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WF-140
/ WF-180
ST
ST
OPERATING INSTRUCTIONS
Edition 1
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.
© Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03
1
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Table of Contents
Troubleshooting
Related Manuals for Weldclass WeldForce WF-140ST
Summary of Contents for Weldclass WeldForce WF-140ST
- Page 1 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 | E.&O.E. | Edition 1.1 | 2019.05.03...
- Page 2 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 24 months.
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Page 3: Table Of Contents
TIG Torch and Spares (Optional Extra): ..................17 Optional Accessories ........................18 Machine Spare Parts: ........................18 Primary Schematic Circuit Diagram ....................20 CARE & MAINTENANCE .........................21 Keep your Welding Machine in Top Condition ................21 Storing the Welder ........................21 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... - Page 4 Preparing Tungsten for DC Electrode Negative (DCEN) Welding .........37 12.1.3 Shielding Gas for TIG Welding ....................38 12.1.4 Typical TIG Welding Settings ....................38 12.2 TIG Welding Troubleshooting .......................39 KNOWLEDGE & RESOURCES ......................40 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...
- Page 5 Sparks & Hot Metal ......................46 14.4.9 Gas Cylinders ........................47 WARRANTY ............................48 15.1 Warranty period ...........................48 15.2 Warranty Includes and Covers......................48 15.3 Warranty Excludes / Does Not Cover ...................48 15.4 Warranty Conditions ........................49 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...
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Page 6: Basic Specifications
Nominal Open Circuit Voltage TIG Tungsten Size 1.6 – 2.4mm 1.6 – 3.2mm Table 1 For full machine specifications, refer to technical data plate on back of machine – or go to: www.Weldclass.com.au/WF-140MST www.Weldclass.com.au/WF-180MST © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 7: Know Your Machine
3. Positive (+) Welding Power Output Connection Socket 4. Negative (-) Welding Power Output Connection Socket Figure 1 3.2 Machine Rear 5. Mains Power Switch 6. 240V AC Mains Power Input Lead Figure 2 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 8: Control Panel
11. Lift TIG Process Indicator Light 12. Selection Knob 13. Arc Force Setting Indicator Light 14. Hot Start Setting Indicator Light 15. Amps Setting Indictor Light 16. Error/Over Temperature Indicator Light 17. LCD Readout Figure 3 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 9: Symbols Chart
Direct Current (DC) Manual – VRD Active Negative TIG Function Positive Stick/MMA Hertz (cycles/sec) Function Hot Start Duty Cycle Amperage Arc Force (Current) Amperage (current) Voltage output Table 2 Voltage output Increase/Decrease © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 10: Controls Explained
1. Press the Selection Knob (12) down until the desired Setting Indicator Light is illuminated (13, 14 or 15) 2. Rotate the Selection Knob (12) to adjust parameter for the chosen Setting Figure 5 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 11: Amps
The VRD function will turn on full welding power/voltage when the resistance between the electrode and work piece is less than 200 Ohms (i.e. metal to metal contact). When the VRD function is active, the VRD Active Indicator Light (9) is illuminated. Figure 7 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 12: Power Supply
Most reputable generator suppliers will be able to specify the THD ratings on their product. Any damage caused by poor quality generator power supply or incorrect use is not covered under warranty. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 13: Golden Rules Of Generator Use
3. NEVER let your generator run out of fuel whilst the welder is plugged in. Following these Golden Rules will significantly reduce the risk of any damage resulting from generator power supply. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 14: Operating Environment
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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 15: Basic Operation
6. Select the required output current using the Selection Knob (12). The LCD Readout (17) will display the set amperage output. 7. Adjust special Function settings if required (refer to 4.2) 8. You are now ready to weld! Figure 8 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 16: Lift Tig Operation
8. Select the required output current using the Selection Knob (12). The LCD Digital Readout (17) will display the set amperage output. 9. You are now ready to weld! Figure 9 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 17: Accessories, Spare Parts & Circuit Diagrams
/ WF-180 8 ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS 8.1 TIG Torch and Spares (Optional Extra): 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 –... -
Page 18: Optional Accessories
Heatsink IGBT Insulation part Insulation part IGBT Recovery diode Rectifier Main PCB EMC PCB assembly sheet Insulation part EMC PCB Rectifier Table 5 EMC PCB assembly sheet EMC PCB Table 6 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... - Page 19 WF-140 / WF-180 WF-140ST Figure 11 WF-180ST Figure 12 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...
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Page 20: Primary Schematic Circuit Diagram
8.4 Primary Schematic Circuit Diagram Figure 13 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 21: 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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 22: 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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 23: The Tig Process
Note: TIG welding is often associated with welding of aluminium, however, aluminium TIG welding is only possible with AC/DC TIG welding machines. This machine is DC only and is not designed for TIG welding of aluminium. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 24: Joint Preparations
Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in the following figures. Figure 18 Figure 14 Figure 19 Figure 15 Figure 20 Figure 16 Figure 21 Figure 17 Figure 22 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... - Page 25 WF-140 / WF-180 Figure 23 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...
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Page 26: Stick (Mma) Basic Welding Guide
Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 27: Types Of Electrodes
11.5.1 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. Its soft arc has minimal spatter, moderate penetration and an easy-to-clean slag. -
Page 28: 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 24 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 29: 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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 30: 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 31: 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 32: 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 33: 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 34: Mma (Stick) Troubleshooting
Figure 35 Electrode too large for joint. Use smaller gauge electrode. Insufficient deposit time at Pause for a moment at edge of edge of weave. weave to allow weld metal build-up. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... - Page 35 Insufficient throat thickness. Travel slightly slower to allow greater build up in throat. Weld current is too high. Decrease welding current. Figure 38 Table 8 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...
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Page 36: Tig Basic Welding Guide
Table 9 * Note that the WeldForce WF-140ST & WF-180ST machines are only capable of DC TIG welding. It cannot perform AC TIG welding required to weld Aluminium. Tungsten Electrode Current Ranges... -
Page 37: Preparing Tungsten For Dc Electrode Negative (Dcen) Welding
12.1.2 Preparing Tungsten for DC Electrode Negative (DCEN) Welding The electrode should be pointed (tapered) according to the welding current. Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. Rule of thumb is that the taper section should be 2.5 times the Electrode Diameter. -
Page 38: Shielding Gas For Tig Welding
1.6mm 1.6mm 10-15 Butt/ Corner (1/16”) (1/16”) (1/16”) 70-90 50-70 Lap / Fillet 3.2mm 80-100 65-85 1.6mm 2.4mm 10-15 Butt/ Corner (1/8”) (1/16”) (3/32”) 90-115 90-110 Lap / Fillet Table 14 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 39: Tig Welding Troubleshooting
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 15 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 40: Knowledge & Resources
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. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... - Page 41 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 | E.&O.E. | Edition 1.1 | 2019.05.03...
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Page 42: 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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 43: Personal Safety
5. Never wear contact lenses while welding. 14.4.3 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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 44: 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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 45: Fumes And Gases
The coatings and any metals containing these elements can give off toxic fumes if welded. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 46: 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 | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 47: Gas Cylinders
5. Use appropriate shielding gas, regulators, hoses, and fittings designed for the specific application; maintain them and their associated parts in good condition. 6. Turn your face away from the valve outlet when opening the cylinder valve. © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03... -
Page 48: Warranty
7. The cost of freight, transport or travel. It is the responsibility of the purchaser to deliver the 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. -
Page 49: Warranty Conditions
/ WF-180 15.4 Warranty Conditions 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. - Page 50 NOTES: © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...
- Page 51 WF-140 / WF-180 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...
- Page 52 © Weldclass | E.&O.E. | Edition 1.1 | 2019.05.03...