Weldclass Weldforce 136S Operating Instructions Manual Download Page 1

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Weldforce 136S
Weldforce 181S

Edition 1.5

OPERATING INSTRUCTIONS



IMPORTANT!

To qualify for full / extended 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 Weldforce 136S

Page 1: ...s 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...

Page 2: ...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 purchas...

Page 3: ...3 Golden Rules of Generator use 10 6 OPERATING ENVIRONMENT 10 6 1 Location 10 6 2 Ventilation 10 7 BASIC OPERATION 11 7 1 Stick MMA Welding Operation 11 8 ACCESSORIES SPARE PARTS CIRCUIT DIAGRAMS 12 8...

Page 4: ...5 Rate of Travel 23 11 8 Making Welded Joints 24 11 8 1 Butt Welds 24 11 8 2 Fillet Welds 25 11 8 3 Vertical Welds 26 11 8 4 Overhead Welds 27 11 9 MMA Stick Troubleshooting 28 12 KNOWLEDGE RESOURCES...

Page 5: ...5A Effective Input Current I1eff 7A 15A Maximum Input Current I1max 27A 34A Output Terminals Dinse style 10 25 Dinse style 10 25 Protection Class IP21 IP23 Stick MMA Welding Welding Current Output 10...

Page 6: ...1 Positive Welding Power Output Connection Socket 2 Error Over Temperature Indicator Light 3 Power On Indicator Light 4 Adjustment Knob 5 Negative Welding Power Output Connection Socket 3 2 Machine Re...

Page 7: ...On Indication Fault Indication Caution Hazard Read Instruction Manual Increase Decrease Single phase Inverter power source DC Stick MMA SMAW Function Power Supply Connection Single Phase Direct Curre...

Page 8: ...ded and thermal protection is activated When thermal protection is activated welding output will be disabled until machines cools sufficiently and overload indicator lamp goes out Power Supply Voltage...

Page 9: ...enough power to enable full output and duty of this welder To ensure full output and duty cycle of this welder a minimum recommended generator size is minimum 7kVa or more Weldforce 181S Generator siz...

Page 10: ...chine has electrical components and control circuit boards which may be damaged by excessive moisture dust and dirt so a clean and dry operating environment is important for reliable product life The...

Page 11: ...e holder and work lead to the Positive Welding Power Output Socket 1 NOTE This polarity connection configuration is valid for most GP General Purpose MMA electrodes There are variances to this also ma...

Page 12: ...e Transformer 13 Inductance Filter 14 Power Transformer 15 Front Panel 16 Back Panel 17 Handle 18 Guide 19 Dinse Socket 20 Complete PCB Kit 21 Cover Kit Metal Panel 22 Bottom Kit 23 IGBT Diode Kit 24...

Page 13: ...Weldforce 136S 181S Weldclass E O E 13 Table 5 Weldforce 136S Figure 7...

Page 14: ...14 Weldclass E O E Weldforce 181S Figure 8...

Page 15: ...Weldforce 136S 181S Weldclass E O E 15 8 3 Primary Schematic Circuit Diagram Weldforce 136S 181S Figure 9...

Page 16: ...into components causing electrical short circuits 9 Check for damaged parts WARNING Before performing cleaning maintenance replacing cables connections make sure the welding machine is switched off an...

Page 17: ...ent 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 ignite the arc The electrode is held...

Page 18: ...to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints In general surfaces being welded should be clean and free of rust sc...

Page 19: ...Weldforce 136S 181S Weldclass E O E 19 Figure 19...

Page 20: ...piece If in doubt consult the electrode data sheet 11 4 Effects of Stick MMA Welding on Various Materials 11 4 1 High Tensile and Alloy Steels The two most prominent effects of welding these steels ar...

Page 21: ...ponents 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 11 5 2 CA...

Page 22: ...auntlets 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 The electrode...

Page 23: ...if it is 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 11...

Page 24: ...t 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 To complete the...

Page 25: ...rizontal 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 f...

Page 26: ...me 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 up at the edges...

Page 27: ...cimen is 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 28 The tip of the electrode may be touched...

Page 28: ...electrode with sufficient 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 electrod...

Page 29: ...igh levels 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 impuri...

Page 30: ...ossible 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 could result in...

Page 31: ...kers should 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...

Page 32: ...ply 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 1674 2 entitle...

Page 33: ...ol of the power tool in unexpected situations 13 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 s...

Page 34: ...le 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 dust Provide adeq...

Page 35: ...mended Protection Fillers For Electric Welding Welding Process Application Approximate Range of Welding Current in Amps Minimum Shade Number of Filter Lens Stick MMA Up to 100 8 100 to 200 10 Table 8...

Page 36: ...ng on a ceiling floor bulkhead or partition can cause fire on the hidden side 7 Do not weld on closed containers such as tanks or drums 8 Connect the work lead clamp to the job as close to the welding...

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