ESAB ST-16 User Manual

INSTRUCTIONS for

F11-744-R

September, 2004

ST-16 MIG WELDING TORCH

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for
arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,"
Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate
this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact
your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

I. INTRODUCTION

The ST-16 Torch, P/N 997498, is a rugged all purpose,
water cooled, manual Mig welding torch designed to
operate at welding currents up to 600 amperes continu­ous duty using argon as the shielding gas. The ST -16 is
intended for use with ESAB wire feeders which have
provision for water cooling and will handle all types of
welding wires in sizes from .030-in. through 7/64-in. di­ameter.

II. DESCRIPTION

To provide maximum resistance to the abuses of day to
day service, the torch is of heavy-duty construction with
metal parts well insulated from current carrying mem­bers. It’s 55-degree, curved stainless steel front body
permits effective operation in tight, hard-to-reach cor­ners and other contained areas. The torch employs metal
nozzles and either slip-in contact tubes or threaded con­tact tips (long or short). Each contact tube is threadless
and is retained by a collet nut supplied with the torch.
All service lines are internally connected to the torch
body and exit from the rear of the torch handle for easy
torch maneuverability. For weld start-stop control, the
torch is provided with a positive action universal lever
switch which can be positioned at any point on the torch
handle preferred by the operator.

For feeding all wires, a self-lined conduit with either a
spring or plastic jumper liner is normally used. An alter­nate replaceable liner conduit system is also available
for feeding 0.35, .045 and 1/16-in. hard wires through a
continuous metal conduit liner.

III. ACCESSORY EQUIPMENT

A. REQUIRED

The ST-16 requires a nozzle (see Table 1), and several
wire feed accessories of the proper size for the wire be­ing used. (Refer to Table 2 if using the self-lined conduit
system or Table 3 if using conduit with continuous or
replaceable liner system). One other accessory whose
selection depends upon wire size is the feed roll on the
wire feeder itself. Selection of this accessory is covered
in the appropriate wire feeder instruction booklet.

Table 1 - Nozzles

Description

No. 8 Nozzle .......................................

No. 10 Nozzle ......................................

No. 10L Nozzle ....................................

No. 12 Nozzle ......................................

No. 12M Med. Length Nozzle ...............

No. 12L Long Length Nozzle ................

No. 12 Spot Welding Nozzle ................

* Requires Sp atter Liner, P/N 633603

B. OPTIONAL

1.

Centering Bushing, P/N 994330 (For use with No.8

and No. 10 nozzles) - Eliminates any possibility of
spatter bridging in the torch. This is accomplished
by using this one-piece centering bushing and spat­ter liner in place of the two individual pieces nor­mally used. Note that it can only be used at maxi­mum current of 350 amps with argon or 550 amps
with C02.

Part No.

P/N 598739*
P/N 598721*
P/N 598891
P/N 633985
P/N 997310
P/N 639756
P/N 993757

Be sure this information reaches the operator.
You can get extra copies through your supplier.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained, and repaired in accordance
with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly
maintained equipment should not be used. Parts that are broken, missing, worn, distorted, or contami­nated should be replaced immediately . Should such repair or replacement become necessary, the manu­facturer recommends that a telephone or written request for service advice be made to the Authorized
Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of the
manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which
results from improper use, faulty maintenance, damage, improper repair, or alteration by anyone other
than the manufacturer or a service facility designated by the manufacturer.

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SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precautionary
information from the references listed in Addi-

tional Safety Information section. Before per­forming any installation or operating procedures, be sure to
read and follow the safety precautions listed below as well as
all other manuals, material safety data sheets, labels, etc.
Failure to observe Safety Precautions can result in injury or
death.

PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip­ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles
are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not
to expose themselves to the rays of the electric-arc or hot
metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a welding
helmet or cap for hair protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may
also be desirable as protection against radiated heat and
sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser

cuffs, or pockets. Sleeves and collars should be kept
buttoned, and open pockets eliminated from the front of
clothing

5. Protect other personnel from arc rays and hot sparks with

a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far. By­standers should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex­plosions. Therefore:

5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.

6. After completing operations, inspect the work area to make
certain there are no hot sparks or hot metal which could
cause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes",
available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move­ment is confined, or if there is danger of
falling.

1. Be sure the power source frame (chassis) is connected to
the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.

4. Use well-maintained equipment. Replace worn or dam­aged cables.

5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from
work and from ground.

7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or an
insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous.

Electric current flowing through any
conductor causes localized Electric and
Magnetic Fields (EMF). Welding and cut­ting current creates EMF around weld­ing cables and welding machines. There­fore:

1. Remove all combustible materials well away from the work
area or cover the materials with a protective non-flam­mable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices
in floors or wall openings and cause a hidden smoldering
fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there are
no substances on the workpiece which might produce
flammable or toxic vapors. Do not do hot work on closed
containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or por­table fire extinguisher. Be sure you are trained in its use.

1. Welders having pacemakers should consult their physician
before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are
unknown.

3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure

them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as

possible to the area being welded.
E. Keep welding power source and cables as far away from

your body as possible.

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11/95

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.
Therefore:

1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.

2. Do not operate near degreasing and spraying operations.
The heat or arc rays can react with chlorinated hydrocar­bon vapors to form phosgene, a highly toxic gas, and
other irritant gases.

3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve
ventilation in the work area. Do not continue to operate if
physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for
specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &

Safety Code

CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin­der, valve, or relief device can injure or
kill. Therefore:

1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from the
compressed gas cylinder. Do not use adaptors. Maintain
hoses and fittings in good condition. Follow manufacturer's
operating instructions for mounting regulator to a com­pressed gas cylinder.

2. Always secure cylinders in an upright position by chain or
strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work tables
or fixtures where they may become part of an electrical
circuit.

3. When not in use, keep cylinder valves closed. Have valve
protection cap in place if regulator is not connected.
Secure and move cylinders by using suitable hand trucks.
Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas As­sociation, 1235 Jefferson Davis Highway, Arlington, VA

22202.

§25249.5 et seq.)

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not perform
any electrical work unless you are qualified to perform
such work.

2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.

3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive
atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and
in good repair.

6. Use equipment only for its intended purpose. Do not
modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec­tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.

The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld­ing and Cutting of Containers That Have Held Hazardous
Substances."

MEANING OF SYMBOLS - As used through­out this manual: Means Attention! Be Alert!
Your safety is involved.

Means immediate hazards which, if not
avoided, will result in immediate, seri­ous personal injury or loss of life.

Means potential hazards which could
result in personal injury or loss of life.

Means hazards which could result in
minor personal injury.

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SP98-10