1. Introduction
This manual provides comprehensive instructions for the safe and effective operation of your STAHLWERK AC/DC TIG 200 CUT ST 3-in-1 welding and plasma cutting machine. This device combines TIG welding, MMA (ARC) electrode welding, and plasma cutting functionalities. Please read this manual thoroughly before initial use and retain it for future reference.
Figure 1: STAHLWERK AC/DC TIG 200 CUT ST machine with included accessories, including TIG torch, plasma torch, ground clamp, electrode holder, air pressure regulator, and consumables.
2. Safety Instructions
Always prioritize safety when operating welding and plasma cutting equipment. Failure to follow safety guidelines can result in serious injury or death.
- Wear appropriate personal protective equipment (PPE), including a welding helmet with suitable shade, welding gloves, protective clothing, and safety shoes.
- Ensure adequate ventilation to avoid inhaling welding fumes and plasma cutting gases.
- Protect bystanders from arc rays and sparks. Use welding screens or barriers.
- Do not operate the machine in damp or wet conditions.
- Ensure proper grounding of the equipment.
- Disconnect power before performing any maintenance or changing accessories.
- Keep a fire extinguisher readily available.
3. Product Overview and Features
The STAHLWERK AC/DC TIG 200 CUT ST is a versatile 3-in-1 device designed for various metalworking tasks. It integrates TIG welding, MMA welding, and plasma cutting capabilities into a single compact unit.
3.1 Key Features
- 3-in-1 Functionality: Combines AC/DC TIG welding, MMA (ARC) welding up to 200 A, and plasma cutting up to 45 A.
- AC/DC TIG Welding: Suitable for welding almost all metals, including steel, stainless steel, aluminum, and copper, using both alternating current (AC) and direct current (DC).
- Precise Plasma Cutting: Capable of cutting conductive metals such as standard steel, stainless steel, copper, aluminum, and titanium with precision.
- Cutting Thickness: Achieves separation cuts up to 12 mm depending on the material (e.g., ST37 structural steel up to 12 mm, V2A/V4A stainless steel up to 8 mm, aluminum up to 5 mm). Cutting current is continuously adjustable from 20 to 45 A.
- Modern IGBT Technology: Ensures high performance and efficiency across all functions.
- HF Ignition: High-frequency ignition for TIG welding and contact HF ignition for CUT plasma.
- Post-Flow Air: Adjustable post-flow for plasma cutting.
- Compact Design: Weighs 15.65 kg for ease of transport.
- ST-Guard Casing: Robust casing designed to protect against external influences.
- Smart Cooling & Overheat Protection: Maximizes operational duration through high-performance cooling and integrated protection.
- Splash Protection: Designed to maintain welding performance even in challenging conditions.
- Automatic Hotstart Function: Increases voltage automatically for optimal ignition results in MMA welding.
- Stable Arc: Consistent power output for uniform welds.
- Anti-Stick Function: Prevents the electrode from sticking during MMA welding.
Figure 2: Overview of the STAHLWERK AC/DC TIG 200 CUT ST, highlighting its multi-process capabilities.
3.2 Included Components
The package typically includes the main welding machine, TIG torch, plasma torch, ground clamp, electrode holder, air pressure regulator with manometer, various TIG consumables (collets, ceramic nozzles), plasma consumables (electrodes, nozzles), a chipping hammer, and a brush. Specific accessories may vary.
Figure 3: Example of included accessories for the welding machine.
4. Setup
Before operating the machine, ensure it is properly set up according to these instructions.
4.1 Power Connection
- Connect the machine to a suitable power supply as indicated on the machine's rating plate. Ensure the power outlet is properly grounded.
4.2 Gas and Air Connections
- For TIG Welding: Connect the inert gas cylinder (e.g., Argon) to the gas inlet on the rear of the machine using the appropriate hose and regulator.
- For Plasma Cutting: Connect an air compressor to the air inlet on the rear of the machine via the included air pressure regulator. Set the air pressure according to the cutting requirements.
4.3 Torch and Ground Clamp Connection
- Connect the TIG torch, MMA electrode holder, or plasma torch to the corresponding connectors on the front panel.
- Connect the ground clamp cable to the designated ground terminal and securely attach the clamp to the workpiece.
Figure 4: Rear connections for torches, ground, and gas/air supply.
5. Operating Modes
The STAHLWERK AC/DC TIG 200 CUT ST offers three primary operating modes: TIG welding, MMA welding, and Plasma cutting. Select the appropriate mode and adjust settings based on your application.
5.1 Control Panel Overview
The control panel features a digital display, mode selection buttons, and rotary knobs for precise parameter adjustment.
Figure 5: Digital control panel for setting welding and cutting parameters.
- Digital Display: Shows current settings (e.g., amperage).
- Mode Selection Buttons: Toggle between 2T/4T, AC/DC, and TIG/MMA/CUT.
- Rotary Knobs: Adjust parameters such as Gas Pre-Flow, AC Balance, Down Slope, and Gas Post-Flow. The main knob controls Welding/Cutting Current.
5.2 TIG Welding (AC/DC)
TIG welding provides high-quality, precise welds. The AC/DC capability allows for welding a wide range of materials.
- Preparation: Ensure the workpiece is clean. Select the appropriate tungsten electrode and gas lens/collet for the material and current. Connect the TIG torch and inert gas supply.
- Settings: Select TIG mode. Choose AC for aluminum and magnesium, DC for steel, stainless steel, copper, and titanium. Adjust welding current, gas pre-flow, AC balance (for AC TIG), down slope, and gas post-flow according to material thickness and desired weld.
- Operation: Initiate the arc using the HF ignition. Maintain a consistent arc length and feed the filler rod into the weld puddle.
Figure 6: TIG welding in progress, demonstrating precision and control.
5.3 MMA (ARC) Welding
MMA welding is suitable for various applications and materials, particularly for outdoor use or on thicker materials.
- Preparation: Select the appropriate electrode for the material. Connect the electrode holder and ground clamp.
- Settings: Select MMA mode. Adjust the welding current based on the electrode diameter and material thickness. The Hotstart and Anti-Stick functions are automatically engaged.
- Operation: Strike the arc by lightly tapping the electrode on the workpiece. Maintain a consistent arc length and travel speed.
Figure 7: MMA welding in action, showing the arc and sparks.
5.4 Plasma Cutting
Plasma cutting allows for fast and precise cutting of conductive metals.
- Preparation: Connect the plasma torch and air compressor. Ensure the air pressure regulator is set to the recommended pressure. Select the appropriate plasma consumables (nozzle, electrode) for the material and thickness.
- Settings: Select CUT mode. Adjust the cutting current (20-45 A) and air post-flow according to the material type and thickness.
- Operation: Position the torch nozzle close to the workpiece. Initiate the arc (contact HF ignition). Move the torch steadily along the cutting line.
Figure 8: Plasma cutting operation, demonstrating the cutting process.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your welding machine.
- Cleaning: Periodically clean the machine's exterior with a dry cloth. Ensure ventilation openings are free from dust and debris.
- Consumables: Regularly inspect and replace worn TIG tungsten electrodes, ceramic nozzles, gas lenses, plasma electrodes, and nozzles.
- Cables and Connections: Check all cables and connections for damage or loose fittings. Replace damaged cables immediately.
- Air Filter: For plasma cutting, regularly check and clean or replace the air filter in the pressure regulator to ensure clean air supply.
7. Troubleshooting
This section addresses common issues you might encounter during operation.
| Problem | Possible Cause | Solution |
|---|---|---|
| No arc / Weak arc | Improper ground connection, incorrect current setting, worn consumables, power supply issue. | Check ground clamp, adjust current, replace consumables, verify power supply. |
| Poor weld quality | Incorrect settings, contaminated workpiece, improper gas flow (TIG), wrong electrode (MMA). | Adjust parameters, clean workpiece, check gas supply/flow, use correct electrode. |
| Plasma torch not cutting | Low air pressure, worn plasma consumables, incorrect current setting. | Check air pressure, replace nozzle/electrode, adjust cutting current. |
| Overheat indicator active | Exceeded duty cycle, blocked ventilation. | Allow machine to cool down, ensure clear ventilation paths. |
8. Specifications
Technical data for the STAHLWERK AC/DC TIG 200 CUT ST.
| Specification | Value |
|---|---|
| Manufacturer | STAHLWERK |
| Model Number | 6920 |
| Dimensions (L x W x H) | 58 x 41 x 55 cm |
| Weight | 16 kg |
| TIG/MMA Welding Current | Up to 200 A |
| Plasma Cutting Current | 20 - 45 A (continuously adjustable) |
| Max. Cutting Thickness (ST37 Steel) | 12 mm |
| Max. Cutting Thickness (Stainless Steel) | 8 mm |
| Max. Cutting Thickness (Aluminum) | 5 mm |
| Technology | IGBT |
| Spare Parts Availability | Information unavailable |
Figure 9: Machine dimensions for planning workspace and storage.
9. Warranty and Support
STAHLWERK provides comprehensive support for its products.
- Warranty: The product comes with a 7-year warranty, offering extended coverage.
- Support: On-site service and support are available via telephone and email.
- Repairs: An in-house workshop is available for fast repairs.
Figure 10: Overview of STAHLWERK's warranty and support services.
10. Official Product Videos
No official product videos from the seller are available for embedding in this manual.
