1. Introduction
This manual provides comprehensive instructions for the safe and efficient operation of your Stayer PRO MAX 185 HF Inverter Welding Machine. This advanced welding unit is designed for both MMA (Manual Metal Arc) and TIG (Tungsten Inert Gas) welding, featuring High Frequency (HF) ignition, pulsed welding, and synergic functions. Please read this manual thoroughly before operating the equipment to ensure proper use, maximize performance, and maintain safety.
The Stayer PRO MAX 185 HF is a professional-grade inverter welder offering a 100% duty cycle at 30°C ambient air temperature, 185A continuous output, and a no-load voltage of 78Vdc. Its lightweight design (3.8 kg) and robust construction comply with European specifications (2011/65/EU, 2014/35/EU, 2014/30/EU, IEC 60974).
2. Safety Instructions
Welding operations involve significant risks. Always adhere to the following safety precautions to prevent injury or damage.
- Electric Shock: Welding current can cause fatal electric shock. Ensure proper grounding. Do not touch live electrical parts. Wear dry, insulated gloves and protective clothing.
- Fumes and Gases: Welding fumes and gases can be hazardous to your health. Work in a well-ventilated area. Use an exhaust system to remove fumes.
- Arc Rays: Arc rays can burn eyes and skin. Wear a welding helmet with appropriate filter lenses and protective clothing. Protect bystanders with welding screens.
- Fire and Explosion: Welding sparks and hot metal can cause fires or explosions. Keep flammable materials away from the welding area. Have a fire extinguisher readily available.
- Burns: Hot metal and slag can cause severe burns. Wear protective gloves and clothing.
- Noise: Excessive noise can damage hearing. Wear hearing protection.
- Pacemakers: Electromagnetic fields from welding can interfere with pacemakers. Consult your doctor before operating welding equipment.
- Maintenance: Disconnect power before performing any maintenance or service.
WARNING: This equipment generates high frequency (HF) energy. Improper use or maintenance can cause interference with other electronic devices. Ensure all connections are secure and the machine is properly grounded.
3. Product Overview and Components
The Stayer PRO MAX 185 HF is a compact and powerful inverter welding machine. Familiarize yourself with its main components and the accessories included.
Figure 3.1: Front view of the Stayer PRO MAX 185 HF welding machine, showing the digital display, control panel, and output terminals.
Figure 3.2: Overview of the Stayer PRO MAX 185 HF's key features, technical data, and standard accessories. This image highlights the machine's capabilities and included items.
Included Components:
- Power cable: 2m x 2.5mm²
- Electrode holder cable: 4m x 22mm² with power regulator and HF control (2T/4T modes)
- Ground clamp cable: 1.5m x 22mm²
- Plastic carrying case
- User Manual and Warranty
Figure 3.3: Detailed view of the electrode holder, featuring an integrated power regulator and controls for High Frequency (HF) welding in 2T and 4T modes. This allows for precise amperage control directly at the point of welding.
4. Setup
Follow these steps to set up your Stayer PRO MAX 185 HF welding machine for operation.
- Placement: Place the welding machine on a stable, level surface in a well-ventilated area, away from flammable materials.
- Power Connection: Connect the power cable to a suitable power outlet. Ensure the power supply matches the machine's requirements (230V). The machine is designed for safe use with stabilized generators.
- Ground Clamp Connection: Connect the ground clamp cable to the appropriate terminal on the welding machine (usually marked with a negative (-) symbol for MMA or TIG DC). Securely attach the ground clamp to the workpiece or welding table, ensuring good electrical contact.
- Electrode Holder Connection: For MMA welding, connect the electrode holder cable to the positive (+) terminal on the welding machine. For TIG welding, connect the TIG torch (not included, but compatible) to the negative (-) terminal and the ground clamp to the positive (+) terminal for DC TIG.
- Gas Connection (for TIG): If performing TIG welding, connect the inert gas cylinder (e.g., Argon) to the TIG torch and the machine's gas inlet (if applicable for external gas control). Ensure the gas regulator is properly installed and adjusted.
- Electrode/Tungsten Installation:
- MMA: Insert the desired coated electrode into the electrode holder.
- TIG: Install a sharpened tungsten electrode into the TIG torch collet.
- Power On: Turn on the main power switch of the welding machine. The digital display will illuminate.
5. Operating Instructions
The Stayer PRO MAX 185 HF offers multiple welding modes for versatility.
Figure 5.1: The Stayer PRO MAX 185 HF in use, demonstrating its capability for various welding tasks. Always wear appropriate personal protective equipment (PPE) when welding.
5.1. Mode Selection
Use the control panel buttons to select the desired welding mode:
- MMA (Manual Metal Arc / Stick Welding): For welding with coated electrodes.
- MMA Pulsed: For MMA welding with a pulsed current, suitable for thinner materials (starting from 40 Amperes).
- MMA Synergic: Automatically adjusts welding parameters based on electrode type and diameter.
- TIG (Tungsten Inert Gas): For precise welding with a non-consumable tungsten electrode and inert gas.
- TIG Pulsed: For TIG welding with a pulsed current, ideal for thin sheets (starting from 15 Amperes).
All modes can be operated with High Frequency (HF) ignition, eliminating the need to scratch the electrode to start the arc.
5.2. Amperage Adjustment
Adjust the welding current (amperage) using the control knob on the machine's front panel or directly on the electrode holder for fine-tuning. The digital display shows the selected amperage.
5.3. 2T / 4T Modes (for TIG and HF-enabled MMA)
- 2T (Two-Touch): Press and hold the torch trigger to start the arc and weld. Release the trigger to stop.
- 4T (Four-Touch): Press and release the trigger to start the arc. Press and release again to stop. This mode is useful for longer welds as it reduces hand fatigue.
5.4. Welding with Coated Electrodes (MMA)
The PRO MAX 185 HF is optimized for various electrode types, including rutile, basic, cellulosic, stainless steel, cast iron, and high-performance electrodes.
- Select MMA mode.
- Adjust amperage according to electrode diameter and material thickness.
- Use the HF start feature to initiate the arc without scratching.
- Maintain a consistent arc length and travel speed.
5.5. TIG Welding
For TIG welding, ensure you have a compatible TIG torch and inert gas supply.
- Select TIG mode.
- Adjust gas flow rate and amperage.
- Use the HF start to initiate the arc without contaminating the tungsten.
- Maintain proper torch angle and tungsten-to-workpiece distance.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your welding machine. Always disconnect the machine from the power supply before performing any maintenance.
- Cleaning: Periodically clean the exterior of the machine with a dry, soft cloth. Use compressed air to blow out dust and debris from the ventilation openings. Do not use solvents.
- Cable Inspection: Regularly inspect all cables (power, electrode, ground) for cuts, cracks, or damaged insulation. Replace damaged cables immediately.
- Connections: Ensure all electrical connections are tight and free from corrosion.
- Fan: Ensure the cooling fan is free from obstructions and operating correctly. The intelligent fan system adjusts speed based on temperature.
- Storage: Store the machine in a dry, clean environment when not in use.
7. Troubleshooting
If you encounter issues with your welding machine, refer to the following common problems and solutions.
| Problem | Possible Cause | Solution |
|---|---|---|
| Machine does not power on. | No power supply; faulty power cable; internal fault. | Check power outlet and circuit breaker. Inspect power cable. If problem persists, contact support. |
| No arc ignition (MMA). | Poor ground connection; incorrect amperage; damp electrode; faulty electrode holder. | Ensure ground clamp has good contact. Adjust amperage. Use dry electrodes. Check electrode holder connections. |
| Arc is unstable or weak. | Low amperage; poor ground; incorrect electrode type; power supply issues. | Increase amperage. Improve ground connection. Use appropriate electrode. Verify stable power supply. |
| Overheat indicator active. | Exceeded duty cycle; blocked ventilation; high ambient temperature. | Allow machine to cool down. Ensure clear ventilation. Reduce welding time or amperage. |
| HF start not working (TIG/MMA). | Incorrect mode selection; poor ground; faulty torch/electrode holder. | Verify HF mode is selected. Check ground connection. Inspect torch/electrode holder. |
For issues not listed here or if troubleshooting steps do not resolve the problem, please contact Stayer customer support.
8. Specifications
Technical specifications for the Stayer PRO MAX 185 HF Inverter Welding Machine.
- Model Number: 1.3538
- Manufacturer: STAYER
- Welding Current (A, X 100%): 185A
- Electrode Diameter (MMA): 1.6 - 5.0 mm
- Weight: 3.8 kg (machine only), 10 kg (packaged)
- Power Supply: AC/DC, 230V
- Power Consumption (KVA): 5.7 KVA
- No-Load Voltage: 78Vdc
- Duty Cycle (at 30°C): 100%
- Dimensions (machine): 37 x 28 x 15 cm
- Package Dimensions: 52 x 43 x 18 cm
- Protection Class: IP21S
- Standards: Complies with 2011/65/EU, 2014/35/EU, 2014/30/EU, IEC 60974
9. Warranty and Support
Your Stayer PRO MAX 185 HF Inverter Welding Machine comes with a manufacturer's warranty. Please refer to the warranty card included in your package for specific terms and conditions, including coverage period and claim procedures.
For technical assistance, spare parts, or warranty claims, please contact Stayer customer support or your authorized dealer.
Stayer Official Website: www.stayer.es
