Weldclass WeldForce WF-140ST Operating Instructions Manual Download Page 39

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WF-140

/ WF-180

© Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03

12.2

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 15

Summary of Contents for WeldForce WF-140ST

Page 1: ...r 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: ...n Register Your Warranty Now Standard warranty without registration is 24 months To qualify for an extended full 36 month warranty on your purchase you must register within 30 days of purchase 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 d...

Page 3: ...nction 11 5 POWER SUPPLY 12 5 1 Electrical Connection 12 5 2 Extension Leads 12 5 3 Generator Use 12 5 3 1 Generator Size 12 5 3 2 Generator Quality Warranty Limitations 12 5 3 3 3 Golden Rules of Generator use 13 6 OPERATING ENVIRONMENT 14 6 1 Location 14 6 2 Ventilation 14 7 BASIC OPERATION 15 7 1 Stick MMA Welding Operation 15 7 2 Lift TIG Operation 16 8 ACCESSORIES SPARE PARTS CIRCUIT DIAGRAMS...

Page 4: ...EL 27 11 5 2 CAST IRON 27 11 5 3 STAINLESS STEEL 27 11 6 Suggested Settings for Typical Stick MMA Applications 27 11 7 MMA Welding Techniques 28 11 7 1 A Word for Beginners 28 11 7 2 The Welder 28 11 7 3 Striking the Arc 28 11 7 4 Arc Length 29 11 7 5 Rate of Travel 29 11 8 Making Welded Joints 30 11 8 1 Butt Welds 30 11 8 2 Fillet Welds 31 11 8 3 Vertical Welds 32 11 8 4 Overhead Welds 33 11 9 MM...

Page 5: ...4 4 1 Personal Safety 43 14 4 2 Arc Rays can Burn Eyes and Skin 43 14 4 3 Noise Can Damage Hearing 43 14 4 4 Work Environment Safety 44 14 4 5 Electricity Can Kill 44 14 4 6 Fumes And Gases 45 14 4 7 Fire Explosive Risks 46 14 4 8 Sparks Hot Metal 46 14 4 9 Gas Cylinders 47 15 WARRANTY 48 15 1 Warranty period 48 15 2 Warranty Includes and Covers 48 15 3 Warranty Excludes Does Not Cover 48 15 4 War...

Page 6: ...yle 10 25 Dinse style 35 50 Protection Class IP23 Stick MMA Welding Welding Current Output 10 140A 10 180A Duty Cycle 140A 25 6V 15 70A 22 8V 60 55A 22 2V 100 180A 27 2V 15 90A 23 6V 60 70A 22 8V 100 Nominal Open Circuit Voltage 55V 70V MMA Electrode Size 1 6 3 2mm 1 6 4 0mm TIG Welding Welding Current Output 10 200A 10 180A Duty Cycle 140A 15 6V 15 70A 12 8V 60 55A 12 2V 100 180A 17 2V 15 70A 12 ...

Page 7: ...OW YOUR MACHINE 3 1 Machine Front 1 Carry Handle 2 Control panel 3 Positive Welding Power Output Connection Socket 4 Negative Welding Power Output Connection Socket 3 2 Machine Rear 5 Mains Power Switch 6 240V AC Mains Power Input Lead 3 4 2 1 Figure 1 5 6 Figure 2 ...

Page 8: ...ht 9 VRD Active Indicator Light 10 Process Selection Button Process 11 Lift TIG Process Indicator Light 12 Selection Knob 13 Arc Force Setting Indicator Light 14 Hot Start Setting Indicator Light 15 Amps Setting Indictor Light 16 Error Over Temperature Indicator Light 17 LCD Readout Figure 3 10 14 7 8 9 11 12 13 15 16 17 ...

Page 9: ...ad Instruction Manual VRD Active TIG Function Stick MMA Function Hot Start Arc Force Amperage current output Voltage output Increase Decrease Single phase Inverter power source DC 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 Table 2 ...

Page 10: ...cess button 10 until the desired Welding Process Indicator Light 8 or 11 is lit 4 2 Setting Selection 1 Press the Selection Knob 12 down until the desired Setting Indicator Light is illuminated 13 14 or 15 2 Rotate the Selection Knob 12 to adjust parameter for the chosen Setting Figure 5 1 2 Figure 4 1 ...

Page 11: ...ll allow This effect will also cause the welding current to increase 0 is Arc Force off 10 is maximum Arc Force around 20 30A higher than the set welding current amps This is practically useful for electrode types that have a higher operating voltage requirement or joint types that require a short arc length such as out of position welds 4 3 Error Over Temperature Indicator Light Error Over Temper...

Page 12: ...h 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 8kVa WF 180ST Generator size should be not less than 8kva An 8kVa generator will not provide enough power to enable full output and duty of this welder However it should provide sufficient power to run a general purpose 3 2mm with reasonable duty...

Page 13: ...MUST be followed 1 Do NOT plug welder into generator until AFTER generator has been started up and is running smoothly 2 UNPLUG welder from generator BEFORE shutting generator down turning generator off 3 NEVER let your 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 ...

Page 14: ...quirements of IP23S as outlined in AS60529 This provides adequate protection against solid objects greater than 12mm and direct protection from vertical drops Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated conditions For further information please refer to AS 60529 6 2 Ventilation Adequate ventilation is required to provide proper...

Page 15: ... This polarity connection configuration is valid for most GP General Purpose MMA electrodes There are variances to this also many electrodes will run in either polarity setting electrodes positive or electrode negative with slight difference in performance If in doubt check the electrode specifications or consult the electrode manufacturer 4 Connect the machine to suitable power Switch the mains p...

Page 16: ...ith clean bare metal with no corrosion paint or scale at the contact point 3 Insert TIG torch power connection into the Negative Welding Power Output Socket 4 4 Connect valve TIG torch gas line to the regulator ensuring all connections are tight 5 Open gas cylinder valve and adjust regulator Flow should be between 5 10 l min depending on application Re check regulator flow pressure with torch valv...

Page 17: ...ard Valved P3 TB17FV Torch Body 17FV Flexible Valved WC 57Y02P Back 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...

Page 18: ...ry diode 12 Main PCB 13 Front panel 14 Euro socket 15 Front panel assembly sheet 16 Knob 17 Control PCB 18 Heatsink 19 Heatsink 20 Heatsink 21 Insulation part 22 IGBT 23 Rectifier 24 EMC PCB assembly sheet 25 EMC PCB Table 5 WF 180ST Ref Description 1 Handle 2 Cover 3 Heatsink 4 Rear panel 5 On Off switch 6 Power cable clip 7 Cooling fan assembly sheet 8 Cooling fan 9 Heatsink 10 Inductor 11 Base ...

Page 19: ...WF 140ST WF 180ST Weldclass E O E Edition 1 1 2019 05 03 19 WF 140ST Figure 11 WF 180ST Figure 12 ...

Page 20: ... 20 Weldclass E O E Edition 1 1 2019 05 03 8 4 Primary Schematic Circuit Diagram Figure 13 ...

Page 21: ...irt and dust further 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 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 for ...

Page 22: ... 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 which ...

Page 23: ...ng this process ideal for welding thin materials Also due to the independence of the arc and the filler metal application TIG welding is very controllable and can therefore achieve very high quality welds with excellent appearance Unlike MIG and MMA welding TIG welding does not produce spatter so clean up is very minimal It is typically used where weld appearance is critical e g handrails or where...

Page 24: ...e necessary 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 scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in the following figures Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure...

Page 25: ...WF 140ST WF 180ST Weldclass E O E Edition 1 1 2019 05 03 25 Figure 23 ...

Page 26: ... to the work 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 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 w...

Page 27: ...oints or 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 11 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 11 5 3 STAINLESS...

Page 28: ... 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 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 m...

Page 29: ...d although 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 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 ...

Page 30: ...trode at 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 ru...

Page 31: ...one leg 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 27 Do not attempt to buil...

Page 32: ...ttom 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 up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 30 illustrates multi run technique and Figure 31 shows the effects of pausing at the edge ...

Page 33: ...hat the 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 32 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 fi...

Page 34: ... Use smaller 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 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 me...

Page 35: ...Figure 37 High 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 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 ...

Page 36: ...trode 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 Application Features Colour...

Page 37: ...weld quality Rule of thumb is that the taper section should be 2 5 times the Electrode Diameter Figure 40 Ideal Tungsten Preparation Stable ARC Diameter of the flat left on the end of the Electrode determines amperage capacity Figure 41 Wrong Tungsten Preparation Wandering ARC Figure 42 Pointing the Tungsten Electrode The electrode should be pointed according to the welding current Figure 43 Elect...

Page 38: ...ng 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 10 Butt Corner 50 60 35 50 Lap Fillet 1 6mm 1 16 60 70 40 60 1 6mm 1 16 1 6mm 1 16 10 15 Butt Corner 70 90 50 70 Lap Fillet 3 2mm 1 8 80 100 65 85 1 6mm 1 16 2 4mm 3 32 10 1...

Page 39: ...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 by contact with work piece or filler ...

Page 40: ...l 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 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 practic...

Page 41: ... with pacemakers 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 inj...

Page 42: ... 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 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 ag...

Page 43: ...better control of the power tool in unexpected situations 14 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 wel...

Page 44: ...e 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 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 w...

Page 45: ...ed 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 TIG Up to 100 10 100 to 200 11 Table 16 14 4 6 Fumes And Gases WARNING Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health 1 Keep your head out of the fumes Do not bre...

Page 46: ...t 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 on closed containers such as tanks or drums 8 Connect the work lead clamp to the job as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock an...

Page 47: ...l shocks and arcs 2 Install and secure cylinders in an upright position by chaining 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 mainta...

Page 48: ...of of purchase or warranty claims made with proof of purchase that is deemed by Weldclass Welding Products to be false misleading incomplete or insufficient 2 Defects or damage resulting from misuse accidents neglect improper maintenance alteration modification use of the product contrary to the applications for which it was designed or failure to heed any of the instructions warnings or guideline...

Page 49: ...er any circumstances be liable for special indirect or consequential damages No employee agent representative distributor or agent of Weldclass is authorised to change this warranty in any way or grant any other warranty Notwithstanding the foregoing in no event shall the warranty period extend more than the stated warranty period plus 6 months from the date Weldclass delivered the product to the ...

Page 50: ... 50 Weldclass E O E Edition 1 1 2019 05 03 NOTES ...

Page 51: ...WF 140ST WF 180ST Weldclass E O E Edition 1 1 2019 05 03 51 ...

Page 52: ... 52 Weldclass E O E Edition 1 1 2019 05 03 www Weldclass com au ...

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