MAC TOOLS TIGW 150/230 V User manual

~July
1993
Effective
With
Form:
Serial
No.
OM-164271
KD468226
1~oLsfi
OWNERS
MANUAL
U

U
Read
and follow
these
instructions
and all
safety
blocks
carefully.
Have
only
trained and
qualified
persons
r~stall,
operate,
or
service this unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
U
Give
this
manual
to
the
operator.
U
For
help,
call
your
distributor
I
TIGW15O/230
V

CC AC/DC
Welding
Power
Source
For
GTAW
And
SMAW
Welding

GTAW
Output:
150
A.
15
V
AC/DC
At 20%
Duty
Cycle

SMAW
Output:
130
A,
25
V
DC
Or
150
A.
25
V
AC
At
20%
Duty
Cycle

Uses
Single-Phase
Input
Power
(See
Rating
Label)

Built-In
Arc
Start For GTAW

Overheating
Protection

Includes
Accessory
Equipment
For
GTAW
cover 8/92

ST.800
197
PRINTED
IN
USA

ARC
WELDING SAFETY
PRECAUTIONS
a
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding.
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE ALL
INSTALLATION, OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The electrode
arid
work
Circuit
IS
electrically
live whenever
the
output
is
on.
The
input
power
circuit and
machine
internal
circuits
are
also
live
wnen
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire are
electncally
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
ne
electrical
parts.
2.
Wear
dry.
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourseif
from
work
and
ground
using
dry
insulating
mats
or
covers.
4..
Disconnect
flout
power
or
stop
engine
before
installing
or
servicing
this
eauipment.
WELDING
can cause
fire
or
explosion.
Sparxs
and
spatter
fly
off
from
the
welding
arc.
The
ftyina
sparks
and
hot
metal,
weld
spatter,
hot
workoiece.
and
hot
equipment
can cause
fires
and
burns. Accidental
contact
of
electrode
orwelding
wire
to
metal
obiects
can
cause
sparks.
overheating,
or
fire.
1.
Protect
yourserf
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35 ft
(10.7
m)
of
the
welding
arc.
If
this is
not
possole.
tightly
cover
them with
approved
covers.
4.
Be
alert
that
weiding
sparks
and
hot
materials
from
welding
can
:rl
small
cracks
and
openings
to
adiacent areas.
Watch
for
fire,
and
keep
a
fire
extinguisher nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden side.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
Connect
work
cable
to
the
work
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.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or cut
oft
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
Shirt.
cuffless
trousers.
high
shoes.
and
a
cap.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local codes.
6.
Turn oft
all
equipment
when
not
in
use.
7.
Do
not
use
worn,
damaged.
undersized, or
poorly
spliced
cables.
B.
Do
not
wrap
cables around
your
body.
9.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
10.
Do
not
touch
electrode
while
in
contact
with the
work
(ground)
Circuit.
11
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12. Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
-
ARC
RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet fitted with
a
proper
shade of
filter
(see
NOISE
can
damage hearing.
ANSI
Z49.
1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2. Wear
approved
safety
glasses.
Side
shields
recommended.
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
3. Use
protective
screens
or
barriers
to
protect
others
from
flash
and
skin.
Noise
from
some
processes
can
damage
and
glare:
warn
others
not
to watch
the
arc.
hearing.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or ear
muffs
if
noise level is
high.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
~:,.I;:
to
your
health.
wearing
an
air.supplied
respirator.
Shielding
gases
used
for
Welcing
produces
fumes
and
gases.
Breathing
these
welding
can
displace
air
causing injury
or
death. Be
sure
the
fumes
and
gases
can
be
hazardous
to
your
health,
breathing
air is
safe.
6.
Do
not
weld
in
locations
near
degreasing, cleaning,
or
spraying
1
Keep
your
heaa
out
of
the
fumes
Do
not
breath the
fumes,
operations.
Theheatand
raysofthearccan
reactwithvaporsto
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated metals, such
as
galvanized,
lead,
or
3.
If
ventilation
is
coor.
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the area
is
well
ventilated,
and
if
necessary,
while
manufacturer
s
:nstruCtiOn
for
metals,
consumables,
coatings.
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and cleaners,
containing
these
elements
can
give
off
toxic
fumes
if
welded.
5.
6.
7.
6.
9.
10.
FLYING
SPARKS
AND
HOT
METAL
can
1.
Wear
approved
face shield
or
safety
goggles.
Side
shields
cause
injury,
recommended.
Chiocing
and
grinding
cause
flying
metal.
As
welds
2.
Wear
proper
body
protection
to
protect
skin.
Cool.
:niey
can
throw
off
slag.

CYLINDERS
can
explode
if
damaged.
Shielding
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.
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
orevent
faIIin~
or
tioping.
3.
Keep
cylinders
away
from
any
welding
or
other electrical
Circuits.
4
Never
allow
a
welding
electrode
to touch
any
cylinder.
5.
Use only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6 Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
B.
Read
and
follow instructions
on
Compressed
gas
cylinders.
associated
equipment.
and
CGA
publication
P-i
listed
in
Safety
Standards.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
We/ding
and
Cutting.
ANSI Standard
Z49.
1.
from
American
Welding
Society.
550
NW.
LeJeune
Rd.
Miami
FL
33126
Safetyand
Health
Standards.
OSHA
29
CFR
1910.
from
Superintendent
of
Documents.
U.S.
Government
Printing
Office.
Washington.
D.C.
20402.
Recommended
Safe Practices
for
the
Preparation
for
We/ding
and
Cutting
of
Containers
That
Have Held
Hazardous
Substances.
American
Welding
Society
Standard
AWS
P4.1,
from
American
Welding
Society.
550
NW.
LeJeune
Rd. Miami,
FL
33126
National
Electrical
Code.
NFPA
Standard
70,
from National Fire
Protection
Association.
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders.
CGA
Pamphlet
P-i.
from
Compressed
Gas Association.
1235
Jefferson
Davis
Highway.
Suite
501.
Arlington,
VA
22202.
Code
for
Safety
in
We/ding
and
Cutting.
CSA
Standard
WI
17
2.
from
Canadian
Standards
Association.
Standards Sales.
178
Rexdale
Boulevard,
Rexdale.
Ontario. Canada M9W
I
R3.
Safe Practices For
Occupation
And
Educational
Eye
And Face Protection.
ANSI
Standard
Z87.
1.
from
American
National
Standards
Institute.
1430
Broadway.
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
518.
from
National
Fire
Protection
Association.
Batterymarch
Park.
Quincy,
MA
02269.
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1

SAFETY
INFORMATION
1
SECTION
2

SPECIFICATIONS
2-1.
Volt-Ampere
Curves
And
Duty
Cycle
Chart
SECTION
3
-
INSTALLATION
3-1.
Installing
Work
Clamp
3
3-2.
Installing
Gas
Supply
3
3-3.
Connecting
Weld
Electrode/Gas
And
Remote
Receptacles
4
3-4.
Connecting
Input
Power
5
SECTION
4
OPERATION
6
SECTION
5
MAINTENANCE
& TROUBLESHOOTING
2
5-i,
RoutirteMairitenance
5-2.
Troubleshooting
8
8
SECTION
6
ELECTRICAL DIAGRAMS
10
SECTION
7
-
PARTS
LIST
Figure
7-1.
Main
Assembly
NOTE ~
Considerations
About
Welding
And
The Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General Conclusions
Section
of
the
U.S
Congress.
Office
of
Technology
Assessment.
Biological
Effects of Power
Frequency
Electric
&
Magnetic
Fields

Background
Pacer.
OTA-BP-E-53
(Washington.
DC:
U.S.
Government
Printing
Office.
May
1989):
there is
now
a
very
large
volume
of scientific
findings
based
on
experiments
at the
cellular
level and from
studies
with
animals
and
people
which
clearly
establish that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in.
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
qotenlial
risks.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to one
side
and
away
from the
operator.
3.
Do
not
coil
or
drape
cables around
the
body.
4~
Keeo
welding
power
source
and cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
tar
complete
information.
mOSiO.I
4/93
13

SECTION
1

SAFETY
INFORMATION
U
Read
all
safety
messages
throughout
this
manual.
modi
293
U
Obey
all
safety
messages
to
avoid
injury.
U
Learn
the
meaning
of
WARNING and
CAUTION.
WARNING a
CAUTION
1
Safety
Alert
Symbol
1
2
22
Signal
Word
\
WARNING
means
possible
death
or Serious
injury
can
happen.
1
~
CAUTION
means
possible
minor
ELECTRIC
SHOCK
can
kiII.~
~
MOVING PARTS
can
injure,
injury
or
equipment
damage
can
S
Do
not
toucn
hve e!ectr,cai
oarts
S
Keep
away
from
movng
parts
happen.

Osconnect
,rrour
power
before
.fb
5
Keep
cli
Daneis
and
covers
closed
3
Statement
Of
Hazard And
L~
nslali,nq
or
servcng
vhen
OOet~t.it~
Result
/
4
Safety
Instructions
To
Avoid
5
Hazard
5 Hazard
Symbol
(If Available)
6
Safety
Banner
~
~~?
READ SAFETY
BLOCKS :t
start
of
Read
safety
blocks for
each
sym.
I
7
NOTE
7~~__NOTE
~~F
Turn
Off
switch when
using high
frequency.
Special
instructions for best
oper
ation

riot
related
to
safety.
Figure
1-1.
Safety
Information
SECTION
2
SPECIFICATIONS
Table
2-1.
Welding
Power Source
Specification
Description
Type
Of
Output
CC
(Constant Current)
AC/DC
(Alternating
CurreritiOirect
Current)
Welding
Processes
Gas
Tungsten
Arc
(GTAW)
And
Shielded
Metal Arc
We~ding
(SMAW)
GTAW
Rated
Weld
Output
150
Amperes
At
15
Volts
AC/DC
SMAW Rated Weld
Output
130
Amperes
At
25
Volts
DC: 150
Amperes
At
25
Volts
AC
Duty
Cycle
20%
(See
Section
2-1)
Type
Of
Input
Power
Single-Phase;
200
or
230 Volts
AC.
60
Hz
Input Amperes
At
R
ated
Outout
59
A
At
200V,
52
A
At
230
V
KVA
Used
At
Rated
Output
12.0
kVA
Max.
Open-Circuit
Voltage
GTAW:
78
Volts:
DC SMAW:
78
Volts:
AC
SMAW:
75
Volts
Input
Power
Cord
6
ft
(1.8
m)
Work
Cable
12
ft
(3.7 m)
Options
See
Rear
Cover
Overall Dimensions
Length:
25-1/2
in
(648
mm):
Width:
13
in
(330
mm);
Height:
18
in
(457
mm)
Weight
Net:
140
lb
(63.5
kg):
Ship:
166
lb
(75
kg)
Items
Included
Wib
GTAW
Torch
With
25
ft
(7.6
m)
Cable
1-27/32
in
Long,
1/2
in
Orifice
Alumina
Gas
Cup
Welding
Power
Source
Remote Hand
Control
With
28
ft
(8.5
m)
Cable 3/32
in
Standard
Length
Collet
Body
Argon
Regulator/Flowmeter
3/32
in
Standard Collet
12-1/2
ft
(3.8
m)
Gas
Hose
Work
Clamp
With 12
ft
(3.7
m)
Cable
Dinse Electrode/Gas Connector
Large
Leather
Welding
Gloves
3/32 x
7
in
2%
Thoriated
Tungsten
Electrode
How-To
VHS
Videotape
3/32
x
18
in
Class
4043
Filler Rods
(10
pieces)
OM-164
271
Page
1

a
CAUTION
EXCEEDING DUTY
CYCLE
RATINGS
wf
II
damage
unit.

Do
not
exceed
indicated
duty
cycles.
80
70
60
U)
50
I-
-J
0
>
30
20
10
0
40
A.
Volt-Ampere
Curves
For
AC
Mode
B.
Volt-Ampere
Curves
For
DC
Mode
U)
w
-J
uJ
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
be
tween
the
curves
shown.
Duty
cycte
is how
long
the
unit
can
operate
within
a
ten
minute
period
without
causing
overheating
or
damage.
This
unit
is rated
at
20%
duty
cycle
allowing
welding
2
minutes
out
of
every
10
minutes
at rated
load.
If
the
welding
amperes
decrease.
the
duty
cycle
increases.
C.
Duty
Cycle
Chart
sabi
i
10/91

ST.l
57625!
ST-157
526/
sbl
22)92

ST-I
57648
Figure
2-1.
Volt-Ampere
Curves
And
Duty
Cycle
Chart
2-1.
Volt-Ampere
Curves
And
Duty
Cycle
Chart
warn?
1
292
AC
AMPERES
80
70
60
U)
50
I-
-J
0
>
40
0
o
30
20
10
0
200
180
80
so
 
r
L~!!~.
100 150
200
DC
AMPERES
20
26 30 40 6050
~8OSO~0
Z
DUTY
CYCLE
OM-164
271
Page
2

3-1.
Installing
Work
Clamp
1
Insulators
2
Bolt
3
Smaller
Hole
2
4
Work
Clamp
Tabs
3
Tools Needed:
Bend
tabs
around
work cable.
3/8
in.
7/16
in
5
Work
Cable
From
Unit
6
Nut
R&. ST-025
1gO.C
Figure
3-1.
InstallIng
Work
Clamp
3-2.
Installing
Gas
Supply
__
a
WARNING
__
Rear
Figure
3-2.
Installing
Supplied Regulator/Flowmeter
SECTION
3INSTALLATION
C

YLINDERS
can
explode
it
damaged.
Keep
cylinders
away
from
welding
and
other
BUILDUP
OF
SHIELDING
GAS
can
harm
)
health
or
kill.
electrical
circuits.

Shut off
shielding
gas
supply
when
not
in
use.

Never
touch
cylinder
with
welding
electrode.

Always
secure
cylinder
to
running
gear,
wall, or
other
stationary
support.
warn4.I
9/9t
Obtain
gas
cylinder
and chain
to
running
gear,
wall,
or
other
station.
ary
support.
1
Cap
2
Cylinder
Valve
Remove
cap.
stand to
side
of
valve,
and
open
valve
slightly.
Gas
flow blows
dust and dirt
from
valve.
Close
valve.
3
Cylinder
4
Regulator
Install
so
face
is
vertical.
5
Flowmeter
6
Flow
Adjust
Typical
flow
rate
is
20 cfh
(cubic
feet
per
hour).
7 Gas
Hose
Connection
8
Gas
Hose
9
Gas
Inlet
Fitting
Connect
gas
hose
between
regula
torlflowmeter
and
welding
power
source.
8
Tools
Needed:
9
~:i~--~
5/8,1-1/Bin
ST.800
198
OM-164
271
Page
3

3-3.
Connecting
Weld
Electrode/Gas And
Remote
Receptacles
a
WARNING
N
OTE
~
Install
supplied
Remote
Fingertip
control
onto
torch
according
to
its
Owners
Manual.
Install
connector
Onto
torch cable
as
shown.
4 Handle
5
Connector
Body
6
Electrode/Gas
Out
Recep
tacle
To
connect
to
receptacle,
align key-
way,
insert
connector,
and turn
clockwise
until
tight.
7
Remote
14
Receptacle
RCI
8
Keyway
9
Fingertip
Control
11
Threaded
Collar
To
connect to
this
receptacle,
align
keyway.
insert
plug.
and
tighten
threaded collar.
Tools
Needed;
~
7/16
in
ST-BOO
222/
Ref
51.159
891-A
ELECTRIC SHOCK
can
kill;
ARCING
can
burn
skin
or
damage
electrical
equipment.

Do
not
touch
live
electrical
parts.
~

Turn Off
welding
power
source
before
making
any
weld
output
connections.

Do
not
change
position
of
welding
cable
connector
while
welding.

Be
sure
connector is
secure
ri
receptacle
before
welding.
gwamt2 r
2/92
1 GTAW
Torch
2
Weld
Output
Cable
3
Dinse
Electrode/Gas Connec
tor
1~-~
For
SMAW.
obtain
kit
159
696
~
from
dealer.
Socket
Information:
Remote
Contactor
A
24
volts
ac.
B
Contact
closure
to
pin
A
completes
24
voltS
ac
contactor
control circuit.
Remote
Amperage
Control
C
Command
reference.
E
Input
command
signal
(potentiometer
wiper).
The
remaining
sockets
are
not
used.
10
Plug
Figure
3-3.
Installing
Supplied
GTAW
Torch
OM-164
271
Page
4

3-4.
Connecting
Input
Power
a
WARNING
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.

Have
only
qualified
persons
install
unit.

Installation
must
meet
National
Electrical
Code
and
all other codes.
A.
Connecting
Input
Power
For
200
Volts
Model
Figure
3-4.
Input
Power
Connections
For
200
Volts
Model
Table
3-1.
Electrical
Service
Requirements*
swsrn3.1 10191
Input
Voltage
200 230
Input Amperes
At
Rated
Output
59
52
Recommended Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
90
80
Input
Conductor
Size
In
AWG/Kcmil2
10
6
Max
Input
Conductor
Length
In
Feet
(Meters)3
177
(54)
134
(41)
Grounding
Conductor
Size
In AWG/Kcmii4
10
8
These
values
are
calculated
from
the
1990
edition of
the National
Electrical Code
(NEC).
1
Recommended fuse
or
circuit
breaker size is
that
closest
to
150% of
rated
input
amperage
of the
welding
power
source.
Article
630-12(a)
of
NEC
allows
fuse
or
circuit breaker
sizing
up
to
200%
of
rated
input
amperage.
2
Input
conductot size
is Icr
insulated
copper
wire with
75C
rating
with
not
more
than
three
single
current-carrying
conductors
in
a
cable
or
raceway
(Table
310-16
of
NEC).
3 Maximum
length
is
to
prevent
more
than
a
3%
voltage
drop
between
service
entrance
and
input
terminals of
the
welding
power
source
(Articles
210-19(a)
and
215-2(b)
of
NEC).
4
The
grounding
conductor
shall be colored
or
identified
as
specified
in
the
NEC.
Grounding
conductor
size
for
copperwire
is
not
required
to
be
larger
than
input
conductor
(Article
250-95
of
NEC).
S-0092F
OM-164
271
Page
5
Have
only
qualified
persons
make
this
installation.
I
18
in
(460
mm)
Open Space
On Sides
And
Rear
For
Good
Airflow
2
Rating
Label
(On
Rear
Panel)
Supply
correct
input
power.
3
Line
Disconnect
Device
Of
Proper
Rating
4
Grounding
Conductor

Green
Or
Green
With
Yellow
Stripe(s)
5
Input
Conductors

Black And
White
Install
grounding
conductor and
input
conductors
from
unit
to
deenergized
line
disconnect de
vice.
Be
sure
grounding
conductor
goes
to an
earth
ground.
6
Overcurrent
Protection
Select
type
and
size
using
Table
3-1. Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
ssb2.33/93 ST-161
454
Tools
Needed:

B.
Connecting
Input
Power
For
230
Volts
Model
Have
only
qualified
persons
make
this
installation.
1
18
in
(460
mm)
Open
Space
On
Sides
And
Rear
For
Good
Airflow
2
Rating
Label
(On
Rear
Panel)
Supply
correct
input
power.
3
Line
Disconnect
Device
Of
Proper
Rating
4
230 Volts
AC
Wall
Recep
tacle
Obtain
and
install
line
disconnect
device
and
wall
receptacle.
5
Input
Conductors

Black
And
White
6
Grounding
Conductor

Green
Select
size
and
length
using
Table
3-1.
Conductor
rating
must
comply
with
national,
state,
and
0-
cal electrical
codes.
Install
and
connect
grounding
con
ductor
and
input
conductors
in
con
duit
or
equivalent
between
wall
re
ceptacle
and
deenergized
line
dis
connect
device.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
7
Overcurrent
Protection
Select
type
and size
using
Table
3-1 Install
into
deenergized
line
disconnect
device
(fused
dis
connect
SwitCh
shown).
S5D2
2
3193

91.156
~56.-A
I
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
Wear
dry insulating gloves, safety
glasses
with
side
shields,
and
a
welding
helmet
with
a
correct
shade
of filter
(see
ANSI
Z49.1).
9b3.1
10/91
Left
Rear
ii
3
7
Tools
Needed:
4
)
Figure
3-5.
Input
Power
Connecti
otis
For
Unit
s
With
Plug
And Wall
Receptacle
SECTION
4

OPERATION
ELECTRIC
SHOCK
can
kill.
READ
SAF
of manual
ElY
BLOCKS
at
beginning
before
proceeding.
MOVING PARTS
can cause
injury.

I

Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined, or
if
there
is a
danger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process.
If
AC
output
is
required,
use
remote
output
control.

Keep
away
from
pinch points
such
as
drive
rolls.

Keep
all
doors,
panels.
covers,
and
guards
closed
and
securely
in
place.
ARCING
can
damage
switch.

Do
not
change
Range/Polarity
switch
position
while

Read
Safety
Precautions
at
beginning
of
this
welding.
manual.
Arcing
inside switch
can
damage
contacts,
causing
switch
to
fail.
Figure
4-1.
Safety
Equipment
OM-164
271
Page
6

1
Weld
Process Switch
Use Switch
to
select weld
process.
In
SMAW
position
(down),
weld
output
goes
On
and
Off
with
Power
switch.
In
GTAW
position
(up).
fingertip
control
turns
on
and
adjusts
full
weld
output
of
unit.
Built-in
arc
starter comes
on
when
needed
to
start
or
stabilize
welding
arc.
No
adjustments
need
ed
for
arc
starter.
2
Output
On
(Contactor)
Light
Light
is
on
whenever
output
(contactor)
is
on
and unit
is
energized.
3
Range/Polarity
Switch
Use switch
to
select
range
and
polarity
of
weld
output.
For
direct
current, use
Electrode
Negative
(DCEN)
or
Electrode
Positive
(OCEP)
posi
tion.
For
alternating
current,
use
AC
Low
or
AC
High
position (see
Warning
at
start
of
Section
4).
Use
table
to
find
suggested
type
of
weld
out
put
for
application.
4
Amperage
Control
This
Control
does
not work
in
GTAW
mode.
Use
control to
adjust
amperage
when
Weld
Process
switch
is in
SMAW
position.
5
Pilot
Light
6
Power
Switch
Use
switch
to
turn
unit,
fan,
and
pilot
light
On
and
Off.
7
Work
Clamp
Use
wire
brush
or
sandpaper
to
clean metal
at
weld
joint
area.
Use
stainless
steel
brush
to
preclean
metal
for
GTAW.
Use
chipping
hammer
to
remove
slag
after
SMAW
weld
ing.
Connect
work
clamp
to
a
clean,
paint-free
location
on
workpiece,
as
close
to
weld
area
as
possible.
8
Fingtertip
Control
Fingertip
control
tums
weld
output
and
988
flow
on
and
oft.
9
High
Temp
Shutdown
Light
When
light
is
on.
unit
has
Shut
down
because
main
transformer
TI
is
too
hot.
The
fan
keeps
running
to
cool
Ti.
Wait
until
light
goes
off
before
trying
to
weld.
FIgure
4-2.
Controls
Welding
Process
Suggested
Weld
Output
GTAW
Of
Steel
Or
Stainless
Steel
Electrode
Negative
(OCEN)
Electrode Positive
(OCEP)
ST-800
199/
Ref.
ST-159
691-A
OM-164
271
Page
1

SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Turn
Off
welding power
source,
and disconnect
input
power
before
inspecting.
maintaining,
or
servicing.
HOT
PARTS
can cause
severe
burns.

Allow
cooling
period
before
maintaining
or
servicing.
5-1.
Routine
Maintenance
MOVING
PARTS
can
cause
injury.

Keep
away
from
moving
parts.
Maintenance and
troubleshooting
to
be
performed
only by
qualified
persons.
swarnA
¶~
219~
Turn
Off
all
power
before
maintaining.
=
3
Months
Aeplace
1~4
Cracked
~LJ
Parts
Torch
Body
Gas
Hose
Torch Cable
Figure
5-1.
Maintenance
Schedule
Ref ST.~56
t56-A
OM-164
271
Page
8

5-2.
Troubleshooting
READ
SAFETY
BLOCKS at
start
of
Section
5
before
proceeding.
Welding
Power
Source Trouble
No
weld
output:
tan
does
not
run.
No
weld
output.
fan
on.
.j..
1

-.
Check
and
replace
line
fuses
or
reset
circuit
breakers
if
open.
Remedy
Be
sure
line
disconnect
device
iS
in
On
position.
Replace
Power
switch
Si
Be
sure
Range/Polarity
switch
is
not set
between
positions.
Check
and
secure
connections
to
Remote
14
receptacle.
Unit
overheated.
Allow
unit
to
cool.
Fan
does
not
run:
weld
output
available.

H
Be
sure
nothing
is
blocking
movement
of fan.
If
fan
does
not
move
freely,
replace
fan
motor.
GTAW
Process Trouble
Difficulty
in
establishing
welding
arc.

-~
Wandering
arc

poor
control
of
arc
di-
 
rection.
Reduce
gas
flow
rate.
Tungsten
electrode
oxidizing
and
not
re-


maining bright
after
conclusion
of
weld.
Use
clean
filler
rod
or
material.
If
Weld
Process
switch is in
GTAW
position.
connect remote control
to
Remote
14
recep
tacle.
Check.
repair,
or
replace
remote
control.
Remedy
Use
proper
size
tungsten
for
welding
amperage.
Place
Weld
Process
switch
in
GTAW
position.
Move
tungsten
closer
to
workpiece.
If
tungsten
is
cold,
arc
starter
may
not start
arc.
Use
touch
start,
if
required.
Check
cables
and torch
for
cracked
or
deteriorated
insulation
of bad
connections.
Repair
or
replace
necessary
parts.
Use
proper
size
tungsten.
Properly
select
and
prepare
tungsten.
Check
and
tighten
all
gas
fittings.
Shield
weld
zone
from drafts.
OM-164
271
Page
9

SMAW
Process
Trouble
Remedy
Erratic
welding
arc.
Erratic
welding
arc
with
excessive


-~
spatter.
Reduce
Amperage
control
setting.
Electrode
freezing
to
work.
I--
Use
dry. properly
stored
electrodes.
Increase
arc
length.
Increase
Amperage
control
setting.
Narrow,
high-crowned
weld bead.
I.
Weld
metal does
not
penetrate
base



metal.
Poor
fusion of
weld
metal
with
base
met-


-~
al.
Slag
trapped
in
weld.
Gas
pockets
or
voids
on surface
or
in-


-~
Shorten
arc
length.
side
a
welding
bead.
H

~
Maintain
smooth,
even
travel
speed.
Tighten
and
clean
connections
both
inside
and
outside
welding
power
source.
Tighten
any
loose
connections
to
Range/Polarity
switch.
Use
dry,
properly
stored
electrodes.
Shorten
arc
length.
Increase
Amperage
control
setting.
Reduce
travel
speed.
Shorten
arc
length.
Reduce
travel
speed.
Increase
Amperage
control
setting.
Improve
design
of
weld
joint.
Thoroughly
clean
lent
area.
Use
proper
electrode
angle.
Use
correct
electrode
size
for
base
material thickness.
Improve
design
of weld
loint.
Shorten
arc
length.
Reduce
travel
speed.
Increase
Amperage
control
setting.
Use
proper
electrode
angle.
Position
electrode
in
center
of
joint.
Shorten
arc
length.
Reduce
trav~
speed.
Increase
Amperage
control
setting.
Gas
trapped
in
weld
bead.
OM-164
271
Page
10

SECTION
6
ELECTRICAL
DIAGRAMS
Figure
6.1.
Circuit
Diagram
For
Welding
Power
Source
SB154
141.8
OM-164
271
Page
11

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261S2-4I
________
~
SC-164
550
FIgure
6-2.
WIring
Dlagrr
,r
Welding
Power
Source

12
ST164
350
Cl)
m
C,
0
z
-4
Cl)
Cl)
-i
11
18
20
19
21

I
Figure
7-1.
MaIn
Assembly

Parts
For
Main
Assembly
NOTE:
All
items
indented
by
a
dot(s)
are
included
with
the
tern
listed
directly
above
Item
Part
No. No.
Description
Item
Part
No.
No
Descriotion
Item Part
No.
No.
Description
1
154
335
Bezel
126
233
Tubing
40 143 976
Connector
w/Sockets
2
134327 Label.
Warning
17
044
482
Suppressor
079 534
Connector
Socket
3
+
155 402
Wrapper
18
150 783
Blade
Amp
66358-6
4
157415
Baffle
19
148808
Motor
41
097924 Knob
5
164431
Circuit
Card
20
155403
Bracket
42
155
500
Light
130 203
Connector & Sockets
21 155
469
Stabilizer
43
148956
Hanote
6
113 746
134201
Connector
Socket
Molex
39-00-0038
Stand-Off
Support
22
22
23
161 344
155 760
155781
Transformer. 200V
Transformer.
230V
Coil.
sec
200V
44
157
957
Light
45
155013
Switch
46
Nameplate
7
8
155
404
603 106
Bracket
Hose
23
24
155
781
155
779
Coil.
sec
230V
Coil,
shunt
200V
47
157958
Light
48
155
422
Front
Panel
9 010865
HoseClamp
24
155779
Coil,
shunt
230V
49
154896
Switch
10
11
12
13
14
14
15
125
785
605227
147571
155399
071 906
047
721
044426
Valve
Nut.
nyl
Handle
Rear
Panel
Cord
Set,
(200V
model
only)
Cord
Set.
(230V
model
only)
Connector,
clamp
25
25
26
27
28
29
160 523
155
780
020 520
083
147
034
893
034260
024 493
155501
Coil.
pri
200V
Coil,
pri
230V
Thermostat.
NC
Grommet
Contactor
Link
Coil
Capacitor
50
154
899
Switch
51
089645
Switch
52
155
406
Bracket
059 712
Clip
048
489
Clamp
128 188 Hose
056 851
Fitting,
3/l6tbg
010606
Fitting,
.625.I8RH
16 154
848
Rectifier
30
155 290
Capacitor
056
108
Fitting,
.425
ID
x
.718
Ig
154695
Rectther
155 107
Cable
Tie
134834
Hose
119 351 Diode
31
157
596
Transformer
121
580
Regulator/Flowmeter
120229
Spacer
32 155499
Transformer
155552
Connector
154696
Rectifier
33 159 102
Plate
159 169
~0-Ring
119607 Diode
34 155288
Coil
120 229
156 327
151
880
Spacer
Capacitor/Resistor
Capacitor
35
36
37
124
511
155 401
155551
Switch
Base
Receptacle
+When
ordering
a
component
originally
dis~
playing
a
precautionary
label,
the
label should
also
be
ordered.
,
154
849 Bus
Bar
38 035 897 Potentiometer
Be
sure
to
provide
Model
and
Serial
Number
602 195
Washer
39 134
900 Strain Relief
when
ordering
replacement
parts.