Weldclass WC-210MST Operating Instructions Manual Download Page 1

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Weldforce 210

MST

& 250

MST

© Weldclass 2020 | E.&O.E.

Weldforce 210MST & 250MST

Synergic MIG – Stick – TIG

Edition 2.7

OPERATING INSTRUCTIONS



IMPORTANT!

To qualify for full 24 month warranty, you must register within 30 days of purchase. See inside for details.

Read these Operating Instructions Completely before attempting to use this machine. Save this manual and

keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for

your protection. Contact your distributor if you do not fully understand anything in this manual.

Summary of Contents for WC-210MST

Page 1: ...you must register within 30 days of purchase See inside for details Read these Operating Instructions Completely before attempting to use this machine Save this manual and keep it handy for quick ref...

Page 2: ...on warranty period and terms can be found at www weldclass com au WarrantyInfo Please register your warranty now by going to www weldclass com au weldforcewarranty You will need a A copy of your purc...

Page 3: ...3 Function Selection 20 4 3 1 Soft Start Adjustment SYN MAN 22 4 3 2 Inductance SYN MAN 22 4 3 3 Burnback Adjustment SYN MAN 22 4 3 4 Post Gas Time SYN MAN 22 4 3 5 Trigger Function SYN MAN 22 4 3 6 S...

Page 4: ...e SYN 34 7 2 Stick MMA Welding Operation 35 7 3 Lift TIG Operation 36 8 ACCESSORIES SPARE PARTS CIRCUIT DIAGRAMS 37 8 1 MIG Torch and Spares 37 8 2 TIG Torch and Spares Optional Extra 38 8 3 Optional...

Page 5: ...ypical MIG Applications 56 11 11 Welding wire Size Selection 56 11 12 MIG Welding Troubleshooting 57 11 12 1 Porosity Problems 57 11 12 2 Wire Feed Problems 58 11 12 3 Weld Quality Problems 59 12 STIC...

Page 6: ...Typical TIG Welding Settings 73 13 2 TIG Welding Troubleshooting 74 14 KNOWLEDGE RESOURCES 75 15 SAFETY 75 15 1 Store and Retain this Manual 75 15 2 Important Safety Information 75 15 3 Welding Opera...

Page 7: ...g Standard AS 60974 1 Power Supply 240V 15 50hz Single Phase See further information under section 5 of this manual Factory Fitted Supply Plug Rating 10A Maximum Input Current I1max 32A Output Termina...

Page 8: ...Duty Cycle 150A 16 0V 30 100A 14 0V 60 80A 13 2V 100 Nominal Open Circuit Voltage Uo 78V Table 2 This table applies when utilizing 10A power supply mode Refer to 5 1 1 1 Machine output on 10A mode is...

Page 9: ...d AS 60974 1 Power Supply 240V 15 50hz Single Phase See further information under section 5 of this manual Factory Fitted Supply Plug Rating 15A Maximum Input Current I1max 38A Output Terminals Dinse...

Page 10: ...A Duty Cycle 180A 17 2V 25 130A 15 2V 60 100A 14 0V 100 Nominal Open Circuit Voltage Uo 60V Table 5 This table applies when utilizing 20A power supply Refer to 5 1 1 1 This table applies if machine is...

Page 11: ...orch 3 Earth Clamp 4 MIG Torch Euro Connector 5 Positive Dinse Socket 6 Negative Dinse Socket 7 MIG Torch Polarity Change Tail 3 2 Machine Rear 13 Mains Power Switch 14 Gas Inlet Connection 15 240V AC...

Page 12: ...12 Weldclass 2020 E O E 3 4 Control Panel 21 Top Selection Knob 22 Bottom Selection Knob 23 LCD Screen Figure 4...

Page 13: ...or 26 Wire Size Indicator 27 Gas Type Indicator 28 Material Thickness Setting 29 Material Thickness Indicator 30 Inductance Setting Indicator 31 Amperage Setting 32 Voltage Setting 33 Wire Speed Setti...

Page 14: ...nductance Control Inductance Control Burnback Control Post Gas Control Torch Trigger Mode Spot Welding Mode Amperage Current Voltage Manual MIG Welding Mode Synergic Auto MIG Welding Mode Wire Diamete...

Page 15: ...Weldforce 210MST 250MST Weldclass 2020 E O E 15 TIG GTAW Function Power Supply Connection Single Phase Direct Current DC Negative Positive Hertz cycles sec Duty Cycle Table 7...

Page 16: ...igure 8 3 Press the Top Selection Knob 21 to select the process 4 1 1 MIG Process In Manual MIG mode MAN the Top Selection Knob 21 adjusts wire speed and the Bottom Selection Knob 22 adjusts the volta...

Page 17: ...lable in SYN process mode 1 Ensure Synergic MIG mode is selected 2 Press and hold the Bottom Selection Knob 22 for 3 seconds until the program number is displayed on the screen 3 Rotate the Bottom Sel...

Page 18: ...xed Argon CO2 2 0 8mm 3 0 9mm 4 1 0mm 5 0 6mm CO2 6 0 8mm 7 0 9mm 8 1 0mm 9 0 8mm Stainless Steel Ss Argon O2 10 0 9mm 11 1 0mm 12 0 8mm Stainless Steel Ss Argon CO2 13 0 9mm 14 1 0mm 15 0 8mm Alumini...

Page 19: ...CO2 Mixed 2 0 8 3 0 9 4 1 0 5 1 2 6 0 6 CO2 7 0 8 8 0 9 9 1 0 10 1 2 11 0 8 Stainless Steel Ss Argon O2 12 0 9 13 1 0 14 0 8 Argon CO2 15 0 9 16 1 0 17 0 8 Aluminium Argon Ar 18 0 9 19 1 0 20 0 8 Gas...

Page 20: ...and the Bottom Selection Knob 22 for 3 seconds until the Menu number is displayed on the screen Figure 11 2 Rotate the Bottom Selection Knob 22 until the desired Menu Function number is displayed Figu...

Page 21: ...dforce 210MST 250MST Weldclass 2020 E O E 21 4 Rotate the Bottom Selection Knob 22 to adjust the Function Setting Figure 14 5 Press the Bottom Selection Knob 22 to confirm the setting Figure 15 Table...

Page 22: ...ent stops If the wire feed and current is stopped at exactly the same time the wire will still be hot and will burn back and stick to the welding tip If this problem is happening increasing the burnba...

Page 23: ...s with different types of electrode and arc length the welding voltage varies to keep the current constant This can cause instability in some welding conditions as Stick welding electrodes will have a...

Page 24: ...ALARM 02 and Welding secondary thermal over temperature error This is a safety device to protect the machine from overheating The machine will not weld until the machine has cooled down sufficiently...

Page 25: ...ber is displayed on the screen 3 Rotate the Bottom Selection Knob 22 until Menu 5 PLG is displayed 4 Press the Bottom Selection Knob 22 The PLG Function Indicator should flash 5 Rotate the Bottom Sele...

Page 26: ...lding up to approximately 200A To enable full output and duty cycle of this welder minimum recommended generator size is 15kVa or larger 5 3 2 Generator Quality Warranty Limitations Avoid using poor l...

Page 27: ...equirements of IP23S as outlined in AS 60529 This provides adequate protection against solid objects greater than 12mm and direct protection from vertical drops Under no circumstances should the unit...

Page 28: ...g Nut Spring c Remove Flange Spacer d Fit the wire spool to the Spool Post ensuring that the wire spool is positioned so that the wire will exit from bottom of spool e Replace Flange Spacer Note orien...

Page 29: ...wire spool is positioned so that the wire will exit from bottom of spool e If using D200 5kg spools Replace Flange Spacer s As some 5kg spools vary in width additional thin spacer is supplied with ma...

Page 30: ...ther causes of excess wire feeding friction causing slippage first such as incorrect worn drive roller worn damaged torch consumables blocked damaged torch wire guide liner before increasing wire feed...

Page 31: ...orce 210MST Figure 18 Weldforce 250MST Figure 19 Tension Arm Tension Lever Knob Drive Roller Wire Inlet Guide Drive Roller Retainer Cap Wire Outlet Tube Tension Arm Tension Lever Knob Drive Roller Wir...

Page 32: ...with the work piece must be firm contact with clean bare metal with no corrosion paint or scale at the contact point 3 Connect the MIG Torch Polarity Change Tail to the Negative Dinse Socket for 210MS...

Page 33: ...e Positive Dinse Socket 210MST or Positive Torch Terminal 260MST Note if this connection is not made there will be no electrical connection to the welding torch 4 Connect the gas regulator to a gas cy...

Page 34: ...d 5 Ensure specific Aluminium contact tip to suit chosen wire or a standard tip in one size oversize e g 1 0mm aluminium wire use standard 1 2mm contact tip TIP For above reasons it is quite common fo...

Page 35: ...ectrode holder and work lead to the Positive Dinse Socket 5 NOTE This polarity connection configuration is valid for most GP General Purpose MMA electrodes There are variances to this If in doubt chec...

Page 36: ...ust be firm contact with clean bare metal with no corrosion paint or scale at the contact point 3 Insert TIG torch power connection into the Negative Dinse Socket 4 Connect TIG torch gas line to the G...

Page 37: ...ss com au BZL25parts BZL 25 Torch Parts Ref Part No Description WC 03614 Complete BZL 25 Torch 3m WC 03615 Complete BZL 25 Torch 4m 1 P3 B25SN Neck 2 P3 B25NS Nozzle Spring Pk2 3 P3 B25TH Tip Holder P...

Page 38: ...k2 WC 57Y05P Back cap Medium Pk2 WC 57Y04P Back cap Short Pk2 P3 10N23 Collet 1 6mm P3 10N24 Collet 2 4mm P3 10N25 Collet 3 2mm P3 10N31 Collect Body 1 6mm Pk2 P3 10N32 Collect Body 2 4mm Pk2 P3 10N28...

Page 39: ...ive Rollers Part No Drive Roller WC 06422 V Groove Steel 0 6mm 0 8 0 9mm WC 06425 Knurled Flux Cored 0 8 0 9mm 1 2mm WC 06426 U Groove Aluminium 0 9 1 0mm V Groove Steel 0 9 1 0mm Table 14 Weldforce 2...

Page 40: ...lter 15 Transformer X Flyback 16 Output Inductor 17 Power Transformer 18 Rear Plastic Panel 19 Handle 20 Door Handle 21 Control Panel Protector Frame 22 Front Plastic Panel 23 Cable Gland 24 Rear Meta...

Page 41: ...Weldforce 210MST 250MST Weldclass 2020 E O E 41 Figure 25 Figure 26...

Page 42: ...ide Panel 23 Dinse Socket 24 Dinse Plug 25 Earth Clamp 26 Drive Roller Fe 27 Torch Connection 28 Drive Roller Alu 29 Anchor for Pressure Roller 30 MIG Torch 31 Wire Conduit Table 17 Ref Description 32...

Page 43: ...Weldforce 210MST 250MST Weldclass 2020 E O E 43...

Page 44: ...44 Weldclass 2020 E O E 8 6 Primary Schematic Circuit Diagram Weldforce 210MST Figure 27...

Page 45: ...Weldforce 210MST 250MST Weldclass 2020 E O E 45 Weldforce 250MST...

Page 46: ...can force dirt and dust further into components causing electrical short circuits 10 Check for damaged parts WARNING Before performing cleaning maintenance replacing cables connections make sure the w...

Page 47: ...used to conduct the welding current to the job MMA welding is commonly known as stick electrode or arc welding 10 2 1 2 Process The MMA process involves the electrode being touched on the job to ignit...

Page 48: ...n which can be used to weld a variety of materials including mild steels stainless steels copper and chrome moly Note TIG welding is often associated with welding of aluminium however aluminium TIG we...

Page 49: ...speed settings well to achieve a quality result However the Synergic programs on this machine make this this very easy and much more foolproof 10 2 3 5 Materials MIG welding can be used with a wide va...

Page 50: ...50 Weldclass 2020 E O E Figure 34 Figure 35 Figure 36 Figure 37...

Page 51: ...lding grade shielding gas The process is normally applied semi automatically however the process may be operated automatically and can be machine operated The process can be used to weld thin and fair...

Page 52: ...excessive wire extension stick out and make a very poor weld The welding wire is not energized until the torch trigger switch is depressed The wire may therefore be placed on the seam or joint prior...

Page 53: ...shielding gas 4 Gas flow rate 11 7 2 Primary Adjustable Variables These control the process after preselected variables have been found They control the penetration bead width bead height arc stabilit...

Page 54: ...welding torch and a line perpendicular to the axis of the weld The longitudinal angle is generally called the Nozzle Angle and can be either trailing pulling or leading pushing Whether the operator i...

Page 55: ...is point if the penetration heat input is too much not enough adjust the voltage setting and repeat the process 4 If not able to achieve a smooth and stable arc with the desired heat input for the wel...

Page 56: ...All 60 220 16 22 1 2mm All 120 350 15 23 Gasless Flux cored Mild Steel Weldclass GL 11 E71T 11 Not required 0 8mm Horizontal 90 150 14 16 Vertical Overhead 60 125 10 12 0 9mm Horizontal 80 200 12 17...

Page 57: ...tly adjusted to at least 15 litres per minute Gas leaks Check for gas leaks between the regulator cylinder connection and in the gas hose to the Power Source Internal gas hose in the Power Source Ensu...

Page 58: ...the wire feed Misalignment of inlet outlet guides Liner blocked with swarf Replace liner Increased amounts of swarf are produced by the wire passing through the feed roller when excessive pressure is...

Page 59: ...too low Increase voltage Excessive spatter Figure 52 Voltage too high Decrease voltage or increase the Current Wire Speed control Voltage too low Increase the voltage or decrease Current Wire Speed Ir...

Page 60: ...pply authority Arc does not have a crisp sound that short arc exhibits when the wire feed speed and voltage are adjusted correctly The MIG torch has been connected to the wrong voltage polarity on the...

Page 61: ...d to the work piece If in doubt consult the electrode data sheet 12 4 Effects of Stick MMA Welding on Various Materials 12 4 1 High Tensile and Alloy Steels The two most prominent effects of welding t...

Page 62: ...subject to higher load stress Also used as a buffer layer prior to hard facing All Positional except for vertical down easy striking smooth running with low spatter easy slag removal 12 5 2 CAST IRON...

Page 63: ...er apron and gauntlets You won t be worrying then about being burnt or sparks setting alight to your clothes Place the work so that the direction of welding is across rather than to or from your body...

Page 64: ...s too short there is the danger of it being blanketed by slag and the electrode tip being solidified in If this should happen give the electrode a quick twist back over the weld to detach it 12 7 5 Ra...

Page 65: ...ctrode at about 20 from vertical and the rate of travel not too fast will help eliminate this The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc T...

Page 66: ...l and the other vertical This is known as a horizontal vertical HV fillet Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45 from the...

Page 67: ...bottom This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges At the completion of each side motion pause for a moment to allow weld metal to build u...

Page 68: ...s positioned in the overhead position as shown in the sketch The electrode is held at 45 to the horizontal and tilted 10 in the line of travel Figure 62 The tip of the electrode may be touched lightly...

Page 69: ...t current to give adequate penetrations Use suitable tools to remove all slag from comers Rust or mill scale or preventing full fusion Clean joint before welding Wrong electrode for position in which...

Page 70: ...ls of Sulphur in steel Use an electrode that is designed for high Sulphur steels Electrodes are damp Dry electrodes before use Welding current is too high Reduce welding current Surface impurities suc...

Page 71: ...eparation 13 1 1 Electrode Polarity Connect the TIG torch to the negative torch terminal and the work lead to the positive work terminal for direct current straight polarity Direct current straight po...

Page 72: ...ntaminated causing lower weld quality Rule of thumb is that the taper section should be 2 5 times the Electrode Diameter Figure 70 Ideal Tungsten Preparation Stable ARC Diameter of the flat left on th...

Page 73: ...IG Welding Settings For Steel Metal Thickness DC Current Amps Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate L min Joint Type Mild Steel Stainless Steel 1 2mm 0 045 45...

Page 74: ...s hose is cut Replace gas hose Gas passage contains impurities Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities Gas regulator turned off Turn on Torch...

Page 75: ...bol to avoid possible injury or death DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided co...

Page 76: ...ould consult their physician s before using this machine WARNING Electromagnetic fields in close proximity to a heart pacemaker could cause interference or failure of the pacemaker The use of a Welder...

Page 77: ...r practices apply to engine driven equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Safe practices are outlined in the Australian Standard AS...

Page 78: ...he power tool in unexpected situations 15 4 2 Arc Rays can Burn Eyes and Skin CAUTION Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin 1 U...

Page 79: ...are that visible smoke or flame may not be present for some time after the fire has started Do not weld or cut in atmospheres containing dangerously reactive or flammable gases vapours liquids and dus...

Page 80: ...kin Use the following table to select the appropriate shade number for a Welding Helmet or Welding Face Shield Recommended Protection Fillers For Electric Welding Welding Process Application Approxima...

Page 81: ...Do not weld where flying sparks can strike flammable material 3 Remove all flammables within 10m of the welding site 4 Be alert that welding sparks and hot materials from welding can easily go throug...

Page 82: ...to a stationary support or equipment cylinder rack to prevent falling or tipping 3 Keep cylinders away from any welding or other electrical circuits 4 Never allow a welding electrode to touch any cyl...

Page 83: ...Weldforce 210MST 250MST Weldclass 2020 E O E 83 NOTES...

Page 84: ...84 Weldclass 2020 E O E www Weldclass com au...

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