Weldclass WeldForce WF-205MST User manual

WF-205MST
© Weldclass 2019 | E.&O.E. | Edition 2.1 1
Edition 2.1
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. | Edition 2.1
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-205MST
© Weldclass 2019 | E.&O.E. | Edition 2.1 3
1CONTENTS...............................................................................................................................................3
2BASIC SPECIFICATIONS ............................................................................................................................7
3KNOW YOUR MACHINE...........................................................................................................................8
3.1 Machine Front................................................................................................................................8
3.2 Machine Side..................................................................................................................................8
3.3 Machine Rear .................................................................................................................................9
3.4 Control Panel..................................................................................................................................9
3.5 LCD Readout.................................................................................................................................10
3.6 Symbols chart...............................................................................................................................11
4CONTROLS EXPLAINED..........................................................................................................................12
4.1 Weld Process Selection ................................................................................................................12
4.1.1 MIG Process: ............................................................................................................................12
4.1.2 Stick & TIG Process:..................................................................................................................12
4.2 MIG Program Selection ................................................................................................................13
4.3 Function Selection........................................................................................................................14
4.3.1 Pre-Gas Time (MIG)..................................................................................................................15
4.3.2 Post-Gas Time (MIG) ................................................................................................................15
4.3.3 Soft-Start Adjustment (MIG) ....................................................................................................15
4.3.4 Burnback Adjustment (MIG) ....................................................................................................15
4.3.5 Spot/Stitch Weld Time (MIG)...................................................................................................15
4.3.6 Stitch Weld Gap/Interval Time (MIG).......................................................................................15
4.3.7 Spool Gun On/Off (MIG) ..........................................................................................................16
4.3.8 Post-Gas Time (TIG)..................................................................................................................16
4.3.9 Slope Down Time (TIG).............................................................................................................16
4.3.10 Hot Start Adjustment (Stick) ................................................................................................16
4.3.11 Arc Force Adjustment (Stick)................................................................................................16
4.3.12 Optional VRD Function (Stick)..............................................................................................16
4.4 Trigger Mode Selection ................................................................................................................17
4.4.1 2T (Standard Trigger)................................................................................................................17
4.4.2 4T (Latch Trigger)......................................................................................................................17
4.4.3 SP (Spot/Stitch) ........................................................................................................................17
4.5 Inductance Control.......................................................................................................................18
4.6 Test Gas ........................................................................................................................................18
4.7 Feed Wire / Wire Inch ..................................................................................................................19
4.8 Job Memory .................................................................................................................................19
4.8.1 Save or Update a Job................................................................................................................19
4.8.2 Recall a Job...............................................................................................................................20

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4© Weldclass 2019 | E.&O.E. | Edition 2.1
4.9 Error/Over Temperature Indicator Light.......................................................................................20
5POWER SUPPLY .....................................................................................................................................21
5.1 Electrical Connection....................................................................................................................21
5.2 Extension Leads............................................................................................................................21
5.3 Generator Use ..............................................................................................................................21
5.3.1 Generator Size..........................................................................................................................21
5.3.2 Generator Quality & Warranty Limitations..............................................................................21
5.3.3 3 Golden Rules of Generator use .............................................................................................21
6OPERATING ENVIRONMENT..................................................................................................................22
6.1 Location........................................................................................................................................22
6.2 Ventilation....................................................................................................................................22
7BASIC OPERATION.................................................................................................................................23
7.1 MIG Welding.................................................................................................................................23
7.1.1 Fitting Wire Spool – 100mm Diameter (1kg)............................................................................23
7.1.2 Fitting Wire Spool – 200mm Diameter (5kg)............................................................................24
7.1.3 Loading Wire Feeder................................................................................................................25
7.1.4 Gasless Welding Setup.............................................................................................................26
7.1.5 Gas MIG Welding Setup ...........................................................................................................27
7.1.6 Additional Setup for MIG welding with aluminium .................................................................28
7.1.7 Spool Gun Setup.......................................................................................................................28
7.1.8 Adjusting Settings for MIG Welding in Manual Mode (Program 0)..........................................29
7.1.9 Adjusting Settings for MIG Welding in Synergic (Auto) Mode .................................................29
7.2 Stick (MMA) Welding Operation ..................................................................................................30
7.3 Lift TIG Operation.........................................................................................................................31
8ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS..............................................................................32
8.1 MIG Torch and Spares: .................................................................................................................32
8.2 TIG Torch and Spares (Optional Extra): ........................................................................................33
8.3 Optional Accessories....................................................................................................................34
8.4 Drive Rollers: ................................................................................................................................34
8.5 Machine Spare Parts: ...................................................................................................................35
8.6 Primary Schematic Circuit Diagram..............................................................................................37
9CARE & MAINTENANCE.........................................................................................................................38
9.1 Keep your Welding Machine in Top Condition.............................................................................38
9.2 Storing the Welder .......................................................................................................................38
10 GENERAL GUIDE TO WELDING .........................................................................................................39
10.1 Duty Cycle Rating .........................................................................................................................39
10.2 Choosing a Welding Process – MIG, Stick or TIG?........................................................................39
10.2.1 The Stick (MMA) Process .....................................................................................................39
10.2.2 The TIG Process....................................................................................................................40

WF-205MST
© Weldclass 2019 | E.&O.E. | Edition 2.1 5
10.2.3 The MIG Process ..................................................................................................................40
10.3 Joint Preparations.........................................................................................................................41
11 MIG BASIC WELDING GUIDE.............................................................................................................43
11.1 MIG Basic Welding Techniques.....................................................................................................43
11.2 Gas Metal Arc Welding (GMAW)..................................................................................................43
11.3 Flux Cored Arc Welding (FCAW) ...................................................................................................43
11.4 Position of MIG Torch...................................................................................................................44
11.5 Distance from the MIG Torch Nozzle to the Work Piece ..............................................................44
11.6 Travel Speed .................................................................................................................................44
11.7 MIG Welding (GMAW) Variables..................................................................................................45
11.7.1 Preselected Variables...........................................................................................................45
11.7.2 Primary Adjustable Variables...............................................................................................45
11.7.3 Secondary Adjustable Variables...........................................................................................45
11.8 Establishing the Arc and Making Weld Beads ..............................................................................47
11.9 MIG Voltage & Wire Speed Settings.............................................................................................47
11.9.1 Setting Wire Speed/Amperage.............................................................................................47
11.9.2 Setting Voltage.....................................................................................................................47
11.9.3 Changing to a different welding wire...................................................................................47
11.9.4 How to determine correct Wire Speed/Voltage Setting ......................................................48
11.10 Suggested Settings for Typical MIG Applications .....................................................................48
11.11 Welding wire Size Selection .....................................................................................................48
11.12 MIG Welding Troubleshooting .................................................................................................49
11.12.1 Porosity Problems ................................................................................................................49
11.12.2 Wire Feed Problems.............................................................................................................50
11.12.3 Weld Quality Problems ........................................................................................................51
12 STICK (MMA) BASIC WELDING GUIDE..............................................................................................53
12.1 Size of Electrodes .........................................................................................................................53
12.2 Storage of Electrodes ...................................................................................................................53
12.3 Electrode Polarity.........................................................................................................................53
12.4 Effects of Stick (MMA) Welding on Various Materials..................................................................53
12.4.1 High Tensile and Alloy Steels................................................................................................53
12.4.2 Manganese Steels ................................................................................................................53
12.4.3 Cast Iron...............................................................................................................................53
12.5 Types of Electrodes ......................................................................................................................54
12.5.1 MILD STEEL: .........................................................................................................................54
12.5.2 CAST IRON:...........................................................................................................................54
12.5.3 STAINLESS STEEL: .................................................................................................................54
12.6 Suggested Settings for Typical Stick (MMA) Applications ............................................................54
12.7 MMA Welding Techniques ...........................................................................................................55

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6© Weldclass 2019 | E.&O.E. | Edition 2.1
12.7.1 A Word for Beginners...........................................................................................................55
12.7.2 The Welder...........................................................................................................................55
12.7.3 Striking the Arc.....................................................................................................................55
12.7.4 Arc Length............................................................................................................................56
12.7.5 Rate of Travel .......................................................................................................................56
12.8 Making Welded Joints..................................................................................................................57
12.8.1 Butt Welds............................................................................................................................57
12.8.2 Fillet Welds...........................................................................................................................58
12.8.3 Vertical Welds ......................................................................................................................59
12.8.4 Overhead Welds...................................................................................................................60
12.9 MMA (Stick) Troubleshooting.......................................................................................................61
13 TIG BASIC WELDING GUIDE..............................................................................................................63
13.1 TIG Electrode Selection and Preparation .....................................................................................63
13.1.1 Electrode Polarity.................................................................................................................63
13.1.2 Preparing Tungsten for DC Electrode Negative (DCEN) Welding .........................................64
13.1.3 Shielding Gas for TIG Welding..............................................................................................65
13.1.4 Typical TIG Welding Settings................................................................................................65
13.2 TIG Welding Troubleshooting.......................................................................................................66
14 KNOWLEDGE & RESOURCES.............................................................................................................67
15 SAFETY..............................................................................................................................................67
15.1 Store and Retain this Manual.......................................................................................................67
15.2 Important Safety Information ......................................................................................................67
15.3 Welding Operation .......................................................................................................................67
15.4 Welding Safety Instructions & Warnings......................................................................................69
15.4.1 Personal Safety.....................................................................................................................70
15.4.2 Arc Rays can Burn Eyes and Skin..........................................................................................70
15.4.3 Noise Can Damage Hearing .................................................................................................70
15.4.4 Work Environment Safety ....................................................................................................71
15.4.5 Electricity Can Kill.................................................................................................................71
15.4.6 Fumes And Gases.................................................................................................................72
15.4.7 Fire & Explosive Risks...........................................................................................................73
15.4.8 Sparks & Hot Metal..............................................................................................................73
15.4.9 Gas Cylinders........................................................................................................................74
16 WARRANTY.......................................................................................................................................75
16.1 Warranty period ...........................................................................................................................75
16.2 Warranty Includes and Covers......................................................................................................75
16.3 Warranty Excludes / Does Not Cover ...........................................................................................75
16.4 Warranty Conditions ....................................................................................................................76

WF-205MST
© Weldclass 2019 | E.&O.E. | Edition 2.1 7
Description
WeldForce WF-205MST
Part Number
WF-06166
Dimensions of Power Source (L x W x H)
550 x 215 x 415mm (including handle)
Weight of Power Source
17kg
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)
30A
Output Terminals
Dinse™ style 35-50
Protection Class
IP23
MIG Welding
Welding Current Output
40 – 200A
Welding Voltage Output
16 – 24V
Wire Feed Speed (m/min)
1.5 – 16.5
Duty Cycle
200A / 24.0V @ 25%
145A / 21.3V @ 60%
110A / 19.5V @ 100%
Nominal Open Circuit Voltage
70V
Spool Size
100mm (1kg) & 200mm (4.5kg or 5kg)
MIG Wire Sizes
0.6, 0.8, 0.9, 1.0mm
Stick (MMA) Welding
Welding Current Output
10 – 200A
Duty Cycle
200A / 28.0V @ 25%
130A / 25.2V @ 60%
100A / 24.0V @ 100%
Nominal Open Circuit Voltage
VRD off 70V / VRD on 13.5V
MMA Electrode Size
1.6 – 4.0mm
TIG Welding
Welding Current Output
10 – 200A
Duty Cycle
200A / 18.0V @ 35%
155A / 16.2V @ 60%
120A / 14.8V @ 100%
Nominal Open Circuit Voltage
65V
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:
www.Weldclass.com.au/WF-205MST

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8© Weldclass 2019 | E.&O.E. | Edition 2.1
3.1 Machine Front
1. Carry Handle
2. Control panel
3. Positive (+) Welding Power Output Connection Socket
4. MIG Torch Euro Connector
5. Spool Gun/TIG torch Interface Connector
6. TIG Torch Gas Connector
7. Negative (-) Welding Power Output Connection Socket
3.2 Machine Side
8. Spool Post
9. Spool Nut
10. Spool Lock Pin
11. Positive (+) MIG Torch Power Connection
12. MIG Torch Polarity Connection Plate
13. Common MIG Torch Power Connection
14. Negative (-)MIG Torch Power Connection
15. Wire Inlet Guide
16. Wire Feed Tension Adjustment Lever
17. Wire Feed Tension Arm/Top Roller
18. Drive Roller
19. Drive Roller Retainer Knob
20. Outlet Wire Guide Tube
3
4
5
6
7
2
1
Figure 1
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20
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12
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19
9
8
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Figure 2

WF-205MST
© Weldclass 2019 | E.&O.E. | Edition 2.1 9
3.3 Machine Rear
21. Mains Power Switch
22. 240V AC Mains Power Input Lead
23. Gas Inlet Connection
3.4 Control Panel
24. MIG Program Selection Button (P)
25. Function Selection Button (Fn)
26. Process Indicator Lights
27. Process Selection Button (Process)
28. Gas Test Button (Test Gas)
29. Left Selection Knob (Voltage Dial)
30. Right Selection Knob (Wire Speed/Amperage Dial)
31. Wire Feed/Load Button (Feed Wire)
32. Trigger Mode Selection Button (Trigger)
33. Trigger Mode Indicator Lights
34. Job Recall Button
35. Job Save Button
36. Right LCD Readout
37. Left LCD Readout
Figure 4
27 32
24
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26
28
29
30
31
33
34
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37
21
22
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Figure 3

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10 © Weldclass 2019 | E.&O.E. | Edition 2.1
3.5 LCD Readout
38. Power On Indicator Light
39. Error/Over Temperature Indicator Light
40. Spool Gun Mode Indicator Light
41. MIG Program Selection Indicator Light
42. Voltage Setting Indicator Light
43. Inductance Setting Indicator Light
44. Seconds Setting Indicator Light
45. Wire Speed Setting Indicator Light
46. Material Thickness Setting Indicator Light
47. Amperage Setting Indicator Light
48. Job Save/Recall Selection Indicator Light
49. VRD Indicator Light
41
38 39 40
42 43 44
45 46
47 48
Figure 5
49