Weldclass FORCE 132MST Operating Instructions Manual

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FORCE 132MST

OPERATING INSTRUCTIONS

Edition 1.1

 IMPORTANT!

To qualify for full extended warranty, you must register within 30 days of purchase. See inside

for details. Read this manual in full before using this machine.

Table of Contents

Troubleshooting

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Summary of Contents for Weldclass FORCE 132MST

Page 1 FORCE 132MST OPERATING INSTRUCTIONS Edition 1.1  IMPORTANT! To qualify for full extended warranty, you must register within 30 days of purchase. See inside for details. Read this manual in full before using this machine. © Weldclass 2024 | E.&O.E.
Page 2 Congratulations & Thank You Congratulations on your purchase! Founded in regional Australia in 1979, Weldclass has grown to become a leading welding equipment brand across Australasia and beyond. From all of us here at Weldclass, thank you for your support! Register Your Warranty Now Standard warranty without registration is 12 months.
Page 3: Table Of Contents
Choosing a Welding Process – MIG, Stick or TIG? ................15 10.2.1 The Stick (MMA) Process .....................15 10.2.2 The TIG Process ........................16 10.2.3 The MIG Process ........................16 10.3 Joint Preparations ........................17 MIG BASIC WELDING GUIDE ......................19 © Weldclass 2024 | E.&O.E.
Page 4 CAST IRON: ...........................29 12.5.3 STAINLESS STEEL: .........................29 12.6 Suggested Settings for Typical Stick (MMA) Applications ............29 12.7 MMA Welding Techniques ......................30 12.7.1 A Word for Beginners ......................30 12.7.2 The Welder ...........................30 12.7.3 Striking the Arc ........................30 © Weldclass 2024 | E.&O.E.
Page 5 Electricity Can Kill .........................44 14.4.6 Fumes And Gases .........................45 14.4.7 Fire & Explosive Risks ......................46 14.4.8 Sparks & Hot Metal ......................46 14.4.9 Gas Cylinders ........................47 WARRANTY ............................47 15.1 Warranty period ...........................47 15.2 Warranty Terms and Conditions ....................47 © Weldclass 2024 | E.&O.E.
Page 6: Basic Specifications
86A / 13.4V @ 60% 66A / 12.6V @ 100% 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/132MST © Weldclass 2024 | E.&O.E.
Page 7: Know Your Machine
5. Wire Feed Tension Arm/Top Roller 6. Drive Roller (Partially visible) 7. Drive Roller Retainer 8. Torch Cable Connection/Housing 3.3 Rear 1. Mains Power Switch 2. 230V Mains Power Input Lead 3. MIG Gas Inlet Connection © Weldclass 2024 | E.&O.E.
Page 8: Controls Explained
4 CONTROLS EXPLAINED 4.1 Control Panel Figure 2 1. Process Mode Selection Select MIG, TIG, or Stick Mode Note that different modes require different each/torch polarity. Refer to chart inside wire feeder door, and/or further information throughout this manual for correct polarity settings. 2.
Page 9: Power Supply
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 2024 | E.&O.E.
Page 10: Basic Operation
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. © Weldclass 2024 | E.&O.E.
Page 11: Gasless Welding Setup
4.1 of this manual for further guidance. 10. IMPORTANT: With gas MIG welding, ‘Push’ the torch so the wire is pointing away from the completed weld metal/joint and into the direction of travel. © Weldclass 2024 | E.&O.E.
Page 12: Stick (Mma) Welding Operation
(4.1.6) will display the set amperage output. 9. Adjust Up-Slope setting via right Secondary Output Knob as/if required (4.1.5) 10. Refer to reference chart inside wire feeder door, and section 4.1 of this manual for further guidance. © Weldclass 2024 | E.&O.E.
Page 13: Accessories & Spare Parts
MIG Torch Spares BZL 15 Series Weldclass.com.au/BZL15 TIG Torch WC-00992 Weldclass.com.au/Tig17v Drive Rollers Weldclass.com.au/132roller Gas Regulator 4-AR1 Weldclass.com.au/regulators Gas Hose WC-03338 Weldclass.com.au/03338 Trolley T100 WC-06235 Weldclass.com.au/t100 Internal Parts / Components Weldclass.com.au/MachineParts 8.2 Primary Circuit Diagram © Weldclass 2024 | E.&O.E.
Page 14: 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 2024 | E.&O.E.
Page 15: General Guide To Welding
10 GENERAL GUIDE TO WELDING 10.1 Duty Cycle Rating Weldclass welding machines are fitted with thermal overload protection which means the machine will cut out when it reaches a certain temperature, to prevent damage to components. The machine will then re- start when it returns to a safe temperature.
Page 16: 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 2024 | E.&O.E.
Page 17: Joint Preparations
Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in the following figures. Figure 3 Figure 6 Figure 7 Figure 4 Figure 8 Figure 5 © Weldclass 2024 | E.&O.E.
Page 19: 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. © Weldclass 2024 | E.&O.E.
Page 20: 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 2024 | E.&O.E.
Page 21: Mig Welding (Gmaw) Variables
Maintain at about 10mm stick-out for solid wire and 15-20mm for gasless wire. Figure 16 2. Wire Feed Speed: Increase in wire feed speed increases weld current/amperage. Decrease in wire feed speed decreases weld current. © Weldclass 2024 | E.&O.E.
Page 22 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 18 Figure 17 Horizontal Butt Weld Vertical Fillet Welds Figure 19 Figure 21 Horizontal Fillet Weld Overhead Fillet Weld Figure 22 Figure 20 © Weldclass 2024 | E.&O.E.
Page 23: 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 24: How To Determine Correct Wire Speed/Voltage Setting
4. The amount of penetration required 5. The deposition rate required 6. The bead profile desired 7. The position of welding 8. Cost of the wire 9. Environment (can shielding gas be used or not?) © Weldclass 2024 | E.&O.E.
Page 25: 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 3 WARNING! Disengage the feed roll when testing for gas flow by ear © Weldclass 2024 | E.&O.E.
Page 26: Wire Feed Problems
Bent liner (Replace liner) This will cause friction between the wire and the liner this reducing wire feed. Table 5 © Weldclass 2024 | E.&O.E.
Page 27: Weld Quality Problems
Figure 28 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 2024 | E.&O.E.
Page 28: Stick (Mma) Basic Welding Guide
Hardened zone and under-bead 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. © Weldclass 2024 | E.&O.E.
Page 29: Manganese Steels
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. Its soft arc has minimal spatter, moderate penetration and an easy-to-clean slag.
Page 30: 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 29 © Weldclass 2024 | E.&O.E.
Page 31: Arc Length
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 32: 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 33: 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 34: 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 35 Figure 42 environment. wind. Electrode damaged i.e. flux Discard damaged electrodes coating incomplete. and only use electrodes with a complete flux coating. Crack occurring in weld metal Rigidity of joint. Redesign to relieve weld joint © Weldclass 2024 | E.&O.E.
Page 36: Tig Basic Welding Guide
DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece. Tungsten Electrode Types Electrode Type Application Features Colour Code Rare-Earth All metals* High-Performance, suitable for both DC (Steel, Purple (Weldclass RE4) Stainless steel etc) and AC (Aluminium)* TIG © Weldclass 2024 | E.&O.E.
Page 37: Preparing Tungsten For Dc Electrode Negative (Dcen) Welding
Rule of thumb is that the taper section should be 2.5 times the Electrode Diameter. Figure 45 Ideal Tungsten Preparation = Stable ARC Diameter of the flat left on the end of the Electrode determines amperage capacity. Figure 46 Wrong Tungsten Preparation = Wandering ARC Figure 47 © Weldclass 2024 | E.&O.E.
Page 38: 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 14 © Weldclass 2024 | E.&O.E.
Page 39: 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 15 © Weldclass 2024 | E.&O.E.
Page 40: Safety
14.3 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 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 2024 | E.&O.E.
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 2024 | E.&O.E.
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 2024 | E.&O.E.
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 2024 | E.&O.E.
Page 45: 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 2024 | E.&O.E.
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 2024 | E.&O.E.
Page 47: Gas Cylinders
15.1 Warranty period Without product registration: 2 years If product has been registered online at Weldclass.com.au/WarrantyRegistration within 30 days of purchase: Conditional 7 years 15.2 Warranty Terms and Conditions Refer to https://www.weldclass.com.au/WarrantyTermsAndConditions for warranty terms and conditions. © Weldclass 2024 | E.&O.E.