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Klutch ST200i Owner's Manual

Dc only inverter stick welder
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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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  Summary of Contents for Klutch ST200i

  • Page 1 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...
  • Page 2: Intended Use

    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.
  • Page 3: General Safety Rules

    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.
  • Page 4 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.
  • Page 5 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.
  • Page 6 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.
  • Page 7: Technical Specifications

    ST200i operation. Replace or repair damaged or worn parts immediately.  Store idle ST200i. When ST200i is not in use, store it in a secure place out of the reach of children. Inspect it for good working condition prior to storage and before re-use.
  • Page 8: Installation

    Power Light The Power Indicator Light is on when the machine is turned on. Thermal Protection Indicator Light When the thermal overload indicator is on, it indicates the machine has exceeded the allowable internal temperature. The machine automatically turns off welding output but the fan will remain on to cool down the internal components.
  • Page 9: Operation

    2. EXTENSION CORD - We do not recommend an extension cord because of the voltage drop they produce. This drop in voltage can affect the performance of the welder. If you need to use an extension cord, we recommend you check with a qualified electrician and your local electrical codes for your specific area.
  • Page 10: Setting Up The Work Piece

    4. SETTING UP THE WORK PIECE 4.1 Welding positions There are two basic positions, for welding: Flat and Horizontal. Flat welding is generally easier, faster, and allows for better penetration. If possible, the work piece should be positioned so that the bead will run on a flat surface.
  • Page 11: Ground Clamp Connection

    5. 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. 6.
  • Page 12 8. SETTING THE AMPERAGE CONTROL The welder has an infinite current control. It is capable of welding with electrodes up to 3/32” diameter. There is no golden rule that determines the exact amperage required for every situation. It is best to practice your welds on scrap metal which matches the metals you intend to work with to determine correct setting for your job.
  • Page 13 9.3 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.
  • Page 14: Maintenance

    Maintain your KLUTCH ST200i. It is recommended that the general condition of KLUTCH ST200i be examined before it is used. Keep KLUTCH ST200i in good repair by adopting a program of conscientious repair and maintenance. Have necessary repairs made by qualified service personnel.
  • Page 15: Troubleshooting

    TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Unit Does Not Power Up Unit Is Not Plugged In Plug In Unit Input Power Circuit Breaker Not On Reset Input Power Circuit Breaker The Main Power Switch Is Not Working Replace Main Power Switch Can Not Create An Arc Work Piece is Painted Or Rusty Remove All Paint And Rust...
  • Page 16: Diagram & Parts List

    DIAGRAM & PARTS LIST Page of 18...
  • Page 17 Reference # Part# Description Qty. Handle Enclosure Heat sink support board Main control board Mounting plate Heat sink assemble Fast recovery diode Power plate Current plate Faceplate Plastic front panel Potentiometer knob
  • Page 18: Warranty

    WARRANTY EFFECTIVE JULY 1, 2014 LIMITED WARRANTY This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from the factory.

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