Weldclass Weldforce 155M Operating Instructions Manual Download Page 59

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Weldforce 155

M &

175

MST

© Weldclass 2020 | E.&O.E.

13.2

TIG Welding Troubleshooting

Troubleshooting – TIG Weld quality

Fault

Cause

Remedy

Excessive bead build up or

poor penetration or

poor fusion at edges of weld

Welding current is too low.

Increase weld current and/or faulty
joint preparation

Weld bead too wide and flat or

undercut at edges of weld or

excessive burn through

Welding current is too high.

Decrease weld current.

Weld bead too small or

insufficient penetration or

ripples in bead are widely
spaced apart.

Travel speed too fast.

Decrease weld current.

Weld bead too wide or

excessive bead build up or

excessive penetration in butt
joint.

Travel speed too fast.

Increase travel speed.

Uneven leg length in fillet joint

Wrong placement of filler rod.

Re-position rod.

Electrode melts or oxidises
when an arc in struck

Torch lead connected to positive
welding terminal.

Connect torch lead to negative
welding terminal.

No gas flowing to welding
region.

Check the gas lines for kinks or
breaks and gas cylinder contents.

Torch is clogged with dust or dirt.

Clean torch.

Gas 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 electrode is too small for
the welding current.

Increase electrode diameter or
reduce the welding current.

Dirty weld pool

Electrode

contaminated

contact with work piece or filler
rod material.

Clean the electrode by grinding off
any contaminates.

Work piece surface has foreign
material on it.

Clean surface.

Gas contaminated with air.

Check gas lines for cuts and loose
fitting or change gas cylinder.

Poor weld pool

Inadequate shielding gas.

Increase gas flow or check gas line
for gas flow problems.

Arc start is not smooth.

Tungsten electrode is too large
for the welding current.

Select the right size electrode.

The wrong electrode is being
used for the welding job.

Select the right electrode type.

Gas flow rate is too high.

Select the right rate for the welding
job.

Incorrect shielding gas is being
used.

Select the right shielding gas.

Poor

Work

Lead/Clamp

connection to work piece.

Improve connection to work piece.

Arc flutters during TIG welding.

Tungsten electrode is too large
for the welding current.

Select the right size electrode.

Table 24

Summary of Contents for Weldforce 155M

Page 1: ...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 ...

Page 2: ...s 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 purchase invoice receipt b Your machine serial number which can be found on the technical data plate on the back of the machine or on the outside of the box that your machine came in Satisfaction Guarant...

Page 3: ...rror Over Temperature Indicator Light 13 5 POWER SUPPLY 13 5 1 Electrical Connection 13 5 2 Extension Leads 13 5 3 Generator Use 13 5 3 1 Generator Size 13 5 3 2 Generator Quality Warranty Limitations 14 5 3 3 3 Golden Rules of Generator use 14 6 OPERATING ENVIRONMENT 14 6 1 Location 14 6 2 Ventilation 14 7 BASIC OPERATION 15 7 1 MIG Welding 15 7 1 1 Fitting Wire Spool 15 7 1 2 Loading Wire Feeder...

Page 4: ...ck MMA Process 33 10 2 2 The TIG Process 34 10 2 3 The MIG Process 34 10 3 Joint Preparations 35 11 MIG BASIC WELDING GUIDE 37 11 1 MIG Basic Welding Techniques 37 11 2 Gas Metal Arc Welding GMAW 37 11 3 Flux Cored Arc Welding FCAW 37 11 4 Position of MIG Torch 38 11 5 Distance from the MIG Torch Nozzle to the Work Piece 38 11 6 Travel Speed 38 11 7 MIG Welding GMAW Variables 39 11 7 1 Preselected...

Page 5: ...2 7 4 Arc Length 49 12 7 5 Rate of Travel 49 12 8 Making Welded Joints 50 12 8 1 Butt Welds 50 12 8 2 Fillet Welds 51 12 8 3 Vertical Welds 52 12 8 4 Overhead Welds 53 12 9 MMA Stick Troubleshooting 54 13 TIG BASIC WELDING GUIDE 56 13 1 TIG Electrode Selection and Preparation 56 13 1 1 Electrode Polarity 56 13 1 2 Preparing Tungsten for DC Electrode Negative DCEN Welding 57 13 1 3 Shielding Gas fo...

Page 6: ...Can Damage Hearing 63 15 4 4 Work Environment Safety 64 15 4 5 Electricity Can Kill 64 15 4 6 Fumes And Gases 65 15 4 7 Fire Explosive Risks 66 15 4 8 Sparks Hot Metal 66 15 4 9 Gas Cylinders 67 16 WARRANTY 67 16 1 Warranty Information 67 ...

Page 7: ...oltage Output 15 19 8V 15 21V Duty Cycle 115A 19 8V 20 65A 17 3V 60 50A 16 5V 100 140A 21V 20 80A 18V 60 60A 17V 100 Nominal Open Circuit Voltage 44V 44V Spool Size 100mm 1kg 200mm 4 5kg or 5kg MIG Wire Sizes 0 6 0 8 0 9mm 0 6 0 8 0 9 1 0mm Stick MMA Welding Welding Current Output N A 20 120A max 150A Duty Cycle 120A 24 8V 30 80A 23 2V 60 60A 22 4V 100 Nominal Open Circuit Voltage 44V MMA Electrod...

Page 8: ...ntrol panel 2 MIG Torch 3 Earth Lead 4 Euro MIG Torch Connection 5 Positive Dinse Socket 6 Negative Dinse Socket 7 Torch Polarity Change Tail 3 2 Machine Rear 8 Mains Power Switch 9 Gas Inlet Connection 10 240V AC Mains Power Input Lead Weldforce 155M Figure 1 Weldforce 175MST ...

Page 9: ...M 175MST Weldclass 2020 E O E 9 3 3 Control Panel 1 Power Indicator LED 2 Thermal Overload Error Indicator LED 3 Output Knob 4 Inductance Arc Force Knob 5 Process Selector Knob Figure 3 Weldforce 155M Weldforce 170M ...

Page 10: ...nce Single phase Inverter power source DC MIG GMAW Function Stick MMA SMAW Function TIG GTAW Function Power Supply Connection Single Phase Direct Current DC Negative Positive Hertz cycles sec Duty Cycle Amperage Current Voltage Electrical Hazard Toxic Gas Fume Hazard Explosive Hazard Eye Injury Hazard Pacemaker Interference Warning Do not suspend from handle Radiation Hazard Table 2 ...

Page 11: ...adjusts arc force and the Output Knob adjusts target amperage output 4 1 3 TIG Process In this mode the Inductance Knob is disabled and the Output Knob adjusts target amperage output 4 2 Welding Power Output Control This output power of the weld is controlled by the Output Knob In MIG MAG process mode the wirespeed and voltage of the arc are both adjusted together as this is a Synergic technology ...

Page 12: ...tance rotate the Inductance Knob Figure 5 4 4 Arc Force Adjustment MMA Stick only Weldforce 175MST only Arc Force setting is adjustable from 0 100 Sometimes called Dig or Arc Control A Stick welder is designed to produce constant output current CC This means with different types of electrode and arc length the welding voltage varies to keep the current constant This can cause instability in some w...

Page 13: ...ic circuit failure issues 5 POWER SUPPLY 5 1 Electrical Connection The Weldforce 155M 175MST machines are designed to operate on a 10A 240V AC power supply 5 2 Extension Leads If an extension cord must be used it should be minimum cable core size 2 0mm2 for length of up to 10m or minimum 2 5mm2 for lengths over 10m Using extension leads of over 50m is not recommended 5 3 Generator Use This machine...

Page 14: ...r generator run out of fuel whilst the welder is plugged in Following these Golden Rules will significantly reduce the risk of any damage resulting from generator power supply 6 OPERATING ENVIRONMENT 6 1 Location The machine 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 reliabl...

Page 15: ...e Tension Nut Spring 3 Remove Flange Spacer 4 Fit the wire spool to the Spool Post Bolt ensuring that the wire spool is position so that the wire will exit from bottom of spool 5 Replace the Flange Spacer as per orientation shown below orientation is different for 100mm 1kg vs 200mm 5kg spools 6 Replace spring Tension Nut Note Adjust tension so that the spool can rotate freely but does not continu...

Page 16: ...by winding the Tension Lever Knob Clockwise will increase tension anticlockwise will decrease drive tension TIP Ideal tension is as little as possible while maintaining a consistent wire feed with no drive roller slippage Check all other causes of excess wire feeding friction causing slippage first such as incorrect contact tip size damaged contact tip blocked damaged torch wire guide liner incorr...

Page 17: ...Weldforce 155M 175MST Weldclass 2020 E O E 17 Figure 8 Tension Arm Tension Lever Knob Drive Roller Wire Inlet Guide Tube Drive Roller Retainer Cap Wire Outlet Tube ...

Page 18: ...piece must be firm contact with clean bare metal with no corrosion paint or scale at the contact point Note if this connection is not made there will be no electrical connection to the welding torch Figure 9 Weldforce 175MST 1 Connect the earth cable quick connector to the Positive Dinse Socket 2 Connect the earth clamp to the work piece Contact with the work piece must be firm contact with clean ...

Page 19: ...to the Positive Terminal Ensure the connection is tight and firm 5 Connect the Earth Polarity Cable coming from top of machine to the Negative Dinse Socket Ensure the connection is tight and firm 6 Connect the earth clamp to the work piece Contact with the work piece must be firm contact with clean bare metal with no corrosion paint or scale at the contact point Note if this connection is not made...

Page 20: ...r machine for your application Ideally 1 0mm or above 4 Ensure the wire drive system is fitted with the correct size U groove drive roller to suit the wire being used 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 for operators to have an extra MIG to...

Page 21: ...ommended drive rollers and MIG torch liners to use for various wires Weldforce 155M Weldforce 175MST Wire Type Wire Size Drive Roller Torch Liner Type Part No Gasless Flux Cored Steel 0 8mm Knurled Groove WC 06425 Blue 0 9mm Red Solid Steel 0 6mm V Groove WC 06422 Blue 0 8 0 9mm Red 0 6mm Blue 0 8 0 9mm Red Stainless Steel 0 8mm Blue Aluminium 0 9mm U Groove WC 06426 Teflon Poly 1 0mm Bronze CuSi ...

Page 22: ...ectrode holder and work lead to the Positive Dinse Socket NOTE This polarity connection configuration is valid for most GP General Purpose MMA electrodes There are variances to this If in doubt check the electrode specifications or consult the electrode manufacturer 4 Connect the machine to suitable power Switch the Mains Power Switch to on to power up the machine 5 Set welding process selector kn...

Page 23: ...the work piece must 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 Gas regulator and ensure gas regulator is connected to Argon gas cylinder Ensure all connections are tight 5 Open gas cylinder valve and adjust regulator Open gas valve on the TIG torch...

Page 24: ...ble or go to http www weldclass com au BZL15 BZL 15 Torch Parts Ref Part No Description 1 P3 B15SN Neck 2 P3 B15NS Nozzle Spring Pk2 3 P3 B15TH Tip Holder Pk2 4 P3 BT6066 Tip 0 6mm Pk5 4 P3 BT6086 Tip 0 8mm Pk5 4 P3 BT609 Tip 0 9mm Pk5 4 P3 BT610 Tip 1 0mm Pk5 4 P3 BTA610 Tip 1 0mm Alu Pk5 4 P3 BTA612 Tip 1 2mm Alu Flux Core Pk5 5 P3 B15N Nozzle Conical Pk2 6 P3 B15NC Nozzle Cylindrical Pk2 Table ...

Page 25: ...tion WC 03614 Complete Torch 3m Euro Connection WC 03615 Complete Torch 4m Euro Connection 1 P3 B25SN Neck 2 P3 B25NS Nozzle Spring Pk2 3 P3 B25TH Tip Holder Pk2 4 P3 BT6066 Tip 0 6mm Pk5 4 P3 BT6086 Tip 0 8mm Pk5 5 P3 BT609 Tip 0 9mm Pk5 5 P3 BT610 Tip 1 0mm Pk5 5 P3 BTA610 Tip 1 0mm Alu Pk5 5 P3 BTA612 Tip 1 2mm Alu Flux Core Pk5 6 P3 B25N Nozzle Conical Pk2 P3 BBSL4 Liner Steel wires 0 6 0 8mm ...

Page 26: ... cap Long Pk2 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 Collect Body 3 2mm Pk2 P3 10N49 TIG Ceramic Cup 5 7 9mm Pk2 P3 10N48 TIG Ceramic Cup 6 9 5mm Pk2 P3 10N47 TIG Ceramic Cup 7 11 1mm Pk2 P3 10N46 TIG Ceramic Cup 8 12 7mm Pk2 P3 10N45 TIG Ce...

Page 27: ...3 TTU2917V 4 TIG Torch Valved 150A 4m WC 06235 Welding Trolley WC 01775 Welding Gloves P6 MPLY MIG Pliers Table 9 8 5 Drive Rollers Drive Rollers Part No Drive Roller WC 06422 0 6 0 8 0 9mm V Groove Steel WC 06425 0 8 0 9 1 2mm Knurled Flux Cored WC 06426 0 9 1 0mm U Groove Aluminium 1 0mm V Groove Steel Table 10 ...

Page 28: ... Process Selection Knob 4 Thermostat 5 Adjustment Knob 6 Solenoid Valve 7 Main Power On Off Switch 8 Input Power Lead 9 Fan 10 Back Panel 11 Handle 12 Front Panel 13 Power Cable Gland 16 Wire Compartment Door Handle 17 Guide 19 Wire Compartment Door 20 Back Panel 21 Front Panel 22 Diaphram 23 Earth Clamp 24 Dinse Socket 25 Polarity Change Lead Dinse Plug 26 Wire Drive Roller 27 Euro Torch Socket 2...

Page 29: ...Weldforce 155M 175MST Weldclass 2020 E O E 29 Weldforce 155M Figure 16 ...

Page 30: ... 30 Weldclass 2020 E O E Weldforce 175MST Figure 17 ...

Page 31: ...Weldforce 155M 175MST Weldclass 2020 E O E 31 8 7 Primary Schematic Circuit Diagram Figure 18 Weldforce 175MST only ...

Page 32: ...e 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 welding machine is switched off and disconnected from the power supply If damaged before further use the welder must be carefully checked by a qualified person to determine that it will operate properly Check ...

Page 33: ...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 ignite the arc The electrode is held in the electrode holder and must be continually replaced as it is consumed The electrode consists of a metal core which is the filler metal covered by a flux coating wh...

Page 34: ...on 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 welding is only possible with AC DC TIG welding machines This machine is DC only and is not designed for TIG welding of aluminium 10 2 3 The MIG Process 10 2 3 1 Description The acronym MIG stands for ...

Page 35: ...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 variety of wires including steel stainless steel gasless wires aluminium silicone bronze hard facing just to name a few 10 3 Joint Preparations In many cases it will be possible to weld steel sections w...

Page 36: ... 36 Weldclass 2020 E O E Figure 25 Figure 26 Figure 27 Figure 28 ...

Page 37: ...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 fairly thick steels and some nonferrous metals in all positions Figure 29 11 3 Flux Cored Arc Welding FCAW This is an electric arc welding process which fuses together the parts to be welded by heating th...

Page 38: ...e 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 to lowering the helmet Figure 31 11 5 Distance from the MIG Torch Nozzle to the Work Piece The welding wire stick out from the MIG Torch nozzle should be between 10mm to 20mm This distance may vary d...

Page 39: ...elding wire 2 Size of welding wire 3 Type of 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 stability deposition rate and weld soundness These variables are 1 Arc Voltage Wire feed speed adjusted simultaneously on Synergic machines 2 Inductance 3 Travel s...

Page 40: ...e 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 is left handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel Figure 33 Figure 34 Horizontal Butt Weld Figure 35 Horizontal Fillet Wel...

Page 41: ...n voltage setting is affected by welding wire type and size shielding gas welding material and joint type Synergic function makes the setup of MIG welding much simpler as follows 1 Select output setting the machine calculates the optimal voltage and wire speed ratio 2 Adjust inductance setting to refine arc characteristics 3 Obviously other variables such as welding joint type position and thickne...

Page 42: ...rectly 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 Ensure the hose from the solenoid valve to the torch adaptor has not fractured and that it is connected to the torch adaptor This should only be done by qualified technician Welding in a windy environm...

Page 43: ...es affecting 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 applied to the pressure roller adjuster Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size Swarf is fed into the conduit liner where it a...

Page 44: ...rease voltage Excessive spatter Figure 43 Voltage too high Decrease voltage or increase the Current Wire Speed control Voltage too low Increase the voltage or decrease Current Wire Speed Irregular weld shape Incorrect voltage and current settings Convex voltage too low Concave voltage too high Adjust voltage and current by adjusting the voltage control and the Current Wire Speed control Wire is wa...

Page 45: ... Contact supply 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 front panel Connect the MIG torch to the positive welding terminal for solid wires and negative welding terminal for gasless wires Refer to the wire manufacturer for the correct polarity T...

Page 46: ...ork 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 these steels are the formation of a hardened zone in the weld area and if suitable precautions are not taken the occurrence in this zone of under bead cracks Hardened zone and under bead cracks in the weld area ...

Page 47: ... components 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 1 Cast Iron Ni Cl NCI Suitable for joining all cast irons Suitable for mehanite alloy and malleable cast iron except white cast iron Weld positions flat horizontal 12 5 3 STAINLESS STEEL 1...

Page 48: ...d 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 The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down If the lead is slung over your shoulder it allows greater freedom of movement a...

Page 49: ...ugh 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 12 7 5 Rate of Travel After the arc is struck your next concern is to maintain it and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away At the sam...

Page 50: ...about 20º 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 joint in thin plate turn the job over clean the slag out of the back and deposit a similar weld Heavy plate will require several runs to complete the joint After completing the first run chip th...

Page 51: ... horizontal 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 45º from the vertical Some electrodes require being sloped about 20º away from the perpendicular position to prevent slag from running ahead of the weld Refer to Figure 48 Do not attempt to build up mu...

Page 52: ... 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 up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 51 illustrates multi run technique and Figure 52 shows the effects of pausing at the edge of weave ...

Page 53: ... specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45º to the horizontal and tilted 10º in the line of travel Figure 53 The tip of the electrode may be touched lightly on the metal which helps to give a steady run A weave technique is not advisable for overhead fillet welds Use a 3 2mm Weldclass 12V Stick electrode at 100 amps and deposit the first run...

Page 54: ...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 welding is done Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult A groove has been formed in the base metal adjacent to the top of a weld and has not been filled by the weld metal undercut Figur...

Page 55: ...lectrode that is designed for high Sulphur steels Electrodes are damp Dry electrodes before use Welding current is too high Reduce welding current Surface impurities such as oil grease paint etc Clean joint before welding Welding in a windy environment Shield the weld area from the wind Electrode damaged i e flux coating incomplete Discard damaged electrodes and only use electrodes with a complete...

Page 56: ...paration 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 polarity is the most widely used polarity for DC TIG welding It allows limited wear of the electrode since 70 of the heat is concentrated at the work piece Tungsten Electrode Types Electrode Type Applica...

Page 57: ...ngsten can become contaminated causing lower weld quality Rule of thumb is that the taper section should be 2 5 times the Electrode Diameter Figure 61 Ideal Tungsten Preparation Stable ARC Diameter of the flat left on the end of the Electrode determines amperage capacity Figure 62 Wrong Tungsten Preparation Wandering ARC Figure 63 Pointing the Tungsten Electrode The electrode should be pointed acc...

Page 58: ... 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 55 30 45 1 0mm 0 040 1 6mm 1 16 5 7 Butt Corner 50 60 35 50 Lap Fillet 1 6mm 1 16 60 70 40 60 1 6mm 1 16 1 6mm 1 16 7 Butt Corner 70 90 50 70 Lap Fillet 3 2mm 1 8 80 100 65 85 1 6mm 1 16 2 4mm 3 32 7 Butt Corn...

Page 59: ...ean torch Gas 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 electrode is too small for the welding current Increase electrode diameter or reduce the welding current Dirty weld pool Electrode contaminated by contact with work piece or filler rod mat...

Page 60: ...d 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 could result in death or serious injury CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTE used to address practices not re...

Page 61: ...acemakers 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 Welder is NOT RECOMMENDED for pacemaker wearers Consult your doctor 9 Ensure that the unit is placed on a stable location before use WARNING If this unit falls while plugged in severe injury ele...

Page 62: ...s 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 1674 2 entitled Safety in Welding and European Standard EN60974 1 entitled Safety in welding and allied processes WARNING Only use safety equipment that has been approved by an appropriate standards agency Unap...

Page 63: ...control of the 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 Use a Welding Helmet or Welding Face Shield fitted with a proper shade filter refer AS 60974 1 AS NZS 1337 1 and AS NZS 1338 1 Safety Standards to protect your face and eyes when welding or...

Page 64: ...sible 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 adequate ventilation in work areas to prevent accumulation of flammable gases vapours and dust 7 Do not apply heat to a container that has held an unknown substance or a combustible material whose cont...

Page 65: ... eyes and skin 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 Approximate Range of Welding Current in Amps Minimum Shade Number of Filter Lens Stick MMA Up to 100 8 100 to 200 10 MIG other than Aluminum and Stainless Steel Up to 150 10 150 to 250 11 MIG of Alu...

Page 66: ...d 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 through small cracks and openings to adjacent areas 5 Watch for fire and keep a fire extinguisher nearby 6 Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 7 Do not weld...

Page 67: ...aining them 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 cylinder 5 Use appropriate shielding gas regulators hoses and fittings designed for the specific application maintain them and their associated parts in good condition 6 Turn your face away fr...

Page 68: ... 68 Weldclass 2020 E O E www Weldclass com au ...

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