Weldclass WeldForce WF-255MST Operating Instructions Manual Download Page 1

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WF-255

MST

© Weldclass 2019 | E.&O.E. | Edition 2.2

Edition 2.2

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-255MST

Page 1: ...n 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 at...

Page 2: ...gister 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 regi...

Page 3: ...2 Post Gas Time MIG 17 4 3 3 Soft Start Adjustment MIG 17 4 3 4 Burnback Adjustment MIG 17 4 3 5 Spot Stitch Weld Time MIG 17 4 3 6 Stitch Weld Gap Interval Time MIG 17 4 3 7 Spool Gun On Off MIG 18 4...

Page 4: ...ire Feeder 28 7 1 3 Gasless Welding Setup 29 7 1 4 Gas MIG Welding Setup 30 7 1 5 Additional Setup for MIG welding with aluminium 31 7 1 6 Spool Gun Setup 31 7 1 7 Adjusting Settings for MIG Welding i...

Page 5: ...50 11 9 MIG Voltage Wire Speed Settings 50 11 9 1 Setting Wire Speed Amperage 50 11 9 2 Setting Voltage 50 11 9 3 Changing to a different welding wire 50 11 9 4 How to determine correct Wire Speed Vo...

Page 6: ...sten for DC Electrode Negative DCEN Welding 67 13 1 3 Shielding Gas for TIG Welding 68 13 1 4 Typical TIG Welding Settings 68 13 2 TIG Welding Troubleshooting 69 14 KNOWLEDGE RESOURCES 70 15 SAFETY 70...

Page 7: ...WF 255MST Weldclass 2019 E O E Edition 2 2 7 16 4 Warranty Conditions 79...

Page 8: ...tandard AS 60974 1 Power Supply 240V 15 50hz Single Phase See further information under section 5 of this manual Factory Fitted Supply Plug Rating 15A Output Terminals Dinse style 35 50 Protection Cla...

Page 9: ...6 2V 60 120A 14 8V 100 Nominal Open Circuit Voltage 65V Table 2 This table applies when upgraded plug fitted rated at 25A Refer to 5 1 Effective Input Current I1eff 21A Maximum Input Current I1max 38A...

Page 10: ...hange Tail 3 2 Machine Side 9 Spool Post 10 Spool Nut 11 Spool Lock Pin 12 Wire Inlet Guide 13 Left Wire Feed Tension Adjustment Lever 14 Left Wire Feed Tension Arm Top Roller 15 Left Drive Roller 16...

Page 11: ...rocess Indicator Lights 29 Process Selection Button Process 30 Gas Test Button Test Gas 31 Left Selection Knob Voltage Dial 32 Right Selection Knob Wire Speed Amperage Dial 33 Wire Feed Load Button Fe...

Page 12: ...am Selection Indicator Light 44 Voltage Setting Indicator Light 45 Inductance Setting Indicator Light 46 Seconds Setting Indicator Light 47 Wire Speed Setting Indicator Light 48 Material Thickness Set...

Page 13: ...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 GM...

Page 14: ...ing the Left Selection Knob adjusts voltage 31 which will change the performance from the automatic program and the Right Selection Knob 32 adjusts target amperage output Right Selection Knob can be p...

Page 15: ...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 1 2mm 6 0 6...

Page 16: ...desired press Fn 27 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...

Page 17: ...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 w...

Page 18: ...ed 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 consta...

Page 19: ...r 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 functio...

Page 20: ...ed 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...

Page 21: ...kly 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 Sa...

Page 22: ...or that selected Job number 3 Press Recall Job button again 36 Figure 15 4 9 Error Over Temperature Indicator Light Error Over Temperature Indicator Light 41 illuminates when duty cycle is exceeded an...

Page 23: ...lug 5 1 1 Setting machine to 15A Input Mode 1 Turn Mains Power Switch 23 Off for at least 10 seconds 2 Press and hold both Left Selection Knob 31 and Right Selection Knob 32 whilst you switch the Main...

Page 24: ...or 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 generator...

Page 25: ...f 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...

Page 26: ...sion and anti clockwise to decrease The spool brake 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 t...

Page 27: ...Diameter 5kg Follow the same procedure as for 300mm spool as above however slide the 200mm Spool Spacer onto the Spool Post before you fit the Wire Spool Take care to ensure that the Spool Lock Pins a...

Page 28: ...ment Lever 13 22 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 slip...

Page 29: ...st be firm contact with clean bare metal with no corrosion paint or scale at the contact point 3 Connect the MIG Torch Polarity Change Tail 8 to the Negative Output Connection 7 Note if this connectio...

Page 30: ...h Polarity Change Tail 8 to the Positive MIG Torch Power Connection 3 Note if this connection is not made there will be no electrical connection to the welding torch 4 Connect the gas regulator to a g...

Page 31: ...pable refer following section for use with a spool gun on the WF 255MST 7 1 6 Spool Gun Setup NOTE Spool Gun is an optional extra for the WF 255MST The spool gun is a very useful addition to a MIG wel...

Page 32: ...4 5 7 Adjust special Function settings if required refer to 4 3 7 1 8 Adjusting Settings for MIG Welding in Synergic Auto Mode 1 Follow above steps for either Gasless Welding Setup or Gas MIG Welding...

Page 33: ...Positive Welding Power Output Socket 3 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 spec...

Page 34: ...G 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 Torc...

Page 35: ...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 B...

Page 36: ...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 B...

Page 37: ...WC 06235 Welding Trolley WC 01775 Welding Gloves P6 MPLY MIG Pliers WC 06203 MIG Spool Gun 8m BZL 25 Table 9 8 4 Drive Rollers Drive Rollers Part No Drive Roller WC 06191 0 6 0 8mm V Groove Steel WC...

Page 38: ...der holder 20 Base panel 21 Transformer 22 Insulation part 23 Front panel 24 Wire connector 25 Euro socket 26 9 Pin socket 27 Power cable clip 28 Gas fitting 29 Central socket 30 Gas fitting 31 Connec...

Page 39: ...WF 255MST Weldclass 2019 E O E Edition 2 2 39 Figure 25...

Page 40: ...40 Weldclass 2019 E O E Edition 2 2 8 6 Primary Schematic Circuit Diagram Figure 26...

Page 41: ...rce 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...

Page 42: ...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 electr...

Page 43: ...TIG 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 alumi...

Page 44: ...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...

Page 45: ...WF 255MST Weldclass 2019 E O E Edition 2 2 45 Figure 33 Figure 34 Figure 35 Figure 36...

Page 46: ...ng 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...

Page 47: ...will 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 j...

Page 48: ...ding 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 dep...

Page 49: ...ine 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...

Page 50: ...is 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 wel...

Page 51: ...18 20 0 9mm All 60 220 16 22 1 2mm 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...

Page 52: ...usted 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...

Page 53: ...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 p...

Page 54: ...w 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 Irregula...

Page 55: ...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 polar...

Page 56: ...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 fo...

Page 57: ...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...

Page 58: ...on 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 el...

Page 59: ...gh 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...

Page 60: ...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 comp...

Page 61: ...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 4...

Page 62: ...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 t...

Page 63: ...specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45 to the horizontal and tilted 10 in the line of travel Figure 61 The tip of the electrode may be touc...

Page 64: ...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 65: ...6 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 imp...

Page 66: ...y 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 pol...

Page 67: ...eld 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 det...

Page 68: ...ettings 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...

Page 69: ...an 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 Tur...

Page 70: ...on 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 s...

Page 71: ...ng 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...

Page 72: ...ctices 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...

Page 73: ...ontrol 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 a...

Page 74: ...at 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 Prov...

Page 75: ...ys from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Use the following table to select the appropriate shade number for a Welding Helmet or Welding...

Page 76: ...n cause sparks overheating or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flammable material 3 Remove all flammables within 10m of...

Page 77: ...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...

Page 78: ...chase 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...

Page 79: ...ircumstances 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 ot...

Page 80: ...80 Weldclass 2019 E O E Edition 2 2 www Weldclass com au WF 255MST...

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