Beruflich Dokumente
Kultur Dokumente
September 2005
Operating Manual
A Division of The Lincoln Electric Company (Aust) Pty Ltd A.B.N. 36 000 040 308
can be dangerous
c. When not welding, make certain no part of the
electrode circuit is touching the work or ground.
Accidental contact can cause overheating and create a
fire hazard.
d. Do not heat, cut or weld tanks, drums or containers
2. a. Welding may produce fumes and gases hazardous to until the proper steps have been taken to insure that
health. Avoid breathing these fumes and gases. When such procedures will not cause flammable or toxic
welding, keep your head out of the fume. Use enough vapours from substances inside. These can cause an
ventilation and/or exhaust at the arc to keep fumes and explosion even though the vessel has been “cleaned”.
gases away from the breathing zone. When welding on For information purchase AS 1674-1990.
galvanised, lead or cadmium plated steel and other e. Vent hollow castings or containers before heating,
metals which produce toxic fumes, even greater care cutting or welding. They may explode.
must be taken.
f. Sparks and spatter are thrown from the welding arc.
b. Do not weld in locations near chlorinated hydrocarbon Wear oil free protective garments such as leather
vapours coming from degreasing, cleaning or spraying gloves, heavy shirt, cuffless trousers, high shoes and
operations. The heat and rays of the arc can react with a cap over your hair. Wear ear plugs when welding out
solvent vapours to form phosgene, a highly toxic gas, of position or in confined places. Always wear safety
and other irritating products. glasses with side shields when in a welding area.
c. Shielding gases used for arc welding can displace air
g. Connect the work cable to the work as close to the
and cause injury or death. Always use enough
welding area as possible. Work cables connected to
ventilation, especially in confined areas, to ensure
the building framework or other locations away from
breathing air is safe.
the welding area increase the possibility of the welding
d. Read and understand the manufacturer’ s instructions current passing through lifting chains, crane cables or
for this equipment and the consumables to be used, other alternate circuits. This can create fire hazards or
including the material safety data sheet (MSDS) and overheat lifting chains or cables until they fail.
follow your employer’s safety practices.
h. Also see Item 7c.
e. Also see Item 7b.
FOR ELECTRICALLY
Parts 1 & 2. e. In some cases it may be necessary to
remove safety guards to perform required
powered equipment
maintenance. Remove guards only when
necessary and replace them when the
maintenance requiring their removal is
complete. Always use the greatest care
when working near moving parts.
6. a. Turn off input power using the disconnect switch at the f. Do not put your hands near the engine fan.
fuse box before working on the equipment. Do not attempt to override the governor or
b. Install equipment in accordance with the SAA Wiring idler by pushing on the throttle control rods
Rules, all local codes and the manufacturer’s while the engine is running.
recommendations. g. To prevent accidentally starting petrol
c. Ground the equipment in accordance with the SAA engines while turning the engine or
Wiring Rules and the manufacturer’s welding generator during maintenance
recommendations. work, disconnect the spark plug wires,
distributor cap or magneto wire as
appropriate.
HAVE ALL INSTALLATIONS, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED BY QUALIFIED PEOPLE
For more detailed information it is strongly recommended that you purchase a copy of “Safety in Welding and Cutting - ANSI Standard Z
49.1” and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the Welding Technology Institute of
Australia, P.O. Box 6165, Silverwater NSW 2128. For copies of various Australian Standards contact your local S.A.A. office.
For welders wearing implanted pacemakers, safe welding There is no question that the fields in arc welding can interfere
practices are particularly important and additional procedures with a pacemakers function. Generally the interference does not
should be followed by those who have decided to continue to permanently damage the pacemaker. Once the wearer leaves the
weld. (Hopefully in keeping with a doctor’s advice). arc welding environment or stops welding, the pacemaker returns
to normal functioning. The welding arc has little or no effect on the
operation of some pacemakers, especially designs that are bi-
The following procedures will not eliminate exposure to EMF or polar or designed to filter out such interference.
the possibility of arc welding having an effect on a pacemaker,
however if followed, they will significantly reduce exposure to
electric and magnetic fields. Electric and magnetic fields are For a welder or anyone working around electrical equipment the
created any time electric current flows through a conductor, selection of a pacemaker is very important. Get a doctor’s advice
however it is not clear whether such exposure affects ones health. about which pacemaker is the least sensitive to interference from
welding while still being medically suitable.
INSTRUCTION NOTES
This part of the manual is important for the correct use of the Viking STP. It does not contain specific instructions for maintenance, as this
power source does not require routine service.
The precautions to be taken are those typical for any electrical welding machine with a metallic frame and cover. It is recommended to avoid
hitting, banging and in any way exposing the welding machine to dropping, sources of excessive heat or other such situations.
In case of transportation and/or storage the welding machine should not be exposed to a temperature outside the range of -25 to +55°C.
Should repairs be required, it is possible to follow the instructions provided by the relevant technical service manual. However, this should
not be attempted unless the necessary technical expertise and tools are available. Generally it is recommended that the nearest field
service shop or the manufacturer be contacted.
Maintenance or repairs performed by technical service centre's not authorised by LiquidArc will immediately render null and void the
manufacturer’s warranty.
SPECIFICATIONS
Model Viking STP
Part No: 02-0037
Primary Input: 240V 50Hz
Rated Current to AS1996.1 15A
Maximum input current
under normal operation: 32A*
OCV Max
MMAW/GTAW 70V
Plasma 210V
Output Range
MMAW 5 - 130A
GTAW 5 - 170A
Plasma 10 - 35A
Duty Cycle MMAW TIG PLASMA
100% 65A, 22.6V 105A, 14.2V 17A
60% 110A, 24.4V 130A, 15.2V 28A
35% 130A, 25.2V 170A, 16.8V 35A
Dimensions L x W x D 410 x 164 x 290mm
Weight kg 14kg
The air plasma cutting process uses air as the primary cutting gas Press the torch button. This will start the flow of shielding gas and
and as a torch cooling gas. HF pilot arc and the welding arc will start.
Set the pressure regulator at 4 bar (settings above 5 bar could When the welding process is terminated by releasing the torch
damage the torch) button the shielding gas will continue to flow (post-flow) to allow
the tungsten electrode to cool in an inert atmosphere. This post-
The pilot arc is established using a HF spark and energizing the flow is adjusted, via the post flow control located on the front
electrovalve. panel (1) from 2 to 20 seconds.
For safety, replace any components after power off at least two and half minutes.
Main switch is on. 1. Supply cable and plug 1. Check if STP28 is Yes - Replace STP28.
PWR (LED) does not light. (STP28). broken.
2. Power switch (STP06). 2. Check STP06 Yes - Replace STP06.
3. Main transformer (STP19). 3. R(CN10-1,5)~123Ω No - Replace STP19.
4. T&C-M (STP30). R(CN1-1,2)~1.2Ω No - Replace STP19.
4. V(+12V,GND)~12Ω No - Replace STP30.
at T&C-M.
5. T&C-F (STP31). 5. V(+12V,GND)~12V Yes - Replace STP31.
at T&C-M.
Fan not working. 1. Fan. Remove CN17 or CN9. Yes - Replace fan.
PWR (LED) lights. 2. T&C-M. Check if V(CN17)=15V DC. No - Replace T&C-M (STP30).
Main switch is on. Check if V(CN9)=15V DC.
Output current is out of 1. CT (STP35). Check if output current No - Try to replace CT or T&C-M.
control. 2. T&C-M (STP30). is normal.
( ) lights at active 1. T201-P (STP27.) First check Section “Power Off” Yes - Replace T201-P
condition. 2. Power transformer (STP36). 4 and 5. Remove the No - Replace power transformer.
blue and red lines of power
transformer.
Check if ( ) lights at active
mode.
Thermal (LED) always 1. T&C-M. Short CN12 (1-2) to check Yes - Replace T&C-M.
lights. 2. Thermal switch (STP22 if thermal (LED) lights. No - Replace STP22 or STP38.
or STP38).
No ignition with H.F. 1. Torch cable. 1. Check if torch cable Yes - Replace torch cable.
active condition. is broken.
2. T&C-M. CN6 at T&C-M. 2. Check if H.F. is normal No - Check for 240V @ CN6
(strong enough). if not 240V replace T&C-M or CN6.
3. T&C-F1 (STP34). 3. Same as 2. Yes - Replace T&C-F1.
H.F. fails. 1. H.F. transformer (STP32). 1. Remove CN6 & CN7 No - Replace STP32.
Scratch to ignite at to check if R(CN6)=95Ω,
TIG mode. R(CN7)=31KΩ.
TIG 2. T&C-M. 2. Check if T&C-M is short Yes - Clear T&C-M.
& around CN7, CN8 and CN26.
Plasma
Air or argon always 1. Valve (STP-20) Remove CN5. Check if No - Replace valve.
flows out. CN5~240V at idle mode.
2. T&C-M. Yes - Replace T&C-M.
Valve does not work 1. Valve (STP20) Remove CN5. Check if Yes - Replace valve.
at active mode. CN5~240V at idle mode.
2. T&C-M. No - Replace T&C-M.
GTAW arc will not start 1. Work return lead not 1. Check work return is Connect work return clamp to job.
connected to the job. connected to the job.
2. Work return lead connected 2. Check work return lead is Connect into correct terminal.
to the wrong output connection. plugged into the (+) output
terminal.
3. Microswitch faulty. 3. Check microswitch. Replace microswitch.
4. GTAW process not selected. 4. Check position on process Select GTAW position.
selection switch.
Plasma arc will not start. 1. Work return lead not 1. Check work return is Connect work return clamp to job.
connected to the job. connected to the job.
2. Work return lead connected 2. Check work return lead is Connect into correct terminal.
to the wrong output connection. plugged into plasma work
terminal.
3.Torch cutting nozzle was not Ensure cutting nozzle is in contact
in contact with part to be cut. with job before pushing torch
button.
4. Retaining shield cup 4. Check retaining shield Fit correctly or replace.
incorrectly fitted or missing. cap.
5. Microswitch faulty. 5. Check microswitch. Replace microswitch.
6. Plasma process not 6. Check position on Select Plasma position.
selected. process selection switch.
Poor quality Plasma cut. 1. Consumables worn. 1. Check condition. Change worn consumables.
2. Incorrect travel speed. Change the travel speed to suit
the plate thickness.
3. Incorrect output setting. 3. Check output setting. Adjust output to suit plate
thickness.
Plasma
Plasma consumables 1. Moisture in air supply. 1.Filter regulator. Clean or replace filter.
short life. Ensure clean dry air supply. Add
additional filtering to air supply.
Air (LED) always lights. 1. Air regulator. 1. Check air flow from No - Replace air regulator
plasma torch is normal.
2. Pressure switch (STP21) 2. Short CN11 to check if No - Replace pressure switch.
air (LED) lights.
3. T&C-M. 3. Same as 2. Yes - Replace T&C-M.
H.F. is normal but 1. Air pressure is too high. 1. Check if air pressure is No - Adjust air regulator to 4 bar.
plasma operation is at about 4 bar.
not continually smooth. 2. T&C-F3.. 2. Check if V(CN23)~12V Yes - Replace T&C-F3.
at active mode.
3. T&C-M. Same as 2. No - Replace T&C-M.
MMAW arc will not start 1. Work return lead not 1. Check work return is Connect work return clamp to job.
connected to the job. connected to the job
2. Work return lead connected 2. Check work return lead is Connect into correct terminal.
to the wrong output connection. plugged into the (+) output
terminal.
Stick 3. MMAW process not selected. 3. Check position on Select MMAW position.
process selection switch.
O.C.V. (+,-) is about 100V 1. T&C-M (STP30). Check if V(CN23)~12V. No - Replace T&C-M.
at Stick mode. 2. T&C-F2 (STP17). Yes - Replace T&C-F2.
2 Check if it is short beween +12V and GND at T&C-M (STP30). Yes - Replace T&C-M (STP30).
4 Check if R(G,S) of Q1~4 and Q6~Q9 at T201-P (STP27) No - Replace T201-P (STP27).
is about 1KΩ.
5 Check if each diode (STP24, 25, 26) is short. 1. If STP-24 or STP-26 is short, replace it respectively
2. If STP-25 is short, check each of three STP-25 by disconnecting
the terminal. Replace the defective one.
Refer to general assembly diagram for location and description of (STP) part numbers.
Main Switch is on. Check if U15-2 at T&C-3 is high. Yes - Replace T&C-3.
( ) lights at idle condition. No - Replace T&C-2.
Main switch is on. 1. Check if U15-2 at T&C-3 is high. Yes - Replace T&C-3.
No signal by scope at CN14-1 No - Check U17-7 at T&C-1.
(on T&C-M) at active condition
( ) does not light. 2. Check if U17-7 at T&C-1 is high. Yes - Replace T&C-2.
No - Check CN18-2 at T&C-M.
Signal is at CN14-1,3,4 (at T&C-M) 1. Check if valve operation is normal. No - Replace T&C-2.
but no H.F. Yes - Further check circuit of item 2.
T&C-M is surely broken.
2. Check if circuit around RLY7 Yes - Fix the circuit.
and RLY8 is open. No - Replace T&C-M and reserve T&C-1,2,3.
2 Strap STP-02 1 x x
3 Bracket STP03 2 x x
4 Fan Guard STP04 2 x x
5 Quick Coupler Plug STP05 1 x x
6 Power Switch STP06 2 x x
7 Supply Cable Holder STP07 1 x x
8 160A Socket STP08 3 x x
9 Switch Socket STP09 1 x x
10 Potentiometer 10kΩ (103) STP10 1 x x
11 STP Toggle Switch STP11 1 x x
12 Argon/Air Outlet STP12 1 x x
13 Potentiometer 1MΩ (105) STP13 1 x x
14 LED STP14 4 x x
15 Choke B STP15 1 x x
16 Choke A STP16 1 x x
17 T&C-F2 Printed Circuit Board STP17 1 x x
18 H.F. Transformer STP18 1 x x
19 Transformer STP19 1 x x
20 Solenoid 230V/50Hz STP20 1 x x
21 Pressure Switch STP21 1 x x
22 Thermal Switch 85°C STP22 1 x x
23 RL1 STP23 1 x x
24 Fast Diode 70FLR100S05 STP24 1 x x
25 Fast Diode 70HFL60S02 STP25 3 x x
26 Fast Diode 40HFLR60S02 STP26 1 x x
27 T201-P Printed Circuit Board STP27 1 x x
28 Supply cable & plug STP28 1 x x
29 HCPWR-220 STP29 1 x x
30 T&C-M Printed Circuit Board STP30 1 x x
31 T&C-F Printed Circuit Board STP31 1 x x
32 H.V. Transformer STP32 1 x x
33 Bottom Cover STP33 1 x x
34 T&C-F1 Printed Circuit Board STP34 1 x x
35 200A CT STP35 1 x x
36 Power Transformer STP36 1 x x
37 Rubber Feet STP37 4 x x
38 Thermal Switch 110°C STP38 1 x x
39 Fan STP39 2 x x
40 Isolator STP40 1 x x
41 EMC Filter LC-30A STP41 1 x
* 42 Power Gas Connector STP42 1 x x
* 43 Plug Switch STP43 1 x x
* 44 T&C-1 PCB STP44 1 x x
* 45 T&C-2 PCB STP45 1 x x
* 46 T&C-3 PCB STP46 1 x x
1 Handle 02-0049 1 x
2 Torch body 02-0041 1 x
3 Electrode 02-0045 1 x
4 Diffuser, swirl ring 02-0046 1 x
5 Nozzle 02-0047 1 x
6 Shield retaining cap 02-0048 1 x
7 Microswitch 02-0052 1 x
IN LINE WITH THE COMPANY'S POLICY OF CONTINUING PRODUCT IMPROVEMENT, SPECIFICATIONS HEREIN ARE SUBJECT TO MODIFICATION OR CHANGE WITHOUT NOTICE