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OPERATING INSTRUCTIONS
To qualify for full 24 month warranty, you must register within 30 days
IMPORTANT!
of purchase. See inside for details.
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Congratulations & thank you for choosing WeldForce!
The WeldForce range from Weldclass provides market leading value, features
and durability. WeldForce machines have been designed with emphasis on
robust construction, with simple and functional operation.
Register Your Warranty Now
Standard warranty without registration is 12 months. To qualify for an
extended full 24 month warranty 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
plate on the back of the machine, or on the outside of the box that your
machine came in.
Using Gasless MIG Wire?
Weldclass Platinum GL-11 is Australia’s No.1 Gasless wire.
Welders right across Australia & beyond rate Platinum GL-11
as the most user-friendly, smoothest running gasless wire
on the market.
Talk to your Weldclass distributor today, or go to:
www.Weldclass.com.au/GL-11
Platinum GL-11
2
Contents
Know Your Machine
Controls Explained
Power Supply
............................................................................................................... 6
Operating Environment
Welding Settings
Tips & Tricks
............................................................................................................... 10
Accessories & Spare Parts:
Care & Maintenance
MIG Basic Welding Guide
MIG Welding Troubleshooting
............................................................................................... 5
.................................................................................................. 5
...................................................................................... 6
...................................................................................................... 10
............................................................................... 11
............................................................................................ 12
................................................................................ 12
.................................................................... 16
MMA (Stick) Basic Welding Guide
MMA (Stick) Troubleshooting
TIG Basic Welding Guide
.................................................................................. 25
...................................................................... 24
............................................................. 18
TIG Welding Troubleshooting
Knowledge & Resources
Safety
Warranty
.............................................................................................................................. 28
....................................................................................................................... 33
................................................................................... 28
...................................................................... 27
3
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Specications
A
15
240
Input Power
V
40-
200
MIG Output Power
160
60
MIG Duty Cycle
0.6
0.9
MIG Wire Size
A
A
%
0.8
1.0
4.5
15
5
Spool Size
30-
170
ARC Output Power
130
60
ARC Duty Cycle
1.6
4.0
MMA Electrode
A
A
%
mm
to
mm
Size
Output Power
Duty Cycle
MIG: 40-200A
ARC/TIG: 30-170A
MIG: 160A @ 60%
ARC/TIG: 130A @ 60%
MIG Wire Size 0.6, 0.8, 0.9, 1.0mm
MMA Electrode Size 1.6 – 4.0mm
TIG Tungsten Size 1.6 – 2.4mm
Spool Size 200mm (4.5kg or 5kg) & 300mm (15kg)
Input Power 240V, 15A
mm
1.6
TIG Tungsten
Size
For full machine specications, refer to technical data plate on back of machine – or go to:
www.Weldclass.com.au/WF-200MST
4
Know Your Machine
1. MIG Torch Euro Connection
2. Spool Gun Connection Socket
3. Spool Gun Switch
4. LCD Current Meter
- Displays output current (amps) in real time*
5. 5. LCD Voltage Meter
- Displays output voltage in real time*
6. Welding Output Mode Switch
- Sets power source in MIG, MMA or Lift TIG
mode*
7. Overload Indicator Lamp*
8. Welding Voltage Adjustment Knob
- Adjusts welding voltage in MIG mode*
6
7
5
8
4
3
9
10
11
12
2
14
1
13
9. MIG Wire Feed Speed Adjustment Knob/
Arc (Stick / TIG) Current Adjustment Knob*
10. MIG Inductance Control Knob*
11. Cooling Fan Inlet (obscured)
12. Positive (+) Welding Power Output
Connection Socket
13. Negative (-) Welding Power Output
Connection Socket
14. MIG Torch Polarity Connection Lead
15. Shielding Gas Inlet Connection
16. 240V AC Mains Power Input Lead
17. Mains Power Switch
18. Wire Spool Holder
19. Wire Drive Inlet Guide
20. Wire Feed Tension Adjustment
21. Wire Feed Tension Arm
22. Wire Drive Roller Retainer
17
16
15
18
20
21
23. Wire Drive Roller (obscured)
Controls Explained
LCD Current & Voltage Display Meters
These indicate the actual voltage and current
readings at the output terminals of the welding
machine. The current meter should read ‘0’ except
when welding is actually taking place. The voltage
meter will indicate output voltage during welding
and the welding open circuit voltage when the
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machine is powered up but not welding. In MIG
mode the open circuit voltage will only appear
once the torch is triggered to activate the circuit,
in MMA and Lift TIG mode, the open circuit voltage
will show on the display continuously. The digital
meters are very sensitive and accurate, so it is not
abnormal to observe some small uctuations on
them when the machine is at rest.
23
22
5
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MIG Voltage & MIG Wire Speed / MMA
& Lift TIG Current Control Knobs
MIG Welding Mode
The MIG voltage control is essentially the power in
the welding arc that sets the heat. The wire speed
feed simply controls the rate at which the welding
wire is fed into the weld pool.
For any voltage position setting, there will be a
specic corresponding ‘sweet spot’ in the wire
feeding speed that will give the smoothest and
most stable welding arc. The correct wire feeding
speed for a given voltage setting is aected by
welding wire type and size, shielding gas, welding
material and joint type.
It is recommended to set the welding voltage as
desired and then slowly adjust the wire speed until
the arc is smooth and stable. When reaching this
point, if the penetration/ heat input is too much/
not enough, adjust the voltage setting and repeat
the process. If the operator is 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).
A chart with recommended settings using this
machine for common welding applications is
located on the underside 0f the wire feeder cover
door and further on in this manual.
Lift TIG Mode
Lift TIG is an arc ignition system for basic TIG welding
that removes the need to ‘scratch’ start or strike the
tungsten on the work piece to start the arc, which
can have a negative eect on the weld quality due
to tungsten contamination. Lift arc starting works
by gently touching the tungsten on the work piece
and then lifting it o. The control circuit will sense
when the tungsten is removed from the work piece
and send a pulse of electricity through the torch
that will cause the TIG arc to initiate.
Overload Indicator Lamp
Lights when duty cycle is exceeded and thermal
protection is activated. When thermal protection
is activated, welding output will be disabled until
machines cools suciently and overload indicator
lamp goes out. Also may activate with inverter
circuit failure issues.
Power Supply
Electrical Connection
The WF-200MST is designed to operate on a 10A
240V AC power supply.
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 length up to 20m. Using
extension leads of over 20m is not recommended.
MMA/ Lift TIG Welding Mode
The current control knob sets the target welding
output current for either mode selected. The
voltage knob has no eect in MMA or TIG mode.
MIG Inductance Control - Inductance adjustment
controls the rate of the current rise and fall as
the welding wire contacts the workpiece (known
as a short circuit). More inductance increases the
short circuit time and decreases the short circuit
frequency rate. This causes a wider and more
penetrating arc, useful for thicker weld joints. Less
inductance will create a narrow more focused arc.
This eect can also be used to ne tune the arc to
produce less splatter. Wire speed, wire size and
type, shielding gas will all change the eect that
the inductance setting has on the welding arc. As
a general rule, CO2 based shielding gas will weld
more smoothly with increased inductance, while
argon shielding gas will perform better with less
inductance. Inductance setting will have no eect
on MIG spray transfer process (as opposed to short
circuit process), MMA or TIG welding process.
Generator Use
This machine has a wide input power variation
tolerance (~170-265V), allowing it to operate o
generator power. However, this machine is NOT
designed for frequent generator use and is NOT
protected against poor quality power or voltage
spikes. Any damage caused by generator power
supply is not covered under warranty.
If generator power must be used, generator size
should be not less than 8kva. 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 not
more than 6%. Most reputable generator supplier will
be able to specify the THD ratings on their product.
Operating Environment
Adequate ventilation is required to provide proper
cooling for the WF-200MST. Ensure that the machine
is placed on a stable level surface where clean cool
air can easily ow through the unit. The WF-200MST
has electrical components and control circuit boards
which may be damaged by excessive dust and dirt,
so a clean operating environment is essential.
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Basic Operation - MIG Welding
1. Fitting Wire Spool
1.1 Open the wire feeder compartment door.
Remove the wire spool holder (18) by
threading it anticlockwise. If using 5kg/ D.200
spool, check that the 5kg spool spacer sleeve
is tted to the spool holder. Fit the wire
spool to spool holder, ensuring that the wire
exits the spool towards the wire feeder from
bottom the spool.
1.2 To replace the spool holder, set the spool
brake tension by adjusting the spool tension
adjustment hex screw in the middle of the
spool holder. Clockwise to increase spool
brake tension 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 the wire is
used up and the spool weight decreases.
WARNING!
Excessive spool brake tension will cause wire
feeding issues and aect welding performance
as well as premature failure/ wear of wire feed
components. Insucient brake tension will
cause the spool to ‘freewheel’ and the welding
wire will unravel from the spool (known as a
‘birds nest’)
necessary, remove and change the drive roller
by unthreading the drive roller retainer (22).
Once the correct drive roller (23) is selected
and tted and the drive roller retainer (22)
is secured in place, manually feed the wire
through the wire drive inlet guide (19),
through the drive roller groove and into the
outlet wire guide tube. Ensuring that the wire
is correctly seated in the drive roller groove,
replace the wire feed tension arm (21) and
lock it into place by pivoting the wire feed
tension adjustment lever (20) back to the
vertical position.
2.3 Adjusting wire feed tension. This is
accomplished by winding the knob on the
tension adjustment lever (20). Clockwise will
increase tension, anticlockwise will decrease
drive tension. Ideal tension is as little as
possible, while maintaining a consistent wire
feed with no drive roller slippage.
2.4 Check all other causes of excess wire feeding
friction causing slippage rst, such as;
incorrect/worn drive roller, worn/damaged
torch consumables, blocked/damaged torch
wire guide liner, before increasing wire feed
tension. There is a number scale on the
tension adjustment lever (20) to indicate the
adjustment position. The higher the number
indicated, the higher the tension that is set.
1.3 Feed the wire from the spool through the wire
drive inlet guide (19) into the wire feeder.
2. Loading Wire Feeder
2.1 Release the wire feed tension arm (21) by
pivoting the wire feed tension adjustment
lever (20) towards you from the vertical
‘locked’ position.
2.2 Check the wire drive roller (23) groove
matches the selected MIG wire type and
size. The drive roller will have two dierent
sized grooves; the size of the groove in use
is stamped on the side of the drive roller.
For ux cored ‘soft’ wire, such as that used in
gasless MIG welding, the drive roller groove
has a serrated prole (known as knurled).
For solid core ‘hard’ MIG wire, the drive roller
groove used has a ‘v’ shaped prole. For
Aluminum solid core ‘soft’ MIG wire, the drive
roller required has a ‘u’ shaped groove. If
WARNING!
Before changing the feed roller or wire spool,
ensure that the mains power is switched o.
WARNING!
The use of excessive feed tension will cause
rapid and premature wear of the drive roller, the
support bearing and the drive motor/gearbox.
2.5 Connect the MIG Torch Euro Connector to the
MIG torch Euro connection socket (1) on the
front of the machine. Secure by rmly hand
tightening the threaded collar on the MIG
Torch connector clockwise.
2.6 Check that the correct matching MIG wire,
drive roller (23) and MIG torch tip are tted.
2.7 Connect the machine to suitable mains power
using the mains input power lead (16). Switch
the mains power switch (17) to ‘on’ to power
up the machine. Set the welding mode switch
(6) to ‘MIG’ position.
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2.8 You are now ready to feed the wire through
the torch. With the wire feeder cover open,
pull the trigger of the MIG torch to check that
the wire is feeding smoothly through the
feeder and into the torch.
2.9 Set the wire feeding speed knob (9) to
maximum. With the torch tip removed from
the torch and the torch laid out as straight as
possible, depress MIG torch trigger until the
wire feeds out through the end of the MIG
torch. Replace the tip on the MIG torch and
trim o any excess wire.
3. Gasless Welding Operation
3.1 Connect the earth cable quick connector to
the positive welding power output socket
(12). Connect the earth clamp to the work
piece. Contact with the work piece must be
rm contact with clean, bare metal, with no
corrosion, paint or scale at the contact point.
3.2 Connect the MIG power connection lead (14)
to the negative welding power output socket
(13). Note if this connection is not made,
there will be no electrical connection to the
welding torch!
3.3 Set the welding voltage adjustment
knob (8), wire speed control knob (9) and
inductance control knob (10) to the desired
positions. You are now ready to weld!
4. Gas MIG Welding Operation
NOTE: Gas MIG welding will require a gas cylinder.
(Argon mix or CO2)
4.1 Connect the earth cable quick connector to
the negative welding power output socket
(13). Connect the earth clamp to the work
piece. Contact with the work piece must be
rm contact with clean, bare metal, with no
corrosion, paint or scale at the contact point.
4.2 Connect the MIG power connection lead (14)
to the positive welding power output socket
(12). Note if this connection is not made,
there will be no electrical connection to the
welding torch!
4.3 Connect the gas regulator to a gas cylinder
(not included with machine) and connect the
gas hose from the regulator to the gas inlet on
the rear of the machine (12). Ensure all hose
connections are tight. Open gas cylinder valve
and adjust regulator, ow should be between
10-25L/min depending on application. Recheck regulator ow pressure with torch
triggered as static gas ow setting may drop
once gas is owing.
4.4 Set the welding voltage adjustment
knob (8), wire speed control knob (9) and
inductance control knob (10) to the desired
positions. You are now ready to weld!
MIG welding with aluminium provides a
unique challenge, due to the low column
strength and surface friction of the wire.
This causes the wire to deform more as it is
pushed through the feed mechanism and the
torch wire delivery liner, greatly increasing
friction. Because good MIG welding results
are dependent on a smooth wire feed, certain
changes must be made to the wire feed
system to minimise friction caused issues.
For a standard ‘push’ fed torch, a length of
no longer than 3m cable should be used, as
well as the torch feed liner must be changed
to a special Teon/PVC liner, rather than the
conventional steel liner. Also the correct
style drive roller must be used and specic
Aluminium rated torch contact tip (or a
standard tip in one size oversize, e.g 0.8mm
aluminium wire, use standard 1.0mm contact
tip). For this reason, it is quite common
for operators to have an extra MIG torch
specically set up for aluminium use, if the
machine is used for welding steel as well.
Another option to overcome the friction
issues is using a spool gun, which will give
better results than a 3m push torch when
welding aluminium. The WF-200MST is spool
gun capable, refer following section for use
with a spool gun on the WF-200MST.
5. Spool Gun Operation
NOTE: Spool Gun is an optional extra for the WF-
200MST.
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 welding tip is very short,
compared with a conventional torch. This greatly
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reduces the wire feeding friction and improves
the wire feed speed smoothness and consistency,
thus the welding quality is greatly improved. This
is especially so with ‘soft’ wires such as Aluminium.
It is dicult to get Aluminium to feed smoothly in
welding machines equipped with standard design
wire feeders, even with special torch liners and
short torch lengths.
6. ARC/ MMA Welding Operation
6.1 Connect the earth cable quick connector to
the negative welding power output socket
(13) Connect the earth clamp to the work
piece. Contact with the work piece must be
rm contact with clean, bare metal, with no
corrosion, paint or scale at the contact point.
The second advantage is that the gun can allow
the use of the small D100 wire spools at a distance
from the power source (This distance is only
limited by the length of the spool gun lead). This
is advantageous for high cost wire, that is not used
commonly such as Stainless Steel or MIG brazing
wire. It saves the outlay cost for a much more
expensive, larger D200 spool.
5.1 Connect the earth cable quick connector to
the negative welding power output socket
(13). Connect the earth clamp to the work
piece. Contact with the work piece must be
rm contact with clean, bare metal, with no
corrosion, paint or scale at the contact point.
5.2 Connect the MIG power connection lead (14)
to the positive welding power output socket
(12). Note if this connection is not made,
there will be no electrical connection to the
welding torch!
5.3 Connect the spool gun Euro Connector to
the MIG torch Euro connection socket (1) on
the front of the machine. Secure by rmly
hand tightening the threaded collar on the
MIG Torch connector clockwise. Connect
the spool gun interface plug to the spool
gun connection socket (2). Set the spool gun
switch (3) to ‘on’ position.
5.4 Connect the gas regulator to a gas cylinder
(not included with machine) and connect the
gas hose from the regulator to the gas inlet on
the rear of the machine (15). Ensure all hose
connections are tight. Open gas cylinder valve
and adjust regulator, ow should be between
10-25 l/min depending on application. Recheck regulator ow pressure with torch
triggered as static gas ow setting may drop
once gas is owing.
5.5 Set the welding voltage adjustment knob (8),
wire speed control knob (9) and inductance
control knob (10) to the desired positions.
You are now ready to weld!.
6.2 Insert an electrode into the electrode holder
and connect the electrode holder and work
lead to the positive welding power output
socket (12).
NOTE: This polarity connection conguration is valid
for most GP (General Purpose) MMA electrodes. There
are variances to this. If in doubt, check the electrode
specications or consult the electrode manufacturer.
6.3 Connect the machine to suitable mains power
using the mains input power lead (16). Switch
the mains power switch (17) to ‘on’ to power
up the machine. Set the welding mode switch
(6) to ‘ARC’.
6.4 Select the required output current using the
current control knob (9). You are now ready to
weld!
7. Lift TIG Operation
NOTE: Lift TIG operation requires an optional valve
control TIG torch, argon gas cylinder & regulator.
7.1 Connect the earth cable quick connector to
the positive welding power output socket
(12). Connect the earth clamp to the work
piece. Contact with the work piece must be
rm contact with clean, bare metal, with no
corrosion, paint or scale at the contact point.
7.2 Insert TIG torch power connection into the
negative welding power output socket
(13). Connect valve TIG torch gas line to the
regulator, ensuring all connections are tight.
7.3 Open gas cylinder valve and adjust regulator,
ow should be between 5-10 l/min depending
on application. Re-check regulator ow
pressure with torch valve open as static gas
ow setting may drop once gas is owing.
7.4 Connect the machine to suitable mains power
using the mains input power lead (16). Switch
the mains power switch (17) to ‘on’ to power
9
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up the machine. Set the welding mode switch
(6) to ‘Lift TIG’.
7.5 Select the required output current using the
current control knob (9). You are now ready to
weld!
NOTE: The WF-200MST is a DC (Direct Current)
output welder only, this means that it is unable to
TIG weld reactive metals such as Aluminium alloys
and Brass (which require AC output). DC TIG output is
suitable for steel, stainless steel and copper. The New
Model is the model in the range that is designed for
TIG welding Aluminium and its alloys.
Welding Settings
Tips & Tricks
Duty Cycle Rating
Welding duty cycle is the percentage of actual
welding time that can occur in a ten minute cycle.
E.g. 20% at 160 amps - this means the welder can
weld at 160 amps for 2 minutes and then the unit
will need to be rested for 8 minutes. All duty cycle
ratings are based on an ambient air temperature of
40°C with 50% humidity, which is the international
standard for such a rating. In an environment with
temperature s exceeding 40°C, the duty cycle will
be less than stated. In ambient temperature less
than 40°C, duty cycle performance will be higher.
10
Accessories & Spare Parts:
MIG Torch Spare Parts:
The MIG Torch supplied with the WF-200MST is a BZL 25 (Binzel 25 style) model.
To view parts for this torch, go to: www.weldclass.com.au/BZL25parts
TIG Torch (Optional Extra):
The compatible TIG torch for this machine is Weldclass 9/17 torch with valve.
To view this torch, go to: www.weldclass.com.au/TigTorch917v
Machine Spare Parts:
For machine parts, go to www.weldclass.com.au/machines or contact
your Weldclass distributor
11
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Care & Maintenance
Keep your Welding Machine in Top
Condition
The WF-200MST does not require any special
maintenance, however the user should take care
of the machine as follows:
• Regularly clean the ventilation slots.
• Keep the casing clean.
• Check all cables before use.
• Check electrode holders, work lead/clamps and
welding torches before use.
• Replace worn electrode holders and earth
clamps, which do not provide a good connection.
• Replace worn torch consumable parts in a timely
manner.
• Replace worn wire drive components in a timely
manner.
Storing the Welder
When not in use the welder should be stored in the
dry and frost-free environment.
WARNING!
Before performing cleaning/maintenance,
replacing cables / connections , make sure the
welding machine is switched o and
disconnected from the power supply.
• Use a soft cloth or brush to clean electrical
components. Do not use liquid cleaning
products, water or especially solvents.
• Do not use compressed air to clean electrical
components as this can force dirt and dust
further into components, causing electrical short
circuits.
• Check for damaged parts.
If damaged, before further use, the welder must be
carefully checked by a qualied person to
determine that it will operate properly. Check for
breakage of parts, mountings and other conditions
that may aect its operation.
Have your welder repaired by an expert. An
authorised service centre should properly repair a
damaged part.
This appliance is manufactured in accordance with
relevant safety standards. Only experts must carry
out repairing of electrical appliances, otherwise
considerable danger for the user may result.
Use only genuine replacement parts. Do not use
modied or non-genuine parts.
MIG Basic
Welding Guide
MIG Basic Welding Techniques
Two dierent welding processes are covered in
this section (GMAW and FCAW), with the intention
of providing the very basic concepts in MIG
welding, where a welding gun is hand held, and
the electrode (welding wire) is fed into a weld
puddle, and the arc is shielded by a gas (GMAW) or
ux cored wire (FCAW).
12
Gas Metal Arc Welding (GMAW)
This process, also known as MIG welding, CO2
welding, Micro Wire Welding, short arc welding,
dip transfer welding, wire welding etc., is an electric
arc welding process which fuses together the parts
to be welded by heating them with an arc between
a solid continuous, consumable electrode and the
work.
Position of MIG Torch
(Fig 1-3)
Shielding is obtained from an externally supplied
welding 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.
GMAW Process
(Fig 1-1)
Weld Metal
Molten Weld Metal
Shielding Gas
Nozzle
Electrode Arc
Base Metal
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 between a continuous ux lled
electrode wire and the work. Shielding is obtained
through decomposition of the ux within the
tubular wire. Additional shielding may or may
not be obtained from an externally supplied gas
or gas mixture. The process is normally applied
semi automatically; however the process may be
applied automatically or by machine.
Push
Vertical Drag Pull
The angle of MIG torch to the weld has an eect on
the width of the weld.
The welding gun should be held at an angle to the
weld joint. (See Secondary Adjustment Variables
below).
Hold the gun so that the welding seam is viewed at
all times. Always wear the welding helmet with
proper lter lenses and use the proper safety
equipment.
CAUTION!!
Do not pull the welding gun back when the arc is
established. This will create excessive wire
extension (stick-out) and make a very poor
weld.
The electrode wire is not energized until the gun
trigger switch is depressed. The wire may therefore
be placed on the seam or joint prior to lowering
the helmet.
o
(Fig 1-4)
5o to 15
Longitudinal Angle
Direction of Travel
It is commonly used to weld large diameter
electrodes in the at and horizontal position and
small electrode diameters in all positions. The
process is used to a lesser degree for welding
stainless steel and for overlay work.
FCAW Process
(Fig 1-2)
Shielding Gas
(Optional)
Molten Metal
Molten
Slag
Slag
Weld Metal
Nozzle
(Optional)
Flux Cored
Electrode
Arc
Base
Metal
o
Transverse
90
Angle
(Fig 1-5)
o
5o to 15
Longitudinal Angle
Direction
of Travel
o
to 60
30
Transverse
Angle
o
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Vertical Fillet Welds (Fig 1-6)
o
10
Longitudinal Angle
o
o
to 60
30
Transverse
Angle
Direction of Travel
(Fig 1-7)
30
Transverse
Angle
o
to 60
o
Direction of Travel
o
10
Longitudinal Angle
o
to 20
30o to 60
Transverse
Angle
o
5o to15
Longitudinal
Angle
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.
o
These variables are:
• Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Secondary Adjustable Variables
These variables cause changes in primary
adjustable variables which in turn cause the
desired change in the bead formation. They are:
1. Stick-Out (distance between the end of the
contact tube (tip) and the end of the electrode
wire). Maintain at about 10mm stick-out
2. Wire Feed Speed. Increase in wire feed speed
increases weld current. Decrease in wire feed
speed decreases weld current.
Distance from the MIG Torch Nozzle
to the Work Piece
The electrode wire stick out from the MIG Torch
nozzle should be between 10mm to 20mm. This
distance may vary depending on the type of joint
that is being welded.
Travel Speed
The speed at which the molten pool travels
inuences the width of the weld and penetration
of the welding run.
MIG Welding (GMAW) Variables
Most of the welding done by all processes is on
carbon steel. The items below describe the welding
variables in short-arc welding of 24gauge (0.024”,
0.6mm) to ¼” (6.4mm) mild sheet or plate. The
applied techniques and end results in the GMAW
process are controlled by these variables.
Electrode Stick-Out
(Fig 1-8)
Gas Nozzle
Tip to
Work Distance
Contact Tip (Tube)
Electrode Wire
Actual
Stick-Out
3. Nozzle Angle. This refers to the position of the
welding gun in relation to the joint. The transverse
angle is usually one half the included angle
between plates forming the joint. The longitudinal
angle is the angle between the centre line of the
welding gun 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).
14
Preselected Variables
Preselected variables depend upon the type
of material being welded, the thickness of the
material, the welding position, the deposition rate
and the mechanical properties.
These variables are:
• Type of electrode wire
• Size of electrode wire
• Type of gas
• Gas ow rate
Transverse & Longitudinal
Nozzle Axes (Fig 1-9)
Longitudinal Angle
Axis of Weld
Transverse Angle
Whether the operator is left handed or right
handed has to be considered to realize the eects
of each angle in relation to the direction of travel.
Nozzle Angle, Right Handed Operator
(Fig 1-10)
Direction of Travel
Leading or “Pushing”
Angle (Forward Pointing)
o
Trailing or “Pulling”
90
Angle (Backward Pointing)
Establishing the Arc and Making
Weld Beads
Before attempting to weld on a nished piece of
work, it is recommended that practice welds be
made on a sample metal of the same material as
that of the nished piece.
The easiest welding procedure for the beginner to
experiment with MIG welding is the at position.
The equipment is capable of at, vertical and
overhead positions.
For practicing MIG welding, secure some pieces of
16 or 18 gauge (1.5mm or 2.0mm) mild steel plate
(150 x 150mm). Use (0.8mm) ux cored gasless
wire or a solid wire with shielding gas.
Setting of the Power Source
Power source and Current (Wire Speed) setting
requires some practice by the operator, as the
welding plant has two control settings that have
to balance. These are the Current (Wire Speed)
control and the welding Voltage Control.
The welding current is determined by the Current
(Wire Speed) control, the current will increase with
increased Current (Wire Speed), resulting in a
shorter arc. Less Current (Wire Speed) will reduce
the current and lengthen the arc. Increasing the
welding voltage hardly alters the current level,
but lengthens the arc. By decreasing the voltage,
a shorter arc is obtained with a little change in
current level.
(Wire Speed) to achieve the same current level.
A satisfactory weld cannot be obtained if the
Current (Wire Speed) and Voltage settings are not
adjusted to suit the electrode wire diameter and
the dimensions of the work piece.
If the Current (Wire Speed) is too high for the
welding voltage, “stubbing” will occur as the wire
dips into the molten pool and does not melt.
Welding in these conditions normally produces a
poor weld due to lack of fusion. If, however, the
welding voltage is too high, large drops will form
on the end of the wire, causing spatter. The correct
setting of voltage and Current (Wire Speed) can be
seen in the shape of the weld deposit and heard by
a smooth regular arc sound.
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas
used depends on the following:
• Thickness of the metal to be welded
• Type of joint
• Capacity of the wire feed unit and power
source
• The amount of penetration required
• The deposition rate required
• The bead prole desired
• The position of welding
• Cost of the wire
When changing to a dierent electrode wire
diameter, dierent control settings are required.
A thinner electrode wire needs more Current
15
by
MIG Welding
Troubleshooting
The general approach to x Gas Metal Arc Welding
(GMAW) problems is to start at the wire spool then
work through to the MIG torch. There are two main
areas where problems occur with GMAW, Porosity
and Inconsistent wire feed.
When there is a gas problem the result is usually
porosity within the weld metal. Porosity always
stems from some contaminant within the molten
weld pool which is in the process of escaping
during solidication of the molten metal.
Contaminants range from no gas around the
welding arc to dirt on the workpiece surface.
Porosity can be reduced by checking the following
points.
WARNING!
Wire Jam Troubleshooting
• If wire jam occurs when the torch becomes hot, this is often because the heat causes the wire and the tip
to expand (which shrinks the hole in the tip). Using a slightly oversize tip can prevent this – eg: for 0.9mm
wire, use a 1.0mm tip.
• Do NOT over-tighten the drive roll tension – this will accelerate wear of the drive system, may distort the
wire & will cause further wire feed problems.
• Refer to page 15-16 for more troubleshooting tips.
16
Wire feeding problems can be reduced by checking the following points.
(Replace liner)
(Replace liner)
Other weld problems can be reduced by checking the following points.
17
by
MMA (Stick) Basic
Welding Guide
Size of Electrodes
The electrode size is determined by the thickness
of metals being joined and can also be governed
by the type of welding machine available. Small
welding machines will only provide current
(amperage) to run smaller sized electrodes.
For thin sections, it is necessary to use smaller
electrodes otherwise the arc may burn holes
through the job. A little practice will soon establish
the most suitable electrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their
original containers.
Electrode Polarity
Electrodes are generally connected to the electrode
holder with the electrode holder connected
positive polarity.
Flat Position,
Down Hand Butt Weld
(Fig 1-11)
Flat Position,
Gravity Fillet Weld
(Fig 1-12)
Horizontal Position,
Butt Weld
(Fig 1-13)
Horizontal-Vertical
(HV) Position
(Fig 1-14)
The work lead is connected to the negative polarity
and is connected to the work piece. If in doubt
consult the electrode data sheet.
Eects of MMA(Stick) Welding
on Various Materials
High Tensile and Alloy Steels
The two most prominent eects 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 underbead cracks in
the weld area may be reduced by using the correct
electrodes, preheating, using higher current
settings, using larger electrodes sizes, short runs
for larger electrode deposits or tempering in a
furnace.
Manganese Steels
The eect on manganese steel of slow cooling from
high temperatures causes embrittlement. For this
reason it is absolutely essential to keep manganese
steelcool during welding by quenching after each
weld or skip welding to distribute the heat.
Cast Iron
Most types of cast iron, except white iron, are
weldable. White iron, because of its extreme
Vertical Position,
Butt Weld
(Fig 1-15)
Vertical Position,
Fillet Weld
(Fig 1-16)
Overhead Position,
Butt Weld
(Fig 1-17)
Overhead Position,
Fillet Weld
(Fig 1-18)
18
brittleness, generally cracks when attempts are
made to weld it. Trouble may also be experienced
when welding white-heart malleable, due to the
porosity caused by gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat
conductivity of copper, making pre-heating of
heavy sections necessary to give proper fusion of
weld and base metal.
Types of Electrodes
Arc Welding electrodes are classied into a number
of groups depending on their applications.
There are a great number of electrodes used for
specialised industrial purposes which are not
of particular interest for everyday general work.
These include some low hydrogen types for high
tensile steel, cellulose types for welding large
diameter pipes, etc. The range of electrodes dealt
with in this publication will cover the vast majority
of applications likely to be encountered; are all
easy to use.
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 Figure 1-19.
Open Square Butt Joint
(Fig 1-19a)
Gap varies from1.6mm (1/16”)
to 4.8mm (3/16”) depending on plate thickness
Single Vee Butt Joint
(Fig 1-19b)
Single Vee Butt Joint
(Fig 1-19c)
Not less than 45˚
Not less than 70˚
MILD STEEL :
E6011 - This electrode is used for all-position welding or
for welding on rusty, dirty, less-than- new metal. It has
repair or maintenance work.
E6013 - This all-position electrode is used for welding
clean, new sheet metal. Its soft arc has minimal spatter,
moderate penetration and an easy-to-clean slag.
E7014 - All positional, ease t o use electrode for use on
thicker steel than E6013. Especially suitable for sheet metal
E7018 - A low-hydrogen, all-position electrode used when
quality is an issue or for hard-to-weld metals. It has the capability of producing more uniform weld metal, which has
better impact properties at low temperatures.
CAST IRON:
ENI-CL - Suitable for joining all cast irons except white
cast iron.
STAINLESS STEEL:
1.6mm (1/16”)
Double Vee Butt Joint
(Fig 1-19d)
1.6mm (1/16”)
Lap Joint (Fig 1-19e)
Not less than 70˚
1.6mm (1/16”) max.
1.6mm (1/16”) max.
E318L-16 - High corrosion resistances. Ideal for dairy
work etc.
Joint Preparations
In many cases, it will be possible to weld steel
sections without any special preparation. For
heavier sections and for repair work on castings,
etc., it will be necessary to cut or grind an angle
Fillet Joint (Fig 1-19f)
19
by
Corner Weld
(Fig 1-19g)
Tee Joints
(Fig 1-19h)
Edge Joint
(Fig 1-19i)
Plug Welds
(Fig 1-19j)
MMA Welding Techniques
- A Word for Beginners
For those who have not yet done any welding, the
simplest way to commence is to run beads on a
piece of scrap plate. Use mild steel plate about
6.0mm thick and a 3.2mm electrode.
Clean any paint, loose scale or grease o the plate
and set it rmly on the work bench so that welding
can be carried out in the down hand position. Make
sure that the Work Lead/Clamp is making good
electrical contact with the work, either directly or
through the work table. For light gauge material,
always clamp the work lead directly to the job,
otherwise a poor circuit will probably result.
The Welder
Place yourself in a comfortable position before
beginning to weld. Get a seat of suitable height
and do as much work as possible sitting down.
Don’t hold your body tense. A taut attitude of
mind and a tensed body will soon make you feel
tired. Relax and you will nd that the job becomes
much easier. You can add much to your peace of
mind by wearing a leather 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 movement and takes a lot of weight o your
hand. Be sure the insulation on your cable and
electrode holder is not faulty; otherwise you are
risking an electric shock.
20
Striking the Arc
Practice this on a piece of scrap plate before going
on to more exacting work. You may at rst
experience diculty due to the tip of the electrode
“sticking” to the work piece. This is caused by
making too heavy a contact with the work and
failing to withdraw the electrode quickly enough.
A low amperage will accentuate it. This freezingon of the tip may be overcome by scratching the
electrode along the plate surface in the same way
as a match is struck. As soon as the arc is established,
maintain a 1.6mm to 3.2mm gap between the
burning electrode end and the parent metal. Draw
the electrode slowly along as it melts down.
Making Welded Joints
Another diculty you may meet is the tendency,
after the arc is struck, to withdraw the electrode so
far that the arc is broken again. A little practice will
soon remedy both of these faults.
Striking an Arc
(Fig 1-20)
20
o
1.6mm (1/16”)
Arc Length
The securing of an arc length necessary to produce
a neat weld soon becomes almost automatic. You
will nd that a long arc produces more heat.
A very long arc produces a crackling or spluttering
noise and the weld metal comes across in large,
irregular blobs. The weld bead is attened and
spatter increases. A short arc is essential if a high
quality weld is to be obtained although if it is too
short there is the danger of it being blanketed by
slag and the electrode tip being solidied in. If this
should happen, give the electrode a quick twist
back over the weld to detach it. Contact or “touchweld” electrodes such as E7014 Stick electrodes
do not stick in this way, and make welding much
easier.
Having attained some skill in the handling of an
electrode, you will be ready to go on to make up
welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as
shown in Figure 1-21, allowing 1.6mm to 2.4mm
gap between them and tack weld at both ends. This
is to prevent contraction stresses from the cooling
weld metal pulling the plates out of alignment.
Plates thicker than 6.0mm should have their mating
edges bevelled to form a 70º to 90º included angle.
This allows full penetration of the weld metal to
the root. Using a 3.2mm E7014 Stick electrode
at 100 amps, deposit a run of weld metal on the
bottom of the joint.
Do not weave the electrode, but maintain a steady
rate of travel along the joint sucient to produce a
well-formed bead. At rst you may notice a
tendency for undercut to form, but keeping the arc
length short, the angle of the electrode 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.
Butt Weld
(Fig 1-21)
20
o
- 30
o
Electrode
Tack Weld
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 time, the electrode has
to move along the plate to form a bead.
The electrode is directed at the weld pool at about
20º from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced.
If the travel is too fast, the bead will be narrow and
strung out and may even be broken up into
individual globules. If the travel is too slow, the
weld metal piles up and the bead will be too large.
Tack Weld
Weld Build Up Sequence
(Fig 1-22)
21
by
Heavy plate will require several runs to complete
the joint. After completing the rst run, chip the
slag out and clean the weld with a wire brush.
It is important to do this to prevent slag being
trapped by the second run. Subsequent runs are
then deposited using either a weave technique
or single beads laid down in the sequence shown
in Figure 1-22. The width of weave should not be
more than three times the core wire diameter of
the electrode.
Multi-Runs in HV Fillet Weld
(Fig 1-24)
C. Vertical Welds
When the joint is completely lled, the back is either
machined, ground or gouged out to remove slag
which may be trapped in the root, and to prepare
a suitable joint for depositing the backing run. If a
backing bar is used, it is not usually necessary to
remove this, since it serves a similar purpose to the
backing run in securing proper fusion at the root of
the weld.
B. Fillet Welds
These are welds of approximately triangular crosssection made by depositing metal in the corner of
two faces meeting at right angles. Refer to Figure
1-14, 1-23 and 1-24.
Electrode Position
for HV Fillet Weld
(Fig 1-23)
A piece of angle iron is a suitable specimen with
which to begin, or two lengths of strip steel may
be tacked together at right angles. Using a 3.2mm
E7014 Stick electrode at 100 amps, position angle
iron with one leg horizontal and the other vertical.
This is known as a horizontal-vertical (HV) llet.
45o from
vertical
o
-70o from
60
line of weld
1. Vertical Up
Tack weld a three feet length of angle iron to your
work bench in an upright position. Use a 3.2mm
E7014 Stick electrode and set the current at 100
amps. Make yourself comfortable on a seat in front
of the job and strike the arc in the corner of the
llet. The electrode needs to be about 10º from the
horizontal to enable a good bead to be deposited.
Refer Fig. 1-25.
Single Run Vertical Fillet Weld
(Fig 1-25)
Use a short arc, and do not attempt to weave on
the rst run. When the rst run has been completed
deslag the weld deposit and begin the second run
at the bottom. This time a slight weaving motion
is necessary to cover the rst run and obtain good
fusion at the edges.
Multi Run Vertical Fillet Weld
(Fig 1-26)
22
Strike the arc and immediately bring the electrode
to a position perpendicular to the line of the llet
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 1-23.
Do not attempt to build up much larger than
6.4mm width with a 3.2mm electrode, otherwise
the weld metal tends to sag towards the base, and
undercut forms on the vertical leg. Multi-runs can
be made as shown in Figure 1-24. Weaving in HV
llet welds is undesirable.
Weaving motion for
second and subsequent
runs
Pause at edge
of weave
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 1-26 illustrates multi-run technique and
Figure 1-27 shows the eects of pausing at the
edge of weave and of weaving too rapidly.
Examples of Vertical Fillet Welds
(Fig 1-27)
CORRECT INCORRECT
Pause at edge of weave
allows weld metal to build
up and eliminates undercut
Note: Weld contour
at edge of weave
2. Vertical Down
The E7014 Stick electrode makes welding in this
position particularly easy. Use a 3.2mm electrode
at 100 amps. The tip of the electrode is held in light
contact with the work and the speed of downward
travel is regulated so that the tip of the electrode
just keeps ahead of the slag. The electrode should
point upwards at an angle of about 45º.
iron at right angles to another piece of waste pipe.
Then tack this to the work bench or hold in a vice
so that 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 1-28). 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 llet welds.
Use a 3.2mm E6013 Stick electrode at 100 amps,
and deposit the rst run by simply drawing the
electrode along at a steady rate. You will notice
that the weld deposit is rather convex, due to the
eect of gravity before the metal freezes.
Overhead Fillet Weld
(Fig 1-28)
3. Overhead Welds
Apart from the rather awkward position necessary,
overhead welding is not much more dicult
that down hand welding. Set up a specimen for
overhead welding by rst tacking a length of angle
45
o
Tilted 10o in
line of travel
to plate
Angle tacked to pipe
23
by
MMA (Stick) Troubleshooting
24
TIG Basic
Welding Guide
TIG Welding is a fusion procedure that uses an
electric ARC created between an infusible tungsten
electrode and base material to be welded. For TIG
welding an inert gas must be used (Argon) which
protects the welding bead. If lling material is
used, it is made up of rods suitable to the material
to be welded (steel, stainless steel, copper etc).
TIG Welding
(Fig 15)
Torch
Electric Current
Inert Gas
Rod
Protective Gas
Tungsten Electrode
Deposit
Melted Area
Penetration
Base Material
In TIG mode, welding is possible in all positions:
at, angle, on the edge, vertical and overhead.
Furthermore, with respect to other types of
welding, the welding joint has greater mechanical
resistance, greater corrosion resistance and limited
heating in the welded area which limits distortion.
Welding can be done even without weld material,
guaranteeing a smooth, shiny weld with no
impurities or slag.
TIG Electrode Selection
and Preparation
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.
Preparing Tungsten for DC Electrode Negative
(DCEN) Welding
(Fig 16-1)
Tungsten Electrode
Tapered End
2.5 x Electrode Diameter
2.5 x Electrode Diameter
Grind end of tungsten on ne grit, hard abrasive
wheel before welding. Do not use wheel for other
jobs or tungsten can become contaminated
causing lower weld quality.
(Fig 16-2)
Stable ARC
Flat
Grinding
Wheel
Straight Ground
Ideal Tungsten Preparation - Stable ARC
Diameter of the at determines amperage capacity.
25
by
(Fig 16-3)
Radial Ground
ARC Welder
Point
Grinding
Wheel
Wrong Tungsten Preparation - Wandering ARC
Diameter of the at determines amperage capacity.
(Fig 17)
Pointing the Electrode
The electrode should be pointed according to the
welding current.
26
TIG Welding Troubleshooting
27
by
Knowledge &
Resources
Please refer to Weldclass website
www.weldclass.com.au for more information.
Safety
Store and Retain this Manual
Retain this manual for the safety warnings and
precautions, assembly, operating, inspection,
maintenance and cleaning procedures. Write the
product’s serial number into the NOTES section at
the rear, and keep this manual and the receipt in a
safe and dry place for future reference.
Important Safety Information
Failure to follow the warnings and instructions
may result in electric shock, re, serious injury and/
or death. Save all warnings and instructions for
future reference.
MIG Welding Operation
1. Maintain labels and nameplates on the
welder. These carry important information. If
unreadable or missing, contact Weldclass for a
replacement.
2. Avoid unintentional starting. Make sure the
welder is setup correctly and you are prepared to
begin work before turning on the welder.
3. Unplug before performing maintenance.
Always unplug the welder from its electrical outlet
before performing any inspection, maintenance,
or cleaning procedures.
4. Never leave the welder unattended while
energised. Turn power o before leaving the
welder unattended.
5. Do not touch live electrical parts. Wear dry,
insulating gloves. Do not touch the electrode or
the conductor tong with bare hands. Do not wear
wet or damaged gloves.
6. Protect yourself from electric shock. Do not
use the welder outdoors. Insulate yourself from the
work piece and the ground. Use non-ammable,
dry insulating material if possible, or use dry rubber
mats, dry wood or plywood, or other dry insulating
material large enough to cover the area of contact
with the work or the ground.
This is the safety alert symbol to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol 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 practices not related to
personal injury.
CAUTION, without the safety alert symbol, is used to
address practices not related to personal injury.
7. Avoid inhaling dust. Some dust created by
power sanding, sawing, grinding, drilling, cutting,
welding and other construction activities, contain
chemicals known to cause cancer, birth defects or
other harm. Your risk from these exposures varies,
depending on how often you do this type of work.
To reduce your exposure to these chemicals, work
in a well-ventilated area, and work with approved
safety equipment, such as dust masks that are
specially designed to lter out microscopic
particles.
8. People with pacemakers should consult their
physician(s) before using this machine.
WARNING!
Electromagnetic elds 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 re may result.
28
10. Transportation Methods. Lift unit with
the handles provided, or use a handcart or
similar device of adequate capacity. If using a
fork lift vehicle, secure the unit to a skid before
transporting.
CAUTION!
Disconnect input power conductors from
de-energized supply line before moving the
welding power source.
11. Exercise good work practices. The warnings,
precautions, and instructions discussed in this
instruction manual cannot cover all possible
conditions and situations that may occur. It must
be understood by the operator that common
sense and caution are factors which cannot be
built into this product, but must be considered by
the operator.
DANGER!
Always wear AS/NZS compliant safety glasses
and full face shield tted with appropriate lter
shade number. (Refer Filter Table on page 17.)
CAUTION!
Heavy-duty work gloves, non-skid safety shoes
and hearing protection used for appropriate
conditions will reduce personal injuries.
CAUTION!
Have the equipment serviced by a qualied
repair person using identical replacement parts.
This will ensure that the safety of the power tool
is maintained.
Personal Safety
Welding Safety Instructions
& Warnings
WARNING!
Protect yourself and others from possible serious
injury or death. Keep children away. Read the
operating/Instruction manual before installing,
operating or servicing this equipment. Have all
installation, operation, maintenance, and
repair work performed by qualied people.
If an operator does not strictly observe all safety
rules and take precautionary actions, welding
products and welding processes can cause serious
injury or death, or damage to other equipment or
property.
Safe practices have developed from past experience
in the use of welding and cutting. These practices
must be learned through study and training before
using this equipment. Some of these practices
apply to equipment connected to power lines;
other 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 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.
Unapproved safety equipment may not provide
adequate protection. Eye and breathing
protection must be AS/NZS compliant for the
specic hazards in the work area.
CAUTION!
Keep the work area well lit. Make sure there is
adequate space surrounding the work area.
Always keep the work area free of obstructions,
grease,oil, trash, and other debris. Do not use
equipment in areas near ammable chemicals,
dust, and vapours. Do not use this product in a
damp or wet location.
1. Stay alert, watch what you are doing and use
common sense when operating equipment. Do
not use a tool while you are tired or under the
inuence of drugs, alcohol or medication.
A moment of distraction when operating
equipment may result in serious personal
injury.
2. Do not overreach. Keep proper footing and
balance at all times. This enables better control of
the power tool in unexpected situations.
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
tted with a proper shade lter (refer AS
60974-1, AS/NZS 1337.1 and AS/NZS 1338.1
Safety Standards) to protect your face and
eyes when welding or watching. (See Filter
Table on Page17).
2. Wear approved safety glasses. Side shields are
recommended.
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3. Use protective screens or barriers to protect
others from ash and glare; warn others not to
watch the arc.
4. Wear protective clothing made from durable,
ame-resistant material (wool and leather)
and foot safety protection.
5. Never wear contact lenses while welding.
Noise Can Damage Hearing
CAUTION!
Noise from some processes can damage
hearing. Use AS/NZS compliant ear plugs or ear
mus if the noise level is high.
Work Environment Safety
DANGER!
Remove any combustible material from the
work area.
1. When possible, move the work to a location well
away from combustible materials. If relocation
is not possible, protect the combustibles with
a cover made of re resistant material.
2. Remove or make safe all combustible materials
for a radius of 10 metres around the work area.
Use a re resistant material to cover or block
all doorways, windows, cracks, and other
openings.
3. Enclose the work area with portable re
resistant screens. Protect combustible walls,
ceilings, oors, etc., from sparks and heat with
re resistant covers.
4. If working on a metal wall, ceiling, etc., prevent
ignition of combustibles on the other side by
moving the combustibles to a safe location.
If relocation of combustibles is not possible,
designate someone to serve as a re watch,
equipped with a re extinguisher, during the
welding process and well after the welding is
completed.
5. Do not weld or cut on materials having a
combustible coating or combustible internal
structure, as in walls or ceilings, without an
approved method for eliminating the hazard.
6. After welding, make a thorough examination
for evidence of re. Be aware that visible
smoke or ame may not be present for some
time after the re has started. Do not weld or
cut in atmospheres containing dangerously
reactive or ammable gases, vapours, liquids,
and dust. Provide adequate ventilation in work
areas to prevent accumulation of ammable
gases, vapours, and dust.
7. Do not apply heat to a container that has
held an unknown substance or a combustible
material whose contents, when heated, can
produce ammable or explosive vapours.
Clean and purge containers before applying
heat. Vent closed containers, including
castings, before preheating, welding, or
cutting.
Electricity Can Kill
DANGER!
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is
on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire,
wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded
equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from the work and the
ground using dry insulating mats or covers.
4. Disconnect input power before installing or
servicing this equipment. Lock input power,
disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.
5. Properly install and ground this equipment
according to national, state, and local codes.
6. Turn o all equipment when not in use.
Disconnect power to equipment if it will be
left unattended or out of service.
7. Use fully insulated electrode holders. Never dip
the holder in water to cool it or lay it down on
the ground or the work surface. Do not touch
holders connected to two welding machines
at the same time or touch other people with
the holder or electrode.
8. Do not use worn, damaged, undersized, or
poorly spliced cables.
9. Do not wrap cables around your body.
10. Connect work piece to a good electrical
ground.
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11. Do not touch the electrode while in contact
with the work (ground) circuit.
12. Use only well-maintained equipment. Repair
or replace damaged parts as soon as practical.
13. In conned spaces or damp locations, do not
use a welder with AC output unless equipped
with a voltage reducer.
Arc rays 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 Face Shield.
1. Use a Welding Helmet or Welding Face Shield
tted with a proper shade of lter (see AS
60974-1, AS/NZS 1337.1 and AS/NZS 1338.1
Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields are
recommended.
3. Use protective screens or barriers to protect
others from ash and glare; warn others not to
watch the arc.
4. Wear protective clothing made from durable,
ame-resistant material (wool and leather)
and foot protection.
5. Never wear contact lenses while welding.
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
breathe the fumes.
2. If inside, ventilate the area and/or use an
exhaust at the arc to remove welding fumes
and gases.
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3. If ventilation is poor, use an approved airsupplied respirator.
4. Read the Safety Data Sheets (SDS) and the
manufacturer’s instruction for the metals,
consumables, coatings, and cleaners.
5. Work in a conned space only if it is well
ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding
can displace air causing injury or death. Be
sure the breathing air is safe.
6. Do not weld in locations near degreasing,
cleaning, or spraying operations. The heat and
rays of the arc can react with vapours to form
highly toxic and irritating gases.
7. Do not weld on coated metals, such as
galvanized, lead, or cadmium plated steel,
unless the coating is removed from the
weld area, the area is well ventilated, and
if necessary, while wearing an air- supplied
respirator. The coatings and any metals
containing these elements can give o toxic
fumes if welded.
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 and re hazards.
9. Do not use a welder to thaw frozen pipes.
10. Remove the stick electrode from the holder
or cut o the welding wire at the contact tip
when not in use.
Sparks & Hot Metal
WARNING!
Chipping and grinding causes ying metal, and
as welds cool they can throw o slag.
1. Wear an AS/NZS approved face shield or safety
goggles. Side shields are recommended.
2. Wear appropriate safety equipment to protect
the skin and body.
Cylinders
Fire & Explosive Risks
WARNING!
Sparks and spatter y o from the welding arc.
The ying sparks and hot metal, weld spatter,
work piece, and hot equipment can cause res
and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or
re.
1. Protect yourself and others from ying sparks
and hot metal.
2. Do not weld where ying sparks can strike
ammable material.
3. Remove all ammables 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 re, and keep a re extinguisher
nearby.
6. Be aware that welding on a ceiling, oor,
bulkhead, or partition can cause re on the
hidden side.
WARNING!
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from
excessive heat, mechanical 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 ttings designed for the specic
application; maintain them and their
associated parts in good condition.
6. Turn your face away from the valve outlet
when opening the cylinder valve.
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7. Do not weld on closed containers such as
tanks or drums.
WARRANTY
Warranty period;
Without product registration: 12 months
If product has been registered online: 24 months
The WF-200MST is warranted against faulty components and manufacturing defects for the warranty
periods shown above.
The warranty period begins on the date of purchase by the end user. Warranty is not transferable and only
claimable by the original purchaser.
If warranty registration has not taken place, it is the sole responsibility of the purchaser to retain proof of
purchase (i.e. a copy of the invoice made out by the distributor or reseller to the owner of the machine
clearly showing the purchase date). Proof of purchase must be provided in the event of any warranty claim.
a) Warranty includes and covers: Manufacturing faults and/or faulty materials that do not allow
the machine to perform the functions for which it was designed, within the warranty period.
b) Warranty Excludes / Does Not Cover:
1. Warranty claims made without proof of purchase, or warranty claims made with
proof of purchase that is deemed by Weldclass Welding Products to be false,
misleading, incomplete or insucient.
2. Defects or damage resulting from: misuse, accidents, neglect, improper maintenance,
alteration/modication, use of the product contrary to the applications for which
it was designed, or failure to heed any of the instructions, warnings or guidelines
issued with the machine, spare parts or accessories that are not genuine.
3. Damage incurred in transport.
4. Operator error, misunderstanding or use contrary to the intended purpose.
5. Parts that are subject to wear and tear from usage or failure caused by the untimely
replacement of such parts.
6. Warranty claims made where the owner/operator of the machine is not willing or
not able to provide any information required by Weldclass Welding Products to
process the warranty claim.
7. The cost of freight, transport or travel. It is the responsibility of the purchaser to
deliver the a product under warranty to the nearest relevant service agent or
distributor.
8. Cost for repairs carried out by a party not approved by Weldclass to carry out repairs.
9. Accessories and attachments such as leads and torches.
This is a repair and/or replacement warranty only and does not allow for a refund. Weldclass reserves
the right to replace faulty product or parts covered under warranty with alternative / equivalent product
or parts should the original unit become obsolete or unavailable. No other warranty is expressed or
implied. This warranty is exclusive and in lieu of all others, including, but not limited to any warranty of
merchantability or tness for any particular purpose. Weldclass shall not under 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 authorised distributor. Warranty is always
dated from original date of purchase - if warranty repairs are made or if warranty replacements are given
this does not extend the warranty period. Any decision regarding any warranty claim is made at the sole
jurisdiction of Weldclass. This warranty policy does not aect the legal rights of any purchaser, distributor
or service agent.
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www.Weldclass.com.au/WF-200MST
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