WELDTECH Workshop Series User manual

OPERATING INSTRUCTIONS
WT205MIG
200A INVERTER MIG WELDER
www.weldtech.net.nz

2
Congratulations on your new Weldtech product!
The Weldtech range from Euroquip uses latest technology design and engineering
to produce welding products that combine market leading value and features with
durability. Designed for discerning operators who seek professional results and
product quality without the price tag of a full professional setup. Design emphasis
is placed on simple, functional design and operation. Weldtech product is subject
to stringent quality control and designed and manufactured to NZ & Australian
standards.
Common use of Weldtech products include:
 • LightEngineering
 • Automotive
 • Home/hobbyEngineering
 • Farming
 • Maintenance&Repairs
Forindustrialweldingsolutions,checkouttheStratarangefromEuroquip:
www.strata.co.nz
Euroquip is a market leading provider of innovative power equipment solutions
to a wide range of industries across New Zealand and Australia. Key product
categories are; welding equipment, air compressors, power generators and
cleaning equipment.
Euroquip’s slogan is ‘empowering industries’, nd out more about the advantage
Euroquip brings at www.euroquip.co.nz.
Providing exceptional product support is a key component of Euroquip’s market
leading customer advantage focus. As part of this program, it is required for all
products to be registered with Euroquip to qualify for product support. Products
not registered with Euroquip are supported by a base 12 month warranty only.
Sparepartsandtechnicalsupportwillnotbeavailableforanunregisteredproduct
outside of this base warranty period. If a Euroquip dealer has not already registered
your product, please register it online at www.euroquip.co.nz. To request a physical
registration form, please contact Euroquip customer service on 0800 387 678.
We Appreciate Your Business!

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WT205MIG Welding Machine
www.weldtech.net.nz
Contents
Welcome to Euroquip..........................................2
KnowYourMachine..............................................5
ControlsExplained.................................................5
Tips & Tricks.................................................................6
QuickStartGuide....................................................7
Basic Operation........................................................7
Accessories..............................................................10
Care&Maintenance..........................................11
WeldingSettings..................................................12
MIGBasicWeldingGuide................................13
MIGWeldingTroubleshooting....................17
MMA(Stick)BasicWeldingGuide................19
MMA(Stick)Troubleshooting.......................25
Knowledge&Resources..................................26
Safety .........................................................................26
Warranty....................................................................31

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WT205MIG
200A - INVERTER MIG WELDER
Powerful - Welds from thin panel steel up to 10mmm
Portable - Heavy duty integrated trolley with lifting points
Digital Microprocessor
Control System - Superior and dynamic arc characteristics
Dimensions: (L x W x H) 900 x 520 x 765mm
Weight: 40kg
Input Power: 230V AC 15A 50/60HZ
Max. Input Current: 41.7A
Generator Capacity: 9.5kVA
Welding Gloves
(#AWG02)
2 Sensor Auto Helmet
(#DW2500)
Professional 4 Sensor Auto Helmet
with Grinding Visor
(#DW4000)
4 Sensor Auto Helmet
with grind
function
(#DW3000)
Mild Steel MIG Wire
5kg/15kg
0.6mm (#MW5KGS06)
0.8mm (#MW5KG08, #MW15KG08)
0.9mm (#MW5KG09, #MW15KG09)
1.0mm (#MW15KG10)
1.2mm (#MW15KG12)
Accessories to help you get the job done!
Welding Magnet
(#WMG05)
Tips
0.6mm (#MMT2406)
0.8mm (#MMT2408)
0.9mm (#MMT2409)
Ideal for workshop projects - cars, trailers and structural steel!
• IGBT Inverter Technology
• Heavydutyintegratedtrolleywithliftingpoints
• 4Rollmetalwirefeedunit
• Digitalmicroprocessorcontrolsystem
• Spoolgunconnection
• Electronicinductancecontrol
• Dualdigitaldisplaymeters
• ReversablepolarityMIGweldingoperation
 -suitableforgasandgaslessMIGwelding
• MMAVRDprotection
• MIGdutycycle200A@15%,155A@100%
• MMAdutycycle200A@10%,155A@100%
MMA Current Output: 25A - 200A
MMADutyCycle: 200A@10%,155A@100%
MIGDutyCycle: 200A@15%,155A@100%
Wire Size: Steel 0.6/0.8/0.9/1.0mm
knurled 0.8/0.9mm
DriveRollers: 0.6/0.8mm‘V’groovewiredriveroller
 0.9/1.0mm‘V’groovedriveroller
0.8/0.9mm knurled drive roller
Spool Gun for Alloy
(#13323)

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WT205MIG Welding Machine
www.weldtech.net.nz
Know Your Machine
*Denotes more detailed explanation of function below.
1. MIG inductance control knob*
2. Welding mode button. Sets power source in MIG
or MMA mode.
3. 2T/4T MIG trigger mode button*
4. VRD Active Indicator*
5. Spool Gun/ Standard Torch selection button
6. Overload/ error indicator*
7. LCD voltage display meter *
8. LCD current/ wire feed speed display meter*
9. MIG wire feed speed adjustment knob/ MMA
current adjustment knob
10. Welding voltage adjustment knob- Adjusts welding
voltage in MIG mode
11. Positive (+) welding power output connection
socket
12. MIG torch power connection lead.
13. Negative (-) welding power output connection
socket
14. Spool gun connection socket
15. MIG torch euro connection socket
16. Wire spool holder.
17. Wire drive inlet guide.
18. Wire feed tension arm (x2)
19. Wire feed tension adjustment (x2)
20. Wire drive roller retainer (x2)
21. Wire drive roller (obscured) (x2)
Controls Explained
MIG Inductance Control (1)
Inductance adjustment controls the rate of the cur-
rent rise and fall as the welding wire contacts the
workpiece (known as a short circuit). More induct-
ance increases the short circuit time and decreases
the short circuit frequency rate. This causes a wider
and more penetrating arc, useful for thicker weld
joints.Lessinductancewillcreateanarrowmorefo-
cused arc. This eect can also be used to ne tune
the arc to produce less splatter. Wire speed, wire size
and type, shielding gas will all change the eect that
the inductance setting has on the welding arc. As a
general rule, CO2 based shielding gas will weld more
smoothly with increased inductance, while argon
shielding gas will perform better with less induct-
ance.Samebasicinductancesettingsuggestionsare
made in the settings table found inside the wire feed
compartment of the machine, or later in this manual.
InductancesettingwillhavenoeectonMIGspray
transferprocess(asopposedtoshortcircuit)orMMA
welding process.
1
4567
8
10
11
2
3
9
12
1314
15
18
16
17
19
20
21

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2T/4T MIG Trigger Mode Button (3)
2T mode the trigger is pulled and held on to activate
the welding circuit, when the trigger is released, the
welding circuit stops. 4T is known as ’latching’mode.
The trigger is pulled once and released to activate
the welding circuit, pulled and released again to
stops the welding circuit. This function is useful for
longer welds as the trigger is not required to be held
on continuously.
MMA VRD Function Indicator (4)
VRD stands forVoltage Reduction Device.This is a
safety system that reduces the output voltage from
theweldingterminalsinMMAmodewhiletheweld-
ing output is not in use, to reduce the risk of electric
shock from the live output voltage.The disadvantage
of this system is that it makes the striking of the arc
more dicult, especially on restarts and with some
types of electrode such as low hydrogen electrodes.
IftheVRDprotectionisactive,thisisindicatedbythe
‘on’light.ItshouldonlyswitchtooinMMAmode
during welding.
Overload/ Error Indicator (6)
Lightswhenovervoltage,overcurrentorelectrical
overheating (due to exceeding duty cycle) is de-
tected and protection is activated. When protection
is activated, welding output will be disabled until the
safety system senses the overload has reduced suf-
cientlyandindicatorlampgoesout.Mayalsotrig-
ger if machine experiences an internal power circuit
failure.
MIG Voltage Display Meter (7)
InMIGmode,displaysweldingvoltage.Hasnofunc-
tioninMMAmode.
Current/ Wire Feed Speed Display
Meter (8)
In MIG mode, displays wire feeding speed in m/
minute prior to welding, during welding displays
weldingcurrentoutput(A).InMMAmode,displays
weldingcurrent(A).Thedisplaymetervaluetypeis
shown by the indicator that is lit.
Tips & Tricks
MIG Voltage & Wire Speed Settings
Voltage is essentially the power in the welding arc
that sets the heat. The wire speed feed simply con-
trols the rate at which the welding wire is fed into the
weldpool.Foranyvoltagepositionsetting,therewill
be a specic corresponding ‘sweet spot’ in the wire
feeding speed that will give the smoothest and most
stable welding arc.
The correct wire feeding speed for a given voltage
setting is aected by welding wire type and size,
shielding gas, welding material and joint type. It is
recommended to set the welding voltage as desired
and then slowly adjust the wire speed until the arc is
smooth and stable. When reaching this point, if the
penetration/ heat input is too much/ not enough,
adjust the voltage setting and repeat the process.
If the operator is not able to achieve a smooth and
stable arc with the desired heat input for the weld,
itislikelythatachangeinwiresizeand/orshielding
gastype is required(assuming all otherfactors are
correct).
A chart with recommended settings using this ma-
chine for common welding applications is located
on the underside of the wire feeder cover door and
further on in this manual.
Duty Cycle Rating
Welding duty cycle is the percentage of actual weld-
ing time that can occur in a ten minute cycle. E.g.
20% at 160 amps - this means the welder can weld at
160 amps for 2 minutes and then the unit will need
to be rested for 8 minutes.
All duty cycle ratings are based on an ambient air
temperatureof40°Cwith50%humidity,whichisthe
international standard for such a rating. In an envi-
ronment with temperatures exceeding 40°C, the
duty cycle will be less than stated. In ambient tem-
perature less than 40°C, duty cycle performance will
be higher.

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WT205MIG Welding Machine
www.weldtech.net.nz
Quick Start Guide
Electrical Connection
TheWT205MIGisdesignedtooperateona15A230V
AC power supply. If an extension cord must be used,
it should be a heavy duty version with a minimum
cablecoresizeof2.5mm2.Itisrecommendedtouse
theEuroquipindustrialduty15Aextensionlead,part
number;16895.
Operating Environment
Adequate ventilation is required to provide proper
coolingfortheWT205MIG.Ensurethatthemachine
is placed on a stable level surface where clean cool
aircaneasilyowthroughtheunit.TheWT205MIG
has electrical components and control circuit boards
which may be damaged by excessive dust and dirt,
so a clean operating environment is essential.
MIG Welding Operation
1. Fitting Wire Spool
1.1 Open the wire feeder compartment door. Re-
move the wire spool retainer by threading it an-
ticlockwise. Fit the wire spool to spool holder,
ensuring that the wire exits the spool towards the
wirefeederfrombottomthespool.Ifusing5kg/
D.200spool,checkthatthe5kgspoolspacerring
is threaded on the spool holder against the wire
spool to hold it in place.
1.2 Replacethespoolretainer.Setthespoolbraketen-
sion by adjusting the spool tension adjustment hex
screw in the middle of the spool holder. Clockwise
to increase spool brake tension and anti-clockwise
to decrease. The spool brake tension should be set
so that the spool can rotate freely, but does not
continue to rotate once the wire feed stops. This
may need to be adjusted as the wire is used up
and the spool weight decreases.
WARNING!
Excessive spool brake tension will cause wire feeding
issues and aect welding performance as well as
premature failure/ wear of wire feed components.
Insucient brake tension will cause the spool to
‘freewheel’ and the welding wire will unravel from
the spool (known as a ‘birds nest’)
Basic Operation
1.3 Feed the wire from the spool through the wire
driveinletguide(17)intothewirefeeder.
2. Loading Wire Feeder
2.1 Release the wire feed tension arm (18) by pivot-
ingthewirefeedtensionadjustmentlever(19)to-
wards you from the vertical ‘locked’position.
2.2 Checkthewiredriveroller(21)groovematchesthe
selectedMIGwiretypeandsize.Thedriverollerwill
have two dierent sized grooves; the size of the
groove in use is stamped on the side of the drive
roller.Foruxcored‘soft’wire,suchasthatusedin
gaslessMIGwelding,thedriverollergroovehasa
serratedprole(knownasknurled).Forsolidcore
‘hard’MIGwire,thedriverollergrooveusedhasa
‘v’ shaped prole. For Aluminum solid core‘soft’
MIGwire,thedriverollerrequiredhasa‘u’shaped
groove. If necessary, remove and change the drive
rollerbyunthreadingthedriverollerretainer(20).
2.3 Oncethe correctdrive roller (21)is selectedand
ttedandthe driveroller retainer (20) issecured
in place, manually feed the wire through the wire
drive inlet guide (17), through the drive roller
grooves and into the outlet wire guide tube. En-
suring that the wire is correctly seated in the drive
roller groove, replace the wire feed tension arms
(18)andlockthemintoplacebypivotingthewire
feed tension adjustment levers (20) back to the
vertical position.
3. Adjusting Wire Feed Tension
This is accomplished by winding the knob on the ten-
sionadjustmentlever(19).Clockwisewillincreaseten-
sion, anti-clockwise will decrease drive tension. Ideal
tension is as little as possible, while maintaining a con-
sistent wire feed with no drive roller slippage. Check
all other causes of excess wire feeding friction causing
slippagerst,suchas;incorrect/worndriveroller,worn/
damagedtorchconsumables,blocked/damagedtorch
wire guide liner, before increasing wire feed tension.
There is a number scale on the tension adjustment le-
ver(19)toindicatetheadjustmentposition.Thehigher
the number indicated, the higher the tension that is set.
WARNING!
Before changing the feed roller or wire spool, ensure
that the mains power is switched o.

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5. Gas MIG Welding Operation
NOTE: Gas MIG welding will require a gas cylinder.
5.1 Connect the earth cable quick connector to the
negativeweldingpoweroutputsocket(13).Con-
nect the earth clamp to the work piece. Contact
with the work piece must be rm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
5.2 ConnecttheMIGpowerconnectionlead (12) to
the positive welding power output socket (11).
Note if this connection is not made, there will be
no electrical connection to the welding torch!
5.3 Connectthegas regulatortoagascylinder(not
includedwithmachine)andconnectthegashose
from the regulator to the gas inlet on the rear of
the machine. Ensure all hose connections are tight.
Open gas cylinder valve and adjust regulator, ow
shouldbebetween10-25l/mindependingonap-
plication.  Re-check regulator ow pressure with
torch triggered as static gas ow setting may drop
once gas is owing.
5.4 Settheweldingvoltageadjustment(9),wirespeed
control(10)andinductancecontrol(1)tothede-
sired settings. You are now ready to weld!
Note to welding with Aluminium and other soft wires.
MIGweldingwithaluminiumprovidesauniquechal-
lenge, due to the low column strength and surface fric-
tion of the wire. This causes the wire to deform more as
it is pushed through the feed mechanism and the torch
wire delivery liner, greatly increasing friction. Because
goodMIGweldingresultsaredependentonasmooth
and concsistent wire feed, changes must be made to
the wire feed system to minimise friction caused issues.
Fora standard‘push’fedtorch,a length ofno longer
than 3m cable should be used, as well as the torch
feed liner must be changed to a specialTeon/ PVC
liner, rather than the conventional steel liner. Also the
correct style drive roller must be used and specic Alu-
miniumratedtorchcontacttip(orastandardtipinone
size oversize, e.g 0.8mm aluminium wire, use standard
1.0mmcontacttip).Forthisreason,itisquitecommon
foroperatorstohaveanextraMIGtorchspecicallyset
up for aluminium use, if the machine is used for weld-
ing steel as well.
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.
3.1 ConnecttheMIGTorchEuroConnectortotheMIG
torchEuroconnectionsocket(15)onthefrontof
themachine.Securebyrmlyhandtighteningthe
threadedcollarontheMIGTorchconnectorclock-
wise.
3.2  Check that the correct matching MIG wire, drive
roller(21)andMIGtorchtiparetted.
3.3 Connect the machine to suitable mains power us-
ingthemainsinputpowerlead.Switchthemains
powerswitchto‘on’topowerupthemachine.Set
theweldingmodetoMIGusingtheselection
button(2).
3.4 You are now ready to feed the wire through the
torch. With the wire feeder cover open, pull the
triggeroftheMIGtorchtocheckthatthewireis
feeding smoothly through the feeder and into the
torch.
3.5Setthewirefeedingspeed(9)tomaximum.With
the torch tip removed from the torch and the torch
laidoutasstraightaspossible,depressMIGtorch
trigger until the wire feeds out through the end
oftheMIGtorch.ReplacethetipontheMIGtorch
and trim o any excess wire.
4. Gasless Welding Operation
4.1 Connect the earth cable quick connector to the
positiveweldingpoweroutput socket(11). Con-
nect the earth clamp to the work piece. Contact
with the work piece must be rm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
4.2 Connectthe MIG powerconnection lead(12) to
the negative welding power output socket (13).
Note if this connection is not made, there will be
noelectricalconnectiontotheMIGtorch!
4.3 Set the welding voltage adjustment (10), wire
speedcontrol (10) andinductance control(1)to
the desired settings. You are now ready to weld!

9
WT205MIG Welding Machine
www.weldtech.net.nz
Another option to overcome the friction issues is using
a spool gun, which will give better results than a 3m
pushtorchwhenweldingaluminium.TheWT205MIGis
spool gun capable, refer following section for use with a
spoolgunontheWT205MIG.
6. Spool Gun Operation
NOTE: Spool Gun is an optional extra for the WT205MIG.
SPOOL GUN PART NUMBER: 13323
Spool Gun Overview
ThespoolgunisaveryusefuladditiontoaMIGwelder.
ItcanbeusedforalltypesofMIGwelding,butithas
two primary advantages over a conventional‘push’wire
feeder. The main advantage is that distance that the
wire has to travel from the spool to the welding tip is
very short, compared with a conventional torch. This
greatly reduces the wire feeding friction and improves
the wire feed speed smoothness and consistency, thus
the welding quality is greatly improved. This is especial-
ly so with ‘soft’wires such as Aluminium. It is dicult to
get Aluminium to feed smoothly in welding machines
equipped with standard design wire feeders, even with
special torch liners and short torch lengths.
The second advantage is that the gun can allow the
use of the small D100 wire spools at a distance from
thepowersource(Thisdistanceisonlylimitedbythe
lengthofthespoolgunlead).Thisisadvantageousfor
highcostwire,thatisnotusedcommonlysuchasStain-
lessSteelorMIGbrazingwire.Itsavestheoutlaycostfor
a much more expensive, larger D200 spool.
6.1 Connect the earth cable quick connector to the
negativeweldingpoweroutputsocket(13).Con-
nect the earth clamp to the work piece. Contact
with the work piece must be rm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
6.2 Connect the MIG power connection lead (12) to
the positive welding power output socket (11).
Note if this connection is not made, there will be
no electrical connection to the welding torch!
6.3 ConnectthespoolgunEuroConnectortotheMIG
torchEuroconnectionsocket(15)onthefrontof
themachine.Securebyrmlyhandtighteningthe
threadedcollarontheMIGTorchconnectorclock-
wise. Connect the spool gun interface plug to the
spoolgunconnectionsocket(14).Selectspoolgun
functionusingthebutton(5)
6.4 Connectthegasregulatortoagascylinder(notin-
cludedwithmachine)andconnectthe gas hose
from the regulator to the gas inlet on the rear of
the machine. Ensure all hose connections are tight.
Open gas cylinder valve and adjust regulator, ow
shouldbebetween10-25l/mindependingonap-
plication.  Re-check regulator ow pressure with
torch triggered as static gas ow setting may drop
once gas is owing.
6.5 Settheweldingvoltageadjustment(9),wirespeed
control(10)andinductancecontrol(1)tothede-
sired settings. You are now ready to weld!
7. ARC/ MMA Welding Operation
7.1 Connect the earth cable quick connector to the
negativeweldingpoweroutputsocket(13)Con-
nect the earth clamp to the work piece. Contact
with the work piece must be rm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
7.2 Insert an electrode into the electrode holder and
connect the electrode holder and work lead to the
positiveweldingpoweroutputsocket(11).
NOTE: This polarity connection conguration is valid for
most GP (General Purpose) MMA electrodes. There are vari-
ances to this. If in doubt, check the electrode specications
or consult the electrode manufacturer.
6.3 Connect the machine to suitable mains power us-
ingthemains inputpowerlead.Set the welding
modetoMMAusingtheselectionbutton(2).
6.4 Select therequiredoutput currentusing thecur-
rentcontrolknob(9).Youarenowreadytoweld!

10
Accessories
Refertopage11forrelatedaccessoriesforthismachine or visit www.weldtech.net.nz for a full range of consumables and accessories. MB25 Torch Consumables Breakdown (Tips,adapterandnozzlesavailableonly)

11
WT205MIG Welding Machine
www.weldtech.net.nz
• Checkallcablesbeforeuse.
• Checkelectrodeholders,worklead/
clamps and welding torches before
use.
• Replacewornelectrodeholdersand
earth clamps, which do not provide a
good connection.
• Replaceworntorchconsumableparts
in a timely manner.
• Replacewornwiredrivecomponents
in a timely manner
• Useasoftclothorbrushtocleanelec-
trical components. Do not use liquid
cleaning products, water or especially
solvents.
• Donotusecompressedairtoclean
electrical components as this can force
dirt and dust further into components,
causing electrical short circuits.
• Check for damaged parts. Do not use
the welder with damaged parts, before
further use. A dam-aged welder must
be carefully checked by a qualied
person to determine that it will oper-
ate properly. Check for breakage of
parts, mountings and other conditions
that may aect its operation.
An authorised service centre should
properlyrepairadamagedpart.Have
your welder repaired by an expert.
This appliance is manufactured in
accordance with relevant safety
standards. Only experts must carry
out repairing of electrical appliances,
otherwise considerable danger for
theusermayresult.Useonlygenuine
replacement parts. Do not use
modied or non-genuine parts.
Storing the Welder
When not in use the welder should be
stored in the dry and frost-free envi-
ronment.
WARNING! Before performing
cleaning/maintenance, replacing
cables / connections , make sure
the welding machine is switched
o and disconnected from the
power supply.
13323 WeldtechLightDutySpoolGun4m
16895 15mH/D15AExtensionLead(3x2.5mm2wiring)
DW1500 AutoDarkeningHelmet,FixedShade
DW3000 AutoDarkeningHelmet,Shade9-13
DW2500 AutoDarkeningHelmet,Shade9-13
DW4000 AutoDarkeningHelmet,Shade9-13w/GrindingVisor
GR101AR ArgonTwinGaugeRegulator
GR101CO2 CO2TwinGaugeRegulator
GADAR ArgonCylindertoCO2RegulatorAdaptorM/M
GADCO2 CO2CylindertoArgonRegulatorAdaptor,F/MtoF/M,
inc. nylon washer
GR119 CO²GasRegulatorHeated230Volt
MT250-3E MB25MigTorch3m(Euro)
MT250-4E MB25MigTorch4m(Euro)
MT250-5E MB25Migtorch5m(Euro)
ALS3550 MMALeadSet300A3mearth+4marc,1/2”DinseConnectors
S400EH 400AScrewTypeElectrodeholder
A400EC 400A Earth clamp
PDL15 Plug,3Pin15A250Vstraight
18020 NozzleConicalSpoolGun2pk
18162 SwanNeckFor13323Spoolgun
MW5KG06 MigWire5kgSpool-0.6mm
MW5KG08 MigWire5kgSpool-0.8mm
MW5KG09 MigWire5kg-0.9mm
MW5KG08FC FluxcoredMigWire-0.8mm,4.5kg
MW5KG09FC FluxcoredMigWire-0.9mm,4.5kg
CP3550 CablePlug-35-50mm³-Male(13mmdiapin)
19270 CoolingFanToSuitWT205MIG
19271 WT205MIGInverterModuleAssembly(Inverter+RectierPCBs)
19272 PowerPCBToSuitWT205MIG
19273 FrontUpperPlasticPanelToSuitWT205MIG
19274 WireFeederAssemblyToSuitWT205MIG
19275 EuroConnectSocketToSuitWT205MIG
19276 FrontPanelPCBToSuitWT205MIG
19277 ControlKnobToSuitWT205MIG
19278 MainControlPCBToSuitWT205MIG
19279 WireSpoolHolderToSuitWT205MIG
19280 MainsPowerSwitchToSuitWT205MIG
19281 GasSolenoidToSuitWT205MIG
17835 4RollWireFeederDriveRoller0.6/0.8mm‘v’groove
17836 4RollWireFeederDriveRoller0.9/1.0mm‘v’groove
17837 4RollWireFeederDriveRoller1.0/1.2mm‘v’groove
17838 4RollWireFeederDriveRoller0.8/0.9mmuxcored
17839 4RollWireFeederDriveRoller1.0/1.2mmuxcored
17841 4RollWireFeederDriveRoller0.8/1.0mm‘u’groove
17843 4RollWireFeederDriveRollerRetainer
Spare Parts, Consumables & Accessories
Part #: Description:
Care & Maintenance
Keep your Welding Machine in Top Condition
TheWT205MIGdoesnotrequireanyspecialmaintenance,however
the user should take care of the machine as follows:
• Regularlycleantheventilationslots.
• Keepthecasingclean.
Common
Consumables/
Accessories
Spare
Parts
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√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
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12
Welding Settings

13
WT205MIG Welding Machine
www.weldtech.net.nz
MIG Basic
Welding Guide
Mig Basic Welding Techniques
Two dierent welding processes are covered in this
section(GMAWandFCAW),withtheintentionofpro-
vidingtheverybasicconceptsinMIGwelding,where
aweldinggunishandheld,andtheelectrode(weld-
ing wire) is fed into a weld puddle, and the arc is
shieldedbyagas(GMAW)oruxcoredwire(FCAW).
Gas Metal ARC Welding (GMAW).
Thisprocess,alsoknownasMIGwelding,CO2weld-
ing,MicroWireWelding,shortarcwelding,diptrans-
fer welding, wire welding etc., is an electric arc weld-
ing process which fuses together the parts to be
welded by heating them with an arc between a solid
continuous, consumable electrode and the work.
Shielding is obtained from an externally supplied
welding grade shielding gas. The process is normally
applied semi automatically; however the process
may be operated automatically and can be machine
operated. The process can be used to weld thin and
fairly thick steels, and some non-ferrous metals in all
positions.
GMAW Process
(Fig 1-1) ShieldingGas
MoltenWeldMetal
Nozzle
Electrode Arc
BaseMetal
SolidiedWeldMetal
Flux Cored Arc Welding (FCAW)
This is an electric arc welding process which fuses to-
gether the parts to be welded by heating them with
an arc between a continuous ux lled electrode
wireandthework.Shieldingisobtainedthroughde-
composition of the ux within the tubular wire. Ad-
ditional shielding may or may not be obtained from
an externally supplied gas or gas mixture. The pro-
cess is normally applied semi automatically; however
the process may be applied automatically or by ma-
chine.
It is commonly used to weld large diameter elec-
trodes in the at and horizontal position and small
FCAW Process
(Fig 1-2) Nozzle
(Optional)
FluxCored
Electrode
Arc
Base
Metal
Solidied
WeldMetal
Slag
Molten
Slag
MoltenMetal
ShieldingGas
(Optional)
Push Vertical Drag Pull
Position of MIG Torch
(Fig 1-3)
TheangleofMIGtorchtotheweldhasaneecton
the width of the weld.
The welding gun should be held at an angle to the
weldjoint.(SeeSecondaryAdjustmentVariablesbe-
low).
Holdthegunsothattheweldingseamisviewedat
all times. Always wear the welding helmet with prop-
er lter lenses and use the proper safety equipment.
CAUTION!
Do not pull the welding gun back when the arc is
established. This will create excessive wire exten-
sion (stick-out) and make a very poor weld.
The electrode wire is not energized until the gun
trigger switch is depressed. The wire may therefore
be placed on the seam or joint prior to lowering the
helmet.
(Fig 1-4) 5oto15o
LongitudinalAngle
Direction of Travel
90oTransverse
Angle
electrode diameters in all positions. The process is
used to a lesser degree for welding stainless steel
and for overlay work.

14
Gas Metal ARC Welding (GMAW).
Thisprocess,alsoknownasMIGwelding,CO2weld-
ing,MicroWireWelding,shortarcwelding,diptrans-
fer welding, wire welding etc., is an electric arc weld-
ing process which fuses together the parts to be
welded by heating them with an arc between a solid
continuous, consumable electrode and the work.
Shielding is obtained from an externally supplied
welding grade shielding gas. The process is normally
applied semi automatically; however the process
may be operated automatically and can be machine
operated. The process can be used to weld thin and
fairly thick steels, and some non-ferrous metals in all
positions.
GMAW Process
(Fig 1-1) ShieldingGas
MoltenWeldMetal
Nozzle
Electrode Arc
BaseMetal
SolidiedWeldMetal
Flux Cored Arc Welding (FCAW)
This is an electric arc welding process which fuses to-
gether the parts to be welded by heating them with
an arc between a continuous ux lled electrode
wireandthework.Shieldingisobtainedthroughde-
composition of the ux within the tubular wire. Ad-
ditional shielding may or may not be obtained from
an externally supplied gas or gas mixture. The pro-
cess is normally applied semi automatically; however
the process may be applied automatically or by ma-
chine.
It is commonly used to weld large diameter elec-
trodes in the at and horizontal position and small
electrode diameters in all positions. The process is
used to a lesser degree for welding stainless steel
and for overlay work.
FCAW Process
(Fig 1-2) Nozzle
(Optional)
FluxCored
Electrode
Arc
Base
Metal
Solidied
WeldMetal
Slag
Molten
Slag
MoltenMetal
ShieldingGas
(Optional)
Push Vertical Drag Pull
Position of MIG Torch
(Fig 1-3)
TheangleofMIGtorchtotheweldhasaneecton
the width of the weld.
The welding gun should be held at an angle to the
weldjoint.(SeeSecondaryAdjustmentVariablesbe-
low).
Holdthegunsothattheweldingseamisviewedat
all times. Always wear the welding helmet with prop-
er lter lenses and use the proper safety equipment.
CAUTION!
Do not pull the welding gun back when the arc is
established. This will create excessive wire exten-
sion (stick-out) and make a very poor weld.
The electrode wire is not energized until the gun
trigger switch is depressed. The wire may therefore
be placed on the seam or joint prior to lowering the
helmet.
(Fig 1-4) 5oto15o
LongitudinalAngle
Direction of Travel
90oTransverse
Angle
(Fig 1-5)
5oto15o
LongitudinalAngle 30oto 60o
Transverse
Angle
Direction
of Travel

15
WT205MIG Welding Machine
www.weldtech.net.nz
(Fig 1-5)
5oto15o
LongitudinalAngle 30oto 60o
Transverse
Angle
Direction
of Travel
Vertical Fillet Welds (Fig 1-6)
10o
LongitudinalAngle
Direction of Travel
10oto 20o
LongitudinalAngle
30oto 60o
Transverse
Angle
30oto 60o
Transverse
Angle
Direction of Travel
(Fig 1-7)
5oto15o
Longitudinal
Angle
30oto 60o
Transverse
Angle
Distance from the MIG Torch Nozzle
to the Work Piece
TheelectrodewirestickoutfromtheMIGTorchnoz-
zle should be between 10mm to 20mm. This dis-
tance may vary depending on the type of joint that
is being welded.
Travel Speed
The speed at which the molten pool travels inu-
ences the width of the weld and penetration of the
welding run.
MIG Welding (GMAW) Variables
Mostoftheweldingdonebyallprocessesisoncar-
bon steel. The items below describe the welding vari-
ablesinshort-arcweldingof24gauge(0.024”,0.6mm)
to¼”(6.4mm)mildsheetorplate.Theappliedtech-
niquesandendresultsintheGMAWprocessarecon-
trolled by these variables.
Preselected Variables
Preselected variables depend upon the type of ma-
terial being welded, the thickness of the material, the
welding position, the deposition rate and the me-
chanical properties.
These variables are:
  • Typeofelectrodewire
  • Sizeofelectrodewire
  • Typeofgas
  • Gasowrate
Primary Adjustable Variables
These control the process after preselected variables
have been found. They control the penetration, bead
width, bead height, arc stability, deposition rate
and weld soundness.
Theyare: • ArcVoltage
  • Weldingcurrent(wirefeedspeed)
  • Travelspeed
Secondary Adjustable Variables
These variables cause changes in primary adjustable
variables which in turn cause the desired change in
the bead formation. They are:
1. Stick-Out (distancebetweentheendofthecon-
tact tube (tip) and the end of the electrode wire).
Maintainatabout10mmstick-out
2. Wire Feed Speed. Increase in wire feed speed
increases weld current. Decrease in wire feed speed
decreases weld current.
Electrode Stick-Out
(Fig 1-8)
GasNozzle
Tip to
Work Distance
ContactTip(Tube)
Electrode Wire
Actual
Stick-Out
3. Nozzle Angle. This refers to the position of the
welding gun in relation to the joint. The transverse
angle is usually one half the included angle between
plates forming the joint. The longitudinal angle is the
angle between the centre line of the welding gun
and a line perpendicular to the axis of the weld. The
longitudinal angle is generally called the Nozzle
Angleandcanbeeithertrailing(pulling)orleading

16
Transverse & Longitudinal
Nozzle Axes (Fig 1-9)
LongitudinalAngle
Transverse Angle
Axis of Weld
(pushing). Whether the operator is left handed or
right handed has to be considered to realize the
eects of each angle in relation to the direction of
travel.
Nozzle Angle, Right Handed Operator
(Fig 1-10)
Direction of Travel
Leadingor“Pushing”
Angle(ForwardPointing) Trailingor“Pulling” Angle(BackwardPointing)
90o
Establishing the Arc and Making Weld Beads
Before attempting to weld on a nished piece of
work, it is recommended that practice welds be
made on a sample metal of the same material as that
of the nished piece.
The easiest welding procedure for the beginner to
experimentwithMIGweldingistheatposition.The
equipment is capable of at, vertical and overhead
positions.
ForpracticingMIGwelding,securesomepiecesof16
or18gauge(1.5mmor2.0mm)mildsteelplate(150
x150mm).Use(0.8mm)uxcoredgaslesswireora
solid wire with shielding gas.
Setting of the Power Source
Power sourceand Current(WireSpeed) setting re-
quires some practice by the operator, as the welding
plant has two control settings that have to balance.
ThesearetheCurrent(WireSpeed)controlandthe
welding Voltage Control.
The welding current is determined by the Current
(WireSpeed)control,thecurrentwillincreasewith
increasedCurrent(WireSpeed),resultinginashorter
arc.LessCurrent(WireSpeed)willreducethecurrent
and lengthen the arc. Increasing the welding voltage
hardly alters the current level, but lengthens the arc.
By decreasing the voltage, a shorter arc is obtained
with a little change in current level.
When changing to a dierent electrode wire dia
eter, dierent control settings are required. A thinner
electrodewireneedsmoreCurrent(WireSpeed)to
achieve the same current level.
A satisfactory weld cannot be obtained if the Current
(WireSpeed)andVoltagesettingsarenotadjustedto
suit the electrode wire diameter and the dimensions
of the work piece.
IftheCurrent(WireSpeed)istoohighfortheweld-
ingvoltage,“stubbing”willoccurasthewiredipsinto
the molten pool and does not melt. Welding in these
conditions normally produces a poor weld due to
lack of fusion. If, however, the welding voltage is too
high, large drops will form on the end of the wire,
causing spatter. The correct setting of voltage and
Current (Wire Speed) can be seen in the shape of
the weld deposit and heard by a smooth regular arc
sound.
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas
used depends on the following:
 • Thicknessofthemetaltobewelded
 • Typeofjoint
 • Capacityofthewirefeedunitandpowersource
 • Theamountofpenetrationrequired
 • Thedepositionraterequired
 • Thebeadproledesired
 • Thepositionofwelding
 • Costofthewire

17
WT205MIG Welding Machine
www.weldtech.net.nz
MIG Welding
Troubleshooting
ThegeneralapproachtoxGasMetalArcWelding
(GMAW)problemsistostartatthewirespoolthen
workthroughtotheMIGtorch.Therearetwomain
areas where problems occur with GMAW, Porosity
and Inconsistent wire feed.
When there is a gas problem the result is usually po-
rosity within the weld metal. Porosity always stems
from some contaminant within the molten weld
pool which is in the process of escaping during so-
lidication of the molten metal.
Contaminants range from no gas around the weld-
ing arc to dirt on the workpiece surface. Porosity can
be reduced by checking the following points.
WARNING!
Disengage the feed roll when testing for gas ow by ear.
Wire feeding problems can be reduced by checking the following points.

18
Other weld problems can be reduced by checking the following points.

19
WT205MIG Welding Machine
www.weldtech.net.nz
Flat Position,
Down Hand Butt Weld
(Fig 1-11)
Flat Position,
Gravity Fillet Weld
(Fig 1-12)
Horizontal Position,
Butt Weld
(Fig 1-13)
Horizontal-Vertical
(HV) Position
(Fig 1-14)
Vertical Position,
Butt Weld
(Fig 1-15)
Vertical Position,
Fillet Weld
(Fig 1-16)
Overhead Position,
Butt Weld
(Fig 1-17)
Overhead Position,
Fillet Weld
(Fig 1-18)
MMA (Stick) Basic
Welding Guide
Size of Electrodes
The electrode size is determined by the thickness of
metals being joined and can also be governed by
thetypeofweldingmachineavailable.Smallweld-
ingmachineswillonlyprovidecurrent(amperage)to
run smaller sized electrodes.
Forthinsections,itisnecessarytousesmallerelec-
trodes otherwise the arc may burn holes through
the job. A little practice will soon establish the most
suitableelectrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their
original containers.
Electrode Polarity
Electrodes are generally connected to the electrode
holder with the electrode holder connected positive
polarity.
The work lead is connected to the negative polarity
and is connected to the work piece. If in doubt con-
sult the electrode data sheet.
Eects of MMA(Stick) Welding on
Various Materials
High Tensile and Alloy Steels
The two most prominent eects of welding these
steels are the formation of a hardened zone in the
weld area, and, if suitable precautions are not taken,
the occurrence in this zone of under-bead cracks.
Hardenedzoneandunderbeadcracksintheweld
area may be reduced by using the correct elec-
trodes, preheating, using higher current settings,
using larger electrodes sizes, short runs for larger
electrode deposits or tempering in a furnace.
Manganese Steels
The eect on manganese steel of slow cooling from
hightemperaturescausesembrittlement.Forthis
reason it is absolutely essential to keep manganese
steelcool during welding by quenching after each
weld or skip welding to distribute the heat.
Cast Iron
Mosttypesofcastiron,exceptwhiteiron,areweld-
able. White iron, because of its extreme brittleness,

20
MILD STEEL :
E6011 - This electrode is used for all-position welding or
for welding on rusty, dirty, less-than- new metal. It has
a deep, penetrating arc and is often the rst choice for
repair or maintenance work.
E6013 - This all-position electrode is used for welding
clean, new sheet metal. Its soft arc has minimal spatter,
moderate penetration and an easy-to-clean slag.
E7014 - All positional, ease to use electrode for use on
thicker steel than E6013. Especially suitable for sheet metal
lap joints, llet welds and general purpose plate welding.
E7018 - A low-hydrogen, all-position electrode used when
quality is an issue or for hard-to-weld metals. It has the ca-
pability of producing more uniform weld metal, which has
better impact properties at low temperatures.
CAST IRON:
ENI-CL -Suitableforjoiningallcastironsexceptwhite
cast iron.
STAINLESS STEEL:
E318L-16 -Highcorrosionresistances.Idealfordairy
work etc.
Electrodes for joining dierent metals:
Joint Preparations
In many cases, it will be possible to weld steel sec-
Open Square Butt Joint
(Fig 1-19a)
Gapvariesfrom1.6mm(1/16”)
to4.8mm(3/16”)dependingonplatethickness
Single Vee Butt Joint
(Fig 1-19b) Notlessthan45°
Single Vee Butt Joint
(Fig 1-19c) Not less than 70°
1.6mm(1/16”)max.
1.6mm(1/16”)
Double Vee Butt Joint
(Fig 1-19d) Not less than 70°
1.6mm(1/16”)max.
1.6mm(1/16”)
Lap Joint (Fig 1-19e)
Fillet Joint (Fig 1-19f)
generally cracks when attempts are made to weld it.
Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by
gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat
conductivity of copper, making pre-heating of heavy
sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
Arc Welding electrodes are classied into a number
of groups depending on their applications. There are
a great number of electrodes used for specialised in-
dustrial purposes which are not of particular interest
for everyday general work. These include some low
hydrogen types for high tensile steel, cellulose types
for welding large diameter pipes, etc. The range of
electrodes dealt with in this publication will cover
the vast majority of applications likely to be encoun-
tered; are all easy to use.
tions without any special preparation. For heavier
sections and for repair work on castings, etc., it will
be necessary to cut or grind an angle between the
pieces being joined to ensure proper penetration of
the weld metal and to produce sound joints.
In general, surfaces being welded should be clean
andfreeofrust,scale,dirt,grease,etc.Slagshouldbe
removed from oxy-cut surfaces. Typical joint designs
areshowninFigure1-19.