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.
The MIG120 Multi is an inverter type welding machine, suitable to carry out
Gas and No Gas CO
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 CO
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.
(TIG welding leads are not supplied with the machine. These are however,
readily available from your CLARKE dealer (Part number 6012233).
A wide selection of accessories and consumables are available from your
CLARKE dealer (see page 36)
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.
Carbon Dioxide (CO2)/Argon Mix6000662
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.
WARNING: AS WITH ALL MACHINERY, THERE ARE CERTAIN HAZARDS
INVOLVED WITH THEIR OPERATION AND USE. EXERCISING RESPECT AND
CAUTION WILL CONSIDERABLY LESSEN THE RISK OF PERSONAL INJURY.
HOWEVER, IF NORMAL SAFETY PRECAUTIONS ARE OVERLOOKED, OR
IGNORED, PERSONAL INJURY TO THE OPERATOR MAY RESULT.
FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY.
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 burns. 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 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 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 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.
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 12). 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 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, 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.
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.
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.
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, C0
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 37.
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 33). 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.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)
Earth
(Green and Yellow)
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
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.
This product may be fitted with a non-rewireable plug. If it is necessary to
change the fuse in the plug, the fuse cover must be refitted. If the fuse cover
becomes lost or damaged, the plug must not be used until a suitable
replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or due
to damage, it should be cut off and a replacement fitted, following the wiring
instructions shown below. The old plug must be disposed of safely, as insertion
into a mains socket could cause an electrical hazard
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 Blue wire must be connected to the terminal marked N or
coloured Black.
•The Brown wire must be connected to the terminal marked L or
coloured Red.
•The Yellow and Green wire must be connected to the terminal
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.
1. Power LED. When the power is switched on at the rear of the machine the
switch will be illuminated, as will the green ‘Power On’ LED.
2. 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.
3. Wire speed /current control knob. A higher current requires a higher wire
speed. Wire speed should be set based upon the table on page 28.
4. Wire thickness selector switch. For use with MIG/Flux welding in one of three
positions (0.6, 0.8/0.9, 1.0).
5. MIG/MMA/LIFT TIG function selector switch for welding mode selection.
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.
WARNING: MAKE SURE THAT THE WELDER IS NOT CONNECTED TO THE
MAINS SUPPLY.
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 by pushing
the latches down and allowing
the side panel to open.
2. Remove the locking nut and
retaining spring.
3. 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 clockwise from the top 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.
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
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.
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.
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.
CONFIGURING THE MACHINE
To prepare the machine for welding it is important that you follow the following
procedure.
Attach the earth clamp to the workpiece as close to the point of welding as
possible without it being intrusive.
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:
2. Switch on using the switch
located on the rear panel.
3. For Flux or MMA welding, select
the appropriate welding rod and
fit it into the welding rod holder.
The following sizes can be used and are available from your CLARKE dealer.
ROD DIAMETERWORKPIECE THICKNESS
MIG0.6 mm
0.8 mm
0.9 mm
1-5 mm
1.0 mm
MMA1.6 mm1.5 - 2.0 mm
2.5 mm2.5 - 3.0 mm
3.2 mm3.5 - 4.5 mm
4. Attach the work 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.
1. Set the rocker switch (1) to either
welding mode.
2. Select the welding wire thickness
using the left rocker switch (2).
• Set the welding voltage (Settings
1-10) using the selector knob (3).
• With practice you will gain a feel
for the correct current setting for
different welding rod thicknesses.
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.
CAUTION: THE DUTY CYCLE MUST BE ADHERED IN ORDER TO PREVENT
THE THERMAL OVERLOAD PROTECTION FROM ACTIVATING
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 45
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.
o
and pull the
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.
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.
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.
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.
Before TIG welding, you must obtain the correct torch and a gas cylinder of
100% pure Argon. (see page 36)
To prepare the unit 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/
2
cm
(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 40
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. The
green light on the front panel will glow.
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.
9. Cover your face with the head shield, bring the torch to within 3-4mm of
o
the work, and at an angle of 40-60
, 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
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.
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.
DEFECTCAUSESSUGGESTIONS
Spark will not startBad clamp connection.
Inverter printed circuit is
defective.
No output voltage Overheated machine (the
amber LED should be on).
Internal relay has failed.Contact your nearest
Inverter printed circuit is
defective.
Wrong output
current
Porosity of weldsAcid electrode on steel
Cracks in weldMaterial being welded is
Limited
penetration
Current selector control is
defective.
Low power supply voltage.Check the mains distribution
with high sulphur content.
Electrode oscillates too
much.
Workpieces are too far
apart.
Workpiece being welded is
cold.
dirty (e.g.oil, paint, rust,
oxides).
Not enough current.
Low current, high welding
rate, reversed polarity.
Electrode inclined in
position opposite to it's
movement.
Check clamp connection.
Contact your nearest
CLARKE dealer.
Wait for thermal cutout to
be reset.
CLARKE dealer.
Contact your nearest
CLARKE dealer.
Contact your nearest
CLARKE dealer.
system.
Use basic electrode.
Move edges to be welded
closer together. Move slowly
at the beginning.
Clean workpiece before
welding is an essential
method of achieving neat
weld beads. Also increase
current output.
Ensure operating
parameters are regulated
and improve preparation of
work pieces.
WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL
COMPONENTS.
WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS
AND MAINTENANCE OPERATIONS. BEWARE HOT SURFACES.
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.
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 condition and secure. They must be in
good condition and not cracked.
Always avoid getting particles of metal inside the machine since they could
cause short circuits.
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.
Check the hose for security and damage.
Wire feed unit:
The feed roller / wire guide plays an important part in achieving consistent
results. 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 antispatter 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.
1Name/address of manufacturer9Energy Supply symbol
2Model Number / Part Number10Range of Output
3Serial / Batch number11Rated No-load Voltage
4Welding Power Source12Conventional Load Voltage
symbol
5British Standards applied13Insulation grade
6Welding Process symbol14Rated Supply Voltage
7Degree of Protection15Rated Maximum Supply Current
8Welding Current symbol16Maximum Effective Supply
Current
This welder is covered by regulations EN 60974-1:2018+A1:2019 / EN 6097410:2014+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,
The following are some of the accessories available from your CLARKE dealer.
Please quote the part numbers shown below:
PartDescriptionPart
number
Welding Wire
Spools
Welding GasCO2 (250g)6000642 For welding mild steel
Welding Tips0.6 mm (pack of 5)8132260
Arc Welding
Rods
Welding Rods4.0 x 400mm E6013 3050598
Welding TorchWelding Torch Assembly
RegulatorArgon Gas Regulator8134140
Flux cored mild steel (mini
spool) 0.9mm
Mild steel (mini) - 0.6mm8132100 Use for gas welding
Mild steel (mini) - 0.8mm8132070 Use for gas welding
Stainless Steel 0.8mm (mini
spool)
CO2 (600g)6000643 For welding mild steel
Argon 6000661
CO2/Argon Mix6000660 For welding stainless/
0.8 mm (pack of 5)8132270
1.0 mm (pack of 5)8132275
1.6 x 300mm 3050590
2.0 x 350mm3050592
2.5 x 350mm3050594
3.25 x 350mm 3050596
(MMA/TIG)
8132110 Use for no gas welding
8132090
6012232
Comment
thin sheet mild steel
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.
These highly popular head-shields activate instantly when the arc is struck and
allow you to have both hands free when welding.
ModelArc
Activated
GWH2✔✔✔6000697
GWH3✔✔✔6000698
GWH4✔✔✔6000706
GWH5✔✔✔6000707
GWH6✔✔✔6000708
GWH7✔✔✔6000709
PG4✔✔✔6000716
HS1✔✔6000700
HSF1✔✔6000705
Grinding
function
Solar
Powered
Fixed
Shade
Flip UpPart
Number
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.