Clarke weld MIG 90EN User Manual (English)

Questions and Answers:

K
Kara VargasAug 14, 2025
Why does my Clarke weld MIG 90EN Welding System produce poor quality welds?
- P
  perrytroyAug 14, 2025
  Poor quality welds with the Clarke Welding System can result from several factors. First, ensure sufficient gas is reaching the weld area and that drafts aren't blowing it away; increase the gas supply if needed. Second, verify you're using the correct gas and wire combination, consulting your MIG welding manual for the proper setup. Also, the workpiece should be clean and dry, free from rust, paint, dampness, oil, or grease. The wire should also be clean and dry. Finally, check the earth clamp and workpiece connection to ensure good contact.
C
Charlotte WestAug 17, 2025
What to do if my Clarke weld MIG 90EN Welding System welder cuts out while in use?
- S
  Stephanie AlexanderAug 18, 2025
  If your Clarke Welding System cuts out during use, it's likely that the duty cycle has been exceeded, activating the auto cut-out. To resolve this, allow the welder to cool for 15-30 minutes before resuming operation. Be aware that repeatedly exceeding the duty cycle can damage the welder, and it might indicate that the welder's output is too small for the application.
T
Thomas GonzalezAug 20, 2025
Why is the wire feed erratic on my Clarke Welding System?
- L
  Leah DanielAug 21, 2025
  Erratic wire feed in your Clarke Welding System can stem from several causes. First, slightly loosen the drum brake if it's too tight. Second, inspect the feed roller for wear and replace it if necessary. Third, increase the pressure on the feed roller, but avoid over-tightening. Fourth, ensure the wire is clean and free from dirt, rust, dampness, or bends; re-cut the wire to ensure cleanliness. Lastly, clean the liner with compressed air if it's partially blocked.
J
Jessica HallAug 25, 2025
What to do if the wire welds itself to the tip on my Clarke Welding System?
- M
  mowenAug 25, 2025
  If the wire welds itself to the tip of your Clarke Welding System, it's likely due to one of two reasons. First, the wire feed speed might be too low. To fix this, unscrew the tip, cut the wire, fit a new tip, and increase the wire speed before operating again. Second, you might be using the wrong size tip. Ensure you fit the correct size tip for your wire.
J
Jonathan LopezAug 27, 2025
Why does the wire feed into a ‘birds nest’ tangle in my Clarke weld MIG 90EN Welding System?
- S
  Scott HernandezAug 27, 2025
  If the wire feeds into a 'birds nest' tangle with your Clarke Welding System, it could be due to a couple of reasons. First, the wire might be welded to the tip. Address this as described above, and also reduce the feed roller pressure so that if a blockage occurs, the wire slips on the roller, preventing further feed. Second, the wire liner may be damaged, preventing smooth operation. If so, renew the wire liner.
V
Veronica WoodsAug 30, 2025
What to do if the feed motor operates but wire will not feed on my Clarke weld MIG 90EN?
- A
  Andrew MossAug 31, 2025
  If the feed motor operates but the wire won't feed in your Clarke Welding System, check the following: Increase roller pressure. Re-cut wire square with no burr. Clean with compressed air or replace liner. Use only good “clean” wire and replace roller.
C
Christopher MillerSep 3, 2025
Why are there loose coils of wire tangling around the wire drum inside my Clarke Welding System?
- T
  Thomas RoweSep 3, 2025
  If loose coils of wire tangle around the wire drum inside your Clarke Welding System, the drum brake is likely too slack. Tighten the drum brake, but be careful not to over-tighten it.
H
hpittmanSep 6, 2025
Why does the wire jam in the tip when welding aluminum with my Clarke weld MIG 90EN?
- J
  johnsonemilySep 6, 2025
  If the wire jams in the tip when welding aluminum with your Clarke Welding System, the tip might be too small. Use a slightly oversized tip; for example, use a 1mm tip for 0.8mm wire. Note that this applies to aluminum only.
C
Chad DiazSep 9, 2025
How to troubleshoot no 'life' from Clarke weld MIG 90EN?
- P
  pughheatherSep 9, 2025
  To solve the problem with your Clarke Welding System, start by checking the fuses and mains lead. Replace fuses as necessary. If the problem persists return welder to your local dealer and check fuse size.

Clarke weld MIG 90EN Specifications

General

Input Voltage	230 V
Welding Current	30-90A
Max Output Current	90A
Wire Diameter	0.6 - 0.8 mm
Type	MIG
Duty Cycle	20% @ 90A
Cooling	Fan Cooled

Summary

Electromagnetic Interference (EMC)

Area Assessment for Interference

User must assess the surrounding area for potential electromagnetic problems before installation.

Methods for Reducing Emissions

Details on reducing electromagnetic emissions from the welding equipment during operation.

General Safety Precautions

Burn and Fume Prevention

Outlines general safety measures including burn and toxic fume prevention.

Fire and Explosion Prevention

Discusses causes of fire and explosion and preventative measures during welding.

Electric Arc Welding Safety

Burn Protection Measures

Details protective clothing and eye/head protection needed for electric arc welding.

Shock Prevention Measures

Essential safety measures to prevent electric shock during welding operations.

Pacemaker User Safety

Advice for individuals with electronic life support devices near welding.

Equipment Safety Details

Covers safe earthing, electrode holders, and connectors for welding equipment.

Working Area Preparation

Area Requirements and Ventilation

Specifies requirements for a safe, spacious, and well-ventilated welding work area.

MIG Welding Specific Safety

Essential MIG Safety Rules

Lists essential 'always' and 'never' rules for safe MIG welding operation.

No-Gas MIG Welding Principles

Welding Process Explanation

Explains the MIG welding process, wire feed, arc striking, and fusion.

Electrical Connections and Safety

Mains Supply and Fuse Details

Details on connecting the welder to the mains supply and fuse specifications.

Extension Cable Guidelines

Specifies minimum cross-section requirements for extension cables based on length.

Initial Setup Procedures

Unpacking and Part Identification

Instructions for unpacking, identifying, and checking components.

Assembly and Installation Guide

Loose Component Assembly

Guides on assembling loose parts for different models and the gas bottle.

Welding Shield Assembly Steps

Step-by-step instructions for assembling the welding shield with glass panels.

Welding Wire Installation

Spool Handling and Replacement

Procedure for removing and replacing the wire spool on the holder.

Wire Threading Process

Detailed steps for threading the welding wire through the machine and torch assembly.

Drive Roller Groove Selection

How to select and change the drive roller groove for different wire sizes.

Gas Welding Conversion

Parts Required for Gas Use

Lists necessary parts like welding wire, contact tips, gas regulator, and gas.

Gas Bottle and Regulator Attachment

Step-by-step guide on how to attach the gas bottle and regulator.

Pre-Operation Setup

Workpiece Preparation Importance

Emphasizes the importance of cleaning the workpiece for a good weld.

Control Panel Settings

Explains how to set the ON/OFF, Wire Feed Speed, and Welding Current controls.

Welding Wire Trimming

Instructions on trimming the welding wire to the correct length.

Earth Lead and Clamp Connection

Guides on connecting the earth lead for both NO-GAS and GAS welding.

Welding Operation

Welding Technique Guide

Step-by-step guide on how to approach the workpiece and initiate welding.

Thermal Overload Function

Explains the thermal overload feature and what to do when it activates.

Welding Tips and Best Practices

General Welding Advice

Provides tips on maintaining torch angle, speed, and keeping parts clean.

Maintenance and Care

Routine Maintenance Checks

Outlines regular checks for cables, earth clamp, gas hose, and internal power supply.

Wire Liner Maintenance

Wire Liner Replacement Steps

Step-by-step guide to replace a damaged or kinked wire liner.

Troubleshooting Common Issues

Problem Diagnosis and Resolution

Lists common problems with causes and remedies for the welder.

Control Settings Reference

MIG 90EN Control Settings

Provides recommended control settings for different materials and thicknesses for the MIG 90EN model.

MIG 100EN & 105EN Control Settings

Recommended settings for MIG 100EN and 105EN models across various materials and thicknesses.

MIG 151EN Control Settings

Recommended control settings for the MIG 151EN model for different materials and thicknesses.

Wiring Diagrams

MIG 90EN Wiring Diagram

Electrical schematic for the MIG 90EN model showing internal connections.

MIG 100EN & 105EN Wiring Diagrams

Electrical schematics for the MIG 100EN and 105EN models.

MIG 151EN Wiring Diagram

Electrical schematic for the MIG 151EN model illustrating its internal wiring.

Parts Diagrams

MIG 90EN Component Diagram

Visual representation of the MIG 90EN components with numbered parts.

MIG 100EN & 105EN Component Diagram

Exploded view of the MIG 100EN and 105EN models showing component locations.

MIG 151TE Component Diagram

Illustrates the physical layout and numbering of parts for the MIG 151TE model.

Parts Lists

MIG 90EN Parts List

Detailed list of parts for the MIG 90EN model with descriptions and part numbers.

MIG 100EN & 105EN Parts List

Comprehensive list of parts for MIG 100EN and 105EN with part numbers.

MIG151TE Parts List

Enumerates all parts for the MIG 151TE, including quantities and part numbers.

Optional Accessories

Available Welding Accessories

Lists optional accessories like welding wire, gas, tips, and regulators.

Support Information

Parts and Service Contact Details

Provides phone numbers and email addresses for parts and service inquiries.

Technical Specifications

Model Specifications Overview

Details key technical specifications for all MIG welder models including power, current, dimensions, and duty cycle.

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Clarke weld MIG 90EN User Manual

Table of Contents

Questions and Answers:

Clarke weld MIG 90EN Specifications

Summary

Electromagnetic Interference (EMC)

Area Assessment for Interference

Methods for Reducing Emissions

General Safety Precautions

Burn and Fume Prevention

Fire and Explosion Prevention

Electric Arc Welding Safety

Burn Protection Measures

Shock Prevention Measures

Pacemaker User Safety

Equipment Safety Details

Working Area Preparation

Area Requirements and Ventilation

MIG Welding Specific Safety

Essential MIG Safety Rules

No-Gas MIG Welding Principles

Welding Process Explanation

Electrical Connections and Safety

Mains Supply and Fuse Details

Extension Cable Guidelines

Initial Setup Procedures

Unpacking and Part Identification

Assembly and Installation Guide

Loose Component Assembly

Welding Shield Assembly Steps

Welding Wire Installation

Spool Handling and Replacement

Wire Threading Process

Drive Roller Groove Selection

Gas Welding Conversion

Parts Required for Gas Use

Gas Bottle and Regulator Attachment

Pre-Operation Setup

Workpiece Preparation Importance

Control Panel Settings

Welding Wire Trimming

Earth Lead and Clamp Connection

Welding Operation

Welding Technique Guide

Thermal Overload Function

Welding Tips and Best Practices

General Welding Advice

Maintenance and Care

Routine Maintenance Checks

Wire Liner Maintenance

Wire Liner Replacement Steps

Troubleshooting Common Issues

Problem Diagnosis and Resolution

Control Settings Reference

MIG 90EN Control Settings

MIG 100EN & 105EN Control Settings

MIG 151EN Control Settings

Wiring Diagrams

MIG 90EN Wiring Diagram

MIG 100EN & 105EN Wiring Diagrams

MIG 151EN Wiring Diagram

Parts Diagrams

MIG 90EN Component Diagram

MIG 100EN & 105EN Component Diagram

MIG 151TE Component Diagram

Parts Lists

MIG 90EN Parts List

MIG 100EN & 105EN Parts List

MIG151TE Parts List

Optional Accessories

Available Welding Accessories

Support Information

Parts and Service Contact Details

Technical Specifications

Model Specifications Overview

Related product manuals