WT160MP - Euroquip
WT160MP
160A INVERTER
MIG/MMA(STICK)/TIG WELDER
OPERATING INSTRUCTIONS
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WT160MP Welding Machine
Contents
Welcome to Euroquip..........................................2
Know Your Machine..............................................5
Controls Explained.................................................5
Quick Start Guide....................................................6
Tips & Tricks.................................................................9
Welding Settings......................................................9
Accessories..............................................................10
Care & Maintenance......................... ...................11
MIG Basic Welding Guide..............................11
MIG Welding Troubleshooting....................15
MMA (Stick) Basic Welding Guide................17
MMA (Stick) Troubleshooting.......................23
TIG Basic Welding Guide...................................24
TIG Troubleshooting...........................................26
Knowledge & Resources..................................27
Safety .........................................................................27
Warranty....................................................................33
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WT160MP
160A - INVERTER MIG/TIG/ARC WELDER
Perfect for welding thin panel and plate up to 8mm thick! Great for
workshop jobs, exhaust systems and anything on the farm.
Powerful - 160A welding power up to 8mm steel thickness
Portable - Only 9kg super light weight and portable
Reliable - Cutting edge inverter technology ensures ultimate reliabilty
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ARC and MIG function for a variety of jobs
Stepless voltage and wire speed control
60% Duty Cycle @ 130A
Lightweight and robust construction - only 9kg
2m direct connect torch with earth & ARC lead set
Lift TIG (torch optional) for fine and delicate welding jobs
Live digital displays for accurate feedback of welding output
Over specified electronic components for increased durability and reliability
Gas/gasless function for welding flux-cored MIG wire
Overload protection for increased reliability and safety
Optional gas regulator for gas shielded welding (#GR101C02)
Dimensions: (L x W x H)
Weight:
Input Power:
395 x 165 x 290mm
9kg
230V, 10A
Output Power:
Duty Cycle:
Electrode Size:
40 - 160A
60% @ 130A
1.6 - 3.2mm
Max. Input Current:
Generator Capacity:
21.5A
5kVA
Wire Size:
Spool Size:
0.6, 0.8, 0.9
Mini Spools - 5kg
With 10A Plug - Ideal for home and workshop power supplies!
Optional accessories to help you get the job done!
Flip Front Helmet
(#AFF1000)
2 Sensor Auto Helmet
(#DW2500)
4 Sensor Auto Helmet
with grind
function
CO2 Regulator
(#GR101CO2)
(#DW3000)
Argon Option
(#GR101AR)
Chipping Hammer
(#SPCH)
TIG Torch
MIG Wire
0.6 (#MWMS06) 0.8 (#MW5KG08)
0.8 (#MWMS08) 0.9 (#MW5KG09)
(#TWP17V-12-2D)
Flux Cored
4
0.8 (#MWMS08FC)
0.9 (#MWMS09FC)
0.8 (#MW5KG08FC)
0.9 (#MW5KG09FC)
MWMS = Mini Spool
MW5KG = 5kg
FC = Flux Cored
Welding Gloves
(#AWG02)
WT160MP Welding Machine
Know Your Machine
7
6
4
1. Direct Connect MIG Torch
2. LCD current meter - Displays output current (amps) in real time*
3
3. LCD Voltage meter - Displays output voltage in real time*
2
4. Welding voltage adjustment knob - Adjusts
welding voltage in MIG mode*
5
8
1
5. MIG wire feed speed adjustment knob/ MMA
current adjustment knob*
6. Overload indicator lamp*
7. Welding output mode switch. Sets power source in MIG, MMA or Lift TIG mode*
11
10
9
8. Cooling Fan Inlet
9. MIG torch power connection lead
14
10. Negative (-) welding power output connection socket
11. Positive (+) welding power output connection socket
13
12. Shielding Gas Inlet Connection
13. 230V AC mains power input lead
14. Mains power switch
12
15. 5kg/ D.200 Wire spool retainer
18
16. 5kg/ D.200 spool adaptor
19
20
17. Wire spool holder
18. Wire drive inlet guide
19. Wire feed tension adjustment
17
20. Wire feed tension arm
21. Wire drive roller retainer
22. Wire drive roller (partially obscured)
Controls Explained
LCD Current & Voltage Display Meters
These indicate the actual voltage and current readings at the output terminals of the welding machine.
The current meter should read ‘0’ except when welding is actually taking place. The voltage meter will
indicate output voltage during welding and the
welding open circuit voltage when the machine
is powered up but not welding. In MIG mode the
21
16
15
22
open circuit voltage will only appear once the torch
is triggered to activate the circuit, in MMA and Lift
TIG mode, the open circuit voltage will show on the
display continuously. The digital meters are very sensitive and accurate, so it is not abnormal to observe
some small fluctuations on them when the machine
is at rest.
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Mig Voltage & Mig Wire Speed / MMA
& Lift Tig Current Control Knobs
MIG Welding Mode
The MIG voltage control is essentially the power in
the welding arc that sets the heat. The wire speed
feed simply controls the rate at which the welding
wire is fed into the weld pool.
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.
For any voltage position setting, there will be a specific 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 affected 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 machine for common welding applications is located
on the underside 0f the wire feeder cover door and
further on in this manual.
MMA/ Lift TIG Welding Mode
Electrical Connection
The current control knob sets the target welding
output current for either mode selected. The voltage
knob has no effect in MMA or TIG mode.
The WT160MP is designed to operate on a 10A 230V
AC power supply. If an extension cord must be used,
it should be no longer than 10m and be a heavy duty
version with a minimum cable core of 2.0mm2. If
an extension lead longer than 10m is required, it is
recommended to use a Euroquip industrial duty 15A
extension lead, part number; #16895.
Lift TIG Mode
Lift TIG is an arc ignition system for basic TIG welding
that removes the need to ‘scratch’ start or strike the
tungsten on the work piece to start the arc, which
can have a negative effect on the weld quality due
to tungsten contamination. Lift arc starting works by
gently touching the tungsten on the work piece and
then lifting it off. The control circuit will sense when
the tungsten is removed from the work piece and
send a pulse of electricity through the torch that will
cause the TIG arc to initiate.
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Quick Start Guide
Operating Environment
Adequate ventilation is required to provide proper
cooling for the WT160MP. Ensure that the machine
is placed on a stable level surface where clean cool
air can easily flow through the unit. The WT160MP
has electrical components and control circuit boards
which may be damaged by excessive dust and dirt,
so a clean operating environment is essential.
WT160MP Welding Machine
MIG Welding Operation
1. Fitting Wire Spool
1.1 Open the wire feeder compartment door. If using
5kg/ D.200 spool, check that the 5kg adaptor (16) is
fitted to the spool holder (17). Fit the wire spool to
spool holder shaft, ensuring that the wire exits the
spool towards the wire feeder from bottom the
spool.
1.2 Set the spool brake tension by adjusting the spool
tension adjustment before replacing the wire
spool retainer. 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 affect welding performance as well as
premature failure/ wear of wire feed components.
1.3 Feed the wire from the spool through the wire
drive inlet guide (18) into the wire feeder.
2. Loading Wire Feeder
2.1 Release the wire feed tension arm (20) by pivoting the wire feed tension adjustment lever (19) towards you from the vertical ‘locked’ position.
2.2 Check the wire drive roller (22) groove matches the
selected MIG wire type and size. The drive roller will
have two different sized grooves; the size of the
groove in use is stamped on the side of the drive
roller. For flux cored ‘soft’ wire, such as that used in
gasless MIG welding, the drive roller groove has a
serrated profile (known as knurled). For solid core
‘hard’ MIG wire, the drive roller groove used has a
‘v’ shaped profile. If necessary, remove and change
the drive roller by rotating anti clockwise and removing the drive roller retainer (21).
2.3 Once the correct drive roller (22) is selected and
fitted and the drive roller retainer (21) is secured
in place, manually feed the wire through the wire
drive inlet guide (18), through the drive roller
groove and into the outlet wire guide tube. Ensuring that the wire is correctly seated in the drive
roller groove, replace the wire feed tension arm
(20) and lock it into place by pivoting the wire feed
tension adjustment lever (19) back to the vertical
position.
3. Adjusting Wire Feed Tension
This is accomplished by winding the knob on the tension adjustment lever (19). Clockwise will increase tension, anti-clockwise will decrease drive tension. Ideal
tension is as little as possible, while maintaining a consistent wire feed with no drive roller slippage. Check
all other causes of excess wire feeding friction causing
slippage first, 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 lever (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 off.
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 Check that the correct matching MIG wire, drive
roller (22) and MIG torch tip are fitted.
3.2 Connect the machine to suitable mains power using the mains input power lead (13). Switch the
mains power switch (14) to ‘on’ to power up the
machine. Set the welding mode switch (7) to ‘MIG’
position.
3.3 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.
3.4 Set the wire feeding speed knob (5) 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 off any excess wire.
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4. Gas MIG Welding Operation
NOTE: Gas MIG welding will require a gas cylinder.
4.1 Connect the earth cable quick connector to the
negative welding power output socket (10). Connect the earth clamp to the work piece. Contact
with the work piece must be firm, contacting with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
4.2 Connect the MIG power connection lead (9) 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!
4.3 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 (12). Ensure all hose connections are
tight. Open gas cylinder valve and adjust regulator,
flow should be between 10-25L/min depending
on application. Re-check regulator flow pressure
with torch triggered as static gas flow setting may
drop once gas is flowing.
4.4 Set the welding voltage adjustment knob (4) and
wire speed control knob (5).
MIG welding with Aluminium and other soft wires.
6.1 Connect the earth cable quick connector to the
negative welding power output socket (10) Connect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
6.2 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 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.
6.3 Connect the machine to suitable mains power
using the mains input power lead (13). Switch
the mains power switch (14) to ‘on’ to power up
the machine. Set the welding mode switch (7) to
‘MMA’.
6.4 Select the required output current using the current control knob (5). You are now ready to weld!
7. Lift TIG Operation
NOTE: Lift TIG operation requires an optional valve control
TIG torch, and argon gas cylinder.
The WT160MP is not designed or recommended for
aluminium MIG welding. For MIG welding aluminium,
the WT200MP is the recommended model in the Weldtech range.
7.1 Connect the earth cable quick connector to the
positive welding power output socket (11). Connect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
5. Gasless Welding Operation
7.2 Insert TIG torch power connection into the negative welding power output socket (10). Connect
valve TIG torch gas line to the regulator, ensuring
all connections are tight.
5.1 Connect the earth cable quick connector to the
positive welding power output socket (11). Connect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or scale
at the contact point.
5.2 Connect the MIG power connection lead (9) to the
negative welding power output socket (10).
NOTE: If this connection is not made, there will be no electrical connection to the welding torch!
5.3 Set the welding voltage adjustment knob (4), wire
and speed control knob (5) to the desired positions. You are now ready to weld!
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6. ARC/ MMA Welding Operation
7.3 Open gas cylinder valve and adjust regulator, flow
should be between 5-10 l/min depending on application. Re-check regulator flow pressure with
torch valve open as static gas flow setting may
drop once gas is flowing.
7.4 Connect the machine to suitable mains power
using the mains input power lead (13) Switch the
mains power switch (14) to ‘on’ to power up the
machine. Set the welding mode switch (7) to ‘Lift
TIG’.
7.5 Select the required output current using the current control knob (5). You are now ready to weld!
WT160MP Welding Machine
NOTE: The WT160MP is a DC (Direct Current) output
welder only, this means that it is unable to TIG weld reactive
metals such as Aluminium alloys and Brass (which require
AC output). DC TIG output is suitable for steel, stainless steel
and copper. The New Model is the model in the range that
is designed for TIG welding Aluminium and its alloys.
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.
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 environment with temperature
s exceeding 40°C, the duty cycle will be less than
stated. In ambient temperature less than 40°C, duty
cycle performance will be higher.
Welding Settings
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Accessories
Refer to page 3 for related accessories for this machine or visit
www.weldtech.co.nz for a full range of consumables and accessories.
MP15 Torch Consumables Breakdown
(Tips, adapter and nozzles available only)
10
WT160MP Welding Machine
Spare Parts for WT160MP
Part #:
Description:
17252
Welding Mode Switch
17253
Digital Display
17254
Main PCB Assembly
17255
Wire Feeder Assembly
17256
Direct Connect MIG Torch Assembly
17257 Cooling Fan
17258
Spool Holder Assembly
17259
Drive Roller 0.6/0.8mm V Groove
17260
Drive Roller 0.8/0.9mm Knurled Groove
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
Care &
Maintenance
Keep your Welding Machine
in Top Condition
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.
The WT160MP 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.
• Replace worn wire drive components 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.
MIG Basic
Welding Guide
Mig Basic Welding Techniques
Two different welding processes are covered in this
section (GMAW and FCAW), with the intention of providing the very basic concepts in MIG welding, where
a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is
shielded by a gas (GMAW) or flux cored wire (FCAW).
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Gas Metal ARC Welding (GMAW).
This process, also known as MIG welding, CO2 welding, Micro Wire Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding 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
Solidified Weld Metal
Molten Weld Metal
Nozzle
Electrode Arc
Base Metal
Flux Cored Arc Welding (FCAW)
This is an electric arc welding process which fuses together the parts to be welded by heating them with
an arc between a continuous flux filled electrode
wire and the work. Shielding is obtained through decomposition of the flux within the tubular wire. Additional shielding may or may not be obtained from
an externally supplied gas or gas mixture. The process is normally applied semi automatically; however
the process may be applied automatically or by machine.
It is commonly used to weld large diameter electrodes in the flat 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) Shielding Gas
(Optional)
Molten Metal
Molten
Slag Slag
Position of MIG Torch
(Fig 1-3)
Push
Vertical
Drag Pull
The angle of MIG torch to the weld has an effect on
the width of the weld.
The welding gun should be held at an angle to the
weld joint. (See Secondary Adjustment Variables below).
Hold the gun so that the welding seam is viewed at
all times. Always wear the welding helmet with proper filter 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 extension (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
90o Transverse
Angle
(Fig 1-5)
Nozzle
(Optional)
5o to 15o
Longitudinal Angle
30o to 60o
Transverse
Angle
Flux Cored
Electrode
Arc
Solidified
Weld Metal
12
Base
Metal
Direction
of Travel
WT160MP Welding Machine
Vertical Fillet Welds (Fig 1-6)
10o to 20o
Longitudinal Angle
10o
Longitudinal Angle
30o to 60o
Transverse
Angle
30o to 60o
Transverse
Angle
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:
Direction of Travel
(Fig 1-7)
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.
1. Stick-Out (distance between the end of the contact tube (tip) and the end of the electrode wire).
Maintain at about 10mm stick-out
Direction of Travel
30o to 60o
Transverse
Angle
5o to15o
Longitudinal
Angle
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)
Distance from the MIG Torch Nozzle
to the Work Piece
The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20mm. This distance may vary depending on the type of joint that
is being welded.
Travel Speed
The speed at which the molten pool travels influences 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 carbon steel. The items below describe the welding variables in short-arc welding of 24gauge (0.024”, 0.6mm)
to ¼” (6.4mm) mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.
Preselected Variables
Preselected variables depend upon the type of material being welded, the thickness of the material, the
welding position, the deposition rate and the mechanical properties.
These variables are:
• Type of electrode wire
• Size of electrode wire
• Type of gas
• Gas flow rate
Gas Nozzle
Contact Tip (Tube)
Tip to
Work Distance
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 leadTransverse & Longitudinal
Nozzle Axes (Fig 1-9)
Transverse Angle
Longitudinal Angle
Axis of Weld
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ing (pushing). Whether the operator is left handed
or right handed has to be considered to realize the
effects 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)
90o
Trailing or “Pulling”
Angle (Backward Pointing)
Establishing the Arc and Making Weld Beads
Before attempting to weld on a finished piece of
work, it is recommended that practice welds be
made on a sample metal of the same material as that
of the finished piece.
The easiest welding procedure for the beginner to
experiment with MIG welding is the flat position. The
equipment is capable of flat, 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) flux cored gasless wire or a
solid wire with shielding gas.
Setting of the Power Source
Power source and Current (Wire Speed) setting requires 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 different electrode wire dia
eter, different control settings are required. A thinner
electrode wire needs more Current (Wire Speed) to
achieve the same current level.
14
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 welding 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 profile desired
• The position of welding
• Cost of the wire
WT160MP Welding Machine
MIG Welding
Troubleshooting
The general approach to fix 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 porosity within the weld metal. Porosity always stems
from some contaminant within the molten weld
pool which is in the process of escaping during solidification of the molten metal.
Contaminants range from no gas around the welding 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 flow by ear.
Wire feeding problems can be reduced by checking the following points.
www.weldtech.net.nz 15
Other weld problems can be reduced by checking the following points.
16
WT160MP Welding Machine
MMA (Stick) Basic
Welding Guide
Flat Position,
Down Hand Butt Weld
(Fig 1-11)
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
suitableelectrode for a given application.
Flat Position,
Gravity Fillet Weld
(Fig 1-12)
Horizontal Position,
Butt Weld
(Fig 1-13)
Storage of Electrodes
Always store electrodes in a dry place and in their
original containers.
Electrode Polarity
Horizontal-Vertical
(HV) Position
(Fig 1-14)
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.
Vertical Position,
Butt Weld
(Fig 1-15)
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
steelcool during welding by quenching after each
weld or skip welding to distribute the heat.
Vertical Position,
Fillet Weld
(Fig 1-16)
Overhead Position,
Butt Weld
(Fig 1-17)
Overhead Position,
Fillet Weld
(Fig 1-18)
Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness,
www.weldtech.net.nz 17
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.
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.
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”)
1.6mm (1/16”) max.
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.
Double Vee Butt Joint
(Fig 1-19d)
Not less than 70°
1.6mm (1/16”)
CAST IRON:
ENI-CL - Suitable for joining all cast irons except white
cast iron.
Lap Joint (Fig 1-19e)
STAINLESS STEEL:
E318L-16 - High corrosion resistances. Ideal for dairy
work etc.
Fillet Joint (Fig 1-19f)
Joint Preparations
In many cases, it will be possible to weld steel sec-
18
1.6mm (1/16”) max.
WT160MP Welding Machine
Corner Weld
(Fig 1-19g)
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.
Tee Joints
(Fig 1-19h)
Edge Joint
(Fig 1-19i)
Plug Welds
(Fig 1-19j)
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
www.weldtech.net.nz 19
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.
Striking an Arc
(Fig 1-20)
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.
20o
1.6mm (1/16”)
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.
Plates thicker than 6.0mm should have their mating
edges bevelled to form a 70º to 90º 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 20º 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.
Butt Weld
o
o
(Fig 1-21) 20 - 30
Electrode
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
20º 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.
20
Tack Weld
Weld Build Up Sequence
(Fig 1-22)
Tack Weld
WT160MP Welding Machine
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 crosssection made by depositing metal in the corner of
two faces meeting at right angles. Refer to Figure
1-14, 1-23 and 1-24.
Electrode Position
for HV Fillet Weld
(Fig 1-23)
Multi-Runs in HV Fillet Weld
(Fig 1-24)
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 10º from the horizontal to
enable a good bead to be deposited. Refer Fig. 1-25.
Single Run Vertical Fillet Weld
(Fig 1-25)
45o from
vertical
60o-70o from
line of weld
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 45º from the vertical. Some electrodes require
being sloped about 20º 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.
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)
Weaving motion for
second and subsequent
runs
Pause at edge
of weave
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.
www.weldtech.net.nz 21
Examples of Vertical Fillet Welds
(Fig 1-27)
CORRECT
Pause at edge of weave
allows weld metal to build
up and eliminates undercut
INCORRECT
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 45º.
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 45º to the horizontal and
tilted 10º 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)
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 angle iron or a length of
22
Tilted 10o in
line of travel
45o to plate
Angle tacked to pipe
WT160MP Welding Machine
MMA (Stick) Troubleshooting
www.weldtech.net.nz 23
TIG Basic
Welding Guide
electrode since 70% of the heat is concentrated at
the work piece.
TIG Welding is a fusion procedure that uses an electric ARC created between an infusible tungsten electrode and base material to be welded. For TIG welding an inert gas must be used (Argon) which protects
the welding bead. If filling material is used, it is made
up of rods suitable to the material to be welded
(steel, stainless steel, copper etc).
TIG Welding
(Fig 15)
Torch
Electric Current
Inert Gas
Tungsten Electrode
Deposit
Melted Area
Rod
Penetration
Protective Gas
Base Material
In TIG mode, welding is possible in all positions: flat,
angle, on the edge, vertical and overhead. Furthermore, with respect to other types of welding, the
welding joint has greater mechanical resistance,
greater corrosion resistance and limited heating in
the welded area which limits distortion. Welding can
be done even without weld material, guaranteeing
a smooth, shiny weld with no impurities or slag.
Tig Electrode Selection
and Preparation
Electrode Polarity
Connect the TIG torch to the negative (-) torch terminal and the work lead to the positive (+) work
terminal for direct current straight polarity. Direct
current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the
Preparing Tungsten for DC Electrode Negative
(DCEN) Welding
(Fig 16-1)
Tungsten Electrode
Tapered End
2.5 x Electrode Diameter
2.5 x Electrode Diameter
Grind end of tungsten on fine grit, hard abrasive
wheel before welding. Do not use wheel for other
jobs or tungsten can become contaminated causing
lower weld quality.
(Fig 16-2)
Stable ARC
Flat
Grinding
Wheel
Straight Ground
Ideal Tungsten Preparation - Stable ARC
Diameter of the flat determines amperage capacity.
24
WT160MP Welding Machine
(Fig 16-3)
ARC Welder
Point
Grinding
Wheel
Radial Ground
Wrong Tungsten Preparation - Wandering ARC
Diameter of the flat determines amperage capacity.
(Fig 17)
Pointing the Electrode
The electrode should be pointed according to the
welding current.
www.weldtech.net.nz 25
TIG Welding Troubleshooting
26
WT160MP Welding Machine
Knowledge &
Resources
Please refer to Euroquip website
www.euroquip.co.nz/ Downloads.html
for knowledgebase articles & operation videos.
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 serious injury.
WARNING! indicates a hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, 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 Euroquip 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.
4. Never leave the welder unattended while energised. Turn power off before leaving the welder
unattended.
5. 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.
6. 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.
7. 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.
8. 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.
9. 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.
www.weldtech.net.nz 27
10. 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.
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!
Disconnect input power conductors from deenergized supply line before moving the welding
power source.
CAUTION!
Heavy-duty work gloves, non-skid safety shoes
and hearing protection used for appropriate
conditions will reduce personal injuries.
11. 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.
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.
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.
28
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
DANGER!
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.
WT160MP Welding Machine
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.
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.
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.
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. 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.
2. Wear dry, hole-free insulating gloves and body
protection.
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. 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.
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. Properly install and ground this equipment according to national, state, and local codes.
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
3. Insulate yourself from the work and the ground
using dry insulating mats or covers.
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.
www.weldtech.net.nz 29
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.
Fumes And Gases
WARNING!
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
30
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.
WT160MP Welding Machine
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Safety Data Sheets (SDS) and the manufacturer’s instruction for the metals, consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.
Shielding ga es used for welding can displace air
causing injury or death. Be sure the breathing air
is safe.
6. 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.
8. Connect the work lead/clamp to the job as close
to the welding area as practical to prevent welding current from travelling long, possibly unknown paths and causing electric shock and fire
hazards.
9. Do not use a welder to thaw frozen pipes.
10. 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.
7. 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.
2. Wear appropriate safety equipment to protect
the skin and body.
Fire & Explosive Risks
Cylinders
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.
1. Wear an AS/NZS approved face shield or safety
goggles. Side shields are recommended.
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.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
1. Protect yourself and others from flying sparks
and hot metal.
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.
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.
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.
7. Do not weld on closed containers such as tanks
or drums.
www.weldtech.net.nz 31
32
WT160MP Welding Machine
Warranty
As part of an on-going commitment to excellence
in product support, Euroquip offers a comprehensive
product warranty program.
party other than an Approved Service Agent, is not
covered under warranty.
In order to qualify for full warranty support, your
product must be registered.
Warranty does not cover pre delivery service and adjustment, or failure that may occur as a result of lack
of/ incorrect pre delivery service and adjustment.
Product not registered with Euroquip is 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.
Warranty does not cover any incidental, indirect or
consequential loss, damage or expense that may result from any defect, failure or malfunction of a product.
If a Euroquip dealer has not already registered your
product, please register it online at www.euroquip.
co.nz. Under ‘Contact Us’ link. To request a physical
registration form, please contact Euroquip customer
service on 0800 387 678.
Should any issue be found to be a combination of a
warranty failure and a non-warranty issue, the repair
cost component to rectify and repair the non-warranty failure is the customers’ full responsibility.
Registered warranty period for the WT160 MP:
Commercial Use: 12 Months
Domestic Use: 24 Months
Warranty covers failure caused by manufacturing
and material defects in the product, during the warranty period specified. The warranty period begins
when the product is purchased by the end user. Warranty is not transferrable and is only claimable by the
original purchaser.
Warranty does not cover parts that are subject to
wear and tear from usage.
Warranty covers failure of a product caused by defective materials and/or manufacturing for the period
given and the usage specified by Euroquip. The warranty period begins when the product is purchased
by the end user. Warranty is not transferrable and is
only claimable by the original purchaser.
Warranty also does not cover failure caused by the
untimely replacement or service of the above wearing parts. Evidence must be provided that the product has been maintained and serviced suitably for a
claim to be considered under warranty.
Failure caused by incorrect operation of the product,
lack of proper care and maintenance of the product,
external damage, external circumstances such as
contaminated fuel or poor water supply, modifications to the product, attempted repair/ service by a
The decision that an issue with a product qualifies as
a warranty claim is made at the sole jurisdiction of
Euroquip.
No costs incurred will be considered under warranty
if repairs are carried out by a party other than a Euroquip Approved Service Agent, unless with prior consent in writing from Euroquip.
It is the responsibility of the purchaser to deliver a
product under warranty to the nearest relevant service agent or product reseller. Warranty does not
cover call outs, mileage and freight costs.
If a product is repaired under warranty, parts and
labour required for the repair will be supplied at
no charge. Warranty assessment and repair will be
scheduled and executed according to the normal
work flow at the service location and depending on
the availability of suitable replacement parts.
This warranty policy is an additional benefit and does
not affect the legal rights of any end user, reseller or
service agent.
Scan here to register your product
www.weldtech.net.nz 33
34
WT160MP Welding Machine
www.weldtech.net.nz 35
Congratulations on your new WELDTECH product. We are proud to have you as our customer and
will strive to provide you with the best service and reliability in the industry. This product is backed
by our extensive warranty and world-wide service network. To locate your nearest distributor or
service agency visit www.weldtech.net.nz, or email us at [email protected]
www.weldtech.net.nz
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