Weldclass Weldforce 210MST User manual

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 1
Weldforce 210MST & 250MST
Synergic MIG – Stick – TIG
Edition 2.7
OPERATING INSTRUCTIONS
IMPORTANT!
To qualify for full 24 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.

.
2© Weldclass 2020 | E.&O.E.
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
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.
Satisfaction Guarantee
For full details on our satisfaction guarantee, refer to www.weldclass.com.au/mbg

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 3
1CONTENTS
1CONTENTS...............................................................................................................................................3
2SPECIFICATIONS ......................................................................................................................................7
2.1 210MST Specifications ...................................................................................................................7
2.2 250MST Specifications ...................................................................................................................9
3KNOW YOUR MACHINE.........................................................................................................................11
3.1 Machine Front..............................................................................................................................11
3.2 Machine Rear ...............................................................................................................................11
3.3 Machine Side................................................................................................................................11
3.4 Control Panel................................................................................................................................12
3.5 LCD Readout.................................................................................................................................13
3.6 Symbols chart...............................................................................................................................14
4CONTROLS EXPLAINED..........................................................................................................................16
4.1 Weld Process Selection ................................................................................................................16
4.1.1 MIG Process: ............................................................................................................................16
4.1.2 Stick (MMA) & TIG Process: .....................................................................................................16
4.2 MIG Synergic Program Selection..................................................................................................17
4.3 Function Selection........................................................................................................................20
4.3.1 Soft-Start Adjustment (SYN/MAN)...........................................................................................22
4.3.2 Inductance (SYN/MAN)............................................................................................................22
4.3.3 Burnback Adjustment (SYN/MAN)...........................................................................................22
4.3.4 Post-Gas Time (SYN/MAN).......................................................................................................22
4.3.5 Trigger Function (SYN/MAN)....................................................................................................22
4.3.6 Spot/Stitch Weld Time (SYN/MAN)..........................................................................................22
4.3.7 Metric/Imperial (SYN/MAN) ....................................................................................................22
4.3.8 Machine Software Information (SYN/MAN).............................................................................23
4.3.9 Plug/Power Supply Selection (SYN/MAN) [Weldforce 210MST only] ......................................23
4.3.10 Hot Start Adjustment (MMA)...............................................................................................23
4.3.11 Arc Force Adjustment (MMA)..............................................................................................23
4.4 VRD Function (Stick).....................................................................................................................23
4.5 Factory Reset................................................................................................................................24
4.6 Errors/Alarms ...............................................................................................................................24
5POWER SUPPLY .....................................................................................................................................25
5.1 Electrical Connection....................................................................................................................25
5.1.1 Weldforce 210MST...................................................................................................................25
5.1.2 Weldforce 250MST...................................................................................................................25
5.2 Extension Leads............................................................................................................................25

.
4© Weldclass 2020 | E.&O.E.
5.3 Generator Use..............................................................................................................................26
5.3.1 Generator Size..........................................................................................................................26
5.3.2 Generator Quality & Warranty Limitations..............................................................................26
5.3.3 3 Golden Rules of Generator use.............................................................................................26
6OPERATING ENVIRONMENT..................................................................................................................27
6.1 Location........................................................................................................................................27
6.2 Ventilation....................................................................................................................................27
7BASIC OPERATION.................................................................................................................................28
7.1 MIG Welding.................................................................................................................................28
7.1.1 Fitting Wire Spool.....................................................................................................................28
7.1.2 Loading Wire Feeder................................................................................................................30
7.1.3 Gasless Welding Setup.............................................................................................................32
7.1.4 Gas MIG Welding Setup ...........................................................................................................33
7.1.5 Additional Setup for MIG welding with aluminium .................................................................34
7.1.6 Adjusting Settings for MIG Welding in Manual Mode (MAN)..................................................34
7.1.7 Adjusting Settings for MIG Welding in Synergic (Auto) Mode (SYN)........................................34
7.2 Stick (MMA) Welding Operation ..................................................................................................35
7.3 Lift TIG Operation.........................................................................................................................36
8ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS..............................................................................37
8.1 MIG Torch and Spares: .................................................................................................................37
8.2 TIG Torch and Spares (Optional Extra): ........................................................................................38
8.3 Optional Accessories....................................................................................................................39
8.4 Drive Rollers: ................................................................................................................................39
8.5 Machine Spare Parts: ...................................................................................................................40
8.6 Primary Schematic Circuit Diagram..............................................................................................44
9CARE & MAINTENANCE.........................................................................................................................46
9.1 Keep your Welding Machine in Top Condition.............................................................................46
9.2 Storing the Welder .......................................................................................................................46
10 GENERAL GUIDE TO WELDING .........................................................................................................47
10.1 Duty Cycle Rating .........................................................................................................................47
10.2 Choosing a Welding Process – MIG, Stick or TIG?........................................................................47
10.2.1 The Stick (MMA) Process .....................................................................................................47
10.2.2 The TIG Process....................................................................................................................48
10.2.3 The MIG Process ..................................................................................................................48
10.3 Joint Preparations ........................................................................................................................49
11 MIG BASIC WELDING GUIDE.............................................................................................................51
11.1 MIG Basic Welding Techniques ....................................................................................................51
11.2 Gas Metal Arc Welding (GMAW)..................................................................................................51
11.3 Flux Cored Arc Welding (FCAW) ...................................................................................................51

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 5
11.4 Position of MIG Torch...................................................................................................................52
11.5 Distance from the MIG Torch Nozzle to the Work Piece..............................................................52
11.6 Travel Speed.................................................................................................................................52
11.7 MIG Welding (GMAW) Variables..................................................................................................53
11.7.1 Preselected Variables...........................................................................................................53
11.7.2 Primary Adjustable Variables...............................................................................................53
11.7.3 Secondary Adjustable Variables...........................................................................................53
11.8 Establishing the Arc and Making Weld Beads ..............................................................................55
11.9 MIG Voltage & Wire Speed Settings.............................................................................................55
11.9.1 Setting Wire Speed/Amperage ............................................................................................55
11.9.2 Setting Voltage.....................................................................................................................55
11.9.3 Changing to a different welding wire...................................................................................55
11.9.4 How to determine correct Wire Speed/Voltage Setting......................................................56
11.10 Suggested Settings for Typical MIG Applications .....................................................................56
11.11 Welding wire Size Selection .....................................................................................................56
11.12 MIG Welding Troubleshooting .................................................................................................57
11.12.1 Porosity Problems................................................................................................................57
11.12.2 Wire Feed Problems.............................................................................................................58
11.12.3 Weld Quality Problems ........................................................................................................59
12 STICK (MMA) BASIC WELDING GUIDE ..............................................................................................61
12.1 Size of Electrodes .........................................................................................................................61
12.2 Storage of Electrodes ...................................................................................................................61
12.3 Electrode Polarity.........................................................................................................................61
12.4 Effects of Stick (MMA) Welding on Various Materials..................................................................61
12.4.1 High Tensile and Alloy Steels................................................................................................61
12.4.2 Manganese Steels ................................................................................................................61
12.4.3 Cast Iron...............................................................................................................................61
12.5 Types of Electrodes ......................................................................................................................62
12.5.1 MILD STEEL: .........................................................................................................................62
12.5.2 CAST IRON:...........................................................................................................................62
12.5.3 STAINLESS STEEL: .................................................................................................................62
12.6 Suggested Settings for Typical Stick (MMA) Applications ............................................................62
12.7 MMA Welding Techniques ...........................................................................................................63
12.7.1 A Word for Beginners...........................................................................................................63
12.7.2 The Welder...........................................................................................................................63
12.7.3 Striking the Arc.....................................................................................................................63
12.7.4 Arc Length............................................................................................................................64
12.7.5 Rate of Travel .......................................................................................................................64
12.8 Making Welded Joints ..................................................................................................................65

.
6© Weldclass 2020 | E.&O.E.
12.8.1 Butt Welds............................................................................................................................65
12.8.2 Fillet Welds...........................................................................................................................66
12.8.3 Vertical Welds ......................................................................................................................67
12.8.4 Overhead Welds...................................................................................................................68
12.9 MMA (Stick) Troubleshooting ......................................................................................................69
13 TIG BASIC WELDING GUIDE..............................................................................................................71
13.1 TIG Electrode Selection and Preparation .....................................................................................71
13.1.1 Electrode Polarity.................................................................................................................71
13.1.2 Preparing Tungsten for DC Electrode Negative (DCEN) Welding .........................................72
13.1.3 Shielding Gas for TIG Welding..............................................................................................73
13.1.4 Typical TIG Welding Settings................................................................................................73
13.2 TIG Welding Troubleshooting.......................................................................................................74
14 KNOWLEDGE & RESOURCES.............................................................................................................75
15 SAFETY..............................................................................................................................................75
15.1 Store and Retain this Manual.......................................................................................................75
15.2 Important Safety Information ......................................................................................................75
15.3 Welding Operation.......................................................................................................................75
15.4 Welding Safety Instructions & Warnings......................................................................................77
15.4.1 Personal Safety.....................................................................................................................78
15.4.2 Arc Rays can Burn Eyes and Skin..........................................................................................78
15.4.3 Noise Can Damage Hearing .................................................................................................78
15.4.4 Work Environment Safety....................................................................................................79
15.4.5 Electricity Can Kill.................................................................................................................79
15.4.6 Fumes And Gases.................................................................................................................80
15.4.7 Fire & Explosive Risks...........................................................................................................81
15.4.8 Sparks & Hot Metal..............................................................................................................81
15.4.9 Gas Cylinders........................................................................................................................82
16 WARRANTY.......................................................................................................................................82
16.1 Warranty Information ..................................................................................................................82

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 7
2SPECIFICATIONS
2.1 210MST Specifications
Description
Weldforce 210MST
Part Number
WC-210MST
Dimensions of Power Source (L x W x H)
460 x 240 x 360mm
Weight of Power Source
13kg
Standard
AS 60974.1
Power Supply
240V +/- 15% 50hz Single Phase
(See further information under section 5 of this manual)
Factory Fitted Supply Plug Rating
10A
Maximum Input Current (I1max)
32A
Output Terminals
Dinse™ style 10-25
Protection Class
IP23
MIG Welding
Spool Size
100mm (1kg) & 200mm (4.5kg or 5kg)
MIG Wire Sizes
0.6, 0.8, 0.9, 1.0mm
Stick (MMA) Welding
MMA Electrode Size
1.6 – 3.2mm
TIG Welding
TIG Tungsten Size
1.6 – 2.4mm
Table 1

.
8© Weldclass 2020 | E.&O.E.
This table applies when utilizing ‘15A’ power supply mode* (Refer to 5.1.1.1)
*If using on 15A power supply15A plug should be installed by a qualified person (i.e. licensed electrician)
Effective Input Current (I1eff)
15A
Maximum Input Current (I1max)
32A
MIG Welding
Welding Current Output
20 – 180A (max 210A)
Welding Voltage Output
15 – 23V
Wire Feed Speed (m/min)
1.5 – 16.5
Duty Cycle
180A / 23.0V @ 20%
100A / 19.0V @ 60%
80A / 18.0V @ 100%
Nominal Open Circuit Voltage Uo
78V
Stick (MMA) Welding
Welding Current Output
20 – 150A
Duty Cycle
150A / 26.0V @ 30%
100A / 24.0V @ 60%
80A / 23.2V @ 100%
Nominal Open Circuit Voltage Uo
VRD off 78V / VRD on 15V
TIG Welding
Welding Current Output
20 – 150A
Duty Cycle
150A / 16.0V @ 30%
100A / 14.0V @ 60%
80A / 13.2V @ 100%
Nominal Open Circuit Voltage Uo
78V
Table 2
This table applies when utilizing ‘10A’ power supply mode** (Refer to 5.1.1.1)
**Machine output on 10A mode is limited / restricted so that effective power draw (I1eff) does not exceed 10A,
for safe and compliant operation.
Effective Input Current (I1eff)
10A
Maximum Input Current (I1max)
25A
MIG Welding
Welding Current Output
20 – 150A (max 170A)
Welding Voltage Output
15 – 21V
Wire Feed Speed (m/min)
1.5 – 16.5
Duty Cycle
150A / 21.5V @ 20%
100A / 19.0V @ 60%
80A / 18.0V @ 100%
Nominal Open Circuit Voltage Uo
78V
Stick (MMA) Welding
Welding Current Output
20 – 130A
Duty Cycle
130A / 25.2V @ 20%
100A / 24V @ 60%
80A / 23.2V @ 100%
Nominal Open Circuit Voltage Uo
VRD on 78V / VRD off 15V
TIG Welding
Welding Current Output
20 – 130A
Duty Cycle
130A / 15.2V @ 35%
100A / 14.0V @ 60%
80A / 13.2V @ 100%
Nominal Open Circuit Voltage Uo
78V
Table 3

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 9
2.2 250MST Specifications
Description
Weldforce 250MST
Part Number
WC-250MST
Dimensions of Power Source (L x W x H)
620 x 260 x 490mm
Weight of Power Source
22kg
Standard
AS 60974.1
Power Supply
240V +/- 15% 50hz Single Phase
(See further information under section 5 of this manual)
Factory Fitted Supply Plug Rating
15A
Maximum Input Current (I1max)
38A
Output Terminals
Dinse™ style 35-50
Protection Class
IP23
MIG Welding
Spool Size
200mm (4.5kg or 5kg) & 300mm (15kg)
MIG Wire Sizes
0.8, 0.9, 1.0, 1.2mm
Stick (MMA) Welding
MMA Electrode Size
1.6 – 4.0mm
TIG Welding
TIG Tungsten Size
1.6 – 3.2mm
Table 4

.
10 © Weldclass 2020 | E.&O.E.
This table applies when utilizing ‘15A’ power supply * (Refer to 5.1.1.1)
*Machine is factory fitted with 15A plug for commissioning purposes only. Whilst 15A plug is fitted, operator
must ensure output and duty cycle limits indicated below are not exceeded.
Effective Input Current (I1eff)
15A
Maximum Input Current (I1max)
34A
MIG Welding
Welding Current Output
20 – 200A
Welding Voltage Output
15 – 23V
Duty Cycle
200A / 24.0V @ 20%
130A / 20.5V @ 60%
100A / 19.0V @ 100%
Nominal Open Circuit Voltage Uo
60V
Stick (MMA) Welding
Welding Current Output
20 – 160A
Duty Cycle
160A / 26.4V @ 25%
110A / 24.4V @ 60%
90A / 23.6V @ 100%
Nominal Open Circuit Voltage Uo
VRD off 60V / VRD on 15V
TIG Welding
Welding Current Output
20 – 180A
Duty Cycle
180A / 17.2V @ 25%
130A / 15.2V @ 60%
100A / 14.0V @ 100%
Nominal Open Circuit Voltage Uo
60V
Table 5
This table applies when utilizing ‘20A’ power supply * (Refer to 5.1.1.1)
*This table applies if machine is connected to 20A power supply & 20A plug is fitted. Plug should only be
installed by a qualified person (such as a licensed electrician).
Effective Input Current (I1eff)
18A
Maximum Input Current (I1max)
39A
MIG Welding
Welding Current Output
20 – 220A (max 250A)
Welding Voltage Output
15 – 25V
Wire Feed Speed (m/min)
2-20m/min
Duty Cycle
220A / 25.0V @ 20%
130A / 20.5V @ 60%
100A / 19.0V @ 100%
Nominal Open Circuit Voltage Uo
60V
Stick (MMA) Welding
Welding Current Output
20 – 180A
Duty Cycle
180A / 27.2V @ 25%
130A / 25.2V @ 60%
100A / 24.0V @ 100%
Nominal Open Circuit Voltage Uo
VRD off 60V / VRD on 15V
TIG Welding
Welding Current Output
20 – 180A
Duty Cycle
180A / 17.2V @ 25%
130A / 15.2V @ 60%
100A / 14.0V @ 100%
Nominal Open Circuit Voltage Uo
60V
Table 6

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 11
Weldforce 210MST Figure 2 Weldforce 250MST
Figure 3
3KNOW YOUR MACHINE
3.1 Machine Front
1. Control panel
2. MIG Torch
3. Earth Clamp
4. MIG Torch Euro Connector
5. Positive Dinse Socket
6. Negative Dinse Socket
7. MIG Torch Polarity Change Tail
3.2 Machine Rear
13. Mains Power Switch
14. Gas Inlet Connection
15. 240V AC Mains Power Input Lead
3.3 Machine Side
18. Positive (+) MIG Torch Power Connection
19. Negative (-) MIG Torch Power Connection
Weldforce 210MST Figure 1 Weldforce 250MST

.
12 © Weldclass 2020 | E.&O.E.
3.4 Control Panel
21. Top Selection Knob
22. Bottom Selection Knob
23. LCD Screen
Figure 4

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 13
3.5 LCD Readout
24. Welding Process Indicator
25. Wire Type Indicator
26. Wire Size Indicator
27. Gas Type Indicator
28. Material Thickness Setting
29. Material Thickness Indicator
30. Inductance Setting Indicator
31. Amperage Setting
32. Voltage Setting
33. Wire Speed Setting
34. Soft Start Indicator
35. Inductance Indicator
36. Burnback Indicator
37. Post Gas Indicator
Figure 6
Figure 5

.
14 © Weldclass 2020 | E.&O.E.
3.6 Symbols chart
I
Power On
O
Power Off
Power On
Indication
Over Temperature
Fault Indicator
Caution / Hazard /
Fault
Read Instruction
Manual
MIG Function
TIG Function
Stick/MMA
Function
Material Thickness
Wire Feed Speed
Soft Start
Inductance Control
Inductance Control
Burnback Control
Post Gas Control
Torch Trigger Mode
Spot Welding
Mode
Amperage
(Current)
Voltage
Manual MIG
Welding Mode
Synergic (Auto)
MIG Welding Mode
Wire Diameter Size
Shielding Gas Type
Electrical Hazard
Toxic Gas/Fume
Hazard
Explosive Hazard
Eye Injury Hazard
Pacemaker
Interference
Warning
Do not suspend
from handle
Radiation Hazard
Single phase
Inverter power
source DC
MIG (GMAW)
Function
Stick/MMA
(SMAW) Function

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 15
TIG (GTAW)
Function
Power Supply
Connection
Single Phase
Direct Current (DC)
–
Negative
+
Positive
Hertz (cycles/sec)
Duty Cycle
Table 7

4CONTROLS EXPLAINED
4.1 Weld Process Selection
1. Press and hold the ‘Top Selection Knob’ (21) until the current Welding Process Indicator Lights
(24) beings flashing.
2. Rotate the ‘Bottom Selection Knob’ (22) until the desired Welding Process Indicator Light (24) is
flashing.
Figure 8
3. Press the ‘Top Selection Knob’ (21) to select the process.
4.1.1 MIG Process:
In Manual MIG mode (MAN) – the ‘Top Selection Knob’ (21) adjusts wire speed and the ‘Bottom
Selection Knob’ (22) adjusts the voltage.
In Synergic (Auto) MIG mode (SYN) – the ‘Top Selection Knob’ (21) adjusts material thickness and the
‘Bottom Selection Knob’ (22) adjusts the inductance.
4.1.2 Stick (MMA) & TIG Process:
The ‘Top Selection Knob’ (21) amperage and the ‘Bottom Selection Knob’ (22) is disabled.
Figure 7
3 sec

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 17
4.2 MIG Synergic Program Selection
(Only available in SYN process mode)
1. Ensure Synergic MIG mode is selected
2. Press and hold the ‘Bottom Selection Knob’ (22) for 3 seconds until the program number is
displayed on the screen.
3. Rotate the ‘Bottom Selection Knob’ (22) until the desired Synergic MIG program is displayed.
Figure 10
Figure 9
3 sec

.
18 © Weldclass 2020 | E.&O.E.
4. Press the ‘Bottom Selection Knob’ (22) to select the program – see below.
Weldforce 210MST
MIG Synergic Program Chart
Program
Wire Size
Wire Type
Shielding Gas
1
0.6mm
Solid Steel (Fe)
Mixed (Argon + CO2)
2
0.8mm
3
0.9mm
4
1.0mm
5
0.6mm
CO2
6
0.8mm
7
0.9mm
8
1.0mm
9
0.8mm
Stainless Steel (Ss)
Argon + O2
10
0.9mm
11
1.0mm
12
0.8mm
Stainless Steel (Ss)
Argon + CO2
13
0.9mm
14
1.0mm
15
0.8mm
Aluminium
Argon
16
0.9mm
17
1.0mm
18
0.8mm
Gasless
Flux Cored Steel
N/A
19
0.9mm
20
1.2mm
21
0.8mm
Aluminium Bronze (CuAl)
Argon (Ar)
22
0.9mm
23
1.0mm
24
0.8mm
Silicone Bronze (CuSi)
Argon (Ar)
25
0.9mm
26
1.0mm
Table 8

Weldforce 210MST & 250MST
© Weldclass 2020 | E.&O.E. 19
Weldforce 250MST
MIG Synergic Program Chart
Program
Wire Size
Wire Type
Gas
1
0.6
Solid Steel (Fe)
Argon + CO2 Mixed
2
0.8
3
0.9
4
1.0
5
1.2
6
0.6
CO2
7
0.8
8
0.9
9
1.0
10
1.2
11
0.8
Stainless Steel (Ss)
Argon + O2
12
0.9
13
1.0
14
0.8
Argon + CO2
15
0.9
16
1.0
17
0.8
Aluminium
Argon (Ar)
18
0.9
19
1.0
20
0.8
Gasless
Flux Cored Steel
N/A
21
0.9
22
1.2
23
0.8
Aluminium Bronze
(CuAl)
Argon (Ar)
24
0.9
25
1.0
26
0.8
Silicone Bronze
(CuSi)
Argon (Ar)
27
0.9
28
1.0
Table 9

.
20 © Weldclass 2020 | E.&O.E.
4.3 Function Selection
1. Press and hold both the ‘Top Selection Knob’ (21) and the ‘Bottom Selection Knob’ (22) for 3
seconds until the Menu number is displayed on the screen.
Figure 11
2. Rotate the ‘Bottom Selection Knob’ (22) until the desired Menu/Function number is displayed.
Figure 12
3. Press the ‘Bottom Selection Knob’ (22) to select desired Menu/Function.
Figure 13
3 sec
3 sec