Weldclass WeldForce WF-201T AC/DC User manual

WF-201T AC/DC
© Weldclass 2019 | E.&O.E. 1
Edition 1
OPERATING INSTRUCTIONS
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.

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2© Weldclass 2019 | E.&O.E.
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.
To qualify for an extended full 36 month warranty on 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.

WF-201T AC/DC
© Weldclass 2019 | E.&O.E. 3
1 CONTENTS
1CONTENTS...............................................................................................................................................3
2BASIC SPECIFICATIONS ............................................................................................................................7
3KNOW YOUR MACHINE...........................................................................................................................8
3.1 Machine Front................................................................................................................................8
3.2 Machine Rear .................................................................................................................................8
3.3 Control Panel..................................................................................................................................9
3.4 LCD Readout.................................................................................................................................10
3.5 Arc Parameter Chart.....................................................................................................................10
3.6 TIG Torch Controls ........................................................................................................................11
3.7 Symbols chart...............................................................................................................................12
4CONTROLS EXPLAINED..........................................................................................................................13
4.1 Weld Process Selection ................................................................................................................13
4.1.1 STICK.........................................................................................................................................13
4.1.2 HF TIG.......................................................................................................................................13
4.1.3 LIFT TIG.....................................................................................................................................13
4.2 Output Current Mode Selection...................................................................................................14
4.2.1 DC (Direct Current)...................................................................................................................14
4.2.2 AC (Alternating Current)...........................................................................................................14
4.3 Function Selection........................................................................................................................15
4.3.1 Spot Weld Function..................................................................................................................15
4.3.2 Pulse Welding Function............................................................................................................15
4.3.3 Normal Welding Function / Off................................................................................................15
4.4 Trigger Mode Selection ................................................................................................................16
4.4.1 2T (Standard Trigger)................................................................................................................16
4.4.2 4T (Latch Trigger)......................................................................................................................16
4.5 TIG Arc Parameters/Characteristics Settings................................................................................16
4.5.1 Pre-Flow Time / PRE GAS (36)..................................................................................................17
4.5.2 Start Current / START AMPS (37)..............................................................................................17
4.5.3 Slope Up / UP SLOPE (38).........................................................................................................17
4.5.4 Trough Current / TROUGH AMPS (39)......................................................................................17
4.5.5 Pulse Wave Width / WIDTH (41) ..............................................................................................17
4.5.6 Pulse Wave Frequency / FREQUENCY (40)...............................................................................17
4.5.7 Base/Peak Current / BASE/PEAK AMP (42) ..............................................................................17
4.5.8 Slope Down / DOWN SLOPE (44) .............................................................................................17
4.5.9 End Current / FINISH AMPS (45) ..............................................................................................17
4.5.10 Post Flow / POST GAS (46) ...................................................................................................17
4.5.11 Clean Width Area / AC BALANCE (43)..................................................................................18

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4© Weldclass 2019 | E.&O.E.
4.6 Remote Controls...........................................................................................................................18
4.6.1 Remote Control TIG Torch........................................................................................................18
4.6.1 Remote Foot Control (Optional Accessory)..............................................................................18
4.7 MMA/Stick Arc Parameters/Characteristics Settings ...................................................................19
4.7.1 Current / Amps (33) .................................................................................................................19
4.7.2 Hot Start Adjustment (34)........................................................................................................19
4.7.3 Arc Force Adjustment (Stick)....................................................................................................19
4.8 LCD Multi-Function Display (26)...................................................................................................20
4.9 Error/Over Temperature Indicator Light.......................................................................................20
5POWER SUPPLY .....................................................................................................................................22
5.1 Electrical Connection....................................................................................................................22
5.2 Extension Leads............................................................................................................................22
5.3 Generator Use ..............................................................................................................................22
5.3.1 Generator Size..........................................................................................................................22
5.3.2 Generator Quality & Warranty Limitations..............................................................................22
5.3.3 3 Golden Rules of Generator use .............................................................................................22
6OPERATING ENVIRONMENT..................................................................................................................23
6.1 Location........................................................................................................................................23
6.2 Ventilation....................................................................................................................................23
7BASIC SETUP..........................................................................................................................................24
7.1 Stick (MMA) Welding Setup .........................................................................................................24
7.2 TIG Welding Setup........................................................................................................................25
8ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS..............................................................................26
8.1 TIG Torch and Spares:...................................................................................................................26
8.2 Optional Accessories....................................................................................................................27
8.3 Machine Spare Parts: ...................................................................................................................27
8.4 Primary Schematic Circuit Diagram..............................................................................................29
9CARE & MAINTENANCE.........................................................................................................................30
9.1 Keep your Welding Machine in Top Condition.............................................................................30
9.2 Storing the Welder .......................................................................................................................30
10 GENERAL GUIDE TO WELDING .........................................................................................................31
10.1 Duty Cycle Rating .........................................................................................................................31
10.2 Choosing a Welding Process – MMA/Stick or TIG?......................................................................31
10.2.1 The Stick (MMA) Process .....................................................................................................31
10.2.2 The TIG Process....................................................................................................................32
10.3 Joint Preparations.........................................................................................................................33
11 STICK (MMA) BASIC WELDING GUIDE..............................................................................................35
11.1 Size of Electrodes .........................................................................................................................35
11.2 Storage of Electrodes ...................................................................................................................35

WF-201T AC/DC
© Weldclass 2019 | E.&O.E. 5
11.3 Electrode Polarity.........................................................................................................................35
11.4 Effects of Stick (MMA) Welding on Various Materials..................................................................35
11.4.1 High Tensile and Alloy Steels................................................................................................35
11.4.2 Manganese Steels................................................................................................................35
11.4.3 Cast Iron...............................................................................................................................35
11.5 Types of Electrodes ......................................................................................................................36
11.5.1 Mild Steel.............................................................................................................................36
11.5.2 Cast Iron...............................................................................................................................36
11.5.3 Stainless Steel ......................................................................................................................36
11.6 Suggested Settings for Typical Stick (MMA) Applications ............................................................36
11.7 MMA Welding Techniques ...........................................................................................................37
11.7.1 A Word for Beginners...........................................................................................................37
11.7.2 The Welder...........................................................................................................................37
11.7.3 Striking the Arc.....................................................................................................................37
11.7.4 Arc Length............................................................................................................................38
11.7.5 Rate of Travel .......................................................................................................................38
11.8 Making Welded Joints ..................................................................................................................39
11.8.1 Butt Welds............................................................................................................................39
11.8.2 Fillet Welds...........................................................................................................................40
11.8.3 Vertical Welds ......................................................................................................................41
11.8.4 Overhead Welds...................................................................................................................42
11.9 MMA (Stick) Troubleshooting.......................................................................................................43
12 TIG BASIC WELDING GUIDE..............................................................................................................45
12.1 TIG Electrode Selection and Preparation .....................................................................................45
12.1.1 Tungsten Electrode Selection & Polarity..............................................................................45
12.1.2 Preparing Tungsten ..............................................................................................................46
12.1.3 Shielding Gas for TIG Welding..............................................................................................47
12.1.4 Typical TIG Welding Settings................................................................................................47
12.2 Starting the Weld .........................................................................................................................48
12.2.1 Lift-Arc Ignition.....................................................................................................................48
12.2.2 HF Ignition............................................................................................................................48
12.3 Main Weld Current.......................................................................................................................49
12.3.1 DC Current............................................................................................................................49
12.3.2 AC Current............................................................................................................................49
12.3.3 Pulse Welding.......................................................................................................................50
12.3.1 AC Balance ...........................................................................................................................51
12.4 Finishing the Weld........................................................................................................................52
12.4.1 Down-Slope..........................................................................................................................52
12.4.1 Post Gas Flow.......................................................................................................................52

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6© Weldclass 2019 | E.&O.E.
12.4.1 Finish Current.......................................................................................................................52
12.5 TIG Welding Troubleshooting.......................................................................................................53
13 KNOWLEDGE & RESOURCES.............................................................................................................54
14 SAFETY..............................................................................................................................................54
14.1 Store and Retain this Manual.......................................................................................................54
14.2 Important Safety Information ......................................................................................................54
14.3 Welding Operation .......................................................................................................................54
14.4 Welding Safety Instructions & Warnings......................................................................................56
14.4.1 Personal Safety.....................................................................................................................57
14.4.2 Arc Rays can Burn Eyes and Skin..........................................................................................57
14.4.3 Noise Can Damage Hearing .................................................................................................57
14.4.4 Work Environment Safety ....................................................................................................58
14.4.5 Electricity Can Kill.................................................................................................................58
14.4.6 Fumes And Gases.................................................................................................................59
14.4.7 Fire & Explosive Risks...........................................................................................................60
14.4.8 Sparks & Hot Metal..............................................................................................................60
14.4.9 Gas Cylinders........................................................................................................................61
15 WARRANTY .......................................................................................................................................62
15.1 Warranty period ...........................................................................................................................62
15.2 Warranty Includes and Covers......................................................................................................62
15.3 Warranty Excludes / Does Not Cover ...........................................................................................62
15.4 Warranty Conditions ....................................................................................................................63

WF-201T AC/DC
© Weldclass 2019 | E.&O.E. 7
2 BASIC SPECIFICATIONS
Description
WeldForce WF-201T AC/DC
Part Number
WF-06172
Dimensions of Power Source (L x W x H)
455 x 305 x 145mm (including handle)
Weight of Power Source
8.5kg
Standard
AS 60974.1
Power Supply
240V +/- 15% 50hz Single Phase
Factory Fitting Supply Plug Rating
15A
Effective Input Current (I1eff)
15A
Maximum Input Current (I1max)
38A
Output Terminals
Dinse™ style 35-50
Protection Class
IP23
AC TIG (GTAW) Welding
Welding Current Output
10 – 200A
Duty Cycle
200A / 18.0V @ 30%
155A / 16.2V @ 60%
120A / 14.8V @ 100%
Nominal Open Circuit Voltage
65V
TIG Tungsten Size
1.6 – 2.4mm
DC TIG (GTAW) Welding
Welding Current Output
10 – 170A
Duty Cycle
170A / 16.8V @ 35%
140A / 15.6V @ 60%
110A / 14.4V @ 100%
Nominal Open Circuit Voltage
65V
TIG Tungsten Size
1.6 – 2.4mm
AC Stick (MMA) Welding
Welding Current Output
10 – 170A
Duty Cycle
170A / 26.8V @ 25%
140A / 25.6V @ 60%
110A / 24.4V @ 100%
Nominal Open Circuit Voltage
65V
MMA Electrode Size
1.6 – 4.0mm
DC Stick (MMA) Welding
Welding Current Output
10 – 170A
Duty Cycle
170A / 26.8V @ 25%
140A / 25.6V @ 60%
110A / 24.4V @ 100%
Nominal Open Circuit Voltage
65V
MMA Electrode Size
1.6 – 4.0mm
Table 1
For full machine specifications, refer to technical data plate on back of machine – or go to:
www.Weldclass.com.au/WF-201T

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8© Weldclass 2019 | E.&O.E.
3 KNOW YOUR MACHINE
3.1 Machine Front
1. Carry Handle
2. Control panel
3. TIG Torch Gas Connector
4. Negative (-) Welding Power Output Connection Socket
5. TIG torch Interface Connector
6. Positive (+) Welding Power Output Connection Socket
3.2 Machine Rear
7. Mains Power Switch
8. 240V AC Mains Power Input Lead
9. Gas Inlet Connection
3
4
5
6
2
1
Figure 1
7
8
9
Figure 2

WF-201T AC/DC
© Weldclass 2019 | E.&O.E. 9
3.3 Control Panel
10. Power On Indicator Light (POWER)
11. Stick (MMA) Process Indicator Light (STICK)
12. Process Selection Button (PROCESS)
13. High Frequency Start TIG Process Indicator Light (HF TIG)
14. Lift Arc Start TIG Process Indicator Light (LIFT TIG)
15. Spot Weld Function Indicator Light (SPOT)
16. Pulse Arc Function Indicator Light (PULSE)
17. Normal Arc Function Indicator Light (NORMAL/OFF)
18. Function Selection Button (FUNCTION)
19. Selection Knob
20. Mode Selection Button (MODE)
21. AC Arc Output Mode Indicator Light (AC)
22. DC Arc Output Mode Indicator Light (DC)
23. Latch Trigger Mode Indicator Light (4T)
24. Trigger Mode Selection Button
25. Normal Trigger Mode Indicator Light (2T)
26. LCD Readout
27. Error/Over Temperature Indicator Light
28. Arc Parameter Chart
Figure 3
15
22
10
12
13
17
19
20
21
23
24
25
26
28
11
14
16
0
27

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10 © Weldclass 2019 | E.&O.E.
3.4 LCD Readout
29. Percentage Setting Indicator Light (%)
30. Hertz/Frequency Setting Indicator Light (Hz)
31. Time/Seconds Setting Indicator Light (SEC)
32. LCD Screen
33. Amperage Setting Indicator Light (AMPS)
34. Hot Start Setting Indicator Light (HOT START)
35. Arc Force Setting Indicator Light (ARC FORCE)
3.5 Arc Parameter Chart
36. Pre-Gas Setting Indicator Light (PRE GAS)
37. Start Amps Setting Indicator Light (START AMPS)
38. Slope-Up Setting Indicator Light (UP SLOPE)
39. Trough Amps Setting Indicator Light (TROUGH AMPS)
40. Pulse Wave Frequency Setting Indicator Light (FREQUENCY)
41. Pulse Wave Width Setting Indicator Light (WIDTH)
42. Base/Peak Amp Setting Indicator Light (BASE/PEAK AMP)
43. AC Arc Balance Setting Indicator Light (AC BALANCE)
44. Slope-Down Setting Indicator Light (DOWN SLOPE)
45. Finish Amps Setting Indicator Light (FINISH AMPS)
46. Post-Gas Setting Indicator Light (POST GAS)
31
29
30
33
32
35
34
Figure 4
38
36
37
4039 42
41
Figure 5
43 44
45
46