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!

3
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

4
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)

5
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

6
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.

7
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.

8
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)