The Weldforce 202T AC/DC is a versatile inverter welding machine designed for TIG (GTAW) and MMA (SMAW) welding processes, offering both AC and DC output current capabilities. It is suitable for a wide range of materials including mild steel, stainless steel, copper, titanium, aluminium, magnesium, and zinc. The machine is designed for professional use and emphasizes durability, value, and features.
Function Description
The Weldforce 202T AC/DC serves as a power source for various welding applications. It supports:
- TIG (GTAW) Welding: This process uses a non-consumable tungsten electrode to create the arc, with an inert gas (typically Argon) shielding the weld pool. The machine offers both High Frequency (HF) start and Lift-Arc start options for TIG welding. HF start eliminates the need for the tungsten electrode to make contact with the job, preventing tungsten contamination, but can cause electromagnetic interference. Lift-Arc start involves briefly touching the tungsten to the workpiece and lifting it to initiate the arc. The machine supports both DC (Direct Current) TIG for ferrous metals and stainless steel, and AC (Alternating Current) TIG for reactive metals like aluminium and magnesium, which require a cleaning action to break through/clean off the oxide layer. Pulse TIG functionality is also available, offering better control over heat input and weld pool management.
- MMA (SMAW) / Stick Welding: This process uses a consumable electrode coated with flux. The machine is suitable for welding various types of electrodes, including general purpose, low hydrogen, stainless steel, cast iron, and manganese steels. It provides features like Arc Force Adjustment (7e) to prevent the electrode from sticking and VRD (Voltage Reduction Device) for enhanced safety.
Important Technical Specifications
- Part Number: WC-202T
- Dimensions: L440 x W170 x H340mm (including handle)
- Weight: 16.5kg
- Standard: AS 60974.1
- Power Supply: 240V +/- 15% 50Hz Single Phase
- Factory Fitted Plug Rating: 10A (can be set to 15A for full output)
- Open Circuit Voltage Uo: VRD ON = 15V / VRD Off = 95A
- TIG Tungsten Size: 1.6 – 2.4mm
- MMA Electrode Size: 1.6 – 4.0mm
- Protection Class: IP23
- TIG (GTAW) Welding Output: 5 – 200A
- Duty Cycle (10A Plug): 180A / 17.2V @ 19%, 115A / 14.6V @ 60%, 100A / 14.0V @ 100%
- Duty Cycle (15A Plug): 180A / 17.2V @ 24%, 115A / 14.6V @ 60%, 100A / 14.0V @ 100%
- Stick (MMA) Welding Output: 5 – 180A
- Duty Cycle (10A Plug): 150A / 26.0V @ 12%, 100A / 24.4V @ 60%, 75A / 23.0V @ 100%
- Duty Cycle (15A Plug): 160A / 26.4V @ 30%, 110A / 24.4V @ 60%, 95A / 23.8V @ 100%
- Maximum Input Current (TIG): 33A (Imax 33A)
- Maximum Input Current (Stick): 33A (Imax 33A)
Usage Features
The Weldforce 202T AC/DC offers a comprehensive control panel and various settings to optimize welding performance:
- Control Panel: Features a clear LCD readout (10) for displaying selected/being adjusted parameters, along with multiple welding mode selection buttons and parameter indicator lights.
- Welding Mode Selection Buttons:
- Pulse/Easy Pulse/Bi-Level: For selecting pulse welding modes.
- Trigger Mode Selection (2T/4T/Spot): Allows selection of 2-Touch, 4-Touch, or Spot welding trigger modes.
- Process Selection (HF TIG/Lift-Arc TIG/MMA): Switches between HF TIG, Lift-Arc TIG, and MMA welding.
- Current Selection (AC/DC): Toggles between AC and DC output current.
- Welding Parameter Indicator Lights: Provide visual feedback for various settings such as Pre-Gas, Start Amps, Slope-Up, Main Amps, Frequency, Balance, Spot Time, Slope-Down, Finish Amps, Post-Gas, and SmartStart AC.
- TIG Torch Controls: Includes a torch trigger button and an optional remote control amperage potentiometer for precise control.
- Remote Controls: Supports an optional remote foot control (WC-06370) for amperage adjustment, allowing the operator to change amperage whilst welding without compromising control of the torch.
- Function Selection:
- ON (Standard Pulse): Enables standard pulse welding, useful for managing heat input and improving weld pool control.
- EASY (Easy Pulse Function): Simplifies pulse settings by automatically setting base and main current ratios.
- BILEVEL (Bi-Level Current Function): A non-pulse function that enables switching between two current levels (I1 & I2) during welding using the torch trigger.
- Trigger Mode Selection:
- 2T (Standard Trigger): Press and hold the trigger to start, release to stop.
- 4T (Latch Trigger): Press and release to start, press and release again to stop.
- SPOT (Spot Weld Function): For short, timed welds.
- TIG Arc Parameters/Characteristics Settings:
- Pre-Gas Time (7a): Adjustable from 0 – 10 seconds, purges the weld area before arc initiation.
- Start Amps (7b): Sets the current at the beginning of the weld.
- Slope Up (7c): Time taken for amperage to ramp up from Start Amps to Main Amps.
- Main Amps (7d): The primary welding current.
- Base Amps (7e): The lower amperage in Pulse or Bi-Level modes.
- Frequency (7f): Pulse frequency in Hz (cycles per second).
- Balance (7g): AC balance setting (1-99%) to adjust the ratio between positive and negative half-cycles, affecting cleaning action and penetration.
- Spot Time (7h): Adjustable from 0 – 10 seconds for spot welding.
- Slope Down (7k): Time taken for amperage to ramp down from Main Amps to End Amps.
- Finish Amps (7l): Sets the current at the end of the weld.
- Post-Gas Time (7m): Adjustable from 0 – 10 seconds, purges the weld area after arc termination to protect the weld pool.
- SmartStart AC (7n): A unique setting for AC TIG welding to ensure a stable arc and prevent tungsten contamination.
- MMA/Stick Arc Parameters/Characteristics Settings:
- Hot Start (7b): Adjustable from 0 – 100%, provides extra power when the weld starts.
- Current / Amps (7d): Main welding current.
- Arc Force Adjustment (7e): Adjustable from 0 – 100%, helps prevent electrode sticking and improves arc stability.
- VRD Function (MMA / Stick): Reduces open circuit voltage for safety.
- LCD Multi-Function Display (10): Displays selected/adjusted parameters and error codes.
- Error/Over Temperature Indicator Light (12): Illuminates when duty cycle is exceeded or thermal protection is activated.
Maintenance Features
Regular care and maintenance are crucial for the longevity and optimal performance of the Weldforce 202T AC/DC:
- Regular Cleaning: Regularly clean the ventilation slots to ensure proper airflow and prevent overheating. Keep the casing clean.
- Cable and Clamp Inspection: Check all cables before use. Replace worn electrode holders, work lead/clamps, and welding torches before use.
- Consumable Replacement: Replace worn torch consumable parts in a timely manner.
- Wire Drive Component Inspection: Replace worn wire drive components in a timely manner.
- Electrical Component Cleaning: Use a soft cloth or brush to clean electrical components. Do not use liquid cleaning products, water, or especially solvents.
- Compressed Air Cleaning: Do not use compressed air to clean electrical components as this can force dirt and dust further into components, causing electrical short circuits.
- Damage Check: Check for damaged parts and repair them promptly.
- Professional Repair: If damaged, the machine must be checked by a qualified person to determine if it will operate properly. Breakage of parts, mountings, and other conditions that may affect its operation should be addressed. Repairs should be carried out by an authorized service centre using genuine replacement parts.
- Storage: Store the welder in a dry, dust-free, and frost-free environment when not in use.
- Troubleshooting Guides: The manual provides detailed troubleshooting guides for both MMA (Stick) and TIG welding, outlining common faults, their causes, and remedies. This helps users diagnose and resolve minor issues.
- Warranty Information: The device comes with a 24-month warranty. Full details on warranty period and terms and conditions are available on the Weldclass website.
Safety Instructions & Warnings
The manual emphasizes several safety precautions:
- Store and Retain Manual: Keep the manual for safety warnings, precautions, assembly, operating, inspection, maintenance, and cleaning procedures.
- Important Safety Information: Failure to follow warnings and instructions may result in electric shock, fire, serious injury, or death.
- Personal Safety: Maintain labels and nameplates, avoid unintentional starting, set up the welder correctly, and unplug before performing maintenance.
- Arc Rays: Wear a welding helmet or welding face shield with a proper shade filter (refer to Table 17 for recommended shade filters). Wear approved safety glasses. Use protective screens or barriers to protect others from flash and glare.
- Noise: Use AS/NZS compliant ear plugs or ear muffs if the noise level is high.
- Work Environment Safety: Remove combustible material from the work area. Ensure the area is clean and free of flammable materials.
- Electricity Can Kill: Do not touch live electrical parts. Wear dry, insulating gloves. Disconnect input power before opening the machine. Ensure all connections are tight and properly grounded.
- Fumes and Gases: Keep your head out of the fumes. Do not breathe the fumes. Ventilate the area and/or use an exhaust. Wear an approved supplied-air respirator if necessary.
- Fire & Explosive Risks: Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs. Install and secure cylinders in an upright position. Never allow welding electrode to touch any cylinder.
- Sparks & Hot Metal: Wear appropriate safety equipment to protect the skin and body. Chipping and grinding causes flying metal and slag.
- Gas Cylinders: Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.
This comprehensive set of features and guidelines ensures that the Weldforce 202T AC/DC is a reliable and safe tool for a variety of welding tasks, provided the user adheres to the instructions.
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