Clarke WH215 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0320
WELDER GENERATOR
MODEL NO: WH215
PART NO: 8130535

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INTRODUCTION
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 document 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.
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
By purchasing this product, the customer is taking on the
obligation to deal with its safe disposal in accordance with the
Waste Electrical and Electronic Equipment (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 at a recognised disposal facility.
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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GENERAL SAFETY PRECAUTIONS FOR ALL TYPES OF
WELDING
FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY
GENERAL PRECAUTIONS
A) BURN PREVENTION
Wear protective clothing - gauntlet gloves designed for use in welding, apron,
and protective shoes. Button any shirt collar and pocket flaps, and wear
cuffless trousers to avoid entry of sparks and slag. Wear a helmet with safety
goggles or glasses with side shields underneath, appropriate filter lenses or
plates (protected by clear glass). This is a MUST for welding (and chipping) to
protect the eyes from radiant energy and spatter. Replace cover glass when
broken, pitted, or spattered. Avoid oily greasy clothing. A spark may ignite
them. Hot metal should never be handled without gloves. First aid facilities and
a qualified first-aid person should be available unless medical facilities are
close by, for immediate treatment of flash burns of the eyes and skin burns. Ear
plugs should be worn when working overhead or in a confined space. A hard
hat should be worn when others are working overhead. Flammable hair
preparations should not be used by persons intending to weld or cut.
NOTE: ALL protective wear including masks & head shields MUST comply
with PPE Directive 89/686/EEC
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 air-supplied respirator. For beryllium, both must be
used. Metals coated with or containing materials that emit toxic fumes should
not be heated unless any coating is removed from the work surface, the area
is well ventilated, or the operator wears an air-supplied respirator. Only work in
a confined space when it is being force ventilated and, if necessary, while
wearing an air-supplied respirator. Vapours from chlorinated solvents can be
decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly
toxic gas, and other lung and eye irritating products. The ultraviolet (radiant)
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.

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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.
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 goggle wearing operator.
To prevent fires and explosion: keep equipment clean and operable, free of
oil, grease, and (in electrical parts) of metallic particles that can cause short
circuits. If combustibles are in the area, do NOT weld. Move the work if
practicable, to an area, free of combustibles.
Avoid working in paint spray rooms, dip tanks, storage areas, ventilators. If the
work cannot be moved, move any combustibles away from sparks and heat
or protect against ignition with suitable fire- resistant covers or shields.
Walls, ceilings and floors near the work should be protected by heat resistant
covers or shields. A ‘fire watcher’ must be standing by, with suitable fire
extinguishing equipment during, and for some time after welding or cutting if:
1. appreciable combustibles are within 10m.
2. appreciable combustibles are further than 10m but can be ignited by
sparks.
3. openings (concealed or visible) in floors or walls can expose combustibles
to sparks.
4. combustibles adjacent to walls, ceilings, roofs or metal partitions can be
ignited by radiant or conducted heat.
After work, check that area is free of sparks, glowing embers and flames. An
empty container that held combustibles or that can produce flammable or
toxic vapours when heated, must never be welded on or cut, unless the
container has first been cleaned. This includes a thorough steam or caustic
cleaning (or a solvent or water washing, depending on the combustible’s
solubility) followed by purging and inerting with nitrogen or carbon dioxide,
and using protective equipment.
Water filling just below the working level may substitute for inerting.

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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.
ELECTRIC ARC WELDING
Comply with the precautions above and this section. Arc welding, properly
done, is a safe process, but a careless operator invites trouble. The equipment
carries high currents at significant voltages. The arc is very bright and hot.
Sparks fly, fumes rise, ultraviolet and infrared energy radiates and work pieces
are hot. The wise operator avoids unnecessary risks and protects himself and
others from accidents.
A) BURN PROTECTION
The welding arc is intense and visibly bright. It’s radiation can damage eyes,
penetrate lightweight clothing, reflect from light coloured surfaces and burn
the skin and eyes. Skin burns resemble acute sunburn, those from gas -
shielded arcs are more severe and painful.
DON’T GET BURNED! FOLLOW ALL SAFETY PRECAUTIONS!
PROTECTIVE CLOTHING
Wear long sleeved clothing (particularly for gas shielded arc) in addition to
gloves, apron and strong shoes. As necessary, use additional protective
clothing such as leather jacket or sleeves, flameproof apron and fire-resistant
leggings. Avoid outer garments of untreated cotton. For bare skin protection
wear dark substantial clothing Keep collars closed to protect the chest and
neck and button any pockets to prevent entry of sparks.
EYE AND HEAD PROTECTION
Protect your eyes from exposure to arc. NEVER look at an electric arc without
a welding helmet or shield containing an appropriate filter plate (Please refer
to the section ‘Welding Shield). Always place over the face before striking an
arc. Protect the filter plate with a clear cover plate. Any 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 the clear cover plate when broken, pitted, or spattered. WE SUGGEST
you wear flash goggles with side shields under the helmet, to give some
protection to the eyes should the helmet not be lowered over the face before
an arc is struck. Looking at an arc momentarily with unprotected eyes
(particularly high intensity gas-shielded arc) can cause a retinal burn that may

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leave a permanent dark area in the field of vision. Before welding whilst
wearing contact lenses, seek advice from your optician.
PROTECTION OF NEARBY PERSONNEL
For production welding, a separate, well vented room or enclosed bay is best.
In open areas, surround the operation with low reflection, 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.
B) TOXIC FUME PREVENTION
Comply with all precautions in 1B.
C) FIRE AND EXPLOSION PREVENTION
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.
D) 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.
E) PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT
DEVICES (PACEMAKERS)
Magnetic fields from high currents can affect pacemaker operation. Persons
wearing pacemakers should consult with their doctor before going near arc
welding or spot welding operations.
F) PROTECTION AGAINST SHOCK
Keep your body and clothing dry. Never work in a damp area without
adequate insulation against electric shock. Stay on a dry duckboard or rubber
mat when dampness or sweat can not be avoided. Sweat, sea water, or
moisture between your 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.

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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 the
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.
2) TORCH
A fully insulated torch should be used without protruding screws or other
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 bare cable. Cables with damaged areas may be taped to
give resistance equivalent to original cable. Keep the 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.

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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. A power disconnect switch
must be available near the welding power source.
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.
ASSESSMENT OF THE 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:
• other supply cables, control cables, signalling and telephone cables;
above, below and adjacent to the welding equipment;
• radio and television transmitters and receivers;
• computer and other control equipment;
• safety critical equipment, e.g. guarding of industrial equipment;
• pacemakers and hearing aids etc;
• equipment used for calibration or measurement;

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• 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.
METHODS OF REDUCING EMISSIONS
MAINS SUPPLY
Welding equipment should be connected to the mains supply according to
the manufacturers recommendations. If interference occurs, it may be
necessary to 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.
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.
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.
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.
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. a ships hull or building
steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances.

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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.
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.