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IMA 594CLA

September 2005

Viking STP Part No. 02-0037

Operating Manual

SAFETY DEPENDS ON YOU


LiquidArc machines are designed and built with safety in mind. However, your overall safety can be
increased by proper installation . . . and thoughtful operation on your part. Read and observe the general
safety precautions on page 2 and follow specific installation and operating instructions included in this
manual.
Most importantly, think before you act and be careful.

A Division of The Lincoln Electric Company (Aust) Pty Ltd A.B.N. 36 000 040 308

35 Bryant Street, Padstow, Sydney 2211, Australia


PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND
BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER
EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION.

ARC WELDING SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill ARC RAYS can burn


1. a. The electrode and work (or ground) circuits are 3. a. Use a shield with the proper filter and cover plates to
electrically “hot” when the welder is on. Do not touch protect your eyes from sparks and the rays of the arc
these “hot” parts with your bare skin or wet clothing. when welding or observing open arc welding.
Wear dry, hole-free gloves to insulate hands. Headshield and filter lens should conform to AS
b. In semi-automatic and automatic wire welding, the 1674.2-1990 standards.
electrode, electrode reel, welding head and nozzle or b. Use suitable clothing made from durable flame
semi-automatic welding gun are also electrically “hot”. resistant material to protect your skin and that of your
c. Insulate yourself from work and ground using dry helpers from the arc rays.
insulation. When welding in damp locations, on metal c. Protect other nearby personnel with suitable non
framework such as floors, gratings or scaffolds, and flammable screening and/or warn them not to watch
when in positions such as sitting or Lying, make the arc or expose themselves to the arc rays or to hot
certain the insulation is large enough to cover your full spatter or metal.

WELDING SPARKS can


area of physical contact with work and ground.
d. Always be sure the work cable makes a good electrical

cause fire or explosion


connection with the metal being welded. The
connection should be as close as possible to the area
being welded.
e. Ground the work or metal to be welded to a good
electrical (earth) ground. 4. a. Remove fire hazards from the welding area. If this is
f. Maintain the electrode holder, work clamp, welding not possible, cover them to prevent the welding sparks
cable and welding machine in good, safe operating from starting a fire. Remember that welding sparks and
condition. Replace damaged insulation. hot materials from welding can easily go through small
g. Never dip the electrode holder in water for cooling. cracks and openings to adjacent areas. Have a fire
extinguisher readily available.
h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because b. Where compressed gases are to be used at the job
voltage between the two can be the total of the open site, special precautions should be used to prevent
circuit voltage of both welders. hazardous situations. Refer to AS1674 Parts 1 & 2
i. When working above floor level, protect yourself from “Safety in Welding and Allied Processes”, WTIA
a fall should you get a shock. Technical Note 7 “Health and Safety in Welding” and
the operating information for the equipment being

FUMES AND GASES


j. Also see items 4c and 6.
used.

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.

Page 2 Viking STP IMA 594CLA


CYLINDER may explode if FOR ENGINE
damaged powered equipment
5. a. Use only compressed gas cylinders containing the 7. a. Turn the engine off before troubleshooting
correct shielding gas for the process used and and maintenance work unless the
properly operating regulators, designed for the gas maintenance work requires it to be
and pressure used. All hoses, fittings, etc. should be running.
suitable for the application and maintained in good
condition. b. Operate engines in open, well ventilated
b. Always keep cylinders in an upright position and areas or vent the engine exhaust fumes
securely chained to an undercarriage or fixed support. outdoors.
c. Cylinders should be located :
• Away from areas where they may be struck or c. Do not add fuel near an open flame,
subjected to physical damage. welding arc or when the engine is running.
Stop the engine and allow it to cool before
• A safe distance from arc welding or cutting refuelling to prevent spilled fuel from
operations and any other source of heat, sparks or vaporizing on contact with hot engine
flame. parts and igniting. Do not spill fuel when
d. Never allow the electrode, electrode holder, or any filling tank. If fuel is spilled, wipe it up and
other electrically “hot” parts to touch a cylinder. do not start engine until fumes have been
eliminated.
e. Keep your head and face away from the cylinder valve
outlet when opening the cylinder valve.
d. Keep all equipment, safety guards, covers
f. Valve protection caps should always be in place and
and devices in position and in good repair.
hand-tight except when the cylinder is in use or Keep hands, hair, clothing and tools away
connected for use. from V-belts, gears, fans and all other
g. Read and follow the instructions on compressed gas moving parts when starting, operating or
cylinders and associated equipment, and AS 2030 repairing equipment.

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.

h. To avoid scalding do not remove the


radiator pressure cap when the engine is
hot.

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.

HOW TO ORDER REPLACEMENT PARTS


To ensure that you receive the correct replacement part the following procedure should be followed:
1. Quote Serial Number and Code Number.
2. Quote the Description, Item Number and Parts List Number of the desired part. When ordering parts for items carrying brand
names of other companies, such as fan motors, drive shafts, etc., be sure to include the other company’s name and part number
and other relevant information.
3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric.
4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Field Service Shop. (The “Lincoln Service Directory”
listing these shops geographically is available on request.)
Note: “Hardware” in the Lincoln Parts Lists are not Lincoln stock items but can be obtained via the Field Service Shop network.
Component parts of assemblies such as stator coils or armature coils, etc., which require electrical testing or locating fixtures are not
considered replaceable items. This is to ensure that the customer receives parts which will keep the welder in the best operating condition.

BUY ONLY GENUINE REPAIR PARTS

IMA 594CLA Viking STP Page 3


WELDING, EMF & PACEMAKERS
All welders should follow safe practices that minimise their
exposure to electric and magnetic fields (EMF). Welders with pacemakers

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.

Some researchers have reported that exposure to EMF may


cause leukemia or other illnesses. These claims originally arose In addition to the normal safety precautions, the following
in relation to high voltage electric power lines and are very much additional procedures should be adopted by welders with
in dispute in the medical and scientific arena, however the best pacemakers.
advice is to minimise your exposure to EMF to protect your health • Use gas welding when the application is suitable.
should doctors eventually decide there is a risk.
• Use the lowest current setting appropriate for the
application. Do not exceed 400 amps. Low current
There are four fundamental facts about EMF: (75-200 amps) direct current (DC) welding should be used
if arc welding is necessary. Do not TIG weld with high
• With direct current (DC), the field strength is relatively frequency.
constant and does not change.
• Do not use repeated, short welds. Wait about ten seconds
• With alternating current (AC), the field strength constantly between stopping one weld and starting the next. When
changes. having difficulty starting an electrode, do not re-strike the
• The greater the current flow, i.e. the higher the amps, the rod repeatedly.
stronger the field created by the current • If you feel light headed, dizzy or faint, immediately stop
• The closer the conductor or electrical device is to the body, welding. Lay the electrode holder down so that it does not
the greater the exposure to the field. contact the work and move away from any welding being
performed. Arrange your work in advance so that, if you
become dizzy and drop the electrode holder, the electrode
holder will not fall on your body or strike the work.

Minimising exposure • Do not work on a ladder or other elevated position or in a


cramped, confined place.
• Do not work alone. Work only in the presence of an
individual who understands these precautions and the
All welders should use the following procedures to minimise EMF possible effect welding may have on your pacemaker.
exposure. • Do not work near spot welding equipment.
• If you have a pacemaker and wish to continue arc welding,
• Route electrode or gun and work cables together. Secure discuss this and any other questions you may have with
them with tape if possible. your physician and follow his or her advice. The doctor may
wish to contact the pacemaker manufacturer for a
• Never coil the electrode lead around your body. recommendation. As mentioned before, the design of the
• Do not place your body between the electrode and work pacemaker significantly affects the degree to which it is
cables. If your electrode cable is on your right side the work subject to interference from a welding circuit. Do not rely on
cable should also be on your right side. the fact that you know another welder with a pacemaker
who has welded for years without experiencing a problem.
• Connect the work cable to the work piece as close as
That welder and his or her pacemaker may be quite
possible to the area being welded. (This is also a good
different from you and your pacemaker.
practice to eliminate a common problem on welding - a
poor work connection.
• Do not work next to the welding power source.

Page 4 Viking STP IMA 594CLA


INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY
WARNING
g. The immunity of other equipment in the environment. The
purchaser/user shall ensure that other equipment being
used in the environment is compatible. This may require
additional protection measures;
This welding machine must be used by trained operators
only. Read this manual carefully before attempting to use h. The time of the day that welding or other activities are to be
the welding machine. carried out.
The size of the surrounding area to be considered will depend on
the structure of the building and other activities that are taking
Conformance place. The surrounding area may extend beyond the boundaries
Products displaying the C-Tick mark are in conformity with of the premises.
Australian/New Zealand requirements for Electromagnetic
Compatibility (EMC). They are: Methods of Reducing Emissions
• manufactured in conformity with Australian/New Zealand
Standard (Emission):- AS/NZS 3652 ‘Electromagnetic Mains Supply
Compatibility - Arc Welding Equipment’ (Identical to and
Welding equipment should be connected to the mains supply
reproduced from British Standard EN 50199)
according to the manufacturer’s recommendations.If interference
• for using with other Lincoln Electric/LiquidArc equipment. occurs, it may be necessary to take additional precautions such
as filtering the mains supply. Consideration should be given to
• designed for industrial and professional use.
shielding the supply cable of permanently installed welding
equipment in metallic conduit or equivalent. Shielding should be
Introduction electrically continuous throughout its length. The shielding should
All electrical equipment generates small amounts of electromag- be connected to the welding power source so that good electrical
netic emission. Electrical emission may be transmitted through contact is maintained between the conduit and the welding power
power lines or radiated through space, similar to a radio source enclosure.
transmitter. When emissions are received by other equipment,
electrical interference may result. Electrical emissions may effect Maintenance of the Welding Equipment
many kinds of electrical equipment: other nearby welding The welding equipment should be routinely maintained according
equipment, radio and TV transmitters and receivers, numerical to the manufacturer’s recommendations. All access and service
controlled machines, telephone systems, computers, etc. Be doors and covers should be closed and properly fastened when
aware that interference may result and extra precautions may be the welding equipment is in operation. The welding equipment
required when a welding power source is used in a domestic should not be modified in any way except for those changes and
establishment. adjustment covered in the manufacturer’s instructions. In
particular, the spark gaps of arc initiation and stabilising devices
Installation and Use should be adjusted and maintained according to the
manufacturer’s recommendations.
The purchaser/user is responsible for installing and using the
welding equipment according to the manufacturer’s instructions. If
Welding Cables
electromagnetic disturbances are detected then it shall be the
responsibility of the purchaser/user of the welding equipment to The welding cables should be kept as short as possible and
resolve the situation with the technical assistance of the should be positioned close together, running at or close to the
manufacturer. In some cases this remedial action may be as floor level.
simple as earthing (grounding) the welding circuit (see note
below). In other cases it could involve constructing an electro- Equipotential Bonding
magnetic screen enclosing the power source and the work
complete with associated input filters. In all cases electromagnet- Bonding of all metallic components in the welding installation and
ic disturbances must be reduced to the point where they are no adjacent to it should be considered. However, metallic
longer troublesome. components bonded to the work piece will increase the risk that
the operator could receive a shock by touching these metallic
Note: The welding circuit may or may not be earthed for safety components and the electrode at the same time. The operator
reasons according to national codes. Changing the earthing should be insulated from all such bonded metallic components.
arrangements should only be authorised by a person who is
competent to assess whether the changes increase the risk of Earthing of the workpiece
injury, eg. by allowing parallel welding current return paths which
may damage the earth circuits of other equipment. Where the workpiece is not bonded to earth for electrical safety,
nor connected to earth because of its size and position, eg. ship’s

Assessment of Area hull or building steelwork, a connection bonding the workpiece to


earth may reduce emissions in some, but not all instances. Care
Before installing welding equipment the purchaser/user shall should be taken to prevent the earthing of work pieces increasing
make an assessment of potential problems in the surrounding the risk of injury to users, or damage to other electrical
area. equipment. Where necessary, the connection of the workpiece to
earth should be made by direct connection to the workpiece, but
The following shall be taken into account: in some countries where direct connection is not permitted, the
a. Other supply cables, control cables, signalling and bonding should be achieved by suitable capacitance, selected
telephone cables above, below and adjacent to the welding according to national regulations.
equipment;
Screening and Shielding
b. Radio and television transmitters and receivers;
Selective screening and shielding of other cables and equipment
c. Computer and other control equipment;
in the surrounding area may alleviate problems of interference.
d. Safety critical safety equipment, eg. guarding of industrial Screening of the entire welding installation may be considered for
equipment; special applications.*
e. The health of people around, eg. the use of pacemakers * Portions of the preceding text are contained in AS/NZS3652:
and hearing aids;; ‘Electromagnetic Compatibility - Arc Welding Equipment’.

f. Equipment used for calibration or measurement;

IMA 594CLA Viking STP Page 5


INTRODUCTION
The welding machine you have purchased has been designed and manufactured using the latest inverter technology.
The high working frequency of the Viking STP eliminates the characteristic noise of older inverter power modules.
Variations in the mains supply within the working limits set forth in this manual will not cause any variation in the output welding current.
LiquidArc has compiled this manual in order that the Viking STP may be used with confidence and safety. Therefore all operators should be
fully acquainted with its contents and made aware that failure to follow its safety recommendation could result in serious damage to people
and property.

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

* Viking STP input drops to 8 amps under full short circuit.

Page 6 Viking STP IMA 594CLA


Start-up Procedure Connection to the Mains Supply
WARNING Power Supply
Carefully read the instruction manual before attempting to Before connecting to the supply make sure that the supply voltage
connect the power source to the mains supply or is between 200 and 255 VAC. With voltages greater than 255 VAC
commence work. the power unit goes into a ‘blocked condition’; in order to prevent
damage to the electronic components.
By following these instructions you will avoid damage due to Note: It is compulsory to have an earth connection.
incorrect installation. Damage caused by incorrect use of the
power source is not covered by manufacturers warranty. Protection
This arc welding machine is a power source designed for
The power unit includes protection against:
professional applications and must only be used by trained
personnel. • Mains overvoltage.
The power source has been designed to operate in environments • Overheating.
where conditions are particularly harsh, with ambient
temperatures between -20 and +40°C, and a maximum humidity Mains Voltage Protection
level of 90% up to +20°C and 50% up to +40°C.
The power unit is protected against fluctuations in the mains
1. Do not place the unit close to walls or in positions where
supply. If the input voltage falls outside the specified range the
the airflow through the cooling slots is obstructed or limited
machine will shut down. A condition indicated by LED 5 (See
in any way. Do not cover the power source with rags, sheets
Fig.1) on the front panel. It will remain in this state until the mains
of paper, plastic covers, etc.
voltage returns to within the preset values, at which time the
2. Make sure the room temperature is lower than 40°C and power source will reset automatically. This feature will not give
that the working area is free from corrosive or conducting protection against the high voltage ‘spikes’ discussed above.
pollutants such as:
a. Damp air mixed with acid or salt dust. Overheating Protection
b. Atmospheres with high concentrations of iron or If the temperature inside the machine exceeds a preset value,
metallic dust. thermostats placed inside the power unit will stop the welding
3. Check that the mains voltage conforms to the value operation, LED 4 will indicate this condition. As soon as
indicated for the power supply. conditions return to normal, the power unit will resume
functioning.
Note: The Viking STP must not be powered by a small
engine driven alternator, owing to the possibility of
damage from high voltage input ‘spikes’. Connection
to such an alternator will void the machine warranty.
4. Check that the mains power rating is adequate for the
requirements of the power unit. If in doubt, consult the table
Short Circuit Dynamic Current
5.
under the heading Specifications.
The protection class for the machine is IP23, which means
Control
that the cover of the power unit protects it from external In stick welding, spatter or sticking of the electrode can occur if
bodies having a diameter larger than 12.5 mm and from the current during the metal transfer phase is too high or low.
water spray up to 60° from the vertical. Such conditions occur most frequently with basic electrodes that
Therefore do not: are traditionally difficult to use. To overcome this problem the
power source incorporates a device that allows the operator to set
• Immerse the power unit in liquid of any kind. the optimum current during short circuiting to give smooth metal
• Place it on muddy or damp surfaces. transfer and ease of operation.

• Insert foreign bodies in or around the cooling air slots.


6. Do not use the power unit without its cover; this could
damage the equipment and is extremely dangerous for the
operator.
Ground Test Procedure
As this unit comprises of sensitive electronic components, it is not
recommended to apply high voltage tests to this equipment.

IMA 594CLA Viking STP Page 7


Figure 1

Front Panel Description Back Panel Description


1. Gas Post Flow - adjustable timer control for post flow of 13. On/Off Switch - lit when power is on.
shielding gas in GTAW mode. 0 to 20 seconds.
14. Gas inlet connection - quick-connect gas inlet connection
for compressed air when used in Plasma mode and Argon
shielding gas when used in GTAW mode.
Led Indicators
15. Compressed air filter regulator - connect air supply from
2. Power - lit when “power” is on.
compressor when using in Plasma mode.
3. Air - lit when the value of the cutting torch air pressure falls
below the minimum level required (4bar/400kPa).
4. Temp - lit when thermal-overload protection has activiated.
5. Warning - lit when power source goes in thermal block
caused by the triggering of the protections or by the main
line voltage that at that time has gone above the allowed
threshold.
6. Process selection switch - selects operation mode
between PLASMA / GTAW / MMAW.
7. Output control - controls output for the operating mode
selected:
Plasma 10-35A
GTAW 5-170A
MMAW 5-130A
8. Torch connection
- in Plasma mode, supplies compressed air to the torch
- in GTAW mode, supplies shielding gas to the torch.
9. Switch connection - Arc Start control in the Plasma and
GTAW modes.
10. Work connection - Work lead connection when used in the
Plasma mode.
11. (-) Output connection - Welding output terminal for the
GTAW, MMAW and Plasma modes.
12. (+) Output connection - Work lead connection when used
in the GTAW and MMAW modes.

Page 8 Viking STP IMA 594CLA


OPERATING INSTRUCTIONS
Start-up Cutting
After having connected the air supply, the work return clamp and
Prior to turning the power source on, connect the welding torch turned on the power source, the air supply is on and the regulator
and work return lead for the process (Plasma/GTAW/MMAW) to adjusted to 4 bar. If OK the AIR led on the front panel will be off.
be used.
Set the desired output current using the output adjustment control
Plasma - use the three terminals located on the front panel. located on the front panel between 10 and 35 amps..
Connect the plasma torch to the terminals marked (-), torch and
switch (8, 9 & 11). Connect the work return lead to the terminal To commence cutting, place the cutting nozzle of the torch onto
marked work (10). Also connect clean dry compressed air supply the part to be cut, ensuring that the work return clamp is also
to quick connect inlet on the filter regulator located on the back of attached to the part to be cut. Press the torch button. The pilot arc
the power source (15). will start and transfer to the work piece and the cutting arc will be
started.
GTAW- Connect the GTAW torch shielding gas hose to the
terminal marked torch (8), arc start lead to the socket marked When the cutting process is terminated by breaking contact with
switch (9) and the welding current lead to the terminal marked (-) the part or releasing the torch button, the airflow will continue for
(11). Connect the work return lead to the terminal marked (+) (12). approximately 30 seconds (post-flow) to allow cooling of the torch.
Connect shielding gas hose (supplied) to the quick-connect gas Cutting Speed
inlet connection (14), (bypassing the compressed air regulator).
Connect the other end to the argon flowmeter (supplied) and The cutting speed is a function of:
attach to Argon gas cylinder. a. thickness and kind of material to be cut
Note: Before opening the gas cylinder ensure the flowmeter b. Value of set current. The current setting has an influence
adjustment knob is fully wound anti-clockwise, then slowly over the quality of the cut edge.
open the cylinder valve. Failure to do this may cause damage c. Geometrical shape of the cut (whether straight or curved).
to the flowmeter.
MMAW - Connect the electrode holder lead to the terminal Consumables
marked (-). Connect the work return lead to the terminal marked
(+). The electrode should be changed when tungsten insert is worn to
a depth of 1mm.
The cutting nozzle should be changed when the cutting hole
Turn on the switch located on the back panel. The switch and the becomes elongated or the quality of cut deteriorates.
PWR led indicator on the front panel will light up.
The diffuser swirl ring and the shield retaining cup should be
changed when there are signs of wear or damage.
Select process mode (Plasma/GTAW/MMAW)
GTAW Mode
Set output adjustment to suit the application at hand.
Plasma 10-35 amps Torch Connection
GTAW5-170 amps Connect the GTAW torch and work return leads.
MMAW 5-130 amps Process Selection
Select GTAW on the process selection switch located on the
front panel (6).
Hot Start
Shielding Gas Circuit
A “hot start” system has been built into the welding current
control, which provides a higher striking current to assist ignition The GTAW welding process uses a shielding gas to protect the
of the arc when using the MMAW mode. molten weld pool, usually Argon.
Connect the flowmeter regulator (supplied) to a gas cylinder.
Note: Before opening the gas cylinder, ensure the flowmeter
Plasma mode adjustment knob is fully wound anti-clockwise, then slowly
open the cylinder valve. Failure to do this may cause damage
to the flowmeter.
Torch Connection Connect the gas supply hose to the flowmeter outlet and attach
the quick-connect fitting on the other end of the hose to the gas
Connect the plasma torch and work return leads. inlet connection on the back of the power source (14), (bypassing
Check torch consumables are in place and are in good condition. the air filter regulator). Adjust the flowmeter to 10 L/min.
Replace if worn.
Welding
Process Selection Having connected the shielding gas supply, the work return clamp
Select Plasma on the process selection switch located on the and having turned on the power source, adjust the gas cylinder
front panel (6). flowmeter to 10 L/min.
Set the desired output current between 5 and 170 amps using the
Cutting Gas Circuit output adjustment control located on the front panel (7).

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.

IMA 594CLA Viking STP Page 9


MMAW Mode Welding
After having connected the electrode holder lead and work return
Torch Connection clamp and having turned on the power source, set the desired
output current between 5 and 130 amps, using the output
Connect the electrode and work return leads. adjustment control located on the front panel (7).

Process Selection Hot Start


Select MMAW on the process selection switch located on the A hot start system has been built into the welding current control,

TROUBLESHOOTING WITH POWER ON


front panel (6). which provides a higher striking current to assist ignition of the arc

For safety, replace any components after power off at least two and half minutes.

Mode Problems (Symptoms) Possible Causes Check Recommended Course of Action

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.

No output at active mode. 1. T&C-M. Check if V(+,-)~340V Yes - Replace T&C-M


PWR (LED) lights and. 2. STP29. at STP29 No - Replace STP29.
STP other LEDs do not light

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).

( ) lights at idle condition. 1. T&C-M. Check if ( ) lights at Yes - Replace T&C-M.


Main switch is on. idle condition.

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.

Page 10 Viking STP IMA 594CLA


TROUBLESHOOTING WITH POWER ON
For safety, replace any components after power off at least two and half minutes.

Mode Problems (Symptoms) Possible Causes Check Recommended Course of Action

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.

TROUBLESHOOTING WITH POWER OFF


Check the following after power off at least two and half minutes.

No. Check Recommended Course of Action

1 Check if STP-11 is broken. Yes - Replace T&C-F (STP31).

2 Check if it is short beween +12V and GND at T&C-M (STP30). Yes - Replace T&C-M (STP30).

3 Check if the Bridge (BR4) at STP29 is short. Yes - Replace STP29.

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.

6 Check if R(P+1, P+2) ~ 330Ω at T&C-F1 (STP34). No - Replace T&C-F1.

7 Check if other components are burnt out or broken. Yes - Replace.

Refer to general assembly diagram for location and description of (STP) part numbers.

IMA 594CLA Viking STP Page 11


TROUBLESHOOTING OF T&C-M
For safety, replace any components after power off at least two and half minutes.
Before you go to the troubleshooting of T&C-M, you should go through
the general troubleshooting guide and make sure T&C-M is broken.

Problems (Symptoms) Check Recommended Course of Action

Vcc-GND is short. 1. Check if it is short between Vcc and GND Yes -


(two test pins) at T&C-M. 1. Replace T&C - 1,2,3.
2. Try to replace U7 at T&C-M.
3. Try to replace U22, BR3 and D19-21 at T&C-M.

2. Check if main transformer (STP19) is broken. Yes - Replace main transformer.

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.

3. Check if CN18-2 at T&C-M is negative Yes - Replace T&C-1.


voltage about 10V. No - Try to replace CT (STP35)
or Z1a, Z1b at T&C-M
or T1 at HCPWR-220 (STP29).

No Signal by scope at CN14-3, 4 Check if U7 at T&C-M is broken. Yes - Replace U7.


(at T&C-M). No - Replace T&C-2.

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.

H.F. is normal but output Try and replace CT (STP35) or T&C-1.


current is abnormal.

Main Switch is on. Check if thermal switch is open No - Replace T&C-2.


Thermal (LED) always lights. or connector is loose.

Page 12 Viking STP IMA 594CLA


WIRING DIAGRAM VIKING STP

IMA 594CLA Viking STP Page 13


General Assembly
AP-102C
Operative: 26/6/01
Supersedes: 14/12/98

Page 14 Viking STP IMA 594CLA


AP-102C
Operative: Sep 2003
Supersedes: 26/6/01

# Indicates a change this printing.


* Items not illustrated. Use only the parts marked “X” in the column under the
Recommended Spare Parts are highlighted in bold heading number called for in the model index page.
Nut, bolt and washer sizes are given so they may be procured locally.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Top Cover STP01

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

BOARD COMPONENTS NOT SHOWN


U1, U2 1C2200 (ON T201-P PCB)
U7 IC 4428 (ON T&C-M PCB)
U3, U4 1C4420 (ON T201-P PCB)

IMA 594CLA Viking STP Page 15


P40 Plasma Torch
AP-104C
Operative: 14/12/98
Supersedes: NEW

AIR COOLED TORCH P40 FOR VIKING STP


Technical Data
Security System: Electrical
Ignition: HF ignition electrode to tip.
Max Cutting Current: 50 amp
Gas Supply: Clean, dry air at 4 bar - 120lt/min

Page 16 Viking STP IMA 594CLA


AP-104C
Operative: 14/12/98
Supersedes: NEW

# Indicates a change this printing.


* Items not illustrated. Use only the parts marked “X” in the column under the
Recommended Spare Parts are highlighted in bold heading number called for in the model index page.
Nut, bolt and washer sizes are given so they may be procured locally.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

- P40 torch, complete, 8 metre cable includes 02-0040N 1


- Torch cable 8 metre 02-0053N 1 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

IMA 594CLA Viking STP Page 17


NOTES

Page 18 Viking STP IMA 594CLA


NOTES

IMA 594CLA Viking STP Page 19


LIMITED WARRANTY IMALAWS1 (11/03)

STATEMENT OF LIMITED WARRANTY CONDITION OF WARRANTY


The Lincoln Electric Company (Australia) Pty Limited ("Lincoln") warrants all new TO OBTAIN WARRANTY COVERAGE:
machinery and equipment ("goods") manufactured by Lincoln against defects in The purchaser must contact Lincoln or Lincoln’s Authorised Service Facility about any
workmanship and material subject to certain limitations hereinafter provided. defect claimed under Lincoln’s warranty.
This warranty is void if Lincoln or its Authorised Service Facility finds that the Determination of warranty on welding and cutting equipment will be made by Lincoln or
equipment has been subjected to improper installation, improper care or abnormal Lincoln’s Authorised Service Facility.
operations. WARRANTY REPAIR
PERIOD OF WARRANTY "LIQUIDARC BRANDED GOODS" If Lincoln or Lincoln’s Authorised Service Facility confirms the existence of a defect
covered by this warranty, the defect will be corrected by repair or replacement at
The period from the commencement of the warranty in respect of goods covered by Lincoln’s option.
this warranty shall be as follows:
At Lincoln’s request, the purchaser must return, to Lincoln or its Authorised Service
Five Years Facility, any "Goods" claimed defective under Lincoln’s warranty.
Handymax 160 FREIGHT COSTS
Three Years The purchaser is responsible for shipment to and from the Lincoln Authorised Service
Handymig All Models Facility.
Maxmig All Models WARRANTY LIMITATIONS
Maxidrive All Models Certain conditions warranties and obligations are implied by law (for example under the
Trade Practices Act 1974) and cannot be excluded or modified ("the statutory
One Year
warranties").
Handytig 130
Viking STP Where the statutory warranties do apply then any express warranties given by Lincoln
PJ20 Plasma (the "express warranties") are given in addition and without derogation from the statutory
PJ35 Plasma warranties. Apart from the express warranties and (in cases where they apply by law but
Promax All Models not otherwise) the statutory warranties Lincoln gives no warranties whether express or
Solex Electronic Lenses implied by operation of law or otherwise in respect of any goods manufactured or
Electronic Welding Helmets supplied by Lincoln or by its authorised distributor.
Any warranty whether express or statutory and the term of any such warranty as set out
6 Months
herein commences on the date Lincoln or Lincoln’s authorised distributorship forwards
Printed Circuit Boards All Models
the goods from the premises of Lincoln or Lincoln’s authorised distributor to the
3 Months purchaser.
MIG Torches All Models In respect of any claim under the warranty herein provided a purchaser must furnish
TIG Torches All Models Lincoln with written notice of any claim under the warranty within the time period of the
Plasma Torches All Models warranty as further specified herein.
Gas & Cutting Equipment All Models
The extent of Lincoln’s warranty whether express or statutory is limited to a liability to
repair, replace or pay to the purchaser an amount equal to:
CUSTOMER ASSISTANCE POLICY a) The cost of replacing the goods;
The business of The Lincoln Electric Company is manufacturing and selling high quality b) The cost of obtaining equivalent goods; or
welding equipment, consumables, and cutting equipment. Our challenge is to meet the c) The cost of having the goods repaired whichever remedy in its absolute
needs of our customers and to exceed their expectations. On occasion, purchasers discretion Lincoln chooses.
may ask Lincoln Electric for advice or information about their use of our products. We Upon request by Lincoln the purchaser must permit Lincoln to inspect the goods the
respond to our customers based on the best information in our possession at that time. subject of any claim under this warranty and Lincoln may at its absolute discretion
Lincoln Electric is not in a position to warrant or guarantee such advice and assumes repair or replace the goods F.O.B. at its own premises or at such other premises as
no liability, with respect to such information or advice. We expressly disclaim any Lincoln may designate provided that all freight charges to and from Lincoln’s premises
warranty of any kind, including any warranty of fitness for any customer’s particular or such other premises as Lincoln may designate shall be paid by the purchaser.
purpose, with respect to such information or advice. As a matter of practical
consideration, we also cannot assume any responsibility for updating or correcting any Subject to the express and statutory warranties hereinbefore provided Lincoln provides
such information or advice once it has been given, nor does the provision of no other warranties in respect of the manufacture or sale of goods and in particular
information or advice create, expand or alter any warranty with respect to the sale of Lincoln shall have no responsibility or liability in respect of:
our products. a) Repairs done to Lincoln’s goods and undertaken by the purchaser outside Lincoln’s
Lincoln Electric is a responsive manufacturer, but the selection and use of specific premises without written authority from Lincoln obtained prior to any such repair;
products sold by Lincoln Electric is solely within the control of, and remains the sole b) Any damage or failure of the goods as a result of normal wear and tear or the
responsibility of the customer. Many variables beyond the control of Lincoln Electric affect neglect misuse abuse or failure to properly service goods by any purchaser.
the results obtained in applying this type of fabrication methods and service
requirements. The liability of Lincoln is limited as hereinbefore provided and Lincoln shall not be liable
for any incidental special or consequential damage suffered by a purchaser whether or
not arising out of circumstances known or foreseeable known by Lincoln and in particular
arising out of the supply of goods to a purchaser or the use of goods by a purchaser
whether based on breach of contract negligence or tort.

IN LINE WITH THE COMPANY'S POLICY OF CONTINUING PRODUCT IMPROVEMENT, SPECIFICATIONS HEREIN ARE SUBJECT TO MODIFICATION OR CHANGE WITHOUT NOTICE

Division of The Lincoln Electric Company (Australia) Pty Ltd


A.B.N. 36 000 040 308
35 Bryant Street, Padstow, Sydney 2211, Australia
Telephone: (02) 9772 7222 Fax: (02) 9792 2420
International: Ph: +61 2 9772 7222 Fax: +61 2 9792 2420

In Australia, LiquidArc Technical Sales Representatives are located in, Mackay,


Bundaberg, Brisbane, Newcastle, Wollongong, Sydney, Melbourne, Adelaide and Perth.
To contact your local LiquidArc Technical Sales Representative, call 1300 728 720 (for
the cost of a local call). Lincoln products are sold primarily through its distributors. Our
Regional Office locations are:
Northern Region: Unit 1/15 Westgate St, Wacol, Qld, 4076 (07) 3271 3000
Central Region: 35 Bryant Street, Padstow, NSW, 2211 (02) 9772 7222
Southern Region: 52b Winterton Road, Clayton, VIC, 3168 (03) 9543 9399
Western Region: 25 Barker Street, Belmont, WA, 6104 (08) 9277 8744
New Zealand: 7B/761 Great South Road, Penrose, Auckland (9) 580 4008
Singapore: 11 Pandan Crescent, Singapore (65) 6773 6689

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