Klutch ST200i, ST80i Owner's Manual

ST200i

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.

Item# 44454

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Thank you very much for choosing a KLUTCH product! For future reference, please complete
the owner’s record below:

Model: _______________ Purchase Date: _______________

Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.

This machine is designed for certain applications only. The distributor cannot be responsible for
issues arising from modification. We strongly recommend this machine not be modified and/or
used for any application other than that for which it was designed. If you have any questions
relative to a particular application, DO NOT use the machine until you have first contacted the
distributor to determine if it can or should be performed on the product.

For technical questions please call the Northern Tool Welder Help Line at 1-877-304-0294.

INTENDED USE

The ST200i is a DC only inverter stick welder with an exceptionally smooth stick welding
performance. It is intended for use for welding steel, stainless steel, cast iron and hard surfacing
using electrodes from 1/16 inch to 5/32 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.

Stick welding gives the operator the flexibility to use this welder for mobile applications,
including outdoor applications. Stick electrodes contain a flux, making welding easy and does
not require the use of a separate shielding gas which can be blown away by the wind in outdoor
applications. Since this welder does not use shielding gas, the operator will not require to have
or maintain shielding gas bottles, a regulator or gas hose. TIG welding does require the use of
Argon shielding gas. The shielding gas replaces the flux that is used in stick welding, providing a
more controlled and cosmetic weld. However, TIG welding is limited to areas inside or where
wind can be controlled, preventing the shielding gas from blowing away.

This unit is intended to be used on a 50 amp 230V AC circuit without the use of an extension
cord. If an extension cord is necessary for your application, please use the appropriate size and
length of extension cord that will handle 50 amps the entire length of the extension. We highly
recommend talking with a qualified electrician for cord size recommendations.

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GENERAL SAFETY RULES

WARNING: Read and understand all instructions. Failure to follow all instructions listed

below may result in serious injury.

CAUTION: Do not allow persons to operate or assemble this ST200i until they have

read this manual and have developed a thorough understanding of how the ST200i works.

WARNING: The warnings, cautions, and instructions discussed in this instruction

manual cannot cover all possible conditions or situations that could 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 supplied by the operator.

SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY CONSIDERATIONS

1.1 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.

-Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.

-Keep harmful arc rays shielded from the view of others.

-Mount the welder on a secure bench
or cart that will keep the welder secure and prevent it from tipping over or falling.

1.2 Your Welder’s Condition

-Check ground cable, power cord and welding cable to be sure the insulation is not damaged.
Always replace or repair damaged components before using the welder.

-Check all components to ensure they are clean and in good operating condition before use.

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1.3 Use of Your Welder

Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do
not immerse them in water. These components and the welder must be completely dry before
attempting to use them.

-Follow the instructions in this manual.

-Keep welder in the off position when not in use.

-Connect ground lead as close to the area being welded as possible to ensure a good ground.

-Do not allow any body part to come in contact with the welding wire if you are in contact with the
material being welded, ground or electrode from another welder.

-Do not weld if you are in an awkward position. Always have a secure stance while welding to
prevent accidents. Wear a safety harness if working above ground.

-Do not drape cables over or around your body.

-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety
glasses while welding.

-Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals,
UV and IR rays.

-Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.

-Keep hands and fingers away from moving parts and stay away from the drive rolls.

-Do not point torch at any body part of yourself or anyone else.

-Always use this welder in the rated duty cycle to prevent excessive heat and failure.

1.4 Specific Areas of Danger, Caution or 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.

- Do not attempt to repair or maintain the welder while the power is on.

-Inspect all cables and cords for any exposed wire and replace immediately if found.

-Use only recommended replacement cables and cords.

-Always attach ground clamp to the work piece or work table as close to the weld area as possible.

-Do not touch the welding wire and the ground or grounded work piece at the same time.

-Do not use a welder to thaw frozen pipes.

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Fumes and Gases

-Fumes emitted from the welding process displace clean air and can result in injury or
death.

-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and

safe.

-Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the

environment where you will be working.

-Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury or

barium). They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator,
respirator with air supply or remove the coating from the material in the weld area.

-The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety

data sheet for the manufacturer’s instructions.

-Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays

and degreasers can be highly toxic when heated.

UV and IR Arc Rays

The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to
your eyes and skin. Do not look at the welding arc without proper eye protection.

-Always use a helmet that covers your full face from the neck to top of head and to the back of each

ear.

-Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output,

use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for
more information.

-Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant

cloth or leather shirts, coats, pants or coveralls are available for protection.

-Use screens or other barriers to protect other people from the arc rays emitted from your welding.

-Warn people in your welding area when you are going to strike an arc so they can protect

themselves.

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. If removal is not possible, tightly

cover them with fireproof covers.

-Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,

cracks or areas you cannot see.

-Keep a fire extinguisher close in the case of fire.

-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.

-Do not have on your person any items that are combustible, such as lighters or matches.

-Keep work lead connected as close to the weld area as possible to prevent any unknown,

unintended paths of electrical current from causing electrical shock and fire hazards.

-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.

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Hot Materials

Welded materials are hot and can cause severe burns if handled improperly.

-Do not touch welded materials with bare hands.

-Do not touch MIG gun nozzle after welding until it has had time to cool down.

Sparks/Flying Debris

Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying

debris.

-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear

plugs to keep sparks out of ears and hair.

Electromagnetic Field

-Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.

-Consult your doctor before using any electric arc welder or cutting device

-Keep people with pacemakers away from your welding area when welding.

-Do not wrap cable around your body while welding.

-Wrap MIG gun and ground cable together whenever possible.

-Keep MIG gun and ground cables on the same side of your body.

Shielding Gas Cylinders Can Explode

High pressure cylinders can explode if damaged, so treat them carefully.

-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.

-Do not touch cylinder with MIG gun.

-Do not weld on the cylinder

-Always secure cylinder upright to a cart or stationary object.

-Keep cylinders away from welding or electrical circuits.

-Use the proper regulators, gas hose and fittings for the specific application.

-Do not look into the valve when opening it.

-Use protective cylinder cap whenever possible

1.5 Proper Care, Maintenance and Repair

-Always have power disconnected when working on internal components.

- Do not touch or handle PC board without being properly grounded with a wrist strap. Put PC board

in static proof bag to move or ship.

-Do not put hands or fingers near moving parts such as drive rolls of fan