Clarke MIG120 MULTI User guide

MIG/MMA/TIG INVERTER WELDER

MODEL NO: MIG120 MULTI

PART NO: 6015601

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC07/24- rev 1

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

MIG120 Multi

Unpacked Weight (kg) 6.8

Dimensions (l x w x h) (mm) 305 x 155 x 233

Power Supply 230V~ 50Hz

Connecting plugs BS1363 (13A)

Max Input Power 3.9 KW

Max Input Current 17.3A

No Load Voltage 63V

Output Welding Current MIG 20A/15V -120A/20v

MMA 20A/18.8V - 100A/24V

TIG 20A/10.8V - 100A/14V

IP Rating IP21S

Insulation Grade Class 1 - Grade H

Suitable Electrode size 1.6-3.2mm

Welding Wire size 0.6mm, 0.8mm, 0.9mm & 1.0mm (flux cored)

0.6mm, 0.8mm (solid)

Welding Capacity (Mild Steel) 1-5 mm (MIG)

1.5-4.5 (MMA)

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.

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PRINCIPLES OF THE MACHINE

The MIG120 Multi is an inverter type welding machine, suitable to carry out Gas and
No Gas CO2 welding, MMA, TIG and MIG (MAG -USA welding). 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.

(TIG torch kit is not supplied with the machine. This are however, is readily available
from your CLARKE dealer (Part number 6012232).

A wide selection of accessories and consumables are available from your CLARKE
dealer (see page 36)

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SUITABILITY OF DIFFERENT METHODS

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 (CO2) 6000642

Stainless Steel Argon 6000663

Aluminium

Thin Sheet Metal/Mild Steel Carbon Dioxide (CO2)/Argon Mix 6000662

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.

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SAFETY PRECAUTIONS FOR ALL 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.

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-, mercury­and 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

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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.

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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

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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.

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.

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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.

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FURTHER PRECAUTIONS FOR MMA WELDING

1. ALWAYS ensure that there is full free air circulating around the outer casing of
the machine and that the louvres are unobstructed.

2. 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 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.

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SAFETY SYMBOLS

The following symbols may be displayed on the machine or its packaging.

Read this instruction
booklet carefully before
use.

Wear welding mask Recycle unwanted

Wear protective gloves General Hazard

Wear a dust mask Warning;- Magnetic field

Do not expose to rain.

materials under WEEE
Directive

created (

Caution:- Hot surface Danger! Harmful fumes

Risk of Electric Shock Do not weld near

flammable or combustible
materials

Do not weld near
flammable or combustible
materials

May interfere with
pacemakers

Danger:- Arc Rays

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ELECTRICAL CONNECTION

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.

Plug must be BS1363/A approved.

Always fit a 13 Amp fuse.

Earth

(Green and Yellow)

Neutral

(Blue)

Ensure that the outer sheath of the cable is firmly held by the clamp

Live

(Brown)

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.

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OVERVIEW & INVENTORY

The MIG120 Multi- welder is fitted with:

1. On/off Switch (at rear)

2. Gas cylinder connecting port (at rear)

3. Wire thickness selector switch

4. MIG/MMA/LIFT TIG function selector switch

5. Current selector knob

6. Positive terminal

7. Negative terminal

8. 1 x Torch Cable/Electrode Holder

9. 1 x Earth Cable/Clamp

10. Overheating LED

11. Power-On LED

12. 1 x MIG welding torch with hose (0.8mm tip)

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Loose items supplied include the following:

13. 1 x Hammer/brush

14. 1 x Face shield

15. 1x Spool of 0.6mm mild steel welding wire

16. 1x Spool of 0.9 mild steel welding wire

17. 1 x 0.6mm welding torch tip

18. 1 x 0.8mm welding torch tip (fitted)

19. 1 x 0.9mm welding torch tip

20. 1 x 0.6/0.8mm wire roller (fitted)

21. 1 x 0.9/1mm wire roller

22. 1 x torch wrench (for changing tips)

23. 1 x 520mm Gas hose

24. 1 x Gas bottle holder (2 pieces)

THE CONTROL FUNCTIONS

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.

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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.

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PREPARATION FOR USE

FITTING THE GAS BOTTLE HOLDER

WARNING: NEVER OPERATE THIS MACHINE WITH THE SIDE
PANELS PARTIALLY OPENED OR REMOVED.

IMPORTANT: Ensure that the
welder is not connected to the
mains supply before opening.

1. Open the side panel by pushing the
latch down and allowing the side
panel to drop down.

2. Remove any loose items that have
been transported inside.

3. Place the lower bottle bracket into
position and secure in place using the
2 screws provided.

4. Secure the top clip in place using the
screw provided.

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.

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MOUNTING THE WELDING WIRE SPOOL

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.

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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 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.

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• 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.

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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:

MIG WELDING WITH GAS

If using 0.9mm wire, connect the
earth clamp to the negative
terminal as shown.

FLUX WELDING NO GAS

If using 0.9mm flux cored wire,
connect the earth clamp to the
positive terminal as shown.

MMA ELECTRODE WELDING

Connect the earth clamp to the
negative terminal and the
electrode holder to the positive as
shown.

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LIFT-TIG WELDING

Connect the earth clamp to the
(+) Positive terminal and the
Welding rod holder lead to the (-)
negative terminal.

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/WIRE

WORKPIECE THICKNESS

DIAMETER

MIG 0.6 mm

0.8 mm
1-5 mm

0.9 mm

1.0 mm

MMA 1.6 mm 1.5 - 2.0 mm

2.5 mm 2.5 - 3.0 mm

3.2 mm 3.5 - 4.5 mm

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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.

CONTROL SETTINGS

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 thickness.

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.

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OPERATING THE WELDER (MIG)

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 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.

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OPERATING THE WELDER (MMA/ARC)

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.

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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.

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TIG WELDING

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/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. 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.

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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.

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WELDING SETTINGS TABLES

L-SHAPED BUTT WELDING

Metal
thickness
(mm)

0.8 0.8 - 0.9 0 60-70 16-16.5 50-60 10 1

1.0 0.8 - 0.9 0 75-85 17-17.5 50-60 10-15 1

1.2 0.8 - 0.9 0 80-90 17-18 50-60 10-15 1

1.6 0.8 - 0.9 0 95-105 18-19 45-50 10-15 1

2.0 1.0 - 1.2 0 - 0.5 110-120 19-19.5 45-50 10-15 1

2.3 1.0 - 1.2 0.5 - 1.0 120-130 19.5-20 45-50 10-15 1

3.2 1.0 - 1.2 1.0 - 1.2 140-150 20-21 45-50 10-15 1

4.5 1.0 - 1.2 1.0 - 1.5 140-150 22-23 40-50 15 1

6.0 1.2 1.2 - 1.5 170-185 24-26 40-50 15-20 Positive

9.0 1.2 1.2 - 1.5 320-340 32-34 40-50 15-20 Positive

Wire
diameter
(mm)

Root gap Welding

current
(A)

Welding
voltage (V)

Welding
speed

Gas Flow
(L/min)

Number
of

ANGLE JOINT (THIN PLATE)

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

FLAT FILLET WELDING LAP JOINT (THIN PLATE)

Metal
thickness
(mm)

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

Wire
diameter
(mm)

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

Welding
current (A)

Welding
voltage
(V)

Welding
speed

Distance between
conductive nozzle
profiles (mm)

Gas Flow
(L/min)

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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.

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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.

No output voltage Overheated machine (the

amber LED should be on).

Internal relay has failed. Contact your nearest CLARKE

Inverter printed circuit is
defective.

Wrong output
current

Porosity of welds Acid electrode on steel

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.

Check clamp connection.
Contact your nearest CLARKE
dealer.

Wait for thermal cutout to be
reset.

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.

Cracks in weld Material being welded is

dirty (e.g.oil, paint, rust,
oxides).
Not enough current.

Limited
penetration

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Low current, high welding
rate, reversed polarity.
Electrode inclined in
position opposite to it's
movement.

30

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.

DEFECT CAUSES SUGGESTIONS

Profile defects Welding parameters are

incorrect.

Follow basic and general

welding principles.
Pass rate is not related to
operating parameter
requirements.
Electrode not inclined
constantly while welding.

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.

Welder does not
feed wire.

Feed motor running
but no wire being
fed from welder tip

Wire welds itself to
tip.

Check fuse size.

Feed motor defective. Return welder to your local

dealer.

Insufficient Feed Roller

Increase roller pressure.
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 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

Renew wire liner.
smooth operation.

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DEFECT CAUSES SUGGESTIONS

Loose coils of wire
tangle around wire

Locking knob too slack. Tighten Locking Knob slightly.

Do not over-tighten.
drum inside
machine.

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.

Welder cuts out
whilst in use.

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.

Duty cycle exceeded (auto cut­out 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.

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CARE AND MAINTENANCE

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
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.

MUST

be kept free from spatter to ensure an

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.

33

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COMPONENT PARTS

NO DESCRIPTION NO DESCRIPTION

1 Handle 13 Base panel

2 Cover panel 14 Potentiometer

3 Main PCB 15 LED

4 Insulation board 1 16 3-gear switch

5 Insulation board 2 17 Coupling device

6 Dam board 18 Torch cable gland 10 dia

7 Centre panel 19 Torch cable gland 12 dia

8 Power switch 20 Wire feeder

9 Entry port 21 Feeding door

10 Power cable 22 Door lock

11 Gas connector 23 Wire spool

12 Cooling fan 24 Hinge

34

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THE MACHINE RATING PLATE

1 Name/address of manufacturer 9 Energy Supply symbol

2 Model Number / Part Number 10 Range of Output

3 Serial / Batch number 11 Rated No-load Voltage

4 Welding Power Source 12 Conventional Load Voltage symbol

5 British Standards applied 13 Insulation grade

6 Welding Process symbol 14 Rated Supply Voltage

7 Degree of Protection 15 Rated Maximum Supply Current

8 Welding Current symbol 16 Maximum 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,

35

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CONSUMABLES

The following are some of the accessories available from your CLARKE dealer. Please
quote the part numbers shown below:

Part Description Part

number

Welding Wire
Spools

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

Welding Tips 0.6 mm (pack of 5) 8132260

Flux cored mild steel (mini
spool) 0.9mm

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)

CO2 (600g) 6000643 For welding mild steel

Argon 6000661

CO2/Argon Mix 6000660 For welding stainless/

0.8 mm (pack of 5) 8132270

8132110 Use for no gas welding

8132090

Comment

thin sheet mild steel

1.0 mm (pack of 5) 8132275

Arc Welding
Rods

Welding Rods 4.0 x 400mm E6013 3050598

Welding Torch Welding Torch Assembly

Regulator Argon Gas Regulator 8134140

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.

1.6 x 300mm 3050590

2.0 x 350mm 3050592

2.5 x 350mm 3050594

3.25 x 350mm 3050596

6012232

(MMA/TIG)

36

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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.

Model Arc

Activated

GWH2 x x x 6000697

GWH3 x x x 6000698

GWH4 x x x 6000706

GWH5 x x x 6000707

GWH6 x x x 6000708

GWH7 x x x 6000709

PG4 x x x 6000716

HS1 x x 6000700

HSF1 x x 6000705

Grinding
function

Solar
Powered

Fixed
Shade

Flip Up Part

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.

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DECLARATION OF CONFORMITY -UK

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DECLARATION OF CONFORMITY - CE

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