Clarke MIG 175TECM, 6015540 User guide

MIG165TEM • MIG175TECM

OPERATING & MAINTENANCE

INSTRUCTIONS

0218

WELDER SPECIFICATIONS

PRIMARY or INPUT POWER DATA 165TEM 175TECM

Primary Volts 230V / 1PH 230V / 1PH

Fuse Rating 16 Amps 20 Amps

Frequency 50Hz 50Hz

SECONDARY DATA

Sec. Volts 18 - 29 V 23 - 42 V

Max. Sec. Amps 150 Amps 170 Amps

USABLE WIRE SIZES

Mild Steel Wire 0.6-0.8mm 0.6-0.8mm

Stainless Steel Wire 0.8mm 0.8mm

Aluminium Wire 0.8mm 0.8mm

USABLE GASES MAIN USES

75% Argon 25% CO2 - Thin Sheet Metal, Mild Steel

100% Argon - Welding Aluminium, Stainless Stl

100% CO2 - Mild Steel

DUTY CYCLE

This model is covered by
regulations EN 60974-1 and
EN 50199, where the Duty
Cycle (X) is expressed as a
percentage of time the
machine may be used in a
given period for a specified
welding current.

i.e. When welding at 85
Amps with a MIG 175TEC,
the machine may be used
for 6 minutes (60%) in any
10 minute period..

............or, the machine may be used continuously, (100%) when welding at 65 Amps.

Interpolate for other welding currents

Please note that 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. ALWAYS CONSULT THE MACHINE’S DATA PLATE

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CONTENTS PAGE

Welder Specifications ........................................................................... 2

Parts & Service Contacts ...................................................................... 3

Guarantee .............................................................................................. 4

Electromagnetic Interference (EMC) .................................................5

Safety Precautions ................................................................................. 7

Additional Safety Precautions for MIG Welding ............................... 12

Principles of Operation .......................................................................14

Electrical Connections .......................................................................15

Assembly .............................................................................................. 16

Welding Shield ........................................... 17

Connecting the Gas Supply ..................... 17

Preparation for Use ....... Installing the Welding Wire ....................... 18

Selecting correct Drive Roller .................. 20

MIG Welding Operation ...................................................................... 21

Tuning the Welder .......................................21

Wire Specification Chart ..................................................................... 22

Welding Tips & Maintenance .............................................................. 22

Troubleshooting ................................................................................... 23

Parts Lists and Diagrams .............................................................. 24 - 28

Wiring Diagrams ........................................................................... 28 - 30

PARTS AND SERVICE CONTACTS

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [email protected]

SERVICE: [email protected]

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Thank you for purchasing this CLARKE MIG Welder, designed to operate using a gas
cylinder with plain metal welding wire ONLY. This is explained in greater detail within
the manual.

Before attempting to operate the machine, it is essential that you read this manual
thoroughly and carefully follow all instructions given. In doing so you will ensure
the safety of yourself and that of others around you, and you can also look forward
to the welder giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period
of 12 months from the date of purchase. Please keep your receipt as proof
of purchase.

This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.

Faulty goods should be returned to their place of purchase, no product
can be returned to us without prior permission.

This guarantee does not effect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with
general household waste. It must be disposed of according to the laws
governing Waste Electrical and Electronic Equipment (WEEE) at a recognised
disposal facility.

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ELECTROMAGNETIC INTERFERENCE (EMC)

Whilst this unit complies with EMC regulations, the user is responsible for installing
and using the welding equipment according to the manufacturers instructions. If
electromagnetic disturbances are detected then it shall be the responsibility of
the user of the welding equipment to resolve the situation. In some cases this
remedial action may be as simple as earthing the welding circuit, see ‘Note’. In
other cases it could involve constructing an electromagnetic screen enclosing
the power source and the work complete with associated input filters. In all cases
electromagnetic disturbances must be reduced to the point where they are no
longer troublesome.

Note - The welding circuit may or may not be earthed for safety reasons. Changing
the earthing arrangements should only be authorised by a person who is
competent to assess whether the changes will increase the risk of injury, e.g. by
allowing parallel welding current return paths which may damage the earth circuits
of other equipment.

1.ASSESSMENT OF AREA

Before installing welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. Avoid using your inverter in
the vicinity of:

a) other supply cables, control cables, signalling and telephone cables;

above, below and adjacent to the welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g. guarding of industrial equipment;

e) pacemakers and hearing aids etc.;

f) equipment used for calibration or measurement;

g) other equipment in the environment. The user shall ensure that other

equipment being used in the environment is compatible. This may
require additional protection measures;

It may be possible to avoid the above by changing the time of day that welding
or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of
the building and other activities that are taking place. The surrounding area may
extend beyond the boundaries of the premises.

2. METHODS OF REDUCING EMISSIONS

2.1 Mains supply

Welding equipment should be connected to the mains supply according to the
manufacturers recommendations. If interference occurs, it may be necessary to

5

take additional precautions such as filtering of the mains supply. 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.

2.2 Maintenance of the welding equipment

The welding equipment should be routinely maintained according to the
manufacturers recommendations. All access and service doors and covers should
be closed and properly fastened when the welding equipment is in operation.
The welding equipment should not be modified in any way except for those
changes and adjustments covered in the manufacturers instructions. In particular,
the spark gaps of arc striking and stabilizing devices should be adjusted and
maintained according to the manufacturers recommendations.

2.3 Welding cables

The welding cables should be kept as short as possible and should be positioned
close together, running at or close to the floor level.

2.4 Equipotential bonding

Bonding of all metallic components in the welding installation and adjacent to it
should be considered. However, metallic components bonded to the work piece
will increase the risk that the operator could receive a shock by touching these
metallic components and the electrodes at the same time. The operator should
be insulated from all such bonded metallic components.

2.5 Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected
to earth because of its size and position, e.g. ships hull or building steelwork, a
connection bonding the workpiece to earth may reduce emissions in some, but
not all instances.

Care should be taken to prevent the earthing of the workpiece increasing the risk
of injury to users, or damage to other electrical equipment.

Where necessary, the connection of the workpiece to earth should be made by
a direct connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitance, selected according to national regulations.

2.6 Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding
area may alleviate problems of interference. Screening of the entire welding
installation may be considered for special applications.

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SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING

1. 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

2. GENERAL PRECAUTIONS

A)Burn prevention

Wear protective clothing - gauntlet gloves designed for use in welding, apron, and
protective shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to
avoid entry of sparks and slag. Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates (protected by clear cover
glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes from
radiant energy and spatter. Replace cover glass when broken, pitted, or spattered.
Avoid oily greasy clothing. A spark may ignite them. Hot metal such as electrode
stubs and workpieces should never be handled without gloves. First aid facilities and
a qualified first aid person should be available unless medical facilities are close by
for immediate treatment of flash burns of the eyes and skin burns. Ear plugs should
be worn when working overhead or in a confined space. A hard hat should be
worn when others work overhead. Flammable hair preparations should not be used
by persons intending to weld or cut.

B) Toxic fume prevention

Severe discomfort, illness or death can result from fumes, vapours, heat, or oxygen
enrichment or depletion that welding (or cutting) may produce. Prevent them
with adequate ventilation. NEVER ventilate with oxygen. Lead-, cadmium-, zinc-,
mercury- and beryllium-, bearing materials, when welded (or cut) may produce
harmful concentrations of toxic fumes. Adequate local exhaust ventilation must
be used, or each person in the area as well as the operator must wear an air­supplied 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 ventilated
and, if necessary, while wearing an air-supplied respirator. Vapours from chlorinated
solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE,
a highly toxic gas, and other lung and eye irritating products. The ultraviolet
(radiant) energy of the arc can also decompose trichloroethylene and
perchloroethylene vapours to form phosgene. DO NOT WELD or cut where solvent
vapours can be drawn into the welding or cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even minute amounts of
trichloroethylene or perchloroethylene.

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C) Fire and explosion prevention

Causes of fire and explosion are:

1) combustibles reached by the arc, flame, flying sparks, hot slag or heated
material;

2) misuse of compressed gases and cylinders;

3) short circuits.

BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes,
through windows or doors, and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 10M.

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 area, do NOT weld or cut. Move the work if practicable, to
an area free of combustibles.

Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot
be moved, move combustibles at least 10M, away out of reach of sparks and
heat; or protect against ignition with suitable and snug fitting, 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:

a) appreciable combustibles (including building construction) are within 10m.
b) appreciable combustibles are further than 10m but can be ignited by sparks.
c) openings (concealed or visible) in floors or walls within 10m can expose

combustibles to sparks.

d) combustibles adjacent to walls, ceilings, roofs or metal partitions can be

ignited by radiant or conducted heat.

After work is done, 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 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 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 or cutting - 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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3. ELECTRIC ARC (MIG, TIG) WELDING

Comply with precautions in 1 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, weldments are hot. The wise operator
avoids unnecessary risks and protects himself and others from accidents.

3A) BURN PROTECTION

Comply with precautions in 2. The welding arc is intense and visibly bright. Its
radiation can damage eyes, penetrate lightweight clothing, reflect from light
coloured surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn,
those from gas - shielded arcs are more severe and painful.

DON’T GET BURNED! COMPLY WITH PRECAUTIONS!

1) Protective clothing

Wear long sleeved clothing (particularly for gas shielded arc) in addition to
gloves, apron and shoes (2A). 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 collar to protect chest and neck and button
pockets to prevent entry of sparks.

2) Eye and head protection

Protect eyes from exposure to arc. NEVER look at an electric arc without
protection. Welding helmet or shield containing a filter plate shade no. 12 or
denser must be used when welding. 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 a 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.

3) Protection of nearby personnel

For production welding, a separate 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.

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3B) TOXIC FUME PREVENTION

Comply with precautions in 2B. Generator engine exhaust must be vented to
the outside air. Carbon monoxide can kill.

3C) FIRE AND EXPLOSION PREVENTION

Comply with precautions in 2C. Equipment’s rated capacity. 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.

3D) 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.

3E) PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPT DEVICES (PACEMAKERS)

Magnetic fields from high currents can affect pacemaker operation. Persons wearing
electronic life support equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding operations.

3F) TO PROTECT AGAINST SHOCK:

Keep body and clothing dry. Never work in damp area without adequate
insulation against electrical shock. Stay on a dry duckboard, or rubber mat
when dampness or sweat can not be avoided. Sweat, sea water, or moisture
between body and an electrically LIVE part - or earthed metal - reduces the
body surface electrical resistance, enabling dangerous and possibly lethal
currents to flow through the body.

1) Earthing the equipment

When arc welding equipment is earthed according to the National
Electrical Code, and the workpiece is earthed, a voltage may exist
between the electrode and any conducting object.

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.

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2) Electrode holders

Fully insulated electrode holders should be used. Do NOT use holders with
protruding screws or with any form of damage.

3) Connectors

Fully insulated lock-type connectors should be used to join welding cable.

4) Cables

Frequently inspect cables for wear, cracks and damage. IMMEDIATELY
REPLACE those with excessively worn or damaged insulation to avoid
possibly lethal shock from bared cable. Cables with damaged areas may
be taped to give resistance equivalent to original cable. Keep cable dry,
free of oil and grease, and protected from hot metal and sparks.

5) Terminals and other exposed parts

Terminals and other exposed parts of electrical units should have insulating
covers secured before operation.

6) Electrode

a) Equipment with output on/off control (contactor)

Welding power sources for use with the gas metal arc welding, gas
tungsten arc welding and similar processes normally are equipped with
devices that permit on/off control of the welding power output. When
so equipped the electrode wire becomes electrically LIVE when the
power source switch is ON and welding gun switch is closed. Never
touch the electrode wire or any conducting object in contact with
the electrode circuit unless the welding power source is off.

b) Equipment without output on/off control (no contactor)

Welding power sources used with shielded metal arc welding and similar
processes may not be equipped with welding power output on/off
control devices. With such equipment the electrode is electrically LIVE
when the power switch is turned ON. Never touch the electrode unless
the welding power source is off.

7) 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. Power disconnect
switch must be available near the welding power source.

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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
annoyance to the operator.
Avoid welding by contact with humid parts nearby combustible liquids. Least of
all, do not weld upon tanks which may contain flammable residuals.

ADDITIONAL SAFETY PRECAUTIONS for MIG WELDING

• ALWAYS ensure that there is full free air circulating around the outer casing of

the machine, and that the louvres are unobstructed.

• 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.

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

working correctly. DO NOT lubricate the regulator.

• ALWAYS use the correct regulator. Regulators are designed to be used with

a specific gases.

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

• ALWAYS keep the free length of gas hose outside the work area.

• ALWAYS remove all flammable materials from the welding area.

• ALWAYS Keep fire extinguisher handy....’Dry Powder, C0

or BCF, NOT Water

2

• 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.

• 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.

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PREPARATION OF THE WORKING AREA

• NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN.

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

important to ensure the appropriate gas is being used. NEVER use gas from
a cylinder, the content of which is unknown.

• NEVER a. Use a damaged cylinder.

b. Lift the cylinder by the valve.

c. Expose the cylinder to a heat source or sparks.

• NEVER continue to weld, if, at any time, you feel even the smallest electric shock.

Stop welding IMMEDIATELY, and DO NOT attempt to use the machine until the fault
is diagnosed and corrected.

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

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

nozzle has been allowed to cool off.

• NEVER connect, disconnect, or attempt to service the MIG torch, until the

machine is switched OFF and disconnected from the mains supply.

• NEVER allow the cables to become wrapped around the operator or any

person in the vicinity.

DANGER - 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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SAFETY EQUIPMENT

A comprehensive range of CLARKE safety equipment for use when
welding is available from your local dealer.

MIG WELDING - PRINCIPLES OF OPERATION

MIG (Metal Inert Gas) welding is a process in which a power wire electrode
is fed continuously into the weld pool at a controlled, constant rate.

The wire is connected to the positive side of a rectified voltage supply. The
workpiece is connected to the negative side of the supply.

When the wire is fed, it comes into contact with the workpiece and an arc
is struck. The arc melts the wire and the material, fusing it together.

The wire, which is fed by the wire feed motor is fed into the weld pool,
burning itself off at a rate dependent upon the selected wire feed speed.

To protect the weld pool from oxidation and impurities during the welding
process, a shielding gas flows over and around the weld pool. This gas flow
must be sufficient to protect the weld, but not wasteful.

NOTE:

coverage is wasteful and expensive

Poor gas coverage will result in poor welding. Excessive gas

.

BENEFITS OF MIG WELDING

1. 50% faster welding time.

2. Operator training time kept to a minimum.

3. There is no slag removal, thus eliminating almost all post-welding

cleaning operations.

4. Minimum waste of welding consumables.

5. Overall, a faster more efficient way of getting the job done.

6. Less heat - less distortion.

7. Ability to weld thin material.

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ELECTRICAL CONNECTIONS

WARNING: THIS MACHINE MUST BE EARTHED.

This welder must be connected to a 230 volt (50Hz) supply, having a rated
capacity of greater than 13 amps.

A 13 Amp (BS1363) plug is not suitable for this device.

Connect the three core mains lead to a suitably fused supply through an
isolator or heavy duty plug.

IMPORTANT: The wires in the mains lead are coloured in accordance with

the following colour code:

Green & Yellow - Earth

Blue - Neutral

Brown - Live

• Connect GREEN & YELLOW coloured cord to plug terminal marked
with a letter “E” or Earth symbol “ ”.

• Connect BROWN coloured cord to plug terminal marked letter “L”

• Connect BLUE coloured cord to plug terminal marked letter “N”

We strongly recommend that this machine is connected to the mains
supply through a Residual Current Device.

IMPORTANT: If in doubt, consult a qualified electrician. Do not attempt
any electrical repairs yourself.

15

ASSEMBLY

Remove contents from carton and check all components as follows:

The side panel is hinged at its rear edge: Open by pulling the securing catch
sideways, lay out all components contained within, and check to ensure that
they are all correct according to the list below.

A - 2 Wheels

B - 1 Axle

C - 2 Wheel retaining washers

D - 2 Wheels

E - 1 Handle

F - 2 Handle Bases

G - 2 Fixing screws

LOOSE ITEMS

1x Mask with fixing screws & washers

1x Mask handle

2x Handle retaining screws

1x Transparent glass

1x Dark glass

1x 0.6mm welding tip

1x 0.8mm welding tip

1x Gas regulator

1x welding torch and lead (Torch and hose assembly is factory fitted )

SHOULD ANY PART BE MISSING OR DAMAGED, CONTACT YOUR LOCAL DEALER
FOR REPLACEMENT.

Fig.1

A. Handle and Wheels

1. Slot the axle (B) through the holes at the rear of the machine and slide a
wheel (A) on to each end followed by the retaining washers.

2. Screw the two casters (D) to the machine.

3. Slide handle (8) and the two bases (F) into the top of the machine, line up
the holes with those in the casing, and secure using the 4 screws provided.

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B. FACE SHIELD

1. Push the two halves of the
shield together as shown.

2. Place the handle into
position and secure using
the plastic screw and clip
provided

3. Working from the inside of
the shield, insert the clear
glass panel into the recess
in the shield, followed by
the dark glass panel.

4. Secure the glass panels
with the lens surround and
plastic screws/clips
provided. The clear glass MUST be on the outside of the shield.

5. Finally use the last plastic screw and clip as shown to fix the two halves of the
shield together.

It is important to pay attention to the notes on welding shield maintenance. When
replacing the glass panels, ONLY use those parts supplied by Clarke International.
The dark panel is a certified, specific optical class, and should not be exchanged
for any other type. The clear glass panel should be replaced when it becomes

badly pitted.

WARNING:

NEVER look at an electric arc without eye protection as this can injure the
eyes permanently. ALWAYS use a protection mask or welding helm

C. GAS SUPPLY

It is necessary to procure a cylinder of gas, suitable for the job in hand.

Locate the gas cylinder on the platform at the rear of the unit, and secure using the
chain provided.

A regulator is provided, complete with outlet pressure gauge for use with argon or
argon mix gas bottles. Should you require to use Carbon Dioxide, it will be necessary
for you to purchase an appropriate regulator with a female connector. Your Clarke
dealer will be happy to advise in this regard.

Ensure the outlet of the gas bottle is clean, then screw on the regulator and tighten.

Always use the appropriate gas for the material being welded.

Attach the nut and tail to the gas hose, using the worm drive clip provided, then
screw the nut on to the regulator outlet and tighten.

Open the gas valve and screw in the regulator knob allow gas into the system to
check for gas leaks. If any are apparent, they must be rectified before proceeding.
Turn off the gas when satisfied the system is leak free.

17

PREPARATION FOR USE

A. Installing the Welding Wire

NOTE: These machines are designed to accept either the Clarke 5kg or 15kg wire
spools of mild steel, stainless steel or aluminium according to the type of metal you
wish to weld.Wire spools must be purchased separately. See your Clarke dealer for
full details.

1. IMPORTANT: Ensure that the gas and electrical supplies are disconnected.

2. REF: FIG 4

Fig.4

To fit the wire spool,
firstly open the side
compartment by
pulling the recessed
catch backwards.

3. Turn the plastic knob with cam (7,) to the
position shown in Fig. 5, so that the latch is
unlocked, and pull off the collar (4).

4. Slide the spool on to the shaft, ensuring
that the Peg ‘A’ locates snugly in locating
hole ‘B’, ensuring the direction of feed of
the wire is in the direction of the arrow.

Replace the collar - 4, (5kg spool ONLY),
and turn the Plastic knob with cam (7) to
the position shown in Fig.6 thereby locking
the spool on the shaft.

1. Pressure plate

2. Mounting Shaft

3. Wire Spool

4. Collar

5. Flat Washer

6. Spring

7. Plastic Nut

Fig.5

Fig.6

NOTE: The Plastic knob, item 7 Fig.4 is also used
to apply slight tension to the wire spool. This
prevents the spool from running freely, which
could cause the wire to unspool, creating a
‘birds nest’ tangle within the side compartment.
Adjust by hand and test the tension.

18

5. Unscrew the pressure roller
bracket securing knob (A, Fig

7), sufficient for it to be pulled
out of its holder. This releases
the pressure roller bracket (B)
which, may then be pulled up
to expose the welding wire.

IMPORTANT!
Before fitting ANY wire, ensure the correct groove on the roller is in place.

(see page 20)

Fig.7

6. Pull out the end of the wire
from the rim of the spool,
taking care NOT to release it.
The spool is wound firmly and
should remain this way.

Ensuring the wire is straight and
not kinked in any way, clip off
the end with a sharp pair of
snips ensuring there are no
burrs or sharp edges.

Proceed to feed it through the
guide tube (C, Fig.8), over the
groove on the roller (D), and
into the wire liner, by about 10

- 15 cm.

7. Reposition the pressure roller bracket and securing knob (A) and tighten
slightly.

Tightening the knob (A) too tightly will crush the wire and damage the
wire feed motor, too loose will not allow the wire to be pulled by the roller.

8. (Ref. Fig 9)
Remove the torch shroud by
twisting it anti clockwise and
pulling it off, then unscrew the
contact tip.

Should any wire protrude from the

tip....pull it out completely and

discard.

19

Fig.8

Fig.9

9. Close the side panel of the machine, and switch on at the mains or isolator.

10. Set the Wire Feed rotary switch, on the front panel, to position 6 OR 7, switch on the
machine and press the trigger.

The wire will feed through the hose and when it appears at the torch end,
release the trigger, switch off the machine and disconnect from the mains
supply. Replace the contact tip and the torch shroud.

IMPORTANT:
Ensure the hose is kept straight during this operation, to assist the wire as it

is fed through to the wire liner and torch.

D. Selecting the Correct Drive Roller Groove

As previously mentioned, it is important that the correct groove in the drive roller is
selected for the particular wire being used. The roller provided, has 0.6 and 0.8mm
grooves, and is factory set with the 0.6mm groove in position.

To change grooves, proceed as follows:

1. With the pressure roller bracket
raised, and the old wire
removed, unscrew the hex
socket head grubscrew
(arrowed, Fig10), using an
appropriate hex. wrench, then
pull the roller from the shaft.

2. Ensure the appropriate groove
is facing inwards, before sliding
the roller on to the shaft.

Re-tighten the grub screw to
lock the roller securely in place.

3. Connect the machine to a 230V AC 50Hz supply.

4. Open the gas valve on the gas cylinder regulator, (turn knob clockwise)and
adjust the gas regulator to the proper setting position. NOTE: this varies with
different metals, thicknesses and currents. Refer to a MIG welding manual
for instructions.

20

Fig.10

OPERATION

1. These machines have 6 welding
positions (see the table which
follows) in which to regulate current
for various conditions, obtainable
through a combination of one 2 ­position (Min-Max) switch (A, Fig11)
and one-3 position switch (B, Fig11).

2. The selection of a welding position
is determined by the thicknessof the
metal to be welded. The thicker it
is, the higher the current must be.

3. According to the thickness to be
welded, the amount of gas
regulated to the work also varies
and must be adjusted accordingly.

4. For welding adjustments, refer to
the Wire Specification Chart which
follows.

Fig.11

WARNING

(i) Make sure all flammable materials are removed from the work area.

(ii) Never look directly at the welding arc, it can seriously damage your

eyes. Always use an approved welding mask or helmet.

(iii) Wear protective clothing so that all skin areas are covered.

(iv) Keep a fire extinguisher handy.

Tuning The Welder

The tuning of a Mig welding machine requires some practice, due to the fact
that - contrary to the arc welding procedure - two parameters must be
accommodated to achieve a perfect weld. These are:

(A) Wire Feed Speed, and (B) Welding Voltage.

It is important to arrive at the correct combination to suit the type and thickness
of material to be welded. The current necessary for welding is directly dependent
upon the wire feed speed. Wire speed is adjusted by turning the adjuster C,
Fig11.

If the wire feed speed is increased, the current is also increased, but the arc
length is decreased. Conversely, if the wire feed speed is decreased, and current
is therefore decreased, the length of arc is increased.

Increase of the welding voltage leads to a longer arc (without substantially
affecting the current). Conversely, a decreased welding voltage results in a
shorter arc, (the current again is not substantially changed).

21

A change in wire diameter results in changed parameters. A smaller diameter
wire requires an increase in wire feed speed to reach the same current. If certain
limits are exceeded, a satisfactory weld cannot be obtained. These are:

A) A too high wire feed speed (too high with regard to the welding voltage)

results in pulsing within the torch. This is because the wire electrode dips into
the puddle and cannot be melted off fast enough.

B) If the welding voltage is set too high, large drops can be seen at the end of

the wire electrode. These drops are often deposited beside the welding seam.

The correct rate of wire feed speed (current) and welding voltage, results in very
little spatter and a continuous, intensive hissing can be heard from the arc.

WIRE SIZE SPECIFICATION CHART

MIG165TEM MIG175TECM

2

1

Switches

Min

3

Max

1

2

Steel wire

diameter

3

6

4

5

(mm)

Wire Speed
adjustment

SWITCH

POSITIONS

1 - MIN
1 - MAX
2 - MIN
3 - MIN
2 - MAX
3 - MAX

1
2
3
4
5
6

0.6

0.6

0.6 - 0.8

0.6 - 0.8

0.8

0.8

LOW
LOW
MED.
MED.
MED. - HIGH
HIGH

WELDING TIPS AND MAINTENANCE

1. Always weld clean, dry and well prepared material.

2. Hold gun at a 45° angle to the workpiece with nozzle about 6mm from the surface.

3. Move the gun smoothly and steadily as you weld.

4. Avoid welding in very draughty areas. A weak pitted and porous weld will result due to air

blowing away the protective welding gas.

5. Keep wire and wire liner clean. Do not use rusted wire.

6. Sharp bends or kinks on the welding hose should be avoided.

7. Try to avoid getting particles of metal inside the machine since they could cause short circuits.

8. If available, use compressed air to periodically clean the hose liner when changing wire spools.

IMPORTANT: Disconnect from power source when carrying out this operation.

9. Occasionally blow dust from the inside welder (LOW PRESSURE AIR). This keeps machine running

cooler. Note: DO NOT blow air over the printed circuit board and electronic components.

10. The wire feed roller will eventually wear during normal use. With the correct tension the pressure

roller must feed the wire without slipping. If the pressure roller and the wire feed roller make
contact (when the wire is in place between them), the wire feed roller must be replaced.

11. Check all cables periodically. They must be in good condition and not cracked.

22

TROUBLE SHOOTING

PROBLEM PROBABLE CAUSE REMEDY

1. No life from
welder

2. No wire feed

3. Feed motor
operates but wire
will not feed

4. Wire welds itself to
tip

5. Wire feeds into
birds nest tangle.

6. Tangled coils of
wire around drum

7. Erratic wire feed

8. Poor quality welds

9. Wire jams in tip
when welding
aluminium

10. Welder cuts out

whilst in use

Check fuses and mains lead a) Replace fuses as necessary.

Motor malfunction

a) insufficient feed roller

pressure
b) Burr on end of wire
c) Liner blocked/damaged

d) Inferior wire

a) Wirefeed speed too low

b) Wrong size tip

a) Wire welded to tip.
b ) Wire liner damaged

preventing smooth

operation.

Drum brake too slack.

a) Drum brake too light
b) Feed roller worn
c) Insufficient pressure on

feed roller

d) Wire dirty, rusty, damp or

bent

e) Liner partially blocked

a) lnsufficient gas at weld

area

b) Incorrect gas/wire

combination

c) Rusty, painted, damp. oily

or greasy work piece
d) Rusty, dirty work.
e) Poor earth contact

Tip too small

Duty Cycle exceeded (auto
cut-out operates)

If problem persists. return welder
to your local dealer.

b) Check fuse size.

Return welder to your local dealer.

a) Increase roller pressure

b) Re-cut wire square
c) Clear with compressed air or

replace liner.

d) Use only good dean wire

a) Unscrew tip cut wire and fit new

tip. Increase wire speed before
operating again.

b) Change tip size.

a) As above plus reduce feed roller

pressure so if blockage occurs
wire sleeps on roller. i.e. no feed

b) Renew wire liner.

Tighten drum brake DO NOT
OVERTIGHTEN

a) Loosen drum brake slightly
b) Check and replace if necessary
c) Increase pressure on feed roller

DO NOT OVER TIGHTEN

d) Re-cut wire and ensure it is clean

e) Clear with compressed air

a) Check gas is not being blown

away by draughts, if so, move to
a sheltered area. If no draught,

increase gas supply.
b) Consult Mig Welding manual
c) Ensure wkpiece is clean and dry
d) Ensure wire is clean and dry
e) Check ground clamp/ wkpiece

connection.

Use slightly oversize tip i.e. for 0.8mm
wire use 1mm tip (Applies to
aluminium only)

Allow welder to cool for 10-30min
before continuing. Note: If duty cycle

is continually exceeded, damage to
welder may result and welder output
is probably too small for application,

23

PARTS DIAGRAM

25

No. Description Qty Part No.

1 P.C. BOARD E0795 220/240V + FUSE “CSA” 1 22710037
3 MOTOR MBT D.40 PINION 1 04600155
4 COMPLETE THERMOSTAT 100ø + SUPPORT 1 04600113
5 RECTIFIER PMS 12/4/2 F 1 22400005
6 COMPLETE FAN 230V 1 04600057
7 DIRECT TORCH CONNECTION COVER 1 21690268
8 HANDLE FOR WELDING UNITS 1 21600042
9 UPPER FRAME SPACER 1 21690232
10 POTENTIOMETER KNOB 1 21690309
11 KNOB FOR RED SWITCH + INDICATOR 1 04600268
12 ZINC CHAIN NR 17 NM 3,1 L=0,76 MT 1 04600205
13 UPPER PANEL PVC 1 33705448
14 DIVIDING PANEL PVC 1 33720089
15 MAT FOR TOOLS 1 30905022
16 PLASTIC WIRE FEEDER D40 ROL.06-08 1 44400008
17 WIRE FEED ROLL D.9X30 0,6-0,8MM KNURLE 1 33805001
17 WIRE FEED ROLL 0,8-1 NYLON 1 33805027
18 CABLE CLAMP FOR HOLE D.20 3 21605010
19 BARBLACK GAS HOSE D.5X10,5 2,2 10900003
20 INPUT CABLE 3X1,5 M 2,5 1 20220014
21 LEFT FRONT HALF-FRAME WIRE FEEDER 1 21690231
22 LOWER FRAME SPACER 1 21690233
23 CURRENT SWITCH 16A 250V 1 22200006
24 YELLOW PILOT-LIGHT SWITCH 16A 250V 1 22200022
25 RIGHT FRONT HALF-FRAME WIRE FEEDER 1 21690230
26 WHEELS-AXLE D.16 L=415 1 55200005
27 WHEEL D.175 2 21625041
28 FRONT PANEL MIG 150 PVC 1 33710305
29 SWITCH 9/12 A CM 13 1 22205001
30 CHOKE MIG 186/196 D.6 50X50 AL 1 44135126
33 TRANSFORMER 1PH MIG 230V 45X90 AL 1 44120047
34 THERMOSTAT 127ø 16A 1 22210016
35 T.C.E3 RED TORCH +1.4 16SQMM M 2,5 1 23000051
36 EARTH CABLE 16 MMSQ M.1,8 1 43210050
37 EARTH CLAMP 120A 1 22110005
38 BACK PANEL 1 33715092
39 COMPLETE SPOOL HOLDER D.50 1 04600001
40 LOWER PANEL 1 33700162
41 LEFT SIDE PANEL MIG 150 PVC 1 33705390
42 WHEEL D.75 2 21625039
43 SLIDE CLIP 1 21690226
44 CARTON MASK 82X108 1 21905019
45 TRANSPARENT GLASS 82X108 ART.470 1 21905020
46 DARK GLASS 82X108 ART.471 BS DIN11 1 21905021
47 REDUCER MINI ARG/UK 1/GAUGE 1 22905004
48 RIGHT SIDE PANEL MIG 150 1 33705362

165TEM

26

No. Description Qty Part No.

1 P.C. BOARD E0795 220/240V + FUSE “CSA” 1 22710037
3 MOTOR MP48 24V 1 04600156
4 COMPLETE THERMOSTAT 100ø + SUPPORT 1 04600113
5 RECTIFIER PMS 16/4/2 F 1 22400009
6 COMPLETE FAN 230V 1 04600057
7 DIRECT TORCH CONNECTION COVER 1 21690268
8 HANDLE FOR WELDING UNITS 1 21600042
9 UPPER FRAME SPACER 1 21690232
10 POTENTIOMETER KNOB 1 21690309
11 KNOB FOR RED SWITCH + INDICATOR 1 04600268
12 ZINC CHAIN NR 17 NM 3,1 L=0,76 MT 1 04600205
13 UPPER PANEL PVC 1 33705448
14 DIVIDING PANEL PVC 1 33720089
15 MAT FOR TOOLS 1 30905022
16 PLASTIC WIRE FEEDER D.48 ROLLS06-08 1 44400003
17 WIRE FEED ROLL D.9X30 0,6-0,8MM KNURLE 1 33805023
17 WIRE FEED ROLL 0,8-1 NYLON 1 33805027
18 CABLE CLAMP FOR HOLE D.20 3 21605010
19 BLACK HOSE D.5X10,5 L=2500 1 30900027
20 INPUT CABLE 3X2,5 M.2,5 1 20220020
21 LEFT FRONT HALF-FRAME WIRE FEEDER 1 21690231
22 LOWER FRAME SPACER 1 21690233
24 YELLOW PILOT-LIGHT SWITCH 16A 250V 1 22200022
25 RIGHT FRONT HALF-FRAME WIRE FEEDER 1 21690230
26 WHEELS-AXLE D.16 L=415 1 55200005
27 WHEEL D.175 2 21625041
28 FRONT PANEL MIG 150 PVC 1 33710305
29 SWITCH 16 A CM 16 1 22205016
30 CHOKE MIG 186/196 D.6 50X50 AL 1 44135126
31 CONTACTOR 220V 10A 1 22225006
32 GAS SOLENOID VALVE 4W 220V 50HZ 1/8"FF 1 22900001
33 TRANSFORMER 1PH MIG 230V 45X90 AL 1 44120031
34 THERMOSTAT 127ø 16A 1 22210016
35 TORCH PLUS 14 MT.2,5 DIR.CON. 1 23000321
36 EARTH CABLE 16 MMSQ M.1,8 1 43210050
37 EARTH CLAMP 120A 1 22110005
38 BACK PANEL 1 33715092
39 COMPLETE SPOOL HOLDER D.50 1 04600001
40 LOWER PANEL 1 33700162
41 LEFT SIDE PANEL MIG 150 PVC 1 33705390
42 WHEEL D.75 2 21625039
43 SLIDE CLIP 1 21690226
44 CARTON MASK 82X108 1 21905019
45 TRANSPARENT GLASS 82X108 ART.470 1 21905020
46 DARK GLASS 82X108 ART.471 BS DIN11 1 21905021
47 REDUCER MINI ARG/UK 1/GAUGE 1 22905004
48 RIGHT SIDE PANEL MIG 150 1 33705362

175TEC

27

TORCH ASSEMBLY - 165TE

No. Description Qty Part No.

1 Complete Torch Handle 1 EM21690339
2 Torch Trigger 1 EM21690340
3 Torch Gas Valve 1 EM23005009
4 Torch Neck 1 EM23005077
5 Thread Guide Wire Liner 1 EM23005091
6 Torch Neck Insulator 1 EM23005090
6a Head Insulator Torch 1 EM23005093
7 Gas Diffuser 1 EM23005096
7a Retainer Spring 1 EM23005095
8 0,6mm Contact Tip 1 EM23005018
8 0,8mm Contact Tip 1 EM23005019
8 1,0mm Contact Tip 1 EM23005020
9 Torch Gas Nozzle 1 EM23005021
9a Spot Welding Nozzle 1 EM23005022
10 Rubber Outer Sleeve 1 EM30900019
11 Torch Gas Hose 1 EM30900008
12 Blue Wire Liner 1 EM23005128
13 Fast Coupling Connector 2 EM22910001
14 Pin For Torch Trigger 1 EM33810090
15 No-gas Torch Contact Spring 1 EM33800009
16 Self Tapping Screw 5 EM21020081
17 Gas Valve W/Torch Neck 1 EM23005075

28

TORCH ASSEMBLY - 175TEC

No. Description Qty Part No.

01 Torch Neckfortorch Plus 14 1 EM23005094
05 0,6mm Contact Tip For Torch T 1.4-1.6 1 EM23005018
05 0,8mm Contact Tip For Torch T 1.4-1.6 1 EM23005019
05 1,0mm Contact Tip For Torch T 1.4-1.6 1 EM23005020
05 1,2mm. Contact Tip For Torch T 1.4-1.6 1 EM23005029
06 Torch Gas Nozzle D.9,5 For Plus 14 1 EM23005117
6A Torch Gas Nozzle Hole D.12 1 EM23005021
08 Spot Welding Nozzle For Plus 14 1 EM23005022
1A Retainer Spring For Torch Plus 15 1 EM23005095
1B Gas Diffuser For Torch Plus 14 1 EM23005096
1C Head Torch Insulator For Plus 14-15 1 EM23005093
1E Torch Neck Insulator X Torch Plus 14 1 EM23005098
1H Torch Neck For Torch Plus 14 1 EM23005099
11 Handle For Torch Plus 14 1 EM23005100
13 Trigger For Torch Plus 14 1 EM23005101
37 Blue Wire Liner 0,8-1 3,3m Direct 1 EM23005025
37 Liner Teflon Blue I ,5x4 M2,7 Direct Con 1 EM23005130
38 Liner Collet 1 EM23005107

29

WIRING DIAGRAM - 165TE

30

WIRING DIAGRAM - 175TEC

31

DECLARATION OF CONFORMITY