Weldforce 135S - Welding machine Weldclass - Free user manual and instructions

Product Type	Inverter Welding Machine (MIG/MMA)
Model	Weldforce 135S
Brand	Weldclass
Max Welding Current	135 A
Duty Cycle	60% at 90A, 30% at 135A
Input Voltage	230V AC, 50/60 Hz
Input Power	3.5 kVA
Welding Processes	MIG (GMAW), MMA (Stick), Lift TIG
Wire Diameter	0.6 - 1.0 mm (MIG)
Electrode Diameter	1.6 - 3.2 mm (MMA)
Dimensions (L x W x H)	360 x 150 x 280 mm
Weight	6.5 kg
Cooling System	Fan forced air cooling
Insulation Class	H
Protection Class	IP21
Welding Current Adjustment	Continuous variable (20 - 135 A)
Synergic Control	No
Gas Valve	Built-in solenoid valve (for MIG)
Spool Gun Compatible	Yes (optional)
Safety Features	Overheat protection, overload protection, short circuit protection
Maintenance	Regularly clean dust from vents, check cables and torch condition
Spare Parts Available	Contact Weldclass service center for parts (torch, liner, contact tips, etc.)
Warranty	2 years (subject to terms)
Manual Languages	English (PDF available for download)

Frequently Asked Questions - Weldforce 135S Weldclass

What welding processes can the Weldforce 135S perform?

The Weldforce 135S supports MIG (GMAW), MMA (Stick), and Lift TIG welding. It is a versatile inverter machine suitable for hobby and light industrial use.

What is the maximum welding thickness for this machine?

For MIG welding, it can weld up to 6 mm steel (single pass). For MMA, up to 5 mm with proper electrode selection. Thicker material may require multiple passes.

What power supply is required?

The machine requires a 230V AC power supply at 50/60 Hz. It draws a maximum current of about 15 A, so a 16 A circuit breaker is recommended.

Can I use a spool gun with the Weldforce 135S?

Yes, the Weldforce 135S is spool gun compatible. You can use an optional spool gun for welding aluminum or other wire materials.

How do I set the wire speed for MIG welding?

Wire speed is adjusted via a knob on the front panel. It is typically set in relation to the welding current. Start with a medium speed and adjust until you get a stable arc and good weld bead.

What safety precautions should I take when using this welder?

Always wear appropriate PPE: welding helmet with appropriate shade, flame-resistant gloves, and clothing. Ensure good ventilation. Do not touch the electrode or work piece when the machine is on. Disconnect power before changing parts.

How do I clean and maintain the welding machine?

Regularly remove dust and debris from the vents with compressed air. Inspect cables and torch for damage. Replace worn contact tips and liners. Keep the machine dry and store in a clean environment.

What is the duty cycle of the Weldforce 135S?

The duty cycle is 60% at 90A and 30% at 135A (10-minute cycle). This means you can weld for 6 minutes at 90A and then need 4 minutes of rest.

Can I use the machine for car body repair?

Yes, it is suitable for thin sheet metal welding on car bodies. Use MIG with 0.6 mm wire and set the current low to avoid burn-through.

Where can I find replacement parts or service?

Contact Weldclass authorised service centres. Common spare parts like contact tips, nozzles, and liners can be purchased from welding supply stores. Refer to the manual for part numbers.

USER MANUAL Weldforce 135S Weldclass

OPERATING INSTRUCTIONS

IMPORTANT!

To qualify for full 12 month warranty, you must register within 30 days of purchase. See inside for details.

WeldForce

by Weldclass

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 6 months. To qualify for an extended full 12 month warranty 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.

Close-up of a metal wire bundle with 'Weldclass' branding, no visible text or symbols on the product itself.

Platinum 12V

Looking for easy-to-use electrodes?

Weldclass Platinum 12V electrodes are rated by many welders across Australia as their favourite GP electrode. Easy-striking, smooth arc, easy spatter removal & all positioning.

Talk to your Weldclass distributor today, or go to: www.Weldclass.com.au/12V

Contents

Know Your Machine....5

Power Supply....6

Operating Environment 6

Tips & Tricks....6

Care & Maintenance....7

MMA (Stick) Basic Welding Guide 7

MMA (Stick) Troubleshooting 13

Knowledge & Resources 14

Safety....14

Warranty....19

Specifications

Output Power 30-140A
Duty Cycle 100A @ 60%
Input Power 240V, 10A
Max. Input Current 21A
Electrode Size 1.6 – 3.2mm
Weight 3.8kg
Dimensions: (L x W x H) 290 x 132 x 275mm

For full machine specifications, refer to technical data plate on back of machine – or go to: www.Weldclass.com.au/WF-135S

Know Your Machine

1. Overload indicator lamp*
2. Power indicator lamp
3. Current adjustment knob
4. Negative (-) welding power output connection socket

5. Positive (+) welding power output connection socket

6. 240V AC mains power input lead

7. Mains power switch
8. Cooling fan inlet

* Overload indicator lamp - Lights when duty cycle is exceeded and thermal protection is activated. When thermal protection is activated, welding output will be disabled until machines cools sufficiently and overload indicator lamp goes out. Also may activate with inverter circuit failure issues.

Power Supply

Electrical Connection

The WF-135S is designed to operate on a 10A 240V AC power supply.

Extension Leads

If an extension cord must be used, it should be minimum cable core size 2.0mm^2 for length of up to 10m, or minimum 2.5mm^2 for length up to 20m. Using extension leads of over 20m is not recommended.

Generator Use

This machine has a wide input power variation tolerance ( 170-265V), allowing it to operate off generator power. However, this machine is NOT designed for frequent generator use and is NOT protected against poor quality power or voltage spikes. Any damage caused by generator power supply is not covered under warranty.

If generator power must be used, generator size should be not less than 7kva. Avoid using poor, low quality generators as these have the greatest risk of power spikes etc. A suitable quality generator should have a THD (total harmonic distortion) rating of not more than 6%. Most reputable generator supplier will be able to specify the THD ratings on their product.

Operating Environment

Adequate ventilation is required to provide proper cooling for the WF-135S. Ensure that the machine is placed on a stable level surface where clean cool air can easily flow through the unit. The WF-135S has electrical components and control circuit boards which may be damaged by excessive dust and dirt, so a clean operating environment is essential.

Basic Operation - ARC/ MMA

1.1 Connect the earth cable quick connector to the negative welding power output socket (4) Connect the earth clamp to the work piece. Contact with the work piece must be a firm contact, with clean bare metal, with no corrosion, paint or scale at the contact point.

1.2 Insert an electrode into the electrode holder and connect the electrode holder and work lead to the positive welding power output socket (5).
NOTE: This polarity connection configuration is valid for most GP (General Purpose) MMA electrodes. There are variances to this. If in doubt, check the electrode specifications or consult the electrode manufacturer.
1.3 Connect the machine to suitable mains power using the mains input power lead (6). Switch the mains power switch (7) to 'on' to power up the machine.
1.4 Select the required output current using the current control knob (3). You are now ready to weld!

Tips & Tricks

Duty Cycle Rating

Welding duty cycle is the percentage of actual welding time that can occur in a ten minute cycle. E.g. 15% at 105 amps - this means the welder can weld at 105 amps for 1.5 minutes and then the unit will need to be rested for 8.5 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 environment with temperatures exceeding 40^ C, the duty cycle will be less than stated. In ambient temperature less than 40^ C, duty cycle performance will be higher.

Lift TIG Operation

The WF-135S is not designed to be used for lift TIG operation, for lift TIG welding, the WF-140ST or WF-180ST models are recommended.

For more useful tips & tricks on welding or selecting the right tool for the job, please visit www.weldclass.com.au

Care & Maintenance

Keep your Welding Machine in Top Condition

The WF-135S 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.
- 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.
- Use a soft cloth or brush to clean electrical 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.

If damaged, before further use, the welder must be carefully checked by a qualified person to determine that it will operate properly. Check for breakage of parts, mountings and other conditions that may affect its operation.

Have your welder repaired by an expert. An authorised service centre should properly repair a damaged part.

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 modified or non-genuine parts.

Storing the Welder

When not in use the welder should be stored in the dry and frost-free environment.

WARNING!

Before performing cleaning/maintenance, replacing cables / connections, make sure the

welding machine is switched off and disconnected from the power supply.

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 welding machines will only provide current (amperage) to run smaller sized electrodes.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode 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 consult the electrode data sheet.

Effects of MMA(Stick) Welding on Various Materials

High Tensile and Alloy Steels

The two most prominent effects 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 electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

Manganese Steels

The effect on manganese steel of slow cooling from high temperatures causes embrittlement. For this

reason it is absolutely essential to keep manganese steel cool 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 weldable. White iron, because of its extreme brittleness, 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 classified into a number of groups depending on their applications. There are a great number of electrodes used for specialised industrial 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 encountered; are all easy to use.

Electrodes for joining different metals:

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 first 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, fillet 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 capability 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.

Flat Position,

Down Hand Butt Weld

(Fig 1-11)

Simple line drawing of a welded joint or weld (no text or symbols)

Flat Position,

Gravity Fillet Weld

(Fig 1-12)

Simple line drawing of a mechanical component with no text or symbols

Horizontal Position,

Butt Weld

(Fig 1-13)

Technical line drawing of a rectangular mechanical component with internal grooves and hatched areas (no text or symbols)

Horizontal-Vertical

(HV) Position

(Fig 1-14)

Diagram of a welded joint with internal threading and a flat base (no text or symbols)

Vertical Position,

Butt Weld

(Fig 1-15)

Simple line drawing of a rectangular block with a vertical spring-like structure embedded in it (no text or symbols)

Vertical Position,

Fillet Weld

(Fig 1-16)

Simple line drawing of a solenoid inside a U-shaped block (no text or symbols)

Overhead Position,

Butt Weld

(Fig 1-17)

Pure geometric diagram of a 3D rectangular prism with internal diagonal hatching and label 'on,' (no text or symbols within the diagram itself)

Overhead Position,

Fillet Weld

(Fig 1-18)

Simple line drawing of a mechanical component with numbered parts (1, 2, 3, 4) and hatched texture, no text or symbols present.

Joint Preparations

In many cases, it will be possible to weld steel sections 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.

Open Square Butt Joint
(Fig 1-19a)

Pure geometric lines forming a cross-like pattern without any text, numbers, or symbols

Gap varies from 1.6mm (1/16")
to 4.8mm (3/16") depending on plate thickness

Single Vee Butt Joint
(Fig 1-19b)

Single Vee Butt Joint

(Fig 1-19c)
Not less than 70°

Double Vee Butt Joint

(Fig 1-19d)
Not less than 70°

Lap Joint (Fig 1-19e)

Fillet Joint (Fig 1-19f)

Corner Weld
(Fig 1-19g)

Simple geometric diagram of two intersecting lines forming an angle (no text or symbols)

Tee Joints
(Fig 1-19h)

Simple diagram showing two semicircular shapes above a horizontal line, no text or symbols present.

Pure diagram of a pipe fitting with no text or symbols

Plug Welds
(Fig 1-19j)

3D rendering of a metallic V-shaped bracket with two circular holes on top (no text or symbols)

3D rendering of a metallic mechanical component with a circular recessed feature on top (no text or symbols)

MMA Welding Techniques - A Word for Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode.

Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the down hand position. Make sure that the Work Lead/Clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

The Welder

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will find that the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting alight to your clothes.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty; otherwise you are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck. As soon as the arc is established, maintain a 1.6mm to 3.2mm gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will find that a long arc produces more heat.

A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick twist back over the weld to detach it. Contact or "touch-weld" electrodes such as E7014 Stick electrodes do not stick in this way, and make welding much easier.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead.

The electrode is directed at the weld pool at about 20^ from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 1-21, allowing 1.6mm to 2.4mm gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment.

Plates thicker than 6.0mm should have their mating edges beveled to form a 70° to 90° included angle. This allows full penetration of the weld metal to the root. Using a 3.2mm E7014 Stick electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a well-formed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20^ from vertical, and the rate of travel not too fast, will help eliminate this.

The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    G --> H["8"]
    H --> I["9"]
    I --> J["10"]
    J --> K["11"]
    K --> L["12"]
    L --> M["13"]
    M --> N["14"]
    N --> O["15"]
    O --> P["16"]
    P --> Q["17"]
    Q --> R["18"]
    R --> S["19"]
    S --> T["20"]
    T --> U["21"]
    U --> V["22"]

Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 1-22. The width of weave should not be more than three times the core wire diameter of the electrode.

When the joint is completely filled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 1-14, 1-23 and 1-24.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 3.2mm E7014 Stick electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet.

Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45^ from the vertical. Some electrodes require being sloped about 20^ away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 1-23.

Do not attempt to build up much larger than 6.4mm width with a 3.2mm electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 1-24. Weaving in HV fillet welds is undesirable.

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm E7014 Stick electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet. The electrode needs to be about 10° from the horizontal to enable a good bead to be deposited. Refer Fig. 1-25.

Single Run Vertical Fillet Weld (Fig 1-25)

Simple line drawing of a mechanical setup with a cylindrical component and a rectangular frame (no text or symbols)

Use a short arc, and do not attempt to weave on the first run. When the first run has been completed deslag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges.

Multi Run Vertical Fillet Weld (Fig 1-26)

At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 1-26 illustrates multi-run technique and Figure 1-27 shows the effects of pausing at the edge of weave and of weaving too rapidly.

Examples of Vertical Fillet Welds (Fig 1-27)
CORRECTINCORRECT

Pause at edge of weave allows weld metal to build up and eliminates undercut

Note: Weld contour when insufficient pause at edge of weave

2. Vertical Down

The E7014 Stick electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45°.

3. Overhead Welds

Apart from the rather awkward position necessary, overhead welding is not much more difficult that down hand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch.

The electrode is held at 45^ to the horizontal and tilted 10^ in the line of travel (Figure 1-28). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead fillet welds.

Use a 3.2mm E6013 Stick electrode at 100 amps, and deposit the first run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

Overhead Fillet Weld (Fig 1-28)

Angle tacked to pipe

MMA (Stick) Troubleshooting

Fault	Cause	Remedy
A gap is left by failure of the weld metal to fill the root of the weld.	Welding current too low.	Increase welding current.
	Electrode too large for joint.	Use smaller diameter electrode.
	Insufficient gap.	Allow wider gap.
Non-metallic particles are trapped in the weld metal.	Non-metallic particles may be trapped in undercut from previous run.	If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode.
	Joint preparation too restricted.	Allow for adequate penetration and room for cleaning out the slag.
	Irregular deposits allow slag to be trapped.	If very bad, chip or grind out irregularities.
	Lack of penetration with slag trapped beneath weld bead.	Use smaller electrode with sufficient current to give adequate penetra-tion. Use suitable tools to remove all slag from comers.
	Rust or mill scale is preventing full fusion.	Clean joint before welding.
	Wrong electrode for position in which welding is done.	Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult.
Figure 1: Example of insufficient gap or incorrect sequence Incorrect Sequence Insufficient Gap
A groove has been formed in the base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut).	Welding current is too high.	Reduce welding current.
	Welding arc is too long.	Reduce the length of the welding arc.
	Angle of the electrode is incorrect.	Electrode should not be inclined less than 45^ to the vertical face.
	Joint preparation does not allow correct electrode angle.	Allow more room in joint for manipulation of the electrode.
	Electrode too large for joint.	Use smaller gauge electrode.
	Insufficient deposit time at edge of weave.	Pause for a moment at edge of weave to allow weld metal build-up.
	Power source is set for MIG (GMAW) welding.	Set power source to STICK (MMA) mode.
Portions of the weld run do not fuse to the surface of the metal or edge of the joint.	Small electrodes used on heavy cold plate.	Use larger electrodes and preheat the plate.
	Welding current is too low.	Increase welding current.
	Wrong electrode angle.	Adjust angle so the welding arc is directed more into the base metal.
	Travel speed of electrode is too high.	Reduce travel speed of electrode.
	Scale or dirt on joint surface.	Clean surface before welding.
Figure 2: Example of Lack of Fusion Lack of fusion caused by dirt; electrode angle incorrect; rate of travel too high Lack of inter-run fusion Lack of side fusion, scale dirt; small electrode; amperage too low Lack of root fusion
Gas pockets or voids in weld metal (porosity)	High levels of sulphur in steel.	Use an electrode that is designed for high sulphur steels.
	Electrodes are damp.	Dry electrodes before use.
	Welding current is too high.	Reduce welding current.
	Surface impurities such as oil, grease, paint, etc.	Clean joint before welding.
	Welding in a windy environment.	Shield the weld area from the wind.
	Electrode damaged i.e. flux coating incomplete.	Discard damaged electrodes and only use electrodes with a complete flux coating.
Crack occurring in weld metal soon after solidification commences	Rigidity of joint.	Redesign to relieve weld joint of severe stresses or use crack resistance electrodes.
	Insufficient throat thickness.	Travel slightly slower to allow greater build up in throat.
	Weld current is too high.	Decrease welding current.
Figure 3: Example of Slag Inclusion trapped [dercut] Not cleaned, or incorrect electrode Slag trapped in root

Knowledge & Resources

Please refer to Weldclass website www.weldclass.com.au for more information.

Safety

Store and Retain this Manual

Retain this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product's serial number into the NOTES section at the rear, and keep this manual and the receipt in a safe and dry place for future reference.

Important Safety Information

Failure to follow the warnings and instructions may result in electric shock, fire, serious injury and/or death. Save all warnings and instructions for future reference.

This is the safety alert symbol to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER! indicates a hazardous situation which, if not avoided, will result in death or loss injury.

WARNING! indicates a hazardous situation which, if not avoided, could result in death or pus injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not voided, could result in minor or moderate injury.

NOTE, used to address practices not related to personal injury.

CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

GENERAL SAFETY WARNINGS

1. Maintain labels and nameplates on the welder. These carry important information. If unreadable or missing, contact Weldclass for a replacement.
2. Avoid unintentional starting. Make sure the welder is setup correctly and you are prepared to begin work before turning on the welder.
3. Unplug before performing maintenance.

Always unplug the welder from its electrical outlet before performing any inspection, maintenance, or cleaning procedures.

1. Never leave the welder unattended while energised. Turn power off before leaving the welder unattended.
2. Do not touch live electrical parts. Wear dry, insulating gloves. Do not touch the electrode or the conductor tong with bare hands. Do not wear wet or damaged gloves.
3. Protect yourself from electric shock. Do not use the welder outdoors. Insulate yourself from the work piece and the ground. Use non-flammable, dry insulating material if possible, or use dry rubber mats, dry wood or plywood, or other dry insulating material large enough to cover the area of contact with the work or the ground.
4. Avoid inhaling dust. Some dust created by power sanding, sawing, grinding, drilling, cutting, welding and other construction activities, contain chemicals known to cause cancer, birth defects or other harm. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals, work in a well-ventilated area, and work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles.
5. People with pacemakers should consult their physician(s) before using this machine.

WARNING!

Electromagnetic fields in close proximity to a heart pacemaker could cause interference, or failure of the pacemaker. The use of a Welder is NOT RECOMMENDED for pacemaker wearers. Consult your doctor.

1. Ensure that the unit is placed on a stable location before use.

WARNING!

If this unit falls while plugged in, severe injury, electric shock, or fire may result.

1. Transportation Methods. Lift unit with the handles provided, or use a handcart or similar device of adequate capacity. If using a fork lift vehicle, secure the unit to a skid before transporting.

CAUTION!

Disconnect input power conductors from de-energized supply line before moving the welding power source.

1. Exercise good work practices. The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be considered by the operator.

Welding Safety Instructions & Warnings

WARNING!

Protect yourself and others from possible serious injury or death. Keep children away. Read the operating/Instruction manual before installing, operating or servicing this equipment. Have all installation, operation, maintenance, and repair work performed by qualified people.

If an operator does not strictly observe all safety rules and take precautionary actions, welding products and welding processes can cause serious injury or death, or damage to other equipment or property.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the European Standard EN60974-1 entitled: Safety in welding and allied processes.

WARNING!

Only use safety equipment that has been approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye and breathing protection must be AS/NZS compliant for the specific hazards in the work area.

DANGER!

Always wear AS/NZS compliant safety glasses and full face shield fitted with appropriate filter shade number. (Refer Filter Table on page 17.)

CAUTION!

Heavy-duty work gloves, non-skid safety shoes and hearing protection used for appropriate conditions will reduce personal injuries.

CAUTION!

Have the equipment serviced by a qualified repair person using identical replacement parts. This will ensure that the safety of the power tool is maintained.

Personal Safety

CAUTION!

Keep the work area well lit. Make sure there is adequate space surrounding the work area. Always keep the work area free of obstructions, grease, oil, trash, and other debris. Do not use equipment in areas near flammable chemicals, dust, and vapours. Do not use this product in a damp or wet location.

1. Stay alert, watch what you are doing and use common sense when operating equipment. Do not use a tool while you are tired or under the influence of drugs, alcohol or medication. A moment of distraction when operating equipment may result in serious personal injury.
2. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.

Arc Rays can Burn Eyes and Skin

CAUTION!

Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin.

1. Use a Welding Helmet or Welding Face Shield fitted with a proper shade filter (refer AS 60974-1, AS/NZS 1337.1 and AS/NZS 1338.1 Safety Standards) to protect your face and eyes when welding or watching. (See Filter Table on Page17).

2. Wear approved safety glasses. Side shields are recommended.

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot safety protection.
5. Never wear contact lenses while welding.

Noise Can Damage Hearing

CAUTION!

Noise from some processes can damage hearing. Use AS/NZS compliant ear plugs or ear muffs if the noise level is high.

Work Environment Safety

DANGER!

Remove any combustible material from the work area.

1. When possible, move the work to a location well away from combustible materials. If relocation is not possible, protect the combustibles with a cover made of fire resistant material.
2. Remove or make safe all combustible materials for a radius of 10 metres around the work area. Use a fire resistant material to cover or block all doorways, windows, cracks, and other openings.
3. Enclose the work area with portable fire resistant screens. Protect combustible walls, ceilings, floors, etc., from sparks and heat with fire resistant covers.
4. If working on a metal wall, ceiling, etc., prevent ignition of combustibles on the other side by moving the combustibles to a safe location. If relocation of combustibles is not possible, designate someone to serve as a fire watch, equipped with a fire extinguisher, during the welding process and well after the welding is completed.
5. Do not weld or cut on materials having a combustible coating or combustible internal structure, as in walls or ceilings, without an approved method for eliminating the hazard.

6. After welding, make a thorough examination for evidence of fire. Be aware that visible smoke or flame may not be present for some time after the fire has started. Do not weld or cut in atmospheres containing dangerously reactive or flammable gases, vapours, liquids, and dust. Provide adequate ventilation in work areas to prevent accumulation of flammable gases, vapours, and dust.

7. Do not apply heat to a container that has held an unknown substance or a combustible material whose contents, when heated, can produce flammable or explosive vapours. Clean and purge containers before applying heat. Vent closed containers, including castings, before preheating, welding, or cutting.

Electricity Can Kill

DANGER!

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on.

The input power circuit and machine internal circuits are also live when power is on. In semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from the work and the ground using dry insulating mats or covers.
4. Disconnect input power before installing or servicing this equipment. Lock input power, disconnect switch open, or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip the holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.

10. Connect work piece to a good electrical ground.

11. Do not touch the electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts as soon as practical.
13. In confined spaces or damp locations, do not use a welder with AC output unless equipped with a voltage reducer.

Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Use the following table to select the appropriate shade number for a Welding Helmet or Welding Face Shield.

1. Use a Welding Helmet or Welding Face Shield fitted with a proper shade of filter (see AS 60974-1, AS/NZS 1337.1 and AS/NZS 1338.1 Safety Standards) to protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields are recommended.
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
5. Never wear contact lenses while welding.

Recommended Protective Filters for Electric Welding
Description of Process	Approximate Range of Welding Current in Amps	Minimum Shade Number of Filter(s)
Manual Metal Arc Welding - Covered Electrodes (MMA)	Less than or equal to 100	8
	100 to 200	10
	200 to 300	11
	300 to 400	12
	Greater than 400	13
Gas Metal Arc Welding (GWAW) (MIG) other than Aluminium And Stainless Steel	Less than or equal to 150	10
	150 to 250	11
	250 to 300	12
	300 to 400	13
	Greater than 400	14
Gas Metal Arc Welding (GWAW) (MIG) Aluminium and Stainless Steel	Less than or equal to 250	12
	250 to 350	13
Gas Tungsten Arc Welding (GTAW) (TIG)	Less than or equal to 100	10
	100 to 200	11
	200 to 250	12
	250 to 350	13
	Greater than 350	14
Flux-Cored Arc Welding (FCAW) - with or without Shielding Gas	Less than or equal to 300	11
	300 to 400	12
	400 to 500	13
	Greater than 500	14
Air - Arc Gouging	Less than or equal to 400	12
Plasma - Arc Cutting	50 to 100	10
	100 to 400	12
	400 to 800	14
Plasma - Arc Spraying	—	15
Plasma - Arc Welding	Less than or equal to 20	8
	20 to 100	10
	100 to 400	12
	400 to 800	14
Submerged - Arc Welding	—	2 (5)
Resistance Welding	—	Safety Spectacles or Eye Shield

Refer to standard AS/NZS 1338.1 for comprehensive information regarding the above table.

Fumes And Gases

WARNING!

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use an exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator.
3. Read the Safety Data Sheets (SDS) and the manufacturer's instruction for the metals, consumables, coatings, and cleaners.
4. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.
5. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapours to form highly toxic and irritating gases.
6. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

Fire & Explosive Risks

WARNING!

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, work piece, and hot equipment can cause fires and burns.

Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 10m of the welding site.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums. Connect the work lead/clamp to the job as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.
8. Do not use a welder to thaw frozen pipes.
9. Remove the stick electrode from the holder or cut off the welding wire at the contact tip when not in use.

Sparks & Hot Metal

WARNING!

Chipping and grinding causes flying metal, and as welds cool they can throw off slag.

1. Wear an AS/NZS approved face shield or safety goggles. Side shields are recommended.
2. Wear appropriate safety equipment to protect the skin and body.

Cylinders

WARNING!

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use appropriate shielding gas, regulators, hoses, and fittings designed for the specific application; maintain them and their associated parts in good condition.
6. Turn your face away from the valve outlet when opening the cylinder valve.

WARRANTY

Warranty period;

Without product registration: 6 months

If product has been registered online: 12 months

The WF-135S is warranted against faulty components and manufacturing defects for the warranty periods shown above.

The warranty period begins on the date of purchase by the end user. Warranty is not transferable and only claimable by the original purchaser.

If warranty registration has not taken place, it is the sole responsibility of the purchaser to retain proof of purchase (i.e. a copy of the invoice made out by the distributor or reseller to the owner of the machine clearly showing the purchase date). Proof of purchase must be provided in the event of any warranty claim.

a) Warranty includes and covers: Manufacturing faults and/or faulty materials that do not allow the machine to perform the functions for which it was designed, within the warranty period.
b) Warranty Excludes / Does Not Cover:

1. Warranty claims made without proof of purchase, or warranty claims made with proof of purchase that is deemed by Weldclass Welding Products to be false, misleading, incomplete or insufficient.
2. Defects or damage resulting from: misuse, accidents, neglect, improper maintenance, alteration/modification, use of the product contrary to the applications for which it was designed, or failure to heed any of the instructions, warnings or guidelines issued with the machine, spare parts or accessories that are not genuine.
3. Damage incurred in transport.
4. Operator error, misunderstanding or use contrary to the intended purpose.
5. Parts that are subject to wear and tear from usage or failure caused by the untimely replacement of such parts.
6. Warranty claims made where the owner/operator of the machine is not willing or not able to provide any information required by Weldclass Welding Products to process the warranty claim.
7. The cost of freight, transport or travel. It is the responsibility of the purchaser to deliver the a product under warranty to the nearest relevant service agent or distributor.
8. Cost for repairs carried out by a party not approved by Weldclass to carry out repairs.
9. Accessories and attachments such as leads and torches.

This is a repair and/or replacement warranty only and does not allow for a refund. Weldclass reserves the right to replace faulty product or parts covered under warranty with alternative / equivalent product or parts should the original unit become obsolete or unavailable. No other warranty is expressed or implied. This warranty is exclusive and in lieu of all others, including, but not limited to any warranty of merchantability or fitness for any particular purpose. Weldclass shall not under any circumstances be liable for special, indirect or consequential damages. No employee, agent, representative, distributor or agent of Weldclass is authorised to change this warranty in any way or grant any other warranty. Notwithstanding the foregoing, in no event shall the warranty period extend more than the stated warranty period plus 6 months from the date Weldclass delivered the product to the authorised distributor. Warranty is always dated from original date of purchase - if warranty repairs are made or if warranty replacements are given this does not extend the warranty period. Any decision regarding any warranty claim is made at the sole jurisdiction of Weldclass. This warranty policy does not affect the legal rights of any purchaser, distributor or service agent.

WeldForce

by Weldclass