Weldclass WeldForce WF-201T AC/DC Operating Instructions Manual Download Page 1

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WF-201

T AC/DC

© Weldclass 2019 | E.&O.E.

Edition 1

OPERATING INSTRUCTIONS



IMPORTANT!

To qualify for full 36 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 WeldForce WF-201T AC/DC

Page 1: ...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 attenti...

Page 2: ...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 y...

Page 3: ...3 Function Selection 15 4 3 1 Spot Weld Function 15 4 3 2 Pulse Welding Function 15 4 3 3 Normal Welding Function Off 15 4 4 Trigger Mode Selection 16 4 4 1 2T Standard Trigger 16 4 4 2 4T Latch Trigg...

Page 4: ...3 3 3 Golden Rules of Generator use 22 6 OPERATING ENVIRONMENT 23 6 1 Location 23 6 2 Ventilation 23 7 BASIC SETUP 24 7 1 Stick MMA Welding Setup 24 7 2 TIG Welding Setup 25 8 ACCESSORIES SPARE PARTS...

Page 5: ...Length 38 11 7 5 Rate of Travel 38 11 8 Making Welded Joints 39 11 8 1 Butt Welds 39 11 8 2 Fillet Welds 40 11 8 3 Vertical Welds 41 11 8 4 Overhead Welds 42 11 9 MMA Stick Troubleshooting 43 12 TIG B...

Page 6: ...nstructions Warnings 56 14 4 1 Personal Safety 57 14 4 2 Arc Rays can Burn Eyes and Skin 57 14 4 3 Noise Can Damage Hearing 57 14 4 4 Work Environment Safety 58 14 4 5 Electricity Can Kill 58 14 4 6 F...

Page 7: ...5A 16 2V 60 120A 14 8V 100 Nominal Open Circuit Voltage 65V TIG Tungsten Size 1 6 2 4mm DC TIG GTAW Welding Welding Current Output 10 170A Duty Cycle 170A 16 8V 35 140A 15 6V 60 110A 14 4V 100 Nominal...

Page 8: ...el 3 TIG Torch Gas Connector 4 Negative Welding Power Output Connection Socket 5 TIG torch Interface Connector 6 Positive Welding Power Output Connection Socket 3 2 Machine Rear 7 Mains Power Switch 8...

Page 9: ...16 Pulse Arc Function Indicator Light PULSE 17 Normal Arc Function Indicator Light NORMAL OFF 18 Function Selection Button FUNCTION 19 Selection Knob 20 Mode Selection Button MODE 21 AC Arc Output Mo...

Page 10: ...GAS 37 Start Amps Setting Indicator Light START AMPS 38 Slope Up Setting Indicator Light UP SLOPE 39 Trough Amps Setting Indicator Light TROUGH AMPS 40 Pulse Wave Frequency Setting Indicator Light FRE...

Page 11: ...WF 201T AC DC Weldclass 2019 E O E 11 3 6 TIG Torch Controls 47 Torch Trigger Button 48 Remote Control Amperage Potentiometer Figure 6 47 48...

Page 12: ...ot Weld Function Pulse Function Alternating Current AC Amperage current output Voltage output AC Arc Balance 2T Normal Trigger Function 4T Latch Trigger Function Single phase Inverter power source AC...

Page 13: ...ierto use and prevents tungsten contamination The disadvantage of HF ignition is that the high energy electrical pulse creates significant electrical and radio signal interference which limits its use...

Page 14: ...ation 4 2 2 AC Alternating Current This is required for welding reactive metals such as Aluminium Magnesium and Zinc When reactive metals are exposed to air they form an oxide layer that insulates the...

Page 15: ...a cyclical manner When used correctly this function has substantial benefits in the TIG welding process including greater weld penetration for less work heat input and greater control of the weld poo...

Page 16: ...sed the welding stops 4 4 2 4T Latch Trigger 4T stands for Four Touch or Latching mode The trigger button is pressed once and released to start welding and then pulled and released again to stop the w...

Page 17: ...en in Spot mode Sets the portion of the weld cycle that is spent welding For example if cycle time is set to 10sec and with is 20 then the machine will weld for 2secs and pause for 8secs 4 5 6 Pulse W...

Page 18: ...ve it is to weld This effect can also be used to reduce heat in the tungsten allowing use of a pointed tungsten tip shape for a more defined arc See 12 3 1 for more information 4 6 Remote Controls 4 6...

Page 19: ...tment Stick 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...

Page 20: ...is activated When thermal protection is activated welding output will be disabled until machines cools sufficiently and overload indicator lamp goes out This may also activate if there are electronic...

Page 21: ...ne off for 10 seconds and the back on E22 Welding torch error during start up Try turning machine off for 10 seconds and the back on Ensure torch is connected correctly Disconnect reconnect welding to...

Page 22: ...ull output and duty cycle of this welder minimum recommended generator size is 10kVa 5 3 2 Generator Quality Warranty Limitations Avoid using poor low quality generators as these have the greatest ris...

Page 23: ...ign of this power source meets the requirements of IP23S as outlined in AS60529 This provides adequate protection against solid objects greater than 12mm and direct protection from vertical drops Unde...

Page 24: ...e Positive Welding Power Output Socket 6 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 spe...

Page 25: ...ded with machine 9 Connect the gas hose to the Gas Inlet Connection tail 9 on the rear of the machine securing it with the hose clamp provided 10 Ensure all connections are tight 11 Open gas cylinder...

Page 26: ...alve 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 C...

Page 27: ...e 6 Power cable clip 7 Fan assembly 8 Fan grill 9 Fan 10 Assembly sheet 11 Main transformer 12 Base panel 13 Hall sensor 14 Support part 15 HF inductor 16 Front panel 17 Front gas fitting 18 Euro sock...

Page 28: ...28 Weldclass 2019 E O E Figure 18...

Page 29: ...WF 201T AC DC Weldclass 2019 E O E 29 8 4 Primary Schematic Circuit Diagram Figure 19...

Page 30: ...orce 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 weldin...

Page 31: ...o 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...

Page 32: ...controllable 10 2 2 3 Advantages Very low amperages can be achieved making this process ideal for welding thin materials Also due to the independence of the arc and the filler metal application TIG w...

Page 33: ...ecessary 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 o...

Page 34: ...34 Weldclass 2019 E O E Figure 29...

Page 35: ...de which may be required with some specialty applications then it does not matter which connections the electrode holder and earth lead are connected to 11 4 Effects of Stick MMA Welding on Various Ma...

Page 36: ...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...

Page 37: ...ron 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 e...

Page 38: ...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 11 7 5 Ra...

Page 39: ...e 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 To com...

Page 40: ...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 41: ...m 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...

Page 42: ...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 38 The tip of the electrode may be touched lightly...

Page 43: ...rent 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 weldi...

Page 44: ...els 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 su...

Page 45: ...lag 12 1 TIG Electrode Selection and Preparation 12 1 1 Tungsten Electrode Selection Polarity Connect the TIG torch to the negative torch terminal and the work lead to the positive work terminal for d...

Page 46: ...Ideal Tungsten Preparation Stable ARC Diameter of the flat left on the end of the Electrode determines amperage capacity Figure 47 Wrong Tungsten Preparation Wandering ARC Figure 48 Pointing the Tungs...

Page 47: ...rgon 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...

Page 48: ...se the Torch Trigger Button and will then proceed to the Slope Up process If Set to 2T Trigger mode machine will proceed directly to the Slope Up process 12 2 2 HF Ignition High Frequency HF Ignition...

Page 49: ...ent is where the welding current flow oscillates back and forth in both directions When reactive metals are exposed to air they form an oxide layer that insulates the base metal and prevents welding c...

Page 50: ...ion of the work piece and gives a much better looking weld appearance The variables are explained further as follows Peak Current this is the main welding current amperage and which is used to melt th...

Page 51: ...e heat in the Tungsten Electrode This gives the disadvantage of reducing the output current that can be used for a given tungsten size to prevent the tungsten overheating More Negative AC Balance will...

Page 52: ...ou want the Finish Current to stop 4 The Post Gas time will then complete 12 4 1 Down Slope This gradually reduces the weld current over the time selected down to Finish Current This allows the operat...

Page 53: ...orch 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...

Page 54: ...us 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 safe...

Page 55: ...his 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 Con...

Page 56: ...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 enti...

Page 57: ...ol 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 s...

Page 58: ...ible 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 ad...

Page 59: ...n 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...

Page 60: ...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 o...

Page 61: ...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...

Page 62: ...urchase 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 accident...

Page 63: ...mstances 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...

Page 64: ...64 Weldclass 2019 E O E www Weldclass com au WF 201T...

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