USER INSTRUCTIONS 200AMP WELDER GENERATOR Model No: WH215 Part No: 8130535

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200AMP WELDER GENERATOR
Model No: WH215
Part No: 8130535
USER INSTRUCTIONS
0706
CONTENTS
Guarantee ...................................................................................................................... 1
Technical Specification ................................................................................................. 2
Generator:
Important Safety Precautions ............................................................. 3
General Safety Precautions ................................................................ 3
Preparation For Use .............................................................................. 5
Extension Cables ................................................................................... 5
Operation .............................................................................................. 6
Shutting Down The Machine ............................................................... 6
Welding:
EMC Regulations ................................................................................... 7
General Safety Precautions ................................................................ 9
ARC Welding Safety Precautions ..................................................... 11
Work Area Preparation ...................................................................... 14
Features ............................................................................................... 15
Thermal Overload .............................................................................. 15
Preparation for Welding ..................................................................... 15
Welding Technique ............................................................................. 17
Duty Cycles ......................................................................................... 21
Electrical Symbols Explained ............................................................. 22
Maintenance .............................................................................................................. 23
Trouble Shooting ........................................................................................................... 23
Declaration of Conformity .......................................................................................... 24
Waste electrical products should not be disposed of with household waste. Please dispose of at your local
recycling facility.
Please Note that details and specifications herein, are correct of time of going to print.
However CLARKE International reserve the right to change specifications at any time without prior notice.
Copyright CLARKE International All rights Reserved 2006.
2
Thank you for purchasing this CLARKE Welder Generator, designed to provide
single phase electrical power for power or arc welding. No other appliance other
than those indicated should be used with this machine.
Please read through this instruction leaflet, and the instruction manuals for the
engine and alternator thoroughly before operating the machine, in doing so you
will ensure the safety of yourself and that of others around you, this will also ensure
that the welder generator will give you long and satisfactory service.
It is important that all accompanying instructions are observed. Clarke International
does not accept responsibility for any injury or damage caused through improper
use.
Please keep these instructions in a safe place for future reference as they are to
be considered an integral part of the machine and must be produced in the
event of sale.
CLARKE 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 is 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.
3
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
4
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.
2
SAFETY PRECAUTIONS
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
1. GENERAL PRECAUTIONS
A) Burn prevention
Wear protective clothing - gauntlet gloves designed for use in welding, hat, 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 flying metal. 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 for each shift 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 touching combustibles on opposite sides should not be welded on (or cut).
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.
7
2. ELECTRIC ARC 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.
2A) 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, hat 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.
8
2B) TOXIC FUME PREVENTION
Comply with precautions in 2-B. Engine exhaust must be vented to the outside air.
Carbon monoxide can kill.
2C) FIRE AND EXPLOSION PREVENTION
Comply with precautions in 2-C. 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.
2D) 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.
2E) PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT 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.
2F) 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 work 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.
9
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 hat 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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FIRE PREVENTION
•
ALWAYS switch the engine OFF when refuelling.
•
ALWAYS refuel away from any source of heat.
•
ALWAYS refuel in a well ventilated area.
•
NEVER overfill fill the tank, fill to the level specified.
•
NEVER smoke whilst refuelling and avoid smoking or using a naked flame
near the machine.
•
NEVER start the engine if there is a fuel spill. Any spillage must be wiped
clean and the machine allowed to dry before attempting to start the engine.
•
ALWAYS store the machine undercover when not in use and away from
damp or wet conditions.
•
NEVER use the machine when it is raining or snowing or in wet or damp
conditions.
•
NEVER operate the machine with wet hands.
•
NEVER use water or any other liquids to clean the unit.
PREVENTION OF ELECTRIC SHOCK
POSITIONING THE MACHINE FOR USE
•
ALWAYS leave at least a 1 metre gap between the machine and any
surrounding building or structure.
•
ALWAYS ensure the machine is on a solid, flat surface.
•
ALWAYS ensure the surrounding area is free from any material that could
burn or be damaged by heat.
•
NEVER move or tilt the machine whilst it is switched on.
•
NEVER cover or enclose the machine whilst it is in use.
•
Be aware of the weight of the machine, do not attempt to lift or move the
machine without the assistance of other personnel or suitable lifting equipment.
EXHAUST GAS PRECAUTIONS
WARNING!: EXHAUST FUMES CAN BE FATAL.
•
ALWAYS ensure that there is adequate ventilation when using the machine.
•
ALWAYS position the machine so that the exhaust is pointing away from
people or animals.
•
If the machine is to be used indoors, the exhaust MUST be piped to
atmosphere
11
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 inflammable residuals.
SAFETY EQUIPMENT
A comprehensive range of CLARKE safety equipment for use when welding is
available from your local CLARKE dealer.
ADDITIONAL SAFETY PRECAUTIONS FOR ARC WELDERS
✗
✗
✗
✗
✗
NEVER attempt to remove any of the panels unless the machine is
disconnected from the supply.
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.
NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN.
NEVER allow children or animals in the vicinity of a welding operation.
✔ ALWAYS remove all flammable materials from the welding area.
ensure that there is full free air circulating around the outer casing of
✔ ALWAYS
the machine, and that the louvres are unobstructed.
arc can seriously damage your eyes. Both the operator and any
✔ Welding
spectators should ALWAYS use a proper welding face shield or helmet, with
suitable filter lenses. Proper gloves and working clothes should be worn at all
times.
wear a pair of safety spectacles/goggles when chipping away slag
✔ ALWAYS
after welding,. Remember, ordinary eye glasses are not safety gasses.
ensure there is adequate ventilation or extraction in the work area
✔ ALWAYS
as the welding process gives off toxic fumes.
✔ ALWAYS ensure there is a fire extinguisher on hand.
ensure that a medical supply is on hand, and that treatment for
✔ ALWAYS
burns is provided.
12
PREPARATION FOR USE
Fuelling:
Fill with fuel, according to the instructions within the engine manual.
NOTE: Always use a fuel funnel to fill the tank so as to avoid accidental spillage of
fuel. If fuel is spilled it must be removed from the unit and the surrounding
area, BEFORE attempting to start the engine.
WARNING:
•
Observe all safety precautions when handling fuel. Always refuel in a
well ventilated area away from any heat sources.
•
Ensure there is adequate fuel in the tank when using the machine.
Running out of fuel or stopping the engine suddenly with a load
connected could cause serious damage.
•
Allow the unit to cool down before refuelling.
•
Be aware that fuel and lubricants are potentially carcinogenic, direct
skin contact should be avoided, wear suitable rubber gloves.
EXTENSION CABLES
All extension cables, from the generator set to the appliance, must be carefully
selected, fitted and maintained. Cables in accordance with IEC 245-4 should
be used.
Cables should be inspected regularly, and should be replaced, not repaired in
the event of a defect.
The length and cross section of conductors should be selected according to
the job to be done. The table below is an indication of the sizes that should be
used.
Conductor (mm2)
Max. Length (M)
Current (Amps)
Single Phase (kW)
1.5
25
10
2.3
2.5
40
16
3.7
4.0
60
28
6.5
IMPORTANT! Ensure the cable is fully unwound when in use to avoid overheating,
and the placing of extra load on the generator.
13
OPERATION - GENERATOR
IMPORTANT! Ensure all precautions are taken, referring to this and the engine
manual, before proceeding.
1.
Start the engine. (refer to engine manual) and allow to run for a few minutes
at full speed in order for it to warm up.
IMPORTANT! Ensure no appliances are connected to the generator when starting
the engine.
2.
Check the condition of the appliance, including the supply cable and the
extension cable if used, and ensure it is switched OFF. Ensure also that the
operating voltage is the same as the output from the generator.
3.
Ensure the voltage selector switch, shown at ‘C’ Fig.2 is set to the deliver the
appropriate output - 115V or 230V.
Fig.1
Fig.2
4.
Turn theGen/Weld knob ‘A’ Fig1, to GEN.
5.
Turn the Welding Current
knob - ‘B’ Fig.1, to
GEN 230V
6.
With the engine running
smoothly, connect the
appliance to the
appropriate receptacle:
BLUE - 230V,
YELLOW - 115V.
5.
Switch ON the appliance.
NOTE: If the AC circuit is overloaded the
circuit protection switch will trip. To reset the
circuit, first disconnect the appliance, and
rectify the cause of the overload. Wait a
short period and then press the appropriate
reset button, shown at ‘A’ and ‘B’, Fig.2.
BE AWARE!
Some appliances draw more current on
start-up than their normal running current,
i.e. electric motors, and compressors. If in
any doubt as to whether an appliance is
compatible or not, please consult your
CLARKE dealer.
Additionally, please refer to the
specifications, to ensure the machine is used
under the correct operating conditions.
14
OPERATION - WELDING
The welding capabilities of your welder are given on the data label printed on the rear
panel of the machine, and reproduced on page 16 . An explanation of markings and
symbols appearing on the data label is shown on page 21.
Thermal Overload Protection
If the duty cycle of the welder is exceeded (see Specifications), the Overload Protection
Device will automatically cut the power to prevent damage to the machine. Should the
cut-out operate, you will have to wait until the transformer cools down (approx. 30 minutes),
when the overload device will automatically reset itself.
Although no harm will be done to the machine if/when the overload device is
actuated, its frequent use could eventually result in damage.
Preparation for Welding
1. Set the GEN/WELD knob - ‘A’, Fig.1 to WELD
2. Set the Welding Current knob - ‘B’, Fig.1, to the appropriate welding current,
noting that TWO ranges are provided - HIGH and LOW.
High range is indicated in RED, Low range in BLACK
3. Connect the welding lead to the appropriate DIN socket:
135Amp - LOW range
200Amp - HIGH range.
4. Connect the earth lead to the COM DIN socket.
Ensure the earth lead is connected to the work piece.
IMPORTANT: Ensure also that the earth clamp is attached to clean, solid metal.
If necessary thoroughly clean with a wire brush or similar to guarantee a
good connection.
5. Select the appropriate electrode, which should be approximately the same
thickness as the piece to be welded, for single pass welding.
NOTE: With practice you will get a feel for the best current settings for different
welding rod thicknesses.
The chart below is an indicator of the thickness of material/welding rod thickness
and the corresponding welding current. This is intended as a guide only.
SIZE OF WELDING ROD
THICKNESS OF METAL
CURRENT SETTING
1/l6 16 swg
1.5 mm
40-55
14 swg
12 swg
2.0 mm
2.5 mm
60-75
75-105
1/8 10 swg
3.25mm
4.0 mm
105-135
135-200
15
SHUTTING DOWN THE MACHINE
IMPORTANT! Never switch OFF the engine whilst an electrical appliance is connected.
1.
Switch OFF the electrical appliance.
2.
Unplug the appliance from the generator.
3.
Switch the engine OFF (refer to engine manual).
4.
Turn the fuel OFF (refer to engine manual).
DUTY CYCLES
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. using the example above:
When welding at 170 Amps 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 120 Amps.
16
MAINTENANCE
•
Check all cables periodically; they must be in good condition and not
cracked.
•
Always ensure the generators air vents are completely clear. Brush away
any dust which may have accumulated.
•
The engine requires periodic servicing. Please refer to the engine manual for
details.
•
If the machine is not going to be used for some time, the engine must be
adequately prepared. Please refer to the engine manual for details.
IMPORTANT - ALWAYS switch the engine OFF before servicing or cleaning.
ELECTRICAL TROUBLE SHOOTING
PROBLEM: No AC Output.
CAUSE:
TROUBLE SHOOTING:
Selector switch in wrong position.
Set selector switch.
Tripped circuit breaker.
Reset AC safety trip.
Poor connection or faulty lead.
Check connection and/or replace
lead.
Broken AC connector.
Contact CLARKE servicing.
Faulty circuit breaker.
Contact CLARKE servicing.
PROBLEM: Erratic Supply.
CAUSE:
TROUBLE SHOOTING:
Incorrect engine RPM.
Set engine RPM - Consult your CLARKE
dealer.
Internal alternator problem.
Contact CLARKE servicing.
ENGINE TROUBLE SHOOTING
Consult the engine manual.
17
WELDING TECHNIQUE
1.
With the welder correctly connected to the mains supply and the leads
attached to the machine, ensure the earth clamp is firmly attached to the
workpiece on CLEAN, SOLID metal, and as close to the proposed weld as is
practical, and the appropriate current setting for the job has been set.
2.
Start the engine
NOTE:
If the machine stops at any time and the amber light on the front panel illuminates,
the thermal cutout has intervened. Wait until the transformer has cooled sufficiently
for work to recommence. This could take considerable time and is denoted by
the amber light going OUT.
3.
Bring the electrode to the work surface at an angle of approx. 70O then,
BEFORE you strike an arc, bring the face shield up to protect your eyes.
Strike an arc by briefly touching the work surface with the tip of the electrode.
Once the arc is struck or primed, raise the electrode slightly and maintain it at a
distance of approx 1.5mm (1/16”) from the work surface, then proceed to move
the electrode along its intended path, keeping the tip in the molten pool at all times
An even crackling noise should be heard, which is an indication of a good weld.
NOTE:
This is the most difficult aspect for most beginners. It is recommended that you
practice on some scrap material in order to get a feel of the operation.
If the electrode is not withdrawn quickly enough once the arc is primed, there is a
possibility that the electrode will weld itself to the workpiece. Should this happen,
give it a sharp tug to free it, and try again. If this fails to free it, turn OFF the machine
immediately as it will quickly overheat.
If you withdraw the electrode too far once the arc is primed, you will lose the arc
and have to try again.
4.
Inspect the job carefully. With a correct combination of electrode size and
current setting the area of weld should be complete fusion of the electrode
and parent metal/s. Any slag which forms on the surface should be chipped
away with a pick/brush.
If the resultant weld looks messy and irregular, this is an indication of porosity
or slag contamination, and you have almost certainly failed to achieve the
correct combination. This is a common problem, so do not worry as practice
will quickly cure this.
The following tips should help you improve your welding technique fairly quickly.
WARNING
When welding ALWAYS ensure there is adequate ventilation in the
work area as the welding process give off toxic fumes
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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.
1. Arc too short
5. Current too low
This causes irregular masses of weld to
be deposited, with slag contamination
on an uneven surface.
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.
2. 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
6. 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.
3. 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.
7. 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.
4. Electrode moved too quickly
This causes poor penetration with a
This should be regular with uniform
ripples and no slag contamination.
‘stringy’ and incomplete weld deposit. Slag
is very hard to remove.
The arc will make a steady, even
crackling sound.
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ELECTRICAL SYMBOLS EXPLAINED
The full technical specification for your welder is to be found printed in a table on the rear
panel of the machine.
The meaning of the markings and symbols shown in the table are explained as follows.
Symbol for dropping characteristic
Symbol for manual arc welding and covered electrodes
Symbol for the mains supply and No. of phases
X
Duty Cycle, expressed as a % in a 10 min period
1~
Single Phase Transformer
_1~
_ V Min. and Max. rated no load voltage
U 0__
50Hz
I2
__A
__
mm
I2 A
Rated frequency for alternating current
Min. and Max. rated value of the welding current
Symbol and dimension for the diameter of reference electrodes
Symbol and dimension for the welding current
nc
Symbol for the number of reference electrodes capable of
being melted with the welding power source, starting from the
cold state without operation of the thermal cut-out
nh
Symbol for the No. reference electrodes being melted with the
welding power source at the hot state, without operation of
the thermal cut-out.
E/h
No. Electrodes that can be burned per hour from the cold state
U 1_ _ _V
__A
I1 max_ _A
Rated value of the supply voltage
Size of the necessary main fuse
Symbol, rated value and dimension of the max. supply current
IP_ _
Degree of protection (e.g. IP21)
H
Code letter for degree of insulation
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TECHNICAL SPECIFICATION
Description:
Model: .................................................................................................................... WH215
Part No: ................................................................................................................ 8130535
General Specifications:
Output: (min/max) ................................................................................... 60 - 200 amps
Open Circuit Voltage: ......................................................................................... 45 - 48V
I.P. Rating: ...................................................................................................................... 23
Electrodes:
Diameters: .................................................................................................... 4 mm (max)
Material Type: ............................................................................................................ ARC
Output Cable Assembly:
Length: .......................................................................................................................... 6m
Cross Sectional Area: .......................................................................................... 25 mm²
Plug Type: .......................................................................................................... DIN Small
Welding Gun Type: ............................................................................ 400A (screw type)
Engine Specifications: (refer to engine manual for complete specifications)
Type: ......................................................................................................................... Petrol
Make: ..................................................................................................................... Honda
Model: ..................................................................................................................... GX390
Capacity: ...................................................................................................... 389 cc/cm³
Oil Capacity: ....................................................................................................... 1.1 Litres
Lubrication Grade: ............................................................................................... 10W 30
Air Filter Type: ............................................................................................................... Dry
Starting System: ........................................................................................................... Pull
Engine Power: ........................................................................................................... 13HP
Fuel Tank Capacity: ........................................................................................... 6.5 Litres
Spark Plug Type: .................................................................................................. BPR 6ES
Fuel Type: ........................................................................................................ UNLEADED
Fuel Consumption: ......................................................................................... 313 g/KwH
Fuel Consumption: (@75% Power) ....................................................... 2.15 Litres/Hour
Cooling System: ............................................................................................................ Air
Choke Type: ......................................................................................................... Manual
Auxiliary Generator: (refer to alternator manual for complete specifications)
Rated Output Power: ...................... 6.5kVA @ 230V (5.2kW) / 4kVA @ 115V (3.2kW)
Rated Output: ........................................................ 23amps @ 230V / 35amps @ 115V
Operating Voltages: .............................................................................. 230/115V - 1ph
Run Time @ Rated Load: (max) .......................................................................... 2 hours
Earthing Type: ..................................................................................................... Floating
Operating Temperature: ........................................................................... -20°C ~ 40°C
Number of Sockets: .................................... 2 x 16amps @ 230V / 2 x 16amps @ 115V
Noise Emissions:
Noise @ 7m: ......................................................................................................... 72dB(A)
Sound Power Measured: ................................................................................... 97dBLWA
Sound Power Guaranteed: ............................................................................... 97dBLWA
Dimensions/Weights:
Product:(LxWxH) ............................................................................... 945 x 690 x 685mm
Weight: ....................................................................................................................... 88Kg
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