Weldclass WeldForce WF-205MST Operating Instructions Manual Download

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© Weldclass 2019 | E.&O.E. | Edition 2.1

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 23

Summary of Contents for WeldForce WF-205MST

Page 1: ...in 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: ...egister 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 data...

Page 3: ... Post Gas Time MIG 15 4 3 3 Soft Start Adjustment MIG 15 4 3 4 Burnback Adjustment MIG 15 4 3 5 Spot Stitch Weld Time MIG 15 4 3 6 Stitch Weld Gap Interval Time MIG 15 4 3 7 Spool Gun On Off MIG 16 4 3 8 Post Gas Time TIG 16 4 3 9 Slope Down Time TIG 16 4 3 10 Hot Start Adjustment Stick 16 4 3 11 Arc Force Adjustment Stick 16 4 3 12 Optional VRD Function Stick 16 4 4 Trigger Mode Selection 17 4 4 ...

Page 4: ... 1 6 Additional Setup for MIG welding with aluminium 28 7 1 7 Spool Gun Setup 28 7 1 8 Adjusting Settings for MIG Welding in Manual Mode Program 0 29 7 1 9 Adjusting Settings for MIG Welding in Synergic Auto Mode 29 7 2 Stick MMA Welding Operation 30 7 3 Lift TIG Operation 31 8 ACCESSORIES SPARE PARTS CIRCUIT DIAGRAMS 32 8 1 MIG Torch and Spares 32 8 2 TIG Torch and Spares Optional Extra 33 8 3 Op...

Page 5: ...rage 47 11 9 2 Setting Voltage 47 11 9 3 Changing to a different welding wire 47 11 9 4 How to determine correct Wire Speed Voltage Setting 48 11 10 Suggested Settings for Typical MIG Applications 48 11 11 Welding wire Size Selection 48 11 12 MIG Welding Troubleshooting 49 11 12 1 Porosity Problems 49 11 12 2 Wire Feed Problems 50 11 12 3 Weld Quality Problems 51 12 STICK MMA BASIC WELDING GUIDE 5...

Page 6: ...ding Gas for TIG Welding 65 13 1 4 Typical TIG Welding Settings 65 13 2 TIG Welding Troubleshooting 66 14 KNOWLEDGE RESOURCES 67 15 SAFETY 67 15 1 Store and Retain this Manual 67 15 2 Important Safety Information 67 15 3 Welding Operation 67 15 4 Welding Safety Instructions Warnings 69 15 4 1 Personal Safety 70 15 4 2 Arc Rays can Burn Eyes and Skin 70 15 4 3 Noise Can Damage Hearing 70 15 4 4 Wor...

Page 7: ... Output 16 24V Wire Feed Speed m min 1 5 16 5 Duty Cycle 200A 24 0V 25 145A 21 3V 60 110A 19 5V 100 Nominal Open Circuit Voltage 70V Spool Size 100mm 1kg 200mm 4 5kg or 5kg MIG Wire Sizes 0 6 0 8 0 9 1 0mm Stick MMA Welding Welding Current Output 10 200A Duty Cycle 200A 28 0V 25 130A 25 2V 60 100A 24 0V 100 Nominal Open Circuit Voltage VRD off 70V VRD on 13 5V MMA Electrode Size 1 6 4 0mm TIG Weld...

Page 8: ...onnection Socket 3 2 Machine Side 8 Spool Post 9 Spool Nut 10 Spool Lock Pin 11 Positive MIG Torch Power Connection 12 MIG Torch Polarity Connection Plate 13 Common MIG Torch Power Connection 14 Negative MIG Torch Power Connection 15 Wire Inlet Guide 16 Wire Feed Tension Adjustment Lever 17 Wire Feed Tension Arm Top Roller 18 Drive Roller 19 Drive Roller Retainer Knob 20 Outlet Wire Guide Tube 3 4...

Page 9: ...rocess Indicator Lights 27 Process Selection Button Process 28 Gas Test Button Test Gas 29 Left Selection Knob Voltage Dial 30 Right Selection Knob Wire Speed Amperage Dial 31 Wire Feed Load Button Feed Wire 32 Trigger Mode Selection Button Trigger 33 Trigger Mode Indicator Lights 34 Job Recall Button 35 Job Save Button 36 Right LCD Readout 37 Left LCD Readout Figure 4 27 32 24 25 26 28 29 30 31 3...

Page 10: ...ram Selection Indicator Light 42 Voltage Setting Indicator Light 43 Inductance Setting Indicator Light 44 Seconds Setting Indicator Light 45 Wire Speed Setting Indicator Light 46 Material Thickness Setting Indicator Light 47 Amperage Setting Indicator Light 48 Job Save Recall Selection Indicator Light 49 VRD Indicator Light 41 38 39 40 42 43 44 45 46 47 48 Figure 5 49 ...

Page 11: ...n Stick MMA Function Material Thickness Wire Feed Amperage current output Voltage output Variable Inductance Increase Decrease Save Settings Recall Settings 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 Table 2 ...

Page 12: ...ding the Left Selection Knob adjusts voltage 29 which will change the performance from the automatic program and the Right Selection Knob 30 adjusts target amperage output Right Selection Knob can be pressed to toggle to adjust Material Thickness instead of Amperage During welding Left LCD Readout 37 will display actual weld voltage and Right LCD Readout 36 will display actual amperage output 4 1 ...

Page 13: ...G mode which allows you to manually adjust volts and wire speed MIG Program Chart Program Wire Size Wire Type Shielding Gas 0 Manual Non Synergic 1 0 6mm Solid Steel Mixed Argon CO2 2 0 8mm 3 0 9mm 4 1 0mm 5 0 6mm Solid Steel CO2 6 0 8mm 7 0 9mm 8 1 0mm 9 0 8mm Flux Cored Steel Gasless or Gas 10 0 9mm 11 1 0mm 12 1 2mm 13 0 8mm Stainless Steel Mixed or Argon 14 0 9mm 15 1 0mm 16 0 8mm Silicone Bro...

Page 14: ...f desired press Fn 25 button to exit the Function setting Figure 8 Functions Chart Display Drive Roller Symbol MIG MODE PrG Pre Gas Time sec PoG Post Gas Time sec SFt Soft Start Adjustment bUb Burnback Adjustment SPt Spot Stitch Weld Time sec GAP Stitch Weld Gap Interval Time sec SPo Spool Gun On Off TIG MODE PoG Post Gas Time sec SLo Slope Up Time sec STICK MMA MODE Hot Hot Start Adjustment ArC A...

Page 15: ...e short period of time that the wire feed will continue to run for after the main welding current 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 burnback adjustment will cause the wire feeder to run for longer after the arc has stopped If the burnback adjus...

Page 16: ...led 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 welding conditions as Stick welding electrodes will have a minimum voltage they can operate with and still have a stable arc Arc Force control boosts the welding...

Page 17: ...er 4T is available for MIG TIG processes 4T stands for Four Touch or Latching mode The trigger is pulled once and released to welding and then pulled and released again to stop the welding This function is useful for longer welds as the trigger is not required to be held on continuously and thus reduced operator fatigue 4 4 3 SP Spot Stitch SP is only available for MIG process Spot Welding trigger...

Page 18: ... to fine tune the arc to produce less spatter This is often effective on thin materials Wire speed wire size and type shielding gas will all change the effect that the inductance setting has on the welding arc Inductance change will have no practical effect on MIG spray transfer process as opposed to short circuit process To adjust inductance only applied in MIG modes 1 Press Left Selection Knob 2...

Page 19: ...ckly and easily recall these settings when you change tasks This makes it much easier and simpler rather than trying to write down settings or tune correct settings every time you change tasks 4 8 1 Save or Update a Job 1 Set all desired settings 2 Press Save Job button 35 3 Rotate Right Selection Knob 30 to choose Job number The Right LCD Readout 36 will alternate between displaying the selected ...

Page 20: ...for that selected Job number 3 Press Recall Job button again 34 Figure 15 4 9 Error Over Temperature Indicator Light Error Over Temperature Indicator Light 39 illuminates when duty cycle is exceeded 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 This may also activate if...

Page 21: ...less wire up to approximately 4mm steel To enable full output and duty cycle of this welder a minimum recommended generator size is minimum 10kVa 5 3 2 Generator Quality Warranty Limitations Avoid using poor low quality generators as these have the greatest risk of power spikes etc A suitable quality generator should have a THD total harmonic distortion rating of no more than 6 Most reputable gene...

Page 22: ...P23S 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 cooling for th...

Page 23: ...he spool towards the wire feeder from bottom of the spool 6 Replace the Washer and Spool Tension Nut NOTE The Spool Nut Spring Spool Post are not required for 100mm spools 7 Feed the wire from the spool through the Wire Inlet Guide 15 into the wire feeder 8 Set the Spool Brake Tension by adjusting the Spool Tension Nut The spool brake tension should be set so that the spool can rotate freely but d...

Page 24: ...e tension should be set so that the spool can rotate freely but does not continue to rotate once the wire feed stops This may need to be adjusted as the wire is used up and the spool weight decreases WARNING Excessive spool brake tension will cause wire feeding issues and affect welding performance as well as premature failure wear of wire feed components Insufficient brake tension will cause the ...

Page 25: ...se 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 worn drive roller worn damaged torch consumables blocked damaged torch wire guide liner before increasing wire feed tension There is a nu...

Page 26: ...ece must be firm contact with clean bare metal with no corrosion paint or scale at the contact point 3 Connect the MIG Torch Polarity Connection Plate 12 to the Negative Output Connection 14 Note if this connection is not made there will be no electrical connection to the welding torch Figure 20 Wire Feed Tension Adjustment Lever Wire Feed Tension Arm Drive Roller Wire Inlet Guide Drive Roller Ret...

Page 27: ...rch Polarity Connection Plate 12 to the Positive MIG Torch Power Connection 11 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 cylinder not included with machine and connect the gas hose from the regulator to the gas inlet connection 23 on the rear of the machine Ensure all hose connections are tight and clamped w...

Page 28: ...e refer following section for use with a spool gun on the WF 205MST 7 1 7 Spool Gun Setup NOTE Spool Gun is an optional extra for the WF 205MST The spool gun is a very useful addition to a MIG welder It can be used for all types of MIG welding but it has two primary advantages over a conventional push wire feeder The main advantage is that distance that the wire has to travel from the spool to the...

Page 29: ...r to 4 5 7 Adjust special Function settings if required refer to 4 3 7 1 9 Adjusting Settings for MIG Welding in Synergic Auto Mode 1 Follow above steps for either Gasless Welding Setup or Gas MIG Welding Setup whichever is relevant 2 Set welding process selector to MIG refer to 4 1 3 Set the MIG Program to the relevant Program number refer to 4 2 4 To set output by Amperage Rotate Right Adjustmen...

Page 30: ...itive Welding Power Output Socket 11 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 21 to on to power up the machine 5 Set welding process selector to Stick refer to 4 ...

Page 31: ...ert TIG torch power connection into the Negative Welding Power Output Socket 7 4 Connect TIG multi pin connector to the TIG Control Spool Gun connection socket 5 5 Connect TIG torch gas line to the TIG Torch Gas Connection 6 on the front of the machine Ensure all connections are tight 6 Open gas cylinder valve and adjust regulator Press Test Gas button 28 to initiate flow of gas through the TIG to...

Page 32: ...arts Ref Part No Description WC 03614 Complete BZL 25 Torch 3m WC 03615 Complete BZL 25 Torch 4m Standard 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 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 B25N Nozzle Pk2 6 P3 BRSL4 Liner Steel wires 6...

Page 33: ...e 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 7 11 1mm Pk2 P3 10N46 TIG Ceramic Cup 8 12 7mm Pk2...

Page 34: ... 06235 Welding Trolley WC 01775 Welding Gloves P6 MPLY MIG Pliers WC 06203 MIG Spool Gun 8m BZL 25 Table 7 8 4 Drive Rollers Drive Rollers Part No Drive Roller WC 06186 0 6 0 8mm V Groove Steel WC 06187 0 8 0 9mm V Groove Steel WC 06188 0 8 0 9mm Knurled Flux Cored WC 06189 0 9 1 2mm Knurled Flux Cored WC 06190 1 0 1 2mm U Groove Aluminium Table 8 ...

Page 35: ... part 21 Wire feeder 22 Wire feeder insulation part 23 Polarity socket 24 Inductor 25 Front panel 26 Wire connector 27 Connector 28 Central socket 29 9 pin socket 30 Gas fitting 31 Euro socket Table 9 Ref Description 32 Knob 33 Front panel assembly sheet 34 Front PCB 35 Insulation cover 36 Assembly sheet 37 PFC inductor 38 Main transformer 39 Gas valve 40 Valve assembly sheet 41 3 way connector A1...

Page 36: ... 36 Weldclass 2019 E O E Edition 2 1 Figure 25 ...

Page 37: ...WF 205MST Weldclass 2019 E O E Edition 2 1 37 8 6 Primary Schematic Circuit Diagram Figure 26 ...

Page 38: ... 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 f...

Page 39: ... 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 shields the...

Page 40: ...function 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 stand...

Page 41: ...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 42: ... 42 Weldclass 2019 E O E Edition 2 1 Figure 33 Figure 34 Figure 35 Figure 36 ...

Page 43: ...ielding 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 37 11 3 Flux Cored Arc Welding FCAW This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc...

Page 44: ... create 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 39 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 ...

Page 45: ...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 2 Welding current wire feed speed 3 Travel speed 11 7 3 Secondary Adjustable Variables These variables cause changes in primary a...

Page 46: ... of the 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 41 Figure 42 Horizontal Butt Weld Figure 43 Horizontal Fill...

Page 47: ...his 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 weld it is likely that a change in wire size and or shielding gas type is required assuming all other factors are correct Synergic function makes the setup of MIG welding much simpler as follows 1 Choos...

Page 48: ...20 0 8mm All 60 220 16 22 0 9mm 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 Vertical Overhead 70 150 12 15 1 2mm Horizontal 160 220 16 18 Vertical Overhead 120 180 16 18 Stainless Steel Stainless Steel 316L Argon or Mix 0 8mm All 60 125 17 22 0 9mm All 75 160 17 22 Al...

Page 49: ...ly 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 environment ...

Page 50: ...fecting 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 accumu...

Page 51: ...too low Increase voltage Excessive spatter Figure 51 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...

Page 52: ...tact 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 Table...

Page 53: ...ece 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 may be...

Page 54: ...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 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 Sta...

Page 55: ...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 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...

Page 56: ...f 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 same tim...

Page 57: ...ctrode 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 r...

Page 58: ...izontal 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 56 Do not attempt to build up much l...

Page 59: ...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 up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 59 illustrates multi run technique and Figure 60 shows the effects of pausing at the edg...

Page 60: ...imen 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 61 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 by s...

Page 61: ...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 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...

Page 62: ...gh 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 electrodes a...

Page 63: ...olarity 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 Code R...

Page 64: ...weld quality Rule of thumb is that the taper section should be 2 5 times the Electrode Diameter Figure 69 Ideal Tungsten Preparation Stable ARC Diameter of the flat left on the end of the Electrode determines amperage capacity Figure 70 Wrong Tungsten Preparation Wandering ARC Figure 71 Pointing the Tungsten Electrode The electrode should be pointed according to the welding current Figure 72 Elect...

Page 65: ...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 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...

Page 66: ...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 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 material...

Page 67: ...tuation 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 related to personal injury CAUTION without the safety alert ...

Page 68: ...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 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 electric shock or fire may result 10 Transportation Methods ...

Page 69: ...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 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 a...

Page 70: ...ol 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 watc...

Page 71: ...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 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...

Page 72: ...s 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 Aluminu...

Page 73: ... 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 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 ...

Page 74: ... 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 maintain them and ...

Page 75: ...f 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 guidelines is...

Page 76: ...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 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 authorised d...

Page 77: ...WF 205MST Weldclass 2019 E O E Edition 2 1 77 NOTES ...

Page 78: ... 78 Weldclass 2019 E O E Edition 2 1 ...

Page 79: ...WF 205MST Weldclass 2019 E O E Edition 2 1 79 ...

Page 80: ... 80 Weldclass 2019 E O E Edition 2 1 www Weldclass com au WF 205MST ...

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