where solvent vapours can be drawn into the welding 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 atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene. FIRE AND EXPLOSION PREVENTION Causes of fire and explosion are: 1. Combustibles reached by the arc, flying sparks, hot slag or heated material; 2. 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. 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 as they can explode. In explosive atmospheres, NEVER weld or cut where the air may contain flammable dust, gas, or liquid vapours.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 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. ELECTRIC ARC 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. 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. PROTECTIVE CLOTHING (PPE) MUST BE WORN 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 on page 16). 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 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

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 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. 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 or 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. PROTECTION AGAINST SHOCK Keep your 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. 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. 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. TERMINALS AND OTHER EXPOSED PARTS Terminals and other exposed parts of electrical units should have insulating covers secured before operation.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 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. 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. 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 Service@clarkeinternational.com ADDITIONAL PRECAUTIONS FOR MMA WELD- ING 1. ALWAYS ensure that there is full free air circulating around the outer casing of the machine and that the louvres are unobstructed. 2. A 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 remove all flammable materials from the welding area. 4. 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. 5. NEVER use or store in a damp environment. DO NOT expose to rain. 6. 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. 7. ALWAYS keep a fire extinguisher handy (Dry Powder, C02 or BCF, NOT Water). 8. 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. 9. NEVER allow the earth cable or torch 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. See page 40. 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 (see page 37). 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 SAFETY SYMBOLS The following symbols may be displayed on the machine or its packaging. Read this instruction booklet carefully before use. Do not expose to rain. Wear welding mask Recycle unwanted materials under WEEE Directive Wear protective gloves General Hazard Wear a dust mask Warning;- Magnetic field created Caution:- Hot surface Danger! Harmful fumes Risk of Electric Shock Do not weld near flammable or combustible materials May interfere with pacemakers Danger:- Arc Rays

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ELECTRICAL CONNECTION This welder MUST be connected to a 230 Volt, 1 phase 50Hz supply through a suitably rated isolator switch. Before switching on, ensure the voltage of your power supply is correct. Connecting it to any other power source may cause damage. The user should purchase a suitable connecting cable capable of handling 32 Amps with a supply plug rated at 32A or better. A length of 2-3 metres is recommended giving mobility to the appliance but without becoming a trip hazard. If the plug has to be changed due to damage a replacement should be fitted following the wiring instructions shown below. If the wire colours of the power cable of this product do not correspond with the markings on the terminals of your plug, proceed as follows.

• The Blue wire must be connected to the terminal which is marked N or Neutral.
• The Brown wire must be connected to the terminal which is marked L or Live.
• The Yellow wire must be connected to the terminal which is marked E or Earth. 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 A POWER SUPPLY. THE INSTALLATION OF THIS APPLIANCE SHOULD BE CARRIED OUT BY A COMPETENT ELECTRICIAN AND BE IN ACCORDANCE WITH CURRENT IEE WIRING REGULATIONS (BS4343). WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE: BLUE = NEUTRAL BROWN = LIVE YELLOW = EARTH Plug must be BS60309 approved. Neutral Live Earth

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com OVERVIEW The MIG150 Multi- welder is fitted with the following features:

1 Digital Current meter (A) 9 Welding voltage selector knob

2 Digital voltage display meter (V) 10 MIG torch connector

3 Power-On LED 11 Negative socket

4 Overheating LED 12 Positive socket

5 2T/4T weld feed selector switch 13 On/off Switch (at rear)

6 MIG/MMA/LIFT TIG function

14 Cylinder holding bracket

7 Wire speed selector knob 15 Gas cylinder connecting port (at

rear)

8 Inductance value selector knob

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com THE CONTROL FUNCTIONS 1. Digital Current display meter (A)

• Displays amperage being drawn by the machine. 2. Digital voltage display meter (V)
• Displays voltage being drawn by the machine. 3. Power-On LED
• When the power is switched on at the back of the machine the switch will be illuminated, as will the green ‘Power On’ LED. 4. Thermal overload LED
• 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. 5. Wire Feed Selector Switch
• 2-Step Welding Mode. In 2-step welding mode the torch operates in the normal way. When the torch trigger is pressed and held, both the wire and the gas are continuously supplied. When the trigger is released, the flow of gas and wire ceases.
• 4-Step Welding Mode. In 4-step welding mode, long welds can be executed without having to continuously hold down the torch trigger. To activate this mode, press and release the torch trigger to initiate the continuous supply of both the wire and the gas. At the end of the weld, press and release the trigger again to cut off the supply of wire and gas. 6. MIG/MMA/LIFT TIG function selector switch
• 3-position switch to select either the standard welding torch, rod welding using the rod/clamp holder. 7. Wire speed control
• A higher current requires a higher wire speed. Wire speed should be set based upon the table on page 32. 8. Inductance value control knob
• Set this control to either HARD or SOFT according to whether the weld being formed is narrow and requiring more penetration (turn left for Hard) or for wide and shallower (turn control to the right). The icons indicate which is appropriate. 9. Welding voltage selector knob
• Increase the welding voltage according to the welding task being performed.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com LOOSE ITEMS SUPPLIED INCLUDE THE FOLLOWING:

• 1 x MIG welding torch with hose (0.8mm tip)
• 1 x Torch Cable/Electrode Holder
• 1 x Earth Cable/Clamp
• 1 x Gas Hose
• 1 x Chipping Hammer/Wire brush
• 1 x Face shield c/w handle, lenses & locking nuts
• 1 x 0.6mm welding torch tip
• 1 x 0.8mm welding torch tip (fitted to torch)
• 1 x 0.9mm welding torch tip
• 1 x 1.0mm welding torch tip
• 1 x 0.6/0.8mm wire roller (fitted)
• 1 x 0.9/1mm wire roller (for no-gas welding)
• 1 x Wrench (for changing torch tips)
• 1 x Gas bottle holder and bracket
• 1 x 0.8mm Welding Wire Spool (0.7kg)
• 1 x 0.9mm Flux-coated Welding Wire Spool (0.45kg)

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ASSEMBLING THE WELDING SHIELD 1. The welding shield shown is supplied flat for shipping. Fold the sides of the shield around and clip to the top panel. 2. Insert both the glass lens panels into the recess inside the shield.

• The clear glass must be fitted first to face the outside. 3. Insert the two plastic screws and use the plastic wingnuts to clamp the glass panels to the shield.
• The clear glass panel should be replaced when it becomes badly pitted. 4. When replacing the glass panels, only use parts supplied by CLARKE International. The dark panel is a certified, optical glass and should not be exchanged for any other type. 5. Secure the handle in position using the plastic nuts provided.
• The handle will be mounted on the inside of the shield.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PREPARING THE WELDER FOR USE FITTING THE GAS BOTTLE HOLDER IMPORTANT: Ensure that the welder is not connected to the mains supply before opening. 1. Open the side panel by sliding the latches up and lifting the panel. 2. Remove any loose items that have been transported inside. 3. Fit the lower bottle bracket into position and secure using the 2 screws provided. 4. Screw the upper bottle retainer to the rear of the machine. 5. Fit the gas cylinder to the rear of the machine. Install the pressure relief valve to the gas cylinder and ensure it is tight to prevent leakage. MOUNTING THE WELDING WIRE SPOOL Select the appropriate wire diameter according to the welding process. After the wire diameter is selected, check that the wire diameter matches the size of the wire feeding wheel and the welding torch components. Spools of welding wire are available from your CLARKE dealer. 1. Open the side panel and remove the locking nut and retaining spring. The retaining locknut nut has a left-hand thread. WARNING: NEVER OPERATE THIS MACHINE WITH THE SIDE PANELS PARTIALLY OPENED OR REMOVED. WARNING: MAKE SURE THAT THE WELDER IS NOT CONNECTED TO THE MAINS SUPPLY.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 2. Place a spool of welding wire over the spindle.

• DO NOT release the tension on the wire, as it will unravel causing feeding problems later.
• The wire will feed off the spool anticlockwise from the bottom of the reel.
• The spool must be fitted in the correct orientation otherwise it will not feed correctly. SETTING THE DRIVE ROLLER SIZE 1. Loosen the tensioning knob and pivot it towards you. 2. Lift up the arm. 3. Take hold of the triangular knob on the drive roller cover and rotate it 90°anticlockwise to release it. 4. Pull the roller retainer off the drive spindle to reveal the roller. 5. Pull the roller off the drive spindle.
• The groove size is stamped on the corresponding side of the roller. Select the groove size according to the size of the wire you are using and put the roller back on the spindle with your chosen side facing you. 6. Replace the drive roller cover back onto the drive spindle with the opening facing right. 7. Ensure that the flanges at the base of the drive roller cover, seat fully into the circular recess in the main moulding and then rotate the drive roller cover through 90° to lock it in place. THREADING THE WIRE IMPORTANT: Do not release the tension on the wire as it will unravel causing feeding problems later. 1. Pull out the end of the wire from the spool, taking care not to release the tension.
• We recommend you cut off and discard the first 10 cm of wire from the spool to avoid any burrs and then straighten the next few centimetres of wire to help with feeding. 2. Loosen the tensioning knob and pivot it towards you.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. Lift up the arm. 4. Feed the wire through the guide, over the drive roller and into the torch liner.

• Push about 10-15 cm into the torch liner. 5. Lower the arm and refit the tensioning knob.
• Tighten the tensioning knob sufficiently to hold in position, but do not fully tighten. NOTE: Correct tension will allow the wire to feed into the torch liner smoothly but will allow the drive roller to slip in the event of a blockage. 6. Close the side panel of the welder. 7. Pull off the torch shroud with a twisting movement, then unscrew the contact tip. 8. Connect the welder to the power supply and switch ON. 9. Set the ‘WIRE FEED’ rotary control on the front panel to position 7 or 8 and squeeze the trigger on the torch body.
• The wire will feed through the hose until it appears at the torch tip.
• Ensuring the hose is free from kinks during this process will assist the wire in its passage through the hose liner. 10. Release the trigger and switch off the welder and disconnect the machine from the mains supply. 11. Refit the appropriate size contact tip (the 0.9 mm tip, for no gas welding is supplied fitted) to suit your wire and replace the shroud.
• A spare 0.6 and 0.9 mm tip are supplied loose and should be used when using 0.6/0.8 mm mild steel solid wire. 12. Trim the welding wire so that it protrudes no more than 5 mm from the end of the contact tip.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CONNECTING THE GAS CYLINDER The welder can be configured to weld, with or without a gas supply according to the type of welding wire being used.

• Mild steel solid core (with gas)
• Flux cored (no gas) 1. Connect a bottled gas cylinder to the connector at the back of the welder. FITTING THE WELDING ROD Select the appropriate welding rod and insert it into the welding rod holder.
• It should be approximately the same thickness as the workpieces being welded.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CONFIGURING THE MACHINE ATTACHMENTS To prepare the machine for welding it is important that you follow the following procedure. Making sure that the ON/OFF switch, located on the rear panel is in the OFF position, connect the welding leads and gas bottle as follows and set the selector switch to the position shown. MIG WELDING WITH GAS Connect the earth clamp to the negative terminal as shown. Set the selector switch to the torch symbol. MIG FLUX WELDING WITH NO GAS Connect the earth clamp to the positive terminal as shown. Set the selector switch to the torch symbol.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com MMA ELECTRODE WELDING Connect the earth clamp to the negative terminal and the electrode holder to the positive terminal as shown. Set the selector switch to the Electrode symbol. LIFT-TIG WELDING Connect the electrode holder lead to the (+) positive terminal and the earthing lead to the negative (-) terminal. 1. Set the selector switch to the TIG torch symbol. 2. Switch on using the switch located on the rear panel.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. For Flux or MMA welding, select the appropriate welding rod and fit it into the welding rod holder. The following sizes of rods can be used and are available from your CLARKE dealer. 4. Attach the earth clamp to the workpiece as close as possible to the area being welded. Clean with a wire brush where necessary to ensure the connection is as clean as possible. PREPARING THE WORKPIECE The area being welded should be perfectly clean. Any coating, plating or corrosion must be removed, otherwise a good weld will be impossible to achieve. ROD DIAMETER WORKPIECE THICKNESS MIG 0.6 mm wire 1-5 mm0.8 mm wire 0.9 mm wire 1.0 mm wire MMA 1.6 mm wire 1.5 - 2.0 mm 2.5 mm wire 2.5 - 3.0 mm 3.2 mm wire 3.5 - 4.5 mm TIG 1.2mm wire 1.0 - 2.0mm 2.4mm wire 2.5 - 3.0mm

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CONTROL SETTINGS Refer to page 14 for control panel functions. MIG WELDING WITH GAS 1. Turn on the gas regulator of the gas cylinder. The gas pressure is shown by the gauge. 2. Turn the gas regulator anticlockwise. Loosen the wire roller while depressing on the torch switch and adjusting the gas flow as required. Check the tension on the wire roller. 3. Depress the torch switch until the wire extends to the nozzle. 4. Set the Wire Feed rocker switch (5) to T2/T4 as required. 5. Set the MIG/MMA/LIFT TIG function selector switch (6) to the torch setting. 6. Set the Wire Speed selector control (7) to an intermediate setting. 7. Set the Welding Current Selector knob (10) according to the size of the weld being performed. 8. Set the Inductance Mode selector knob (8) left or right according to the shape of the weld (either deep/ narrow or wide/shallow. 9. Confirm the torch and cables are configured as shown on page 21. FLUX WELDING WITH NO GAS 1. Set the rocker switch (5) to T2/T4 as required. 2. Set the MIG/MMA/LIFT TIG function selector switch (6) to the Torch setting. 3. Set the Wire Speed selector control (7) to an intermediate setting. 4. Set the Welding Current Selector knob (10) according to the size of the weld being performed. 5. Set the Mode selector knob (8) to left or right according to the shape of the weld (either deep/narrow or wide/shallow. 6. Confirm the torch and cables are configured as shown on page 21. MMA ELECTRODE WELDING 1. Set the MIG/MMA/LIFT TIG function selector switch (6) to the electrode setting. 2. Set the Welding Current Selector knob (10) according to the size of the weld being performed.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. Set the Mode Selector knob (8) to left or right according to the shape of the weld (either deep/narrow or wide/shallow. 4. Confirm the electrode and cables are configured as shown on page 21. 5. Take the electrode holder, install the electrode. Aim at the welding line and scratch the work piece to start the arc. The “working” indicator will be on. With practice you will gain a feel for the correct current setting for different welding rod thicknesses. TIG WELDING (SEE ALSO PAGE 28) 1. Set the rocker switch (5) to T2/T4 as required. 2. Set the MIG/MMA/LIFT TIG function selector switch (6) to the TIG torch setting. 3. Set the Wire Speed Selector control (7) to an intermediate setting. 4. Set the Welding Current Selector knob (10) according to the size of the weld being performed. 5. Set the Mode selector knob (8) to left or right according to the shape of the weld (either deep/narrow or wide/shallow. 6. Confirm the torch and cables are configured as shown on page 21.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com OPERATING THE WELDER (MIG) 1. With the welding current set and the wire trimmed, set the wire feed control to an intermediate setting. 2. Plug the machine into the power supply and switch on. 3. Cover your face with the welding mask supplied. 4. Approach the work with the torch tip at an angle of about 45o and pull the torch trigger fully.

• As the wire touches the workpiece an arc will be struck. 5. In order to produce a satisfactory weld, the control may be fine tuned as required. This will come with practice.
• MIG welding is an acquired skill. It is strongly advised that, if you are not fully familiar with this type of welding, you practice on a piece of material with the same characteristics as your workpiece until you are satisfied with the result and you have set your welder to produce a satisfactory weld.
• One of the problems experienced with novice welders is the welding wire sticking to the contact tip. This is as a result of the wire feed speed being too slow. It is always better therefore to start with too high a speed and back off slightly to avoid the possibility of the wire welding itself to the tip.
• The speed of wire delivery will increase automatically as the current is increased.
• Listen to the sound made. An irregular crackling sound denotes too high a wire speed. Decrease the voltage/speed until a regular, strong buzzing sound is heard. WELDING TECHNIQUE
• Try to maintain the tip of the nozzle at an angle of approx 45oand at a constant distance of approx 5-7mm from the workpiece.
• Try to maintain a constant speed of movement with the torch.
• DO NOT weld in windy conditions or in an area where ventilation is a problem, or where air flow fluctuates.
• ALWAYS keep the wire and nozzle clean...NEVER use rusted wire.
• Avoid sharp bends or kinks in the welding hose. CAUTION: THE DUTY CYCLE MUST BE ADHERED IN ORDER TO PREVENT THE THERMAL OVERLOAD PROTECTION FROM ACTIVATING

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com THERMAL OVERLOAD The ‘Thermal Overload’ shuts off the welder when it becomes too hot, due to the duty cycle being exceeded. This is to prevent any damage to the machine. When this occurs, the warning lamp shown will light up. Allow the welder to cool until the amber light extinguishes before resuming work.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com OPERATING THE WELDER (MMA/ARC) The consumable electrode is connected to a high amperage low voltage supply which creates an electric arc between the electrode and the workpiece. The most difficult aspect of the arc welding process, particularly for beginners, is that of striking an arc. We strongly recommend that you practice on some pieces of scrap metal to get the feel of the operation before you start an actual welding job. 1. Holding the welding mask close-up to your face, give a short stroke with the electrode on the workpiece. As soon as the arc is primed, withdraw the electrode from the workpiece to leave a gap. The current will flow across the gap with a crackling noise and a brilliant arc. Continue to weld in one direction, maintaining the small gap as you go. 2. As soon as the arc is struck, maintain a distance from the workpiece equal to the diameter of the electrode. Keep this distance as constant as possible for the duration of the weld. As you advance along the workpiece the angle of the electrode must be maintained at between 20º and 30º. NOTE: When you prime the arc be sure to withdraw the electrode swiftly to leave the gap, otherwise the electrode will weld itself to the workpiece. If this occurs give the electrode a short sharp jerk to free it and, if necessary, prime the arc again. If you cannot free the electrode, switch the machine off immediately and free it. Take care the electrode will get red hot very quickly and will be capable of burning through welding gloves. 3. At the finish of the weld, bring the end of the electrode backward in order to fill the weld crater and then quickly lift the electrode from the weld pool to extinguish the arc. 4. Inspect the job carefully. Any slag forming on the surface should be chipped away with a chipping hammer or pick. ALWAYS wear your safety goggles when chipping away slag. WARNING: WHEN WELDING ALWAYS ENSURE THERE IS ADEQUATE VENTILATION IN THE WORK AREA DUE TO TOXIC FUMES. WARNING: DO NOT STRIKE THE ELECTRODE ON THE WORKPIECE, AS THIS MAY DAMAGE THE ELECTRODE. WARNING: WELDING ARCS PRODUCE HARMFUL UV/IR LIGHT WHICH CAN SERIOUSLY DAMAGE YOUR EYES. ALWAYS USE A WELDING FACE-SHIELD WITH A SUITABLE FILTER THAT CONFORMS TO CURRENT STANDARDS. WARNING: PROTECT BYSTANDERS BY USING WELDING SCREENS.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com OPERATING THE WELDER (TIG WELDING) TIG welding is primarily for very thin materials. It uses a non-consumable tungsten (or tungsten alloy) electrode held in a torch. A shielding gas (100% Argon), is fed through the torch to protect:

• The electrode
• Molten weld pool
• Solidifying weld metal from contamination by the atmosphere The electric arc is produced by the passage of current through the conductive, ionized shielding gas. The arc is established between the tip of the electrode and the work. Heat generated by the arc melts the base metal. Once the arc and weld pool are established, the torch is moved along the joint and the arc progressively melts the joined surfaces. Filler wire, if used, is usually added to the leading edge of the weld pool to fill the joint. This process is ideally suited for welding thin metals such as car body panels, pressure vessels, heat exchangers, pipes etc., where accuracy and a high quality weld is desired, as it produces a very low porosity weld. MAIN FEATURES OF TIG WELDING 1. Electronic control of welding current. 2. Forced air cooling. 3. A thermal overload protection device prevents overheating. TIG WELDING PROCESS ADVANTAGES
• It produces superior quality welds, generally free of defects.
• It is free of the spatter which occurs with other arc welding processes.
• It can be used with or without filler metal as required.
• It allows excellent control of root pass weld penetration.
• It can produce welds at high speeds.
• It allows precise control of the welding variables.
• It is capable of welding very thin material (0.5mm), without undue distortion. LIMITATIONS 1. Greater weld dexterity is required. 2. The DC output is not suitable for welding aluminium.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TIG WELDING Before TIG welding, you must obtain the correct torch and a gas cylinder of 100% pure Argon. (see page 40) To prepare the machine for TIG welding, adopt the following procedure. 1. Plug the work clamp lead in to the +ve terminal, and secure the work clamp to the workpiece.

• For good contact, the work clamp must be attached to clean bare metal. Clean with a wire brush where necessary. 2. Plug the torch lead to the -ve terminal. 3. Screw the pressure regulator on to the gas bottle tightly, and attach the gas hose to the inlet connector securely, with a hose clip. 4. Turn the pressure regulator knob to set a pressure of approx. 2.5kg/cm2 (35 lbf/in2). 5. Ensure the electrode at the torch nozzle, protrudes by 4 - 5mm, also ensure that the electrode is sharply pointed with an angle of 40o- 60o if it is not, grind it to shape. 6. Set the welding current in accordance with the thickness of the material to be welded and the size of tungsten electrode to be used. 7. Switch on using the switch mounted on the rear panel. 8. If the machine stops at any time and the amber light comes on, the thermal overload has intervened. Wait until the welder has cooled sufficiently (the amber light goes out) before restarting work.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 9. Cover your face with the head shield, bring the torch to within 3-4mm of the work, and at an angle of 40-60o, so that the ceramic nozzle gently touches the work surface. 10. Scratch the tip of the electrode against the piece to be welded, as soon as the welding arc starts, remove the electrode to a distance of 3-4 mm, and continue the weld. (See notes below).

• This method is referred to as ‘Scratch Arc’. 11. To stop welding, simply remove the torch from the workpiece. 12. Turn off the gas as soon as you finish welding. Notes:
• To avoid a visible strike mark on the surface of the workpiece it is advisable to strike the arc in the joint where the mark will be concealed by the weld.
• Thin sheet and stainless steel may be welded with or without filler, similar to gas welding.
• The filler is fed in at the edge of the pool. The rod must not touch the tip of the electrode or enter the arc. The end of the rod must always be shielded by the argon atmosphere to prevent as far as possible the formation of oxides of its surface. When welding stainless steel and copper, it is often possible to feed in the filler continuously at the edge of the pool.
• The arc length generally varies between 3 and 6 mm depending on the type of joint, type and thickness of material and so on.
• The torch is advanced in the direction of welding, without lateral movement, maintaining the torch angle of 45o to the workpiece.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com WELDING SETTINGS TABLES L-SHAPED BUTT WELDING ANGLE JOINT (THIN PLATE) FLAT FILLET WELDING LAP JOINT (THIN PLATE) Metal thickness (mm) Wire diameter (mm) Root gap Welding current (A) Welding voltage (V) Welding speed Gas Flow (L/min) 0.8 0.8 - 0.9 0 60-70 16-16.5 50-60 10 1.0 0.8 - 0.9 0 75-85 17-17.5 50-60 10-15 1.2 0.8 - 0.9 0 80-90 17-18 50-60 10-15 1.6 0.8 - 0.9 0 95-105 18-19 45-50 10-15 6.0 1.2 1.2 - 1.5 170-185 24-26 40-50 15-20 9.0 1.2 1.2 - 1.5 320-340 32-34 40-50 15-20 Metal thickness (mm) Wire diameter (mm) Welding current (A) Welding voltage (V) Welding speed Distance between conductive nozzle profiles (mm) Gas Flow (L/min) 1.6 0.8-0.9 65-75 16-17 40-45 10 10-15 2.3 0.8-0.9 80 - 100 19-20 40-45 10 10-15 3.2 1.0-1.2 130 - 150 20-22 35-40 10-15 10-15 4.5 1.0-1.2 150 - 180 21-23 30-35 10-15 10-15 Metal thickness (mm) Wire diameter (mm) Welding current (A) Welding voltage (V) Welding speed Distance between conductive nozzle profiles (mm) Gas Flow (L/min) 0.2 0.8 - 0.9 60-70 16-17 40-45 10 10-15 1.2 0.8 - 0.9 80-90 18-19 45-50 10 10-15 1.6 0.8 - 0.9 90-100 19-20 45-50 10 10-15 2.3 0.8 - 0.9 100-130 100-130 45-50 10 10-15 1.0-1.2 120-150 120-150 45-50 10 10-15

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com WELDING PITFALLS The arc welding technique is an acquired skill and requires considerable practice before perfect results are obtained. The diagrams below will help to explain the pitfalls in your technique and how to overcome them. ARC TOO SHORT This causes irregular masses of weld to be deposited, with slag contamination on an uneven surface. ARC TOO LONG This causes poor penetration resulting in a weak weld with excessive spatter and porosity. Surface of the weld is rough and the arc makes a hissing sound ELECTRODE MOVED TOO SLOWLY This causes a very wide and heavy deposit which overlaps at the sides. It is wasteful both in terms of time and electrode use. ELECTRODE MOVED TOO QUICKLY This causes poor penetration with a ‘stringy’ and incomplete weld deposit. Slag is very hard to remove. CURRENT TOO LOW This causes poor penetration and causes the electrode to stick to the workpiece too readily. Also results in a very irregular and high weld deposit. Slag is very hard to remove. CURRENT TOO HIGH This causes excessive penetration with spatter and deep pointed crater. It may also cause holes to be burned in the workpiece. Burns electrodes very quickly. THE PERFECT WELD With the correct combination of arc length, current regulation, inclination and speed of the electrode, you will, with practice, produce the perfect weld. This should be regular with uniform ripples and no slag contamination. The arc will make a steady crackling sound.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TROUBLESHOOTING Your CLARKE 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. DEFECT CAUSES SUGGESTIONS Spark will not start Bad clamp connection. Inverter printed circuit is defective. Check clamp connection. Contact your nearest CLARKE dealer. No output voltage Overheated machine (the amber LED should be on). Wait for thermal cutout to be reset. Internal relay has failed. Contact your nearest CLARKE dealer. Inverter printed circuit is defective. Contact your nearest CLARKE dealer. Wrong output current Current selector control is defective. Contact your nearest CLARKE dealer. Low power supply voltage. Check the mains distribution system. Porosity of welds Acid electrode on steel with high sulphur content. Electrode oscillates too much. Workpieces are too far apart. Workpiece being welded is cold. Use basic electrode. Move edges to be welded closer together. Move slowly at the beginning. Cracks in weld Material being welded is dirty (e.g.oil, paint, rust, oxides). Not enough current. Clean workpiece before welding is an essential method of achieving neat weld beads. Also increase cur- rent output. Limited penetration Low current, high welding rate, reversed polarity. Electrode inclined in position opposite to it's movement. Ensure operating parameters are regulated and improve preparation of work pieces.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com Profile defects Welding parameters are incorrect. Pass rate is not related to operating parameter requirements. Electrode not inclined constantly while welding. Follow basic and general welding principles. High Sprays Electrode is too inclined. Make appropriate corrections. Arc is unstable Insufficient current. Check condition of electrode and earth wire connection. Electrode melts obliquely Electrode core is not centred. Magnetic blow phenomenon. Replace electrode. Connect two earth wires to opposite sites of the work piece. No response from welder. Check fuses and power lead. Replace fuses as necessary. If problem persists return welder to your local dealer. Check fuse size. Welder does not feed wire. Feed motor defective. Return welder to your local dealer. Feed motor running but no wire being fed from welder tip Insufficient Feed Roller pressure. Increase roller pressure. Burr on end of wire. Re-cut wire square with no burr. Liner blocked or damaged. Clean with compressed air or replace liner. Inferior wire Use only good “clean” wire. Roller worn out. Replace roller. Wire welds itself to tip. Wire feed speed too low. Unscrew tip, cut wire and fit new tip. Increase wire speed before operating again. Wrong size tip. Fit correct size tip. Wire feeds into ‘birds nest’ tangle. Wire welded to tip. As previous plus reduce feed roller pressure. Wire liner damaged preventing smooth operation. Renew wire liner. DEFECT CAUSES SUGGESTIONS

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com Loose coils of wire tangle around wire drum inside machine. Locking knob too slack. Tighten Locking Knob slightly. Do not over-tighten. Erratic wire feed. Tensioning Knob too tight. Loosen Tensioning Knob slightly. Tension roller worn. Check and replace if necessary. Insufficient pressure on tension roller. Increase pressure on tension roller Caution: DO NOT over-tighten. Wire dirty, rusty, damp or bent. Re-cut wire and ensure it is clean. Liner partially blocked. Clean with compressed air. Poor quality welds. Insufficient gas at weld area. Check that gas is not being blown away by draughts and if so move to a more sheltered work area. If not, increase gas supply. Rusty, painted, damp, oil or greasy workpiece. Ensure workpiece is clean and dry. Rusty/dirty wire. Ensure wire is clean and dry. Poor earth contact. Check earth clamp/workpiece connection. Welder cuts out whilst in use. Duty cycle exceeded (auto cut- out operates). Allow welder to cool 15-30 mins before continuing. Note: If duty cycle is continually exceeded, damage to the welder may result and welder output is probably too small for application. DEFECT CAUSES SUGGESTIONS

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CARE AND MAINTENANCE The machine requires no maintenance other than the following guidelines. Cleaning at frequent intervals is advisable if the unit is operating in a very dusty environment. Avoid getting particles of metal inside the machine since they could cause short circuits. 1. Keep the louvres clean to avoid a build up of dirt and oxides inside the machine which can reduce machine output. 2. Check all cables periodically for good condition and security. 3. Always inspect the earth cable and torch hose before use, to ensure they are in perfect condition and that the earth clamp is clean and secured correctly to the cable. 4. Check the hose for security and damage. Wire feed unit: The feed roller / wire guide plays an important part in achieving consistent results. Periodically check the feed roller groove, removing any deposits. Torch: Protect the torch hose assembly from mechanical wear. If the liner is blocked it must be replaced. Contact tip: The contact tip is a consumable item and must be replaced when the bore becomes enlarged or oval. The contact tip MUST be kept free from spatter to ensure an unimpeded flow of gas. To keep the contact tip free from spatter, we recommend the use of anti-spatter spray (6000715) available from your CLARKE dealer. Torch shroud: The torch shroud must also be kept clean and free from spatter. Build-up of spatter inside the gas cup can cause a short circuit at the contact tip which will result in expensive machine repairs. WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL COMPONENTS. WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS AND MAINTENANCE OPERATIONS. BEWARE HOT SURFACES.

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

1 Plastic front plate 14 Power cable/ plug 27 Potentiometer 3

2 Quick socket 15 Rocker switch 28 Shunt

3 Quick socket holder 16 Rear panel 29 Operating knob

4 Front panel 17 Main PCB board 30 Door lock

5 Base panel 18 Cooling fan 31 Side panel

6 Vertical panel 19 Fan base 32 Flip cover

7 Wire feed holder 20 Power board panel 33 Handle Hinge

8 Wire feeder 21 EMC board 34 Industrial plug 32Amp

9 Wire feed spool 22 Power supply board 35 Top bracket clamp

10 Solenoid valve 23 Control board 36 Bottom pallet

11 Cooling fan 24 3-point switch 37 Hinge

12 Fan cover 25 Potentiometer 1 38 Euro-torch connector

13 Cable gland 26 Potentiometer2

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com THE MACHINE RATING PLATE This welder is covered by regulations EN 60974-1:2018+A1:2019 / EN 60974- 10:2014+A1:2015, where the Duty Cycle is expressed as a percentage of time the machine may be used in a given period for a specified welding current. e.g. When welding at 140 Amps the machine may be used for 6 minutes (60%) in any10 minute period,

1 Name/address of manufacturer 9 Energy Supply symbol

2 Model Number 10 Range of Output

3 Part number 11 Rated No-load Voltage

4 Welding Power Source 12 Conventional Load Voltage

5 Standards applied 13 Insulation grade

6 Welding Process symbols 14 Rated Supply Voltage

7 Degree of Ingress Protection 15 Rated Maximum Supply Current

8 Welding Current symbol 16 Max Effective Supply Current

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CONSUMABLES The following are some of the accessories available from your CLARKE dealer. Please quote the part numbers shown below: A Gas Regulator, Arc Activated Headshields, Anti-spatter Spray, Swan Necks, Torch Shrouds and Torch Liner are also available from your CLARKE dealer or our parts division. Item Description Part number Comment Welding Wire Spools Flux cored mild steel (mini spool) 0.9mm

8132110 Use for no gas welding

Mild steel (mini) - 0.6mm 8132100 Use for gas welding Mild steel (mini) - 0.8mm 8132070 Use for gas welding Stainless Steel 0.8mm (mini spool) 8132090 Welding Gas CO2 (250g) 6000642 For welding mild steel CO2 (600g) 6000643 For welding mild steel Argon 6000661 For aluminium/stainless CO2/Argon Mix 6000660 For welding stainless/ thin sheet mild steel Welding Tips 0.6 mm (pack of 5) 8132260 0.8 mm (pack of 5) 8132270 1.0 mm (pack of 5) 8132275 Arc Welding Rods 1.6 x 300mm 3050590 2.0 x 350mm 3050592 2.5 x 350mm 3050594 3.25 x 350mm 3050596 Welding Rods 4.0 x 400mm E6013 3050598 Welding Torch TK9 TIG Torch Kit 6012236 Regulator Argon Gas Regulator 8134140 Welding Apron 610mm x 915mm 6000920 Gauntlets Leather (EN407 rated) 8133492 Welding screen WSC2 and replacement screen 6000945 6000910

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ARC ACTIVATED HEADSHIELDS These highly popular head-shields activate instantly when the arc is struck and allow you to have both hands free when welding. 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. Model Arc Activated Grinding function Solar Powered Fixed Shade Flip Up Part Number GWH4 X X X 6000706 GWH5 X X X 6000707 GWH6 X X X 6000708 GWH7 X X X 6000709 GWH8 X X X 6000714 PG4 X X X 6000716 HS1 X X 6000700 HSF1 X X 6000705

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

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