Clarke 100EN Operating & Maintenance Manual Download Page 1 | Manualshive

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OPERATING & MAINTENANCE

INSTRUCTIONS

Models

90EN, 100EN, 105EN & 151EN

0502

GAS/NO-GAS MIG WELDER

GAS/NO-GAS MIG WELDER

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Summary of Contents for 100EN

Page 1: ...OPERATING MAINTENANCE INSTRUCTIONS Models 90EN 100EN 105EN 151EN 0502 GAS NO GAS MIG WELDER GAS NO GAS MIG WELDER...

Page 2: ...und 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 d...

Page 3: ...ling the Welding Wire 16 Selecting the Drive Roller Groove 18 Converting to Gas Supply 18 Preparation for Use Preparing the Work 20 Setting the Controls 20 Welding Wire Preparation 21 Attaching the Ea...

Page 4: ...AREA Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area Avoid using your welder in the vicinity of a other supply cable...

Page 5: ...evel 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...

Page 6: ...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...

Page 7: ...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 spa...

Page 8: ...Eye and head protection Protecteyesfromexposuretoarc NEVERlookatanelectricarcwithoutprotection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place...

Page 9: ...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...

Page 10: ...rces 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 pow...

Page 11: ...ls 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 NEVER use or store in a wet...

Page 12: ...as flows over and around the weld pool This gas flow is provided by a flux core within the welding wire electrode The flux melts due to the heat produced giving off a gas This gas prevents oxygen in t...

Page 13: ...Replacement fuse covers can be obtained from your local dealer or most electrical stockists Fuse Rating The fuse in the plug must be replaced with one of the same rating 13 amps and this replacement...

Page 14: ...e care MIG 90EN 105EN 110EN 1 Rubber Feet with washers and screws 4 pcs 2 2 Piece Welding Mask 3 Welding Mask handle complete with plastic nut and 2xplastic screws 4 Package containing 1x Clear Glass...

Page 15: ...fastening band which is threaded through the opening provided on the rear panel of the machine on welding shield maintenance given on page 23 When replacing the glass panels use ONLY those parts supp...

Page 16: ...ious damage C INSTALLING THE WELDING WIRE NOTE These machines are supplied with a Clarke Mini spool of mild steel flux cored welding wire A 5kg spool is available from your Clarke dealer See Accessori...

Page 17: ...ll off the torch shroud by twisting it anti clockwise then unscrew the contact tip 6 Closethesidepanelofthe machine plug into a 230V 50HZ outlet or switch on isolator switch on the machine and press t...

Page 18: ...hen be turned fully clockwise to lock the roller securely in place D CONVERTING TO GAS WELDING For welding stainless steel or aluminium it is necessary to convert your NO GAS machine to GAS operation...

Page 19: ...tles is based on the action of a needle operated by a knob placed over a graduated dial plate from 0 to 6 acting on the valve of the bottle With the knob turned to position 0 there is no gas flow befo...

Page 20: ...ill illuminate if the Thermal Overload intervenes See Thermal Overload on page 23 ii WIRE FEED SPEED CONTROL The WIRE FEED Rotary Control Knob with graduations from 0 to 10 is used to control the wire...

Page 21: ...D Attach the Earth Lead Clamp 1 NO GAS WELDING For NO GAS welding to take place the earth cable MUST be connected to the POSITIVE terminal and the torch lead to the NEGATIVE terminal as shown in FIG...

Page 22: ...weld Oneoftheproblemsexperiencedwithnovicewelders istheweldingwirestickingtothe contact tip This is as a result of the wire feed speed being too slow It is always better thereforetostartwithtoohighasp...

Page 23: ...ecured correctly to the cable Check the gas hose for security and serviceability As a general rule the power supply should be inspected internally at least annually Consult your CLARKE dealer WARNING...

Page 24: ...ted Note that a dowel is used to locate the two halves of the handle Ensure it is correctly lined up before tightening the five securing screws 9 Pull the hose so that it is as straight as possible an...

Page 25: ...rum brake tangle around wire Caution Do not over tighten drum inside machine 7 Erratic wire feed a Drum brake too tight a Loosen drum brake slightly b Feed roller worn b Check and replace if necessary...

Page 26: ...0 2 MIN 6 2 MIN 6 1 0 2 0 1 MAX 6 2 MAX 6 2 0 3 0 2 MAX 7 8 2 MAX 7 8 STEEL A B C 0 8 1 MIN 7 8 1 0 2 0 2 MIN 7 8 2 0 3 0 2 MAX 9 Workpiece Thickness mm Welding Position Wire Speed Adjustment 0 8 mm...

Page 27: ...MAX 7 2 MAX 7 3 0 2 MAX 7 8 2 MAX 7 8 STEEL A B C 0 8 1 MIN 6 1 0 2 0 2 MIN 6 2 0 3 0 2 MAX 7 8 Workpiece Thickness mm Welding Position Wire Speed Adjustment 0 8 mm Gas Welding Wire ALUMINIUM CONTROL...

Page 28: ...3 0 6 0 A 3 MAX 8 A 3 MAX 8 1 STEEL CONTROL SETTINGS REFERENCE TABLES B MIGs 151EN A B C D 0 6 0 8 A 2 MIN 5 0 8 1 0 A 3 MIN 6 1 0 1 2 1 2 3 MAX 6 1 2 2 0 A 2 MAX 6 2 0 3 0 A 3 MAX 8 Workpiece Thickn...

Page 29: ...WIRING DIAGRAMS MIG 100EN 105EN 30...

Page 30: ...PARTS DIAGRAM MIG 100EN 105EN 34...

Page 31: ...N33805074 15 Ball Bearing 1 EN21500001 16 Torch Grommet On Front Panel 1 EN21690001 17 Left upper Panel 1 EN33705032 18 Female Dinse Plug 2 EN22100002 19 Right upper Panel 1 EN33705031 20 Amber Pilot...

Page 32: ...60 For welding Stainless Thin Sheet MS 3 Welding Tips 0 6mm pack of 5 8132260 0 8mm pack of 5 8132270 1 0mm pack of 5 8132040 4 Gas Regulator 8132000 In addition to the above your Clarke dealer can pr...

Page 33: ...Y 10 minute period the machine may operate for 6 minutes and must have a down time of 4 minutes 90EN 100EN 105EN 151TE Power Supply 230V 50Hz 1Ph 230V 50Hz 1Ph 230V 50Hz 1Ph 230V 50Hz 1Ph Fuse Rating...

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