Stick ST80i Mini 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 Welder Specifications ...........................
Intended Use The Klutch Stick ST80i is a DC-only inverter stick mini welder with an exceptionally smooth stick welding performance in an extremely small package. It is intended for use for welding steel, stainless steel, cast iron, and hard surfacing, using electrodes from 1/16 inch to 3/32 inch With the extreme portability of this welder, the operator has the flexibility to use this welder for mobile applications, including outdoor applications.
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 welder. 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, gas hose, and fittings for the specific application. Do not look into the valve when opening it. Use protective cylinder cap whenever possible. ⚠CAUTION Proper Care, Maintenance, and Repair Always have power disconnected when working on internal components.
Main Parts of ST80i 3 3 1 4 9 6 2 8 7 Figure 1.
Setting Up Equipment ⚠WARNING ELECTRIC SHOCK CAN KILL! High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This welder must be grounded while in use to protect the operator from electrical shock. Do not remove the grounding prong or alter the plug in any way. Use only the supplied adapter between the welder's power cord and the power source receptacle.
Operating Instructions ⚠WARNING High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.
2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil, or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3. ELECTRODE The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows between the electrode (rod) and the grounded metal work piece.
a. When proper rod is used: i. The bead will lay smoothly over the work without ragged edges. ii. The base metal puddle will be as deep as the bead that rises above it. iii. The welding operation will make a crackling sound similar to the sound of eggs frying. b. When a rod too small is used: i. The bead will be high and irregular. ii. The arc will be difficult to maintain. c. When the rod is too large: i. The arc will burn through light metals. ii. The bead will undercut the work. iii.
begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet. b. Striking the arc Scratch the work piece with the end of the electrode to start the arc and then raise it quickly about 1/8 inch gap between the rod and the work piece, see following illustration: It is important that the gap be maintained during the welding process and it should not be too wide or too narrow.
c. Types of weld bead The following paragraphs discuss the most commonly used arc welding beads. The stringer bead 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 Used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the electrode.
D. Ideal weld. 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.
Maintenance ⚠WARNING ELECTRIC SHOCK CAN KILL! Touching live electrical parts can cause fatal shocks or severe burns. Do not touch live electrical parts Wear dry, hole-free insulating gloves and body protection. Disconnect input power before installing, maintaining or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147. Maintenance Interval Maintenance Point Before Each Use Inspect all cords and power cables.
Failure Possible Cause Corrective Action Unit is not plugged in. Plug in unit. Input power circuit breaker is not on. Reset the input power circuit breaker. The main power switch is not working. Replace the main power switch. The internal temperature is too high. Leave the power on and let the fan cool the unit. Output will continue when the unit has cooled. Input Power Voltage is Too High or Too Low. Meter Input Power Voltage.
Parts Diagram Parts List Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part Number 105300024 125300005 105300025 105300005 105300026 105300027 125300003 105200063 105200058 105300028 105300029 105300030 105300031 105300032 105300033 105200203 105200037 105300022 105300034 105300035 105300036 105300037 125300004 Item Description SHOULDER STRAP ENCLOSURE MAIN CONTROL PC BOARD INDICATOR LIGHTS POTENTIOMETER FRONT PLASTIC BEZEL FRONT NAMEPLATE ST80i MINI POTENTIOMETER KNOB WELD POWER QUICK CONNECTOR WE
Replacement Parts For replacement parts and technical questions, please call Customer Service at 1-800-222-5381. Not all product components are available for replacement. The illustrations provided are a convenient reference to the location and position of parts in the assembly sequence. When ordering parts, the following information will be required: item description, item model number, item serial number/item lot date code, and the replacement part reference number.
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.
