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manual abstract
For options and accessories see back of book or contact your distributor. 1 2 3 4 5 7 6 2-2. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Locate unit near correct input power supply. Position unit so air can circulate. For information about sources of high-frequency see Section 6. For carts and caster kits see back of book or contact your distributor. Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 1 2 Movement ST-802 238 4 18 in (460 mm) Location And Airflow OR 18 in (460 mm) 18 in (460 mm) 3 18 in (460 mm) OM-355 Page 10 2-3. Dimensions And Weights Dimensions Height 21 in (533 mm) Width 13-5/8 in (346 mm) Length 22-1/8 in (562 mm) A 21-5/16 in (541 mm) A B 13/16 in (21 mm) C 12-7/16 in (316 mm) D 1–1/16 in (27 mm) E 4 Holes E 1/2 (13 mm) Front B Weight C ST-802 259 D 210 lbs (95 kg) 2-4. Specifications Mode Rated Output at 40% Duty Cycle Rated Input, 60 HZ, Single-Phase KVA KW Welding Amperage Range Max. Open-Circuit Voltage DC TIG 150 Amps at 16 Volts 230 V–38 A - (2)* 8.7 - (0.50)* 4.0 - (0.3)* 10–180 80 DC Stick 150 Amps at 26 Volts 230 V–42 A - (2)* 9.7 - (0.50)* 5.7 - (0.3)* 10–180 80 AC TIG 150 Amps at 16 Volts 230 V–67 A - (2)* 15.5 - (0.50)* 4.9 - (0.3)* 15–180 80 AC Stick 150 Amps at 26 Volts 230 V–53 A - (2)* 12.2 - (0.50)* 6.2 - (0.3)* 15–180 80 * () While idling. 2-5. Duty Cycle Chart Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. 40% Duty Cycle at 150 A AC/DC ST-188 276-A 4 Minutes Welding 6 Minutes Resting 2-6. Volt-Ampere Curves ssb1.1 10/91 – ST-188 277 / ST-188 278 Volt-amperecurves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. AC MODE 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 300 350 AMPERES VOLTS Stick MIN Stick MAX DC MODE 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 AMPERES VOLTS TIG–MIN STICK–MIN STICK–MAX TIG–MAX 2-7. Weld Output Terminals And Selecting Cable Sizes ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Weld Output Terminals Welding Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 Electrode Work 200 3 2 1 1/0 2/0 3/0 4/0 4/0 Ref. ST-802 238 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D OM-355 Page 11 OM-355 Page 12 2-8. Remote 14 Receptacle Remote control device has complete control of amperage at all times when connected to Remote 14 receptacle. NOTE Socket* Socket Information A 24 volts DC. B Contact closure to A completes 24 volts DC contactor control circuit. C Command reference; 0 to +10 volts DC output to remote control. A J B K I L N H D Remote control circuit common. C D M G E F A E 0 to +10 volts DC input command signal from remote control. ST-802 238 K Chassis common. *The remaining sockets are not used. 2-9. Shielding Gas Connections Ref. ST-802 238 / Ref. ST-802 258 / Ref. ST-157 858 Turn Off power before connecting to receptacle. 1 Gas Valve In Fitting Fitting has 5/8-18 right-hand threads. Located on rear of unit. 2 Gas Valve Out Fitting Gas connection is integrated into the Electrode weld output terminal by means of a flow-through type connector. 3 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 4 Regulator/Flow Gauge Connect regulator/flow gauge to gas cylinder. Connect gas hose to gas in fitting. 5 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). 5 2 4 1 5/8, 1-1/8 in Tools Needed: 3 OM-355 Page 13 2-10. Electrical Service Guide NOTE All values calculated at 40% duty cycle. Input Voltage 230 Input Amperes at Rated Output 67 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 100 Min Input Conductor Size In AWG/Kcmil 8 Max Recommended Input Conductor Length In Feet (Meters) 166 (51) Min Grounding Conductor Size In AWG/Kcmil 8 Reference: 1996 National Electrical Code (NEC) S-0092-J 2-11. Connecting Input ...