Stick/TIG ST80i Plus Welder Owner’s Manual WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
® Thank you very much for choosing a Klutch product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it. This welder is designed for certain applications only.
Table of Contents Intended Use .......................................................................................................................................... 4 Important Safety Information ............................................................................................................... 5 General Safety Rules ............................................................................................................................ 6 Specifications of Welder ........................
Intended Use The Klutch Stick/TIG ST80i Plus is a DC-only, inverter stick welder with an exceptionally smooth stick welding performance. Its intended use is for welding steel, stainless steel, cast iron, and hard surfacing using electrodes from 1/16 inch to 3/32 inch. This unit can also perform lift start DC TIG welding on steel and stainless steel materials with the optional TIG Torch #44455*. Argon shielding gas along with a regulator, gas hose, and TIG filler rod would also be required for TIG welding.
Important Safety Information ⚠WARNING Read and understand all instructions. Failure to follow all instructions may result in serious injury or property damage. The warnings, cautions, and instructions in this manual cannot cover all possible conditions or situations that could occur. Exercise common sense and caution when using this tool. Always be aware of the environment and ensure that the tool is used in a safe and responsible manner.
parts. Air vents on the tool often cover moving parts and should be avoided. Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems, and hearing protection when appropriate. This applies to all persons in the work area. Do not overreach.
⚠WARNING Your Welding Environment Keep the environment you will be welding in free from flammable materials. Always keep a fire extinguisher accessible to your welding environment. Always have a qualified person install and operate this equipment. Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet or poorly ventilated areas. Always have your welder maintained by a qualified technician in accordance with local, state, and national codes.
⚠WARNING Electrical Shock Electric arc welders can produce a shock that can cause injury or death. Touching electrically live parts can cause fatal shocks and severe burns. While welding, all metal components connected to the wire are electrically hot. Poor ground connections are a hazard, so secure the ground lead before welding. Wear dry protective apparel: coat, shirt, gloves, and insulated footwear. Insulate yourself from the work piece. Avoid contacting the work piece or ground.
Warn people in your welding area when you are going to strike an arc so they can protect themselves. ⚠WARNING Fire Hazards Do not weld on containers or pipes that contain or have had flammable, gaseous, or liquid combustibles in them. Welding creates sparks and heat that can ignite flammable and explosive materials. Do not operate any electric arc welder in areas where flammable or explosive materials are present. Remove all flammable materials within 35 feet of the welding arc.
Do not weld on the cylinder Always secure the cylinder upright to a cart or stationary object. Keep cylinders away from welding or electrical circuits. Use the proper regulators, a gas hose, and fittings for the specific application. Do not look into the valve when opening it. Use protective a cylinder cap whenever possible. ⚠CAUTION Proper Care, Maintenance, and Repair Always have power disconnected when working on internal components.
Main Parts of Welder 2 1 9 7 3 5 8 6 4 Figure 1.
Reference 1 2 3 4 5 6 7 8 9 Subassembly Input Power Indicator Light Weld Process Selector Switch Output Amperage Control Ground Cable and Clamp Negative (-) Weld Output Terminal Electrode Holder and Cable Positive (+) Weld Output Terminal Shoulder Strap Alarm/Overload Indicator Light Setting Up Equipment ⚠WARNING ELECTRIC SHOCK CAN KILL! High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle.
DC STICK WELDING ASSEMBLY ⚠CAUTION Be aware that the ELECTRODE HOLDER will be electrically HOT when the Input Power Switch on the welder is turned ON. 1. 2. 3. 4. 5. Install the ground cable quick connector to the negative (-) Weld Output Connector (Figure 1). Secure the ground clamp to the work piece. Install the electrode cable quick connector to the positive (+) Weld Output Connector. Flip the Weld Process Selector Switch left to the STICK position (Figure 1). Turn On the Input Power Switch.
rust, scale, oil, or paint or it will create brittle and porous welds. If the base metal pieces to be joined are thick or heavy, it may be necessary to bevel the edges with a metal grinder. The correct bevel should be around 60 degree. Refer to the following illustration: Based on different welding positions, there are different welding joints. See the following illustration for reference. 2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil, or paint on the ground clamp.
flows between the electrode (rod) and the grounded metal work piece. The intense heat of the arc between the rod and the grounded metal melts the electrode and the flux. 4. SELECTING THE PROPER ELECTRODE There is no golden rule that determine the exact rod or heat setting required for every situation. The type and thickness of metal and the position of the work piece determine the electrode type and the amount of heat needed in the welding process. Heavier and thicker metals required more amperage.
a. Holding the electrode The best way to grip the electrode holder is the way that feels most comfortable to you. Position the electrode to the work piece when striking the initial arc. It may be necessary to hold the electrode perpendicular to the work piece. Once the arc is started, the angle of the electrode in relation to the work piece should be between 10 and 30 degrees. This will allow for good penetration, with minimal spatter.
c. Types of weld bead The following paragraphs discuss the most commonly used arc welding beads. The stringer bead is formed by traveling with the electrode in a straight line while keeping the electrode centered over the weld joint. Stringer Bead Weave Bead The weave bead is used when you want to deposit metal over a wider space than would be possible with a stringer bead. It’s made by weaving from side to side while moving with the electrode.
A solid weld bead requires that the electrode be moved slowly and steadily along the weld seam. Moving the electrode rapidly or erratically will prevent proper fusion or create a lumpy, uneven bead. ⚠WARNING ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece. f. Finish the bead As the coating on the outside of the electrode burns off, it forms an envelope of protective gases around the weld.
⚠CAUTION Be aware that the TIG torch will be electrically HOT when the Input Power Switch on the welder is turned ON. 1. Remove the ground cable and the electrode holder from the weld output connections. Install the ground cable to the positive (+) weld output connection. 2. Secure the ground clamp to the work piece 3. Connect a regulator to a bottle of ARGON gas, then connect the gas connection from the TIG torch to the regulator. 4.
Maintenance Interval Maintenance Point Before Each Use Inspect all cords and power cables. Replace any cords or power cables that are damaged or cracked. Every 3 Months Inspect all warning and caution labels attached to this unit. If they are worn, torn, or otherwise unreadable, replace them. Inspect, clean, and tighten all weld power connections. Every 6 months Unplug the welder and blow out or vacuum the inside.
Failure Possible Cause Cannot Create an Arc Corrective Action Work piece is painted or rusty. Remove all paint and rust. Ground clamp is connected where there is paint or rust. Remove all paint and rust so the ground clamp is connected to bare metal. Ground clamp is not electrically connected to the work piece. Make sure the ground clamp is connected to the work piece. The Process Selector Switch is in the wrong positon. Make sure the Stick/TIG selector switch is in the STICK position.
Parts Diagram Page 22 of 25
Parts List Reference 1 NOT SHOWN 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number 105300064 105300065 125300008 105200037 105300022 105300066 105300067 105300019 105300016 105300068 105300017 105300018 105300015 105300013 105300069 105300070 105300071 105300072 105300073 125300009 105200063 105300007 105300074 105300009 105300010 125300002 Item Description HANDLE SHOULDER STRAP ENCLOSURE INPUT POWER SWITCH INPUT POWER CORD BACK PANEL BEZEL FAN SUPPORT BOX FAN IGBT HEAT SINK HEAT SINK HEAT S
Limited Warranty Northern Tool and Equipment Company, Inc. ("We'' or "Us'') warrants to the original purchaser only ("You'' or ''Your'') that the Klutch product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of three years from date of purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions.
Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.
