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Weldclass Weldforce 155M Operating Instructions Manual

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Weldforce 155
175
M &
MST
Weldforce 155M
Weldforce 175MST
OPERATING INSTRUCTIONS
Edition 2.6
 IMPORTANT!
To qualify for extended 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.
© Weldclass 2020 | E.&O.E.
1

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Summary of Contents for Weldclass Weldforce 155M

  • Page 1 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. © Weldclass 2020 | E.&O.E.
  • Page 2 Congratulations & thank you for choosing Weldclass! The Weldforce range from Weldclass provides market leading value, features and durability. Register Your Warranty Now To qualify for an extended warranty, you must register within 30 days of purchase. Full details on warranty period and terms can be found at www.weldclass.com.au/WarrantyInfo...

  • Page 3: Table Of Contents

    Additional Setup for MIG welding with Aluminium (Weldforce 175MST only) ......20 7.1.6 Settings for MIG Welding ......................20 7.1.1 Drive Rollers & Torch Liners for different Wires ...............21 Stick (MMA) Welding Operation (Weldforce 175MST only) ............22 © Weldclass 2020 | E.&O.E.
  • Page 4 Lift TIG Operation (Weldforce 175MST only)................23 ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS ................24 MIG Torch and Spares for Weldforce 155M: ................24 MIG Torch and Spares for Weldforce 175M: ................25 TIG Torch and Spares (Optional Extra for Weldforce 175MST only): ..........26 Optional Accessories ........................27...
  • Page 5 Store and Retain this Manual .......................60 15.2 Important Safety Information ......................60 15.3 Welding Operation ........................60 15.4 Welding Safety Instructions & Warnings ..................62 15.4.1 Personal Safety ........................63 15.4.2 Arc Rays can Burn Eyes and Skin ..................63 © Weldclass 2020 | E.&O.E.
  • Page 6 Work Environment Safety ....................64 15.4.5 Electricity Can Kill .........................64 15.4.6 Fumes And Gases .........................65 15.4.7 Fire & Explosive Risks ......................66 15.4.8 Sparks & Hot Metal ......................66 15.4.9 Gas Cylinders ........................67 WARRANTY ............................67 16.1 Warranty Information ........................67 © Weldclass 2020 | E.&O.E.

  • Page 7: Basic Specifications

    60A / 12.4V @ 100% Nominal Open Circuit Voltage TIG Tungsten Size 1.6 – 2.4mm Table 1 For full machine specifications, refer to technical data plate on back of machine – or go to: http://www.weldclass.com.au/155M www.Weldclass.com.au/170MST © Weldclass 2020 | E.&O.E.

  • Page 8: Know Your Machine

    6. Negative Dinse Socket 7. Torch Polarity Change Tail Weldforce 155M Figure 1 Weldforce 175MST 3.2 Machine Rear 8. Mains Power Switch 9. Gas Inlet Connection 10. 240V AC Mains Power Input Lead Figure 2 © Weldclass 2020 | E.&O.E.

  • Page 9: Control Panel

    Weldforce 155 M & 3.3 Control Panel 1. Power Indicator LED 2. Thermal Overload / Error Indicator LED 3. Output Knob 4. Inductance (/Arc Force) Knob 5. Process Selector Knob Weldforce 155M Weldforce 170M Figure 3 © Weldclass 2020 | E.&O.E.

  • Page 10: Symbols Chart

    Explosive Hazard Inverter power source DC MIG (GMAW) Eye Injury Hazard Function Pacemaker Stick/MMA Interference (SMAW) Function Warning TIG (GTAW) Do not suspend Function from handle Power Supply Radiation Hazard Connection Table 2 Single Phase © Weldclass 2020 | E.&O.E.

  • Page 11: Controls Explained

    4 CONTROLS EXPLAINED 4.1 Weld Process Selection (Weldforce 175MST only) 1. Rotate ‘Process Selector Knob’ (5) to desired position. Figure 4 4.1.1 MIG/MAG Process: In this mode the Inductance Knob adjusts inductance (arc focus) and the Output Knob adjusts target output (power).

  • Page 12: Inductance Control (Mig/Mag Only)

    0 is Arc Force off, 100% is maximum Arc Force. This is practically useful for electrode types that have a higher operating voltage requirement or joint types that require a short arc length such as out of position welds. © Weldclass 2020 | E.&O.E.

  • Page 13: Error/Over Temperature Indicator Light

    5 POWER SUPPLY 5.1 Electrical Connection The Weldforce 155M & 175MST machines are designed to operate on a 10A 240V AC power supply. 5.2 Extension Leads If an extension cord must be used, it should be minimum cable core size 2.0mm for length of up to 10m, or minimum 2.5mm...

  • Page 14: Generator Quality & Warranty Limitations

    For further information please refer to AS 60529. Ventilation Adequate ventilation is required to provide proper cooling for the machine. Ensure that the machine is placed on a stable level surface where clean cool air can easily flow through the unit. © Weldclass 2020 | E.&O.E.

  • Page 15: Basic Operation

    100mm/1kg vs 200mm/5kg spools) 6. Replace spring & Tension Nut. Note: Adjust tension so that the spool can rotate freely, but does not continue to rotate (free- wheel) once the wire feed stops. Figure 7 © Weldclass 2020 | E.&O.E.

  • Page 16: Loading Wire Feeder

    Weldforce 155M: The serrated (knurled) groove side of the drive roller can be used for both Gasless MIG welding and Solid steel MIG wire in either 0.8 or 0.9mm. The smooth ‘V’ groove side is for 0.6mm solid steel wire.
  • Page 17 Weldforce 155 M & Tension Arm Tension Lever & Knob Wire Outlet Tube Drive Roller Drive Roller Retainer Cap Wire Inlet Guide Tube Figure 8 © Weldclass 2020 | E.&O.E.

  • Page 18: Gasless Welding Setup

    3. Connect the Torch Polarity Change Tail to the Negative Dinse Socket. Note: if this connection is not made, there will be no electrical connection to the welding torch! Figure 10 © Weldclass 2020 | E.&O.E.

  • Page 19: Gas Mig Welding Setup

    5. Connect the Torch Polarity Change Tail to the Positive Dinse Socket. Note: if this connection is not made, there will be no electrical connection to the welding torch! Figure 12 © Weldclass 2020 | E.&O.E.

  • Page 20: Additional Setup For Mig Welding With Aluminium (Weldforce 175Mst Only)

    2. Replace the liner in the MIG Torch with a special Graphite/Teflon/PVC liner (rather than the conventional steel liner). The Weldclass Universal Graphite liner kit is recommended (P3-CTUL09) 3. Choose the largest dimeter wire possible that can be used by your machine for your application.

  • Page 21: Drive Rollers & Torch Liners For Different Wires

    Gasless/Flux- WC-06425 Cored Steel 0.9mm 0.6mm Blue 0.8-0.9mm V-Groove Solid Steel 0.6mm WC-06422 Blue 0.8-0.9mm Stainless-Steel 0.8mm Blue 0.9mm U-Groove Aluminium WC-06426 Teflon / 1.0mm Poly Bronze 0.8mm U or V-Groove WC-06422 (CuSi/CuAl) Table 5 © Weldclass 2020 | E.&O.E.

  • Page 22: Stick (Mma) Welding Operation (Weldforce 175Mst Only)

    5. Set welding process selector knob to ‘MMA’ 6. Select the required output current using the Output Knob. 7. Adjust Arc Force as required using the Output Knob 8. Inductance (/Arc Force) Knob. 9. You are now ready to weld! Figure 13 © Weldclass 2020 | E.&O.E.

  • Page 23: Lift Tig Operation (Weldforce 175Mst Only)

    6. Connect the machine to suitable power. Switch the Mains Power Switch to ‘I’ to power up the machine. 7. Set Process Selector Knob to ‘TIG’ 8. Select the required output current using the Output Knob. 9. You are now ready to weld! Figure 14 © Weldclass 2020 | E.&O.E.

  • Page 24: Accessories, Spare Parts & Circuit Diagrams

    8 ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS 8.1 MIG Torch and Spares for Weldforce 155M: The MIG Torch supplied with the Weldforce 155M is a BZL 15 (Binzel 15 style) model. To view parts for this torch, see below table or go to: http://www.weldclass.com.au/BZL15 BZL 15 Torch Parts Ref.

  • Page 25: Mig Torch And Spares For Weldforce 175M

    Tip 1.0mm Alu Pk5 P3-BTA612 Tip 1.2mm Alu/Flux Core Pk5 P3-B25N Nozzle – Conical Pk2 P3-BBSL4 Liner – Steel wires 0.6-0.8mm P3-BRSL4 Liner – Steel wires 0.9-1.2mm P3-CTUL09 Liner – Aluminium wire 0.9-1.2mm Table 7 © Weldclass 2020 | E.&O.E.

  • Page 26: Tig Torch And Spares (Optional Extra For Weldforce 175Mst Only)

    8.3 TIG Torch and Spares (Optional Extra for Weldforce 175MST only): The compatible TIG torch for this machine is the Weldclass 3-TTU2917V/4 torch. To view this torch and parts, go to: www.weldclass.com.au Part No. Description 3-TTU2917V/4 Complete TIG Torch – Valved 150A 4m...

  • Page 27: Optional Accessories

    Welding Gloves P6-MPLY MIG Pliers Table 9 8.5 Drive Rollers Drive Rollers Part No. Drive Roller WC-06422 0.6/0.8/0.9mm V-Groove (Steel) WC-06425 0.8/0.9/1.2mm Knurled (Flux Cored) WC-06426 0.9/1.0mm U-Groove (Aluminium) + 1.0mm V-Groove (Steel) Table 10 © Weldclass 2020 | E.&O.E.

  • Page 28: Machine Spare Parts

    8.6 Machine Spare Parts: For machine parts, go to www.weldclass.com.au/machines or contact your Weldclass distributor. Handle Weldforce 155M Front Panel Ref. Description Power Cable Gland Earth Lead Cable Wire Compartment Door Handle Adjustment Knob Guide Main Power On/Off Switch Wire Compartment Door...
  • Page 29 Weldforce 155 M & Weldforce 155M Figure 16 © Weldclass 2020 | E.&O.E.
  • Page 30 Weldforce 175MST Figure 17 © Weldclass 2020 | E.&O.E.

  • Page 31: Primary Schematic Circuit Diagram

    Weldforce 155 M & 8.7 Primary Schematic Circuit Diagram Weldforce 175MST only Figure 18 © Weldclass 2020 | E.&O.E.

  • Page 32: Care & Maintenance

    Use only genuine replacement parts. Do not use modified or non-genuine parts. 9.2 Storing the Welder When not in use the welder should be stored in the dry, dust-free and frost-free environment. © Weldclass 2020 | E.&O.E.

  • Page 33: General Guide To Welding

    10.2.1.5 Materials MMA welding can be used with a wide variety of electrodes including general purpose, low hydrogen, stainless steel, iron powder, hard facing & cast iron just to name a few. © Weldclass 2020 | E.&O.E.

  • Page 34: The Tig Process

    It does not rely on the operator to feed in filler wire like TIG welding. Also because the filler wire is on a roll it lasts significantly longer than a Stick welding electrode so © Weldclass 2020 | E.&O.E.

  • Page 35: Joint Preparations

    Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in the following figures. Figure 19 Figure 22 Figure 23 Figure 20 Figure 24 Figure 21 © Weldclass 2020 | E.&O.E.
  • Page 36 Figure 25 Figure 26 Figure 28 Figure 27 © Weldclass 2020 | E.&O.E.

  • Page 37: Mig Basic Welding Guide

    It is commonly used to weld large diameter wires in the flat and horizontal position and small wire diameters in all positions. The process is used to a lesser degree for welding stainless steel and for overlay work. Figure 30 © Weldclass 2020 | E.&O.E.

  • Page 38: Position Of Mig Torch

    Generally solid wire is about 10mm and flux-cored/gasless wire about 15-20mm. 11.6 Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run. © Weldclass 2020 | E.&O.E.

  • Page 39: Mig Welding (Gmaw) Variables

    1. Stick-Out: This is the distance between the end of the contact tube (tip) and the end of the welding wire). Maintain at about 10mm stick-out for solid wire and 15-20mm for gasless wire. Figure 32 © Weldclass 2020 | E.&O.E.
  • Page 40 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 34 Figure 33 Horizontal Butt Weld Vertical Fillet Welds Figure 35 Figure 37 Horizontal Fillet Weld Overhead Fillet Weld Figure 38 Figure 36 © Weldclass 2020 | E.&O.E.

  • Page 41: Establishing The Arc And Making Weld Beads

    11.8 Establishing the Arc and Making Weld Beads Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the finished piece. The easiest welding procedure for the beginner to experiment with MIG welding is the flat position.

  • Page 42: Mig Welding Troubleshooting

    Do not restrict gas flow by allowing spatter to build up inside the torch nozzle. Check that the MIG torch O-rings are not damaged on the Euro connector. Table 12 WARNING! Disengage the feed roll when testing for gas flow by ear © Weldclass 2020 | E.&O.E.

  • Page 43: Wire Feed Problems

    Bent liner (Replace liner) This will cause friction between the wire and the liner this reducing wire feed. Table 14 © Weldclass 2020 | E.&O.E.

  • Page 44: Weld Quality Problems

    Figure 44 Excessive weld stresses. Increase weld metal strength or revise design. Excessive voltage. Decrease voltage. Cooling rate too fast. Slow the cooling rate by preheating part to be welded or cool slowly. © Weldclass 2020 | E.&O.E.
  • Page 45 (+) welding terminal for exhibits when the wire feed front panel. solid wires and negative (-) speed and voltage are welding terminal for gasless adjusted correctly wires. Refer to the wire manufacturer for the correct polarity. Table 15 © Weldclass 2020 | E.&O.E.

  • Page 46: Stick (Mma) Basic Welding Guide

    Most types of cast iron, except white iron, are weldable. White iron, because of its extreme 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. © Weldclass 2020 | E.&O.E.

  • Page 47: Types Of Electrodes

    12.5.1 MILD STEEL: 1. General Purpose “GP” E6013 (Weldclass 12V): This all-position electrode is used for maintenance and fabrication. Works well on mild steel, galvanized steel, sheet metal, steel tube and RHS.

  • Page 48: Mma Welding Techniques

    Another difficulty 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. Figure 45 © Weldclass 2020 | E.&O.E.

  • Page 49: Arc Length

    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. © Weldclass 2020 | E.&O.E.

  • Page 50: Making Welded Joints

    Plates thicker than 6.0mm should have their mating edges beveled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 3.2mm Weldclass 12V Stick electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

  • Page 51: Fillet Welds

    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 Weldclass 12V Stick electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet.

  • Page 52: Vertical Welds

    Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm Weldclass 12V 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 fillet. The electrode needs to be about 10º...

  • Page 53: Overhead Welds

    Use a 3.2mm Weldclass 12V Stick electrode at 100 amps, and deposit the first run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

  • Page 54: Mma (Stick) Troubleshooting

    Power source is set for MIG Set power source to STICK (GMAW) welding. (MMA) mode. Portions of the weld run do Small electrodes used on heavy Use larger electrodes and © Weldclass 2020 | E.&O.E.
  • Page 55 Redesign to relieve weld joint soon after solidification severe crack commences resistance electrodes. Insufficient throat thickness. Travel slightly slower to allow greater build up in throat. Weld current is too high. Decrease welding current. Figure 59 Table 17 © Weldclass 2020 | E.&O.E.

  • Page 56: Tig Basic Welding Guide

    DC Current (Amps) Guide For Selecting Filler Wire Diameter 1.6mm (1/16”) 60 – 115 Filler Electrode Diameter DC Current (Amps) 2.4mm (3/32”) 100 – 165 1.6mm (1/16”) 20 – 90 3.2mm (1/8”) 135 – 200 © Weldclass 2020 | E.&O.E.

  • Page 57: Preparing Tungsten For Dc Electrode Negative (Dcen) Welding

    The electrode should be pointed according to the welding current. Electrode Angles Angle @ Range of Current (Amps) 30° 0 – 30 60-90° 30 -120 90-120° 120 - 250 Figure 64 120° ≥250 Table 21 © Weldclass 2020 | E.&O.E.

  • Page 58: Shielding Gas For Tig Welding

    Lap / Fillet 1.6mm 60-70 40-60 1.6mm 1.6mm Butt/ Corner (1/16”) (1/16”) (1/16”) 70-90 50-70 Lap / Fillet 3.2mm 80-100 65-85 1.6mm 2.4mm Butt/ Corner (1/8”) (1/16”) (3/32”) 90-115 90-110 Lap / Fillet Table 23 © Weldclass 2020 | E.&O.E.

  • Page 59: Tig Welding Troubleshooting

    Select the right shielding gas. used. Poor Work Lead/Clamp Improve connection to work piece. connection to work piece. Arc flutters during TIG welding. Tungsten electrode is too large Select the right size electrode. for the welding current. Table 24 © Weldclass 2020 | E.&O.E.

  • Page 60: Knowledge & Resources

    15.3 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.
  • Page 61 12. Do not use this machine for pipe thawing. This machine was not designed for pipe thawing and will be a significant electrical & heat hazard if attempt is made to use for thawing pipe. © Weldclass 2020 | E.&O.E.

  • Page 62: Welding Safety Instructions & Warnings

    CAUTION! Have the equipment serviced by a qualified repair person using identical replacement parts. This will ensure that the safety of the power tool is maintained. © Weldclass 2020 | E.&O.E.

  • Page 63: Personal Safety

    5. Never wear contact lenses while welding. 15.4.3 Noise Can Damage Hearing CAUTION! Noise from some processes can damage hearing. Use AS/NZS compliant ear plugs or ear muffs if the noise level is high. © Weldclass 2020 | E.&O.E.

  • Page 64: Work Environment Safety

    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. © Weldclass 2020 | E.&O.E.

  • Page 65: Fumes And Gases

    5. Work in a confined 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. © Weldclass 2020 | E.&O.E.

  • Page 66: Fire & Explosive Risks

    WARNING! Chipping and grinding causes flying metal, and as welds cool they can throw off 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. © Weldclass 2020 | E.&O.E.

  • Page 67: Gas Cylinders

    6. Turn your face away from the valve outlet when opening the cylinder valve. 16 WARRANTY 16.1 Warranty Information For full details on warranty period and terms and conditions, go to www.weldclass.com.au/WarrantyInfo © Weldclass 2020 | E.&O.E.
  • Page 68 © Weldclass 2020 | E.&O.E.

This manual is also suitable for:

Weldforce 175mst

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