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Please read and save these instructions . Read through this ow ners manual carefully beforeusing prod uct. Protect yourself and others by observing all safety inform ation, warnings, andcautions. Failure to comply wi th instruct ions could result in personal injury and/or damage toproduct or property. Please retain instructions for future reference.

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Northern Industrial Welding

Operating Instruct ions and Parts Manual ST80i

Welding

DescriptionST80i portable DC inverter arc

welderAC single phase 120V (110-

120V), 60HZ . 20 amp time delayedfuse or circuit breaker is recommended,Overload protection. An ideal stick unitto weld all sorts of carbon steel,stainless steel and DIY jobs.Tig torchoption available

Unpacking1.1 Remove cartons, bags orStyrofoam containing the welder and accessories.1.2 Check the contents with the packing list below.

1.3 After unpacking unit, inspect carefully for any damage that may haveoccurred during transit. Check for loose, missing, or damaged parts. Shippingdamage claim must be filed with carrier.

ITEM QTY.

Portable Arc Welder 1 unit

Welding cable with electrode holder 1pc

Grounding cable with earth clamp 1pc

Operators Manual 1set

Sample electrodes 1 bag

Carry strap 1pc


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Operating Instructions and Parts Manual

ST80i

Specifications and DimensionMODEL ST80i

Power supply (v) 1ph-120V-60HZ

No-load voltage (v) 75V

Output Range (A) 20-75A 90A Peak

Duty cycle (%) 20% @75ASuggested electrode E6013,E7014,E7018, Stainless steel

Electrode Diameter (Inch) 1/16, 5/64, 3/321.6mm2.0mm2.4mm

DimensionsLength x Width x Height

300x120x240MM / 12x5x9 inches

Weight (Ibs) 4.5Kgs 9.9Lbs

Know your Welder

Indicating LightPower, Thermal Protection

There are two indicating lights : power indicator and thermal indicator. When themachine is turned on, the power indicator will be on to show it. When the thermalindictor is on, it shows the machine is overloaded working and the internal

temperature is too high. The machine will turn off automatically but the fan willstill be working. When the internal temperature is decreased, the machine willturn on automatically.Current AdjustmentCurrent adjustment is on the front panel of machine. It is an infinite current outputadjustmentOutput +ConnectorThis is the connector for welding cable most often when STICK welding. Whenthis machine is used for TIG welding, this connector is for the grounding cable.Ground Cable and ClampThe ground cable and clamp is attached to the work piece to complete the flow ofcurrent needed to weld.

MAX/MINSwitch

Ground Ca

Thermal Indi

Power Indicating light

Welding cable andelectrode holder

Current adjustment

Output+connector

Ground Cableand clamp

Strap

Thermal protectionIndicating light

Output-connector


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Welding Cable and Electrode HolderOne end of cable is connected to output connectors of the machine. Theelectrode is clamped in the electrode holder for welding.Output - ConnectorThis is the connector for grounding cable when STICK welding. When thismachine is used for TIG welding, this connector is for the TIG torch

Power CordThe power cord connects the welder to the 110-120v volt power supply.Plug the 15 amp plug into a 115 volt/20 amp receptable to supply powerto the welderWiring Diagrams


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General Safety Information1.1 Your Welding Environment-Keep the environment you will bewelding in free from flammablematerials.-Always keep a fire extinguisher

accessible to your weldingenvironment.-Always have a qualified personinstall and operate this equipment.-Make sure the area is clean, dry andventilated. Do not operate the welderin humid, wet or poorly ventilatedareas.-Always have your welder maintainedby a qualified technician inaccordance with local, state andnational codes.-Always be aware of your workenvironment. Be sure to keep other

people, especially children, awayfrom you while welding.-Keep harmful arc rays shielded fromthe view of others.-Mount the welder on a secure benchor cart that will keep the weldersecure and prevent it from tippingover or falling.1.2 Your Welders Condition-Check all cables, power cord andwelding cable to be sure theinsulation is not damaged. Alwaysreplace or repair damagedcomponents before using the welder.

-Check all components to ensure theyare clean and in good operatingcondition before use.1.3 Use of Your Welder

Do not operate the welder if theoutput cable, electrode, or any partof the system is wet. Do not immersethem in water. These componentsand the welder must be completelydry before attempting to use it.

-Follow the instructions in this manual.-Keep welder in the off position whennot in use.-Connect ground lead as close to thearea being welded as possible to

ensure a good ground.-Do not allow any body part to comein contact with the electrode if you arein contact with the material beingwelded, ground or electrode fromanother welder.-Do not weld if you are in an awkwardposition. Always have a securestance while welding to preventaccidents. Wear a safety harness ifworking above ground.-Do not drape cables over or aroundyour body.-Wear a full coverage helmet with

shade (see ANSI Z87.1 safetystandard) and safety glasses whilewelding.-Wear proper gloves and protectiveclothing to prevent your skin frombeing exposed to hot metals, UV andIR rays.-Do not overuse or overheat yourwelder. Allow proper cooling timebetween duty cycles.-Always use this welder in the ratedduty cycle to prevent excessive heatand failure.1.4 Specific Areas of Danger, Caution or

Warning Electrical Shock

Electric arc welders canproduce a shock thatcan cause injury or

death. Touching electrically live partscan cause fatal shocks and severeburns. While welding, all metalcomponents connected to the unit areelectrically hot. Poor ground


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connections are a hazard, so securethe 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 maintainthe welder while the power is on.-Inspect all cables and cords for anyexposed wire and replaceimmediately.-Use recommended replacementcables and cords.-Always attach ground clamp to thework piece work table as close to theweld area as possible.-Do not touch the electrode and theground or grounded work piece at thesame time.

-Do not use a welder to thaw frozenpipes.Fumes and Gases

-Fumes emitted from thewelding process displaceclean air and can result in

injury or death.-Do not breathe in fumes emitted by

the welding process. Make sure yourbreathing air is clean and safe.-Work only in a well-ventilated area oruse a ventilation device to remove

welding fumes from the environmentwhere you will be working.-Do not weld on coated materials(galvanized, cadmium plated orcontaining zinc, mercury or barium).They will emit harmful fumes that aredangerous to breathe. If necessaryuse a ventilator, respirator with airsupply or remove the coating from thematerial in the weld area.-The fumes emitted from somemetals when heated are extremely

toxic. Refer to the material safetydata sheet for the manufacturersinstructions.-Do not weld near materials that willemit toxic fumes when heated.Vapors from cleaners, sprays and

degreasers can be highly toxic whenheated.

UV and IR Arc Rays

The welding arcproduces ultraviolet (UV)and infrared (IR) rays

that can cause injury to your eyesand skin. Do not look at the weldingarc without proper eye protection.-Always use a helmet that coversyour full face from the neck to top ofhead and to the back of each ear.-Use a lens that meets ANSI

standards and safety glasses. Forwelders under 160 Amps output, usea shade 10 lens; for above 160 Amps,use a shade 12. Refer to the ANSIstandard Z87.1 for more information.-Cover all bare skin areas exposed tothe arc with protective clothing andshoes. Flame-retardant cloth orleather shirts, coats, pants or

coveralls are available for protection.-Use screens or other barriers toprotect other people from the arc raysemitted from your welding.

-Warn people in your welding areawhen you are going to strike an arcso they can protect themselves.

Fire Hazards

Do not weld on containersor pipes that contain orhave had flammable,

gaseous or liquid combustibles inthem. Welding creates sparks andheat that can ignite flammable and


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explosive materials.-Do not operate any electric arcwelder in areas where flammable orexplosive materials are present.-Remove all flammable materialswithin 35 feet of the welding arc. If

removal is not possible, tightly coverthem with fireproof covers.-Take precautions to ensure thatflying sparks do not cause fires orexplosions in hidden areas, cracks orareas you cannot see.-Keep a fire extinguisher close in thecase of fire.-Wear garments that are oil-free withno pockets or cuffs that will collectsparks.-Do not have on your person anyitems that are combustible, such aslighters or matches.

-Keep work lead connected as closeto the weld area as possible toprevent any unknown, unintendedpaths of electrical current fromcausing electrical shock and firehazards.

Hot Materials

Welded materials are hotand can cause severeburns if handled

improperly.-Do not touch welded materials withbare hands.

-Do not touch electrode holder afterwelding until it has had time to cooldown.

Sparks/Flying Debris

Welding creates hotsparks that can causeinjury. Chipping slag off

welds creates flying debris.-Wear protective apparel at all times:ANSI-approved safety glasses or

shield, welders hat and ear plugs tokeep sparks out of ears and hair.

Electromagnetic Field

-Electromagnetic fieldscan interfere with variouselectrical and electronic

devices such as pacemakers.-Consult your doctor before using anyelectric arc welder or cutting device-Keep people with pacemakers awayfrom your welding area when welding.-Do not wrap cable around your bodywhile welding.-Wrap welding cable and groundcable together whenever possible.-Keep welding cable and groundcables on the same side of your body.

Shielding Gas CylindersCan Explode

High pressure cylinders can explodeif damaged, so treat them carefully.-Never expose cylinders to high heat,sparks, open flames, mechanicalshocks or arcs.-Do not touch cylinder with weldingcable.-Do not weld on the cylinder.-Always secure cylinder upright to acart or stationary object.-Keep cylinders away from welding orelectrical circuits.

-Use the proper regulators, gas hoseand fittings for the specific application.-Do not look into the valve whenopening it.-Use protective cylinder capwhenever possible.1.5 Proper Care, Maintenance AndRepair


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-Always have power disconnectedwhen working on internalcomponents.

- Do not touch or handle PC boardwithout being properly grounded

with a wrist strap. Put PC board instatic proof bag to move or ship.

-Do not put hands or fingers nearmoving parts such as fan.

AssemblyThis unit is assembled when out offactory.

Installation1. Power requi rementAC single phase 120v (110-120V),60HZ fused with a 20amp timedelayed fuse or circuit breaker isrequired. DO NOT OPERATE THISUNIT if the ACTUAL power sourcevoltage is less than 105 volts ac orgreater than 132 volts ac.

High voltage danger from powersource! Consult a qualifiedelectrician for proper installation ofreceptacle. This welder must begrounded while in use to protectthe operator from electrical shock. Do not remove grounding prongor alter the plug in any way. Donot use any adapters between thewelders power cord and the powersource receptacle. Make sure thePOWER switch is OFF whenconnecting your welders powercord to a properly grounded120Vac, 60Hz, single phase, 20amp power source.2. Extension cordDuring normal use an extension cordis not necessary. It is stronglyrecommended that an extension cordshould not be used because of thevoltage drop they produce. This dropin voltage can affect the performanceof the welder. If you need to use an

extension cord it must be a #12gauge cord at the smallest.-Do not use an extension cord over25 ft. in length.3. Setting up the work piece3.1 Welding positionsThere are two basic positions, forwelding: Flat and Horizontal. Flatwelding is generally easier, faster,and allows for better penetration. Ifpossible, the work piece should bepositioned so that the bead will run ona flat surface.3.2 Preparing the Joint

Before welding, the surface of workpiece needs to be free of dirt, rust,scale, oil or paint. Or it will createbrittle and porous weld. If the basemetal pieces to be joined are thick orheavy, it may be necessary to bevelthe edges with a metal grinder. Thecorrect bevel should be around 60

degrees. See followingpicture:

Based on different welding position,there are different welding joint, seefollowing images for more information


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4. Ground clamp connectionClear any dirt, rust, scale, oil or painton the ground clamp. Make certainyou have a good solid groundconnection. A poor connection at theground clamp will waste power andheat. Make sure the ground clamptouches the metal.5. ElectrodeThe welding electrode is a rod coatedwith a layer of flux. When welding,electrical current flows between theelectrode (rod) and the groundedmetal work piece. The intense heat ofthe arc between the rod and the

grounded metal melts the electrodeand the flux. The most popularelectrodes are:-E6011 60,000 PSI tensile strengthdeep penetrating applications.-E6013 60,000 PSI tensile strengthused for poor fit up applications-E7014 70,000 PSI tensile strengthused for high deposition and fasttravel speeds with light penetration-E7018 70,000 PSI tensile strength,

Used for out of position and tacking.6. Selecting the proper electrodeThere is no golden rule thatdetermine the exact rod or heatsetting required for every situation.The type and thickness of metal and

the position of the work piecedetermine the electrode type and theamount of heat needed in the weldingprocess. Heavier and thicker metalsrequired more amperage. It is best topractice your welds on scrap metalwhich matches the metal you intendto work with to determine correct heatsetting and electrode choice. Seefollowing some helpful troubleshooting tips to determine if you areusing a correct electrode

1. When proper rod is used:a. The bead will lay smoothly overthe work without ragged edgesb. The base metal puddle will be as

deep as the bead that risesabove it

c. The welding operation will make

a crackling sound similar to thesound of eggs frying

2. When a rod too small is used

a. The bead will be high andirregular

b. The arc will be difficult tomaintain

3. When the rod is too large

a. The arc will burn through lightmetals

b. The bead will undercut the work


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c. The bead will be flat and porousd. Rod may be freeze or stick to

work pieceNote: Rate of travel over the workalso affects the weld. To ensureproper penetration and enough

deposit of rod, the arc must be movedslowly and evenly along the weldseam.

Operation1. Setting the amperage controlThe welder has an infinite outputcurrent control. It is capable ofwelding with 1/16" and 5/64" and3/32" electrodes.There is no golden rule thatdetermines the exact amperagerequired for every situation. It is bestto practice your welds on scrap metalwhich matches the metals you intend

to work with to determine correctsetting for your job. The electrodetype and the thickness of the workpiece metal determine the amount ofheat needed in the welding process.Heavier and thicker metals requiremore voltage (amperage), whereaslighter and thinner metals require lessvoltage (amperage).2. Welding techniquesThe best way to teach yourself how toweld is with short periods of practiceat regular intervals. All practice weldsshould be done on scrap metal that

can be discarded. Do not attempt tomake any repairs on valuableequipment until you have satisfiedyourself that your practice welds areof good appearance and free of slagor gas inclusions.2.1 Holding the electrodeThe best way to grip the electrodeholder is the way that feels mostcomfortable to you. To Position theElectrode to the work piece whenstriking the initial arc it may be

necessary to hold the electrodeperpendicular to the work piece.Once the arc is started the angle ofthe electrode in relation to the workpiece should be between 10 and 30degrees. This will allow for good

penetration, with minimal spatter.2.2 Striking the arc

EXPOSURE TO A WELDING ARCIS EXTREMELY HARMFUL TO THEEYES AND SKIN. Never strike an arc or beginwelding until you have adequateprotection. Wear flameproof welding gloves,heavy long-sleeved shirt, cufflesstrousers, high-topped shoes and awelding helmet or shield.Scratch the work piece with the end

of electrode to start arc and thenraise it quickly about 1/8 inch gapbetween the rod and the work piece.

See following picture

It is important that the gap bemaintained during the welding

process and it should be neither toowide or too narrow. If too narrow, therod will stick to the work piece. If toowide, the arc will be extinguished.It needs much practice to maintainthe gap. Beginners may usually getsticking or arc extinguishing. Whenthe rod sticks to the work piece,gently rock it back and forth to makethem separate. If not, the circuit isshort connection, and it will overloadthe welder.


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A good arc is accompanied by a crisp,cracking sound. The sound is similarto that made by eggs frying. To lay aweld bead, only 2 movements arerequired; downward and in thedirection the weld is to be laid, as in

following figure:

2.3 Types of weld beadThe following paragraphs discuss themost commonly used arc weldingbeads.The stringer bead Formed bytraveling with the electrode in astraight line while keeping it centeredover the weld joint.

The weave beadUsed when youwant to deposit metal over a widerspace than would be possible with astringer bead. It is made by weavingfrom side to side while moving withthe electrode. It is best to hesitate

momentarily at each side beforeweaving back the other way toimprove penetration.

2.4 Welding position

Flat position is the easiest of thewelding positions and is mostcommonly used. It is best if you canweld in the flat position if at allpossible as good results are easier toachieve.

The horizontal positionisperformed very much the same asthe flat weld except that the angle isdifferent such that the electrode, andtherefore the arc force, is directedmore toward the metal above theweld joint. This more direct anglehelps prevent the weld puddle fromrunning downward while still allowing

slow enough travel speed to achievegood penetration. A good startingpoint for your electrode angle is about30 degrees DOWN from beingperpendicular to the work piece.

2.5 Judge a good weld beadWhen the trick of establishing andholding an arc has been learned, the

next step is learning how to run agood bead. The first attempts inpractice will probably fall short ofacceptable weld beads. Too long ofan arc will be held or the travel speedwill vary from slow to fast (seefollowing)


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A. Weld speed is too fast.B. Weld speed is too slow.C. Arc is too long.D. Ideal weld.

A solid weld bead requires that theelectrode be moved slowly andsteadily along the weld seam. Movingthe electrode rapidly or erratically willprevent proper fusion or create alumpy, uneven bead. To preventELECTRIC SHOCK, do not performany welding while standing, kneeling,or lying directly on the grounded work.2.6 Finish the beadAs the coating on the outside of theelectrode burns off, it forms anenvelope of protective gasses aroundthe weld. This prevents air fromreaching the molten metal andcreating an undesirable chemicalreaction. The burning coating,however, forms slag. The slagformation appears as anaccumulation of dirty metal scale onthe finished weld. Slag should beremoved by striking the weld with achipping hammer.

PEENING THE SLAG FROM AWELD JOINT CAUSES SMALLCHIPS OF METAL TO FLYTHROUGH THE AIR Metallic chips f lying through theair can cause eye injury o r injury toother parts of the head, hands orexposed portions of the body. Wear goggles or eye glasses withside shields and protect the hands

and other exposed parts of thebody with protective garments, orif possibl e, work with a shieldbetween the body and the workpiece.The intense heat produced at the arc

sets up strains in the metal joined bywelding. Peening the weld not onlyremoves the scale left behind in thewelding but relieves the internalstrains developed by the heating andcooling process. With thehammer/brush after it is cooled.

MaintenanceThe welder needs regularmaintenance as following:Periodically clean dust, dirt, grease,etc. from your welder. Every sixmonths, or as necessary, remove the

cover panel from the welder and air-blow any dust and dirt that may haveaccumulated inside the welder.Replace power cord, ground cable,ground clamp, or electrode assemblywhen damaged or worn.MINOR AND ROUTINEMAINTENANCEStore in a clean dry

facility free from corrosive gas,excess dust and high humidity.

Temperature range from 10F

120F and the relative humidity notmore than 90%.

When transporting or storing thewelder after use, it is recommendedto repack the product as it wasreceived for protection. (Cleaning isrequired before storage and you mustseal the plastic bag in the box forstorage


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Trouble shooting Chart

No. Breakdown Analysis Solutions

Poor ventilation leads toover-heat protection

Improve ventilation

Internal temperature is

too high

Will automatically recover

when the temperature

lowers.1

Yellow

Indicator is

onUsing over the rated

duty-cycle

Will automatically recover

when the temperature

lowers.

2

The

adjustment

knob on

the front

panel didnt

work

Potentiometer broken

(current regulation)

Replace the

potentiometer.

Switch broken Replace the switch

Fan broken Replace or repair the fan

3

Cooling

Fan not

working or

turning

very slowly

Wire broken or fallen off Check connections

Over voltage, under

voltageSee No. 1

Welder getting

overheated

See No. 14No no-load

voltage

Switch broken Replace the switch


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Electrode Holders

capacity is too small;

Replace with a higher

Amperage Holder

Cable is of small sizeReplace it with anotherone in conformity with the

requirement

Socket loosen5

Electrode

Holder and

Cable

getting

hot;+ -

polar

sockets

becoming

hot

High resistance between

the electrode holder and

the cable

Remove the oxide coating

and tighten it

Resume power over a

long period of time(more than two days)

Not a failure. Trip caused

by the main power filterscapacity charging. Switch

on the main power

source.

6

Power

source

tripping

In the process of welding Contact us

7 OthersContact us


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WarrantyLIMITED ONE-YEAR WARRANTY

Should this product fail to perform satisfactorily due to a defect or poorworkmanship within ONE YEAR from the date of purchase, return it tothe place of purchase and it will be replaced, free of charge. Incidental or

consequential damages are excluded from this warranty.

Repair Parts ListReference

numberDescription Part number Qty

1 Handle 2.05.08.118 1

2 Enclosure 1.1.01.01.0148 1

3 PCB 1.1.05.02.0288 1

4 Plastic front panel 2.05.05.701 1

5 Switch (RoHS) 2.07.11.017 1

6 - output cable 1.2.08.02.2108 1

7 + output cable 1.2.08.01.1604 1

8 Front assembly 1.2.01.01.3645 1


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9Dins connector

(copper)ROHS2.07.57.147 2

10Thermal protection

Indicating light1.2.07.02.3010 1

11 Power Indicating light 1.2.07.02.3011 1

12 Output fixed board 1.1.03.04.0137 2

13 Bottom panel 1.1.01.04.0340 1

14 Temperature relay 1.2.07.02.3008 1

15Driver module

ROHS1.1.05.03.0025 1

16

Intermediate-frequency transformer

120V2.07.25.819 1

17

Transformer fixed

board 1.1.02.01.0750 1

18Fanwiring harness

ROHS)1.2.07.02.0614 1

19 Plastic back panel 2.05.05.702 1

20Powerline with plug

RoHS2.03.05.133 1

21 Wave switch (ROHS) 2.07.80.213 1

Other Safety and Standards InformationThis manual is designed to inform the operator of safety and general use of thismodel only. For further information about welding safety refer to the following

standards and comply with them where applicable.

ANSI Standard Z49.1 SAFETY INWELDING AND CUTTING obtainablefrom: American Welding Society 550 NWLe Jeune Road, Miami, FL 33126Tel. (800) 443-9353Fax (305) 443-7559www.amweld.org or www.aws.org


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ANSI Standard Z87.1 SAFE PRACTICEFOR OCCUPATION AND EDUCATIONALEYE AND FACE PROTECTIONObtainable from: American NationalStandards Institute (ANSI) 11 West 42ndSt. New York, NY 10036

Tel. (212) 642-4900Fax (212) 398-0023 www.ansi.org

NFPA Standard 51B CUTTING ANDWELDING PROCESS obtainable from:National Fire Protection Association,1 Batterymarch Park, P.O. Box 9101Quincy, MA 02269-9101Tel. (617) 770-3000Fax (617) 770-0700 www.nfpa.org

OSHA Standard 29 CFR, Part 1910,Subpart Q. WELDING, CUTTING ANDBRAZING obtainable from your state

OSHA office or from: U. S. Dept. of LaborOSHA, Office of Public Affairs RoomN3647, 200 Constitution Ave. NWWashington, DC 20210 www.osha.gov

CSA Standard W117.2 Code forSAFETY IN WELDING AND CUTTINGObtainable from: Canadian StandardsAssociation, 178 Rexdale Blvd.,Etobicoke, Ontario M9W 1R3www.csa.ca

American Welding Society Standard A6.0WELDING AND CUTTING CONTAINERSWHICH HAVE HELD COMBUSTIBLESObtainable from: AmericanWelding Society, 550 NW Le Jeune RoadMiami, FL 33126Tel. (800) 443-9353Fax (305) 443-7559www.amweld.org orwww.aws.org

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