Lincoln Electric INVERTEC IM904 User's Manual
Contents
1. ule Y Jio Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo 6 Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos OA VE 5 0 0 9 THEW EKA 9 z Vi S BET freA eis AIX Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo A 520 81 21 18 2 EU OMAR RSR ez 119 59 8 HEHA READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESE2. 2 vL ra 1 zao 2 46 21 5 LE ovn anvo coe e v DIAGRAMS avo Ovi ECH EAE avan asnas 300 053273 130334 90 ET SOVHSINI voez 210012 2090 gt lz 2 0 RE Arer 9 96 nr eu ur en Cie e m avisorau 9 SC ES EN e fase 9021 Budd anya NOLLO3NNOO 39 0 an pa EE NOIL9310Hd zs lar nt aos nonoa HV or MSWHOJSNYML NVW VOB NOLLOSLOMd 210012 VGIONOL 99 LL 3802 99 115 DSALYSANI INVHOVIG INVER
3. A 5 Output Connections externe Seege eegen A 5 Wire Feeder Output Connections ss A 5 0006 2119102 Section B Safety 6 0 08 B 1 General Description B 2 Recommended Equipment sise B 2 Operating ut TEE B 2 Design Features and B 2 Welding E ee B 2 2 Operational Features Controls B 3 Welding 0 6 110 EE B 4 Welding Parameters and Guidelines sse B 5 Welding Procedures for Steel Horizontal Filet B 5 Welding Procedures for Stainless Steel Horizontal Fillet B 6 c Section C 001015266550116 a EE RE C 1 LN 742 or 511 10 Wire Feeder Connection Instructions C 1 1 210 06 nnmnnn nanum nanna nnmnnn nananana nnna nana Section D Safety uiro EE D 1 Input Filter Capacitor Discharge D 1 Preventive Maintenance AER D 2 Troubleshooting nine Section E How Use Troubleshooting GUN Ensiasunnon 1 Troubleshooting Guide us 2 E 6 LB L Te LC Section F Wiring Diagramme EERS F 1 thru F 3 Dimension PM ET F 4 EE 540 Se
4. LEd 2138110 3909 V HO SLNINOdNOD LOVX3 MOHS LON AVI NVHOVIQ SIHL 3191409 V JO ALIISV3ONVHOUSLNI IHL 9 19344 GHVOS 02812 GALNId V 40 HO SLN3NOdWOO 300015 7 LINDUID 742405 OL M AD SIVNINHAL 193NNOO 3009 7 19373 1 201 H3d SNIHOVW INdNI 3SVHd 33H L 404 1InONIO 5 OL M N S IYNINHAL 2 153009 VIH 10818 19071 TVNOLLVN 3SvHd STONIS HOS 318V9 LNANI HLM 63119405 LON 53 NO4 Z 1 0 Aldd NS OL 50 37 3LIHM 8 QFY 8 LO3NNOO 3009 2 10379 TWNOLLVN OL 0 27 N3349 122002 INANI 3SVHd HO NOLLWINSNI A009 3GIAOHd OL 3071 0 37 1 00 14408 OL SQV3 131IHM 9 18 L93NNOO 3009 91419373 1VNOLLVN ONNOY9 OL N3349 193NNOO 3SVHd TIONIS HOS 278 2 1691 HLIM 311006 S3NIHOVW 404 L ova 3svo WUo4ivid asvo AVAL anosus WollO8 VN 40 3015 LN3NOdWOO 0 2230235 9 12 38 6 ALIAVO HOLOSNNOO QNVOB O d 1 40 CAMAN LNONId asyo 3svo 8 8 1009 0109 46513 H3d 21080 5 3
5. Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm INVERTEC STT CE LINCOLN C1 ACCESSORIES c1 OPTIONS ACCESSORIES K940 SENSE LEADS These leads are used to accu rately sense arc voltage One set is required for each STT Il power source A 10 ft and 25 ft set are provid ed as standard with the machine Additional sets are available in 10 ft K940 10 25 ft K940 25 and 50 ft K940 50 lengths K942 1 REMOTE CONTROL Allows remote adjust ment of Peak and Background Current settings REMOTE RECEPTACLE For optional remote interface Connection to the STT 10 Wire Feeder or Robotic Control 1 The 10 pin MS connector labeled Remote Control located on the front panel of the STT is used for remote control of the power source Control for the PEAK PB pot and BACKGROUND BG pot cur rent along with the trigger switch is provide through this connector 2 Refer to figure C 1 below for details about the remote receptacle J38 Note that pins J and B are shorted together This short circuit tells the REMOTE PROTECTION BOARD STT control board to accept PEAK and BACK GROUND inputs on this connector rather than from the front panel controls If this short is removed the front panel controls will be active
6. CS SC oF 75 TRAVEL N Z t 1 11 1 my END VIEW FRONT VIEW Table B 1 100 CO Gas Shield Set for Steel Mode Plate Thickness mm Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm Table B 2 75 CO 25 Ar Gas Shield Set for Steel Mode D Plate Thickness mm Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm OPERATION B 6 Stainless Steel Horizontal Fillet See Table B 3 and B 4 DIRECTION OF TRAVEL ij 75 11 my TOP VIEW 1 1 DIRECTION 7 OF 45 TRAVEL RE CH RECH MER 1 N 11 1 Lu END VIEW FRONT VIEW Table B 3 90 He 7 5 Ar 2 5 CO Gas Shield Set for Steel Mode D Plate Thickness mm Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm Table B 4 98 Ar 2 O2 Gas Shield Set for Stainless Steel Mode Plate Thickness mm
7. 8 1 A 7 WIRE FEEDER J39 N gt ELECTRODE SENSE LEAD PORTION OF G3136 WIRING DIAGRAM REFER TO ACTUAL DIAGRAM PASTED INSIDE YOUR MACHINE INVERTEC STT CE LINCOLN 5 C 2 ACCESSORIES 2 LN 742 STT 10 WIRE FEEDER CONNECTION INSTRUCTIONS The LN 742 or STT 10 is the recommended wire feed er for use with the INVERTEC STT CE Refer to the LN 742 or STT 10 Operator Manual for Wire Feed Operation Refer to Figure C 2 or C 3 and follow the instructions below to connect the LN 742 or STT 10 WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the discon nect switch or fuse box before connecting the wire feeder 1 Turn the INVERTEC STT II CE power off 2 Connect the ARC SENSE LEAD MS connector to the mating connector on STT Il front panel REMOTE a 4 WORK LEAD CONTROL ELECTRODE ARC SENSE ELECT AND ARC SENSE WORK CABLES SHOULD BE TAPED TOGETHER 3 Connect the electrode lead Twist Mate to out put terminal on STT Il 4 Connect the other end of electrode lead Step 3 and the ARC SENSE LEAD lead with ring lug step 2 together to the gun block on the LN 742 5 Connect work lead between STT terminal and the work piece 6 Connect the ARC SENSE LEAD WORK lead with alligator clip to work piece NOTE For best
8. By adding a switch between pins J and a LOCAL REMOTE control switch can be created Switch open for local and closed for remote 3 For robotic control of the PEAK CURRENT a 0 to 10 volt DC signal is applied between pins A and with applied to The BACKGROUND CURRENT is controlled with a similar signal applied between pins A and C with applied to pin C In this application pins J and B must be shorted as described in 2 above NOTE These analog signals should be isolated from the robot circuitry to prevent interference 4 The trigger switch is connected between pins D and F These connections are in parallel with the trigger switch from the wire feeder 5 The digital meters for PEAK and BACKGROUND currents will show preset values in both local and remote operation 0 ARC 5 1 45 go 5 J19 m P a VOLTAGE i 290 1 T Ke 7 BUM CONNECTION i 3 gt 291 4 3 H ARC 4 4 438 i 4 3 Je 2 Ba BG SC 10K 2120 amp 6 J38 10 G 48A 1 9 gt s j PB 330 4 12 65 De 320 8 4 F TRIGGER E 212B amp 5 11 gt H GND lt k 3 Eee lt 2 1 OPTIONAL 298 lt 7 i REMOTE
9. NOTES INVERTEC STT CE LINCOLN 5 NOTES INVERTEC STT CE LINCOLN 5 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO J Keep flammable materials away el material combustible fuera del de trabajo l cart de tout mat riel inflammable Sie brennbarres Material Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra 555 0 5 15 189 12 16 6 2 717 NTUSHILT FSU GH CSA ORIUBRT ER Xe uc a Sal e sis
10. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spill
11. Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 AUG 06 LINCOLN 5 material to protect your skin and that of your helpers from the arc rays Protect other
12. 3003 SNOISH3A 3 0 6 NO IN3S3Hd H3H9IH 60601 3009 SNOISN3A NO 135394 TN H3H9IH 6060 3405 SNOISN3A NO 35230 LON NOISH3A NY3dOHN3 NO LON 40209 Q31SIML Y Jequunu epoo 1ueuudinbe y e 94 6 ou sjeued y JO euo UO ou pejsed si epoo sejnomed oyloeds siy Aq 104 eq jou JO SI 61 SIUL LON JO 2019 16 0 30 1360039 9128 00 ALIAVO 3NFINI bi 18181 EF 181279 NOLLVH3dO 9 96 SI NMOHS NOLLO3NNOO HOH NOLLISOd NI HOLIMS 30 14 HN 13S G3HO LVW V JYV SHOLIOVdVO ZO 19 ON LAS GSHOLWW V SHOLSIS3H H303318 6Y AN Kl elsi EI 13S G3HO1VW V 5300 6 LNALNO nsiHL 0 713 03 1 2 530016 1nd1nO SQ NAHL 1d TN NOILVH3dO 9 SI NMOHS NOILO3NNOO 39 170 04 HO NOLLO3NNOO 31 vitidOHddV NO 0 37 A 39V 1d
13. HA ETBRMLTK EW EL TRHOKRERE RA 2 18 87 18 3 ERE REA ol AIXAM SALAD HAY zeit AS PSP HHCH ani SP A 59 ED 56 15 2 L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
14. SA TR D ve ween NO1ONITHVG 1 VOLE At Epe NOLL23NNOO SNS BOVLION F 2 quos anya iue t a 2 012 DC CH INVERTEC STT CE LINCOLN E 23 LL Ba m A w ONE nn 9e V r1 eg ere om a aa de MT 15 008 7 033104 pa 193NNOO3M 5 Ov YIWYOISNYYL NVW za NOLLI31OMd 210012 Kach 19511 3003 303 39 LLS OALYSANI 9 F 3 DIMENSION PRINT STT CE DIAGRAMS ES 8 e um e Y INVERTEC STT CE LINCOLN E 1 9 98B M18706 NOTES INVERTEC STT CE LINCOLN 5
15. a DC voltmeter Polarity of capacitor terminals is marked on PC board above terminals Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS CAPACITOR TERMINALS Jf PA POWER RESISTOR INSULATED PLIERS INVERTEC STT CE LINCOLN 5 D 2 MAINTENANCE D 2 PREVENTIVE MAINTENANCE 1 Perform the following preventive maintenance pro cedures at least once every six months It is good practice to keep a preventive maintenance record a record tag attached to the machine works best 4 2 Remove the machine wraparound cover and per form the input filter capacitor discharge procedure detailed at the beginning of this chapter 5 3 Clean the inside of the machine with a low pres sure airstream Be sure to clean the following components thoroughly 6 Power Switch Driver Protection and Control printed circuit boards Power Switch Main Transformer Input Rectifier 7 Heat Sink Fins INVERTEC STT LINCOLN 5 Input Filter Capacitors Output Terminals Lower base compartment Examine capacitors for leakage or oozing Replace if needed Examine wraparound cover for dents or breakage Repair as needed Cover must be kept in good condition to assure high voltage parts are protected and correct spacings are maintained Check electrical ground continuity Using an ohm meter me
16. input voltages fuses and time power is applied to the input voltage reconnect proce machine dures See Installation section 2 If high input voltage 380VAC or higher is applied the capacitors may need conditioning Let the unloaded machine idle for 30 minutes Machine loses output while welding 1 Check to make sure the fans are The thermal indicator light is lit running and operating correctly Normal welding output returns after about 10 minutes Welding application may exceed recommended duty cycle If all recommended possible areas of misadjustment have 7 Dirt and dust may have clogged checked and the problem persists the cooling channels Blow out Contact your local Lincoln unit with clean dry compressed Authorized Field Service al Facility Air intake and exhaust louvers may be blocked due to inade quate clearance around machine Machine has low OCV and loses 1 Check for faulty connection on output while attempting to weld plug J1 on Control Board and plug J1 on Current Sense Board Check for faulty Current Sense Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC STT II CE LINCOLN 5 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of
17. knob allows preset adjustment of the amplitude of the background current up to 125 amperes 2B BACKGROUND CURRENT DISPLAY METER This is a digital meter for displaying the preset Background Current This meter GA 9 displays 1 increments This meter does not indicate the actual welding cur rent only the preset current CURRENT OUTPUT CONTROL The beginning portion of the welding arc is a pulse of current referred to as Peak Current This knob allows preset adjust ment of the amplitude of the peak current up to 450 amperes 3B PEAK CURRENT DISPLAY METER This is a digital meter for displaying the preset GA Peak Current This meter displays in 1 amp increments This meter does not indicate actual welding current only the preset current 4 HOT START CONTROL POTENTIOMETER 50 more current during the initial start of the weld for improved arc starting and bead appearance This control adjusts the dura tion of this Hot Start current The control range is from 0 to 10 where 0 corresponds to the zero or no Hot Start and 10 is maximum for a Hot Start lasting for about four 4 seconds Hot Start provides approximately 25 to TAILOUT Alters the current waveform to increase deposit rate and travel speed The Minimum set ting sets STT Il to the original STT waveform As tailout is increased peak and Background current may need to be reduced
18. nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 3 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying ope
19. not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 5 CYLINDER may explode if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properl
20. opere com 25 tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e 47TTLA 351 515 2 e 1 5 51 e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes e opere com os paineis abertos ou guardas removidas 0 91 1 THE RE ERE 21 58 25 21 2517 25 x e maol wel Me z e Aale WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO J Keep flammable materials away el material combustible fuera del rea de trabajo Kg l cart de tout mat riel inflammable AP ternen Sie brennbarres Material LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR SBM BHO gt
21. right inside edge of the machine up to the power switch located on the front panel 4 Strip away 102 mm 4 in of the outer jacket Trim fillers and strip conductor jackets to connect to the power switch ductors to the power switch termi nals labeled U V and W Tighten the connections to 3 0 Nm 27 in Ib torque 5 Connect the three phase line con D 6 Securely tighten the cable strain relief located on the case back of the machine GROUND CONNECTION 1 Connect the ground terminal to earth ground per National Electrical Code 2 Replace the wraparound cover of the INVERTEC STT II CE INVERTEC STT Il CE LINCOLN 5 A 5 ACCESS DOOR LOCATION VOLTAGE SWITCH 4A SLOW BLOW FUSE 380 415 OR 380 460 440 460 200 230 OR 200 208 200 208 NOT PRESENT ON ALL MODELS FIGURE A 2 RECONNECT PANEL INPUT VOLTAGE RECONNECT PROCEDURE As shipped from the factory multiple voltage machines are internally configured for the highest input voltage 440 460 VAC for Code 11366 and 380 415 VAC for Code 11367 1 For Connections to 440 or 460 VAC verify the internal configurations to the procedures shown below and refer to Figure A 2 2 For Connections to 200 208 220 230 380 400 or 415 VAC follow the procedure shown below and refer to figure A 2 A WARNING NOTE Turn main power to the machine OFF before performing the reconnect procedure Failure to d
22. the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page LCE i iv 51211211017 E Section A Technical Specifications ss A 1 A 2 200611011 A 3 cred eM E A 3 UU ue NEE A 3 Machine Grounding and High Frequency Interference Protection A 3 36 A 3 Supply CONNECIIONS Input Cable Installation and A 4 Ground 6611017 2 name d esse KEA A 4 Input Voltage Reconnect Procedure
23. the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire
24. 15 ELECTRODE TERMINAL This twist mate connection is the positive output ter minal for connecting an electrode cable to the wire feeder conductor block Refer to the Accessories Section for wire feeder connection instructions WELDING OPERATION Familiarize yourself with the controls on the INVERTEC STT II CE before beginning to weld Familiarize yourself with the operating manual for the wire feeder and the wire feeder controls before begin ning to weld Set the Wire Size and Wire Type selection switches per the appropriate wire Refer to Operational Features and Controls in this section for the function of these switches INVERTEC STT CE LINCOLN B 5 WELDING PARAMETERS AND GUIDE LINES The INVERTEC STT CE is neither a constant cur rent CC nor a constant voltage CV power source In general wire diameter will be increased one size compared to conventional CV power sources The larger the wire diameter the higher the deposition rate Up to 1 16 Wire sizes below 035 are unnecessary for most applications The INVERTEC STT CE is a current controlled machine which is capable of chang ing the electrode current quickly in order to respond to the instantaneous requirements of the arc and opti mize performance sensing changes in welding current and hence the electrode state the power source will supply varying output currents to minimize spatter The Peak and Background curren
25. INVERTEC STT ge For use with machines having Code Numbers 11366 11367 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful ISO IEC 60974 1 CC OPERATOR S MANUAL Kc RM EEE 180 9001 Desi pn ined and Manufac ality Program Ci d b COLN e Copyright 2006 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS
26. LEAD ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON THE WIRE FEEDER CONTACT BLOCK REMOTE ND ARC SENSE LEAD WORK SHOULD BE LOCATED AS CLOSE AS POSSIBLE TO THE WELDING ARC 17657 3 FIGURE STT 10 to STT CONNECTION INVERTEC STT CE LINCOLN 5 D 1 WARNING 09 to follow this capacitor discharge procedure can result in electric shock INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Turn off input power or disconnect input power lines 2 Remove hex head screws from side and top of machine and remove wrap around machine cover 8 Be careful not to make contact with the capacitor terminals that are located in the center of the Switch Boards 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE MAINTENANCE D 1 5 Locate the two capacitor terminals large hex head cap screws shown in Figure 0 1 Use safety glasses electrically insulated gloves and insulated pliers Hold body of the resistor and connect resistor leads across the two capacitor ter minals Hold resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat discharge procedure for capacitor on other side of machine Check voltage across terminals of all capacitors with
27. LTAGE AUXILIARY POWER Peak Current 0 450 Amps 88 VDC Maximum 115 4 Amps Background 0 125 Amps 42 VAC 4 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT VOLTAGE FUSE SUPER LAG INPUT AMPERE TYPE 75 C TYPE 75 C AND FREQUENCY OR BREAKER RATING ON COPPER COPPER SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE IN CONDUIT IN CONDUIT AWG IEC SIZES AWG IEC SIZES 200 50 60 208 50 60 380 50 60 400 50 60 415 50 60 WEIGHT 100 Ibs 46 kg 1115 VAC not present on European Models INVERTEC STT Il CE LINCOLN 5 A 3 Read and understand entire Installation Section before starting installation WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before installing this equipment Turn the power switch on the Invertec STT OFF before connecting or discon necting input power lines output cables or control cables Do not touch electrically hot parts Always connect the ground terminal toa good electrical earth ground SELECT SUITABLE LOCATION Locate the machine where there is free circulation of clean air Place the machine so that air can freely cir culate into the sides and out of the rear of the machine Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatur
28. N SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te a l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 5 98 688 5 29 12 2 235 V KEE ER e SH7IAE e SHAB MAS sis PARAH 587E 7 lue d bacs oe Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien 9 Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten
29. T CONNECTIONS Refer to the Accessories section of this manual for instructions on connecting a wire feeder to the INVERTEC STT II CE The LN 742 or STT 10 wire feeder is the recommended feeder for use with the INVERTEC STT CE INVERTEC STT Il CE LINCOLN 5 B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand entire section before operating machine GENERAL WARNINGS SAFETY PRECAUTIONS WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 4 40 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles DW can burn Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual INVERTEC STT CE LINCOLN 5 B 2 OPERATION GENERAL DESCRIPTION The INVERTEC STT II CE is a 225 ampere inverter based arc welding power source specifically designed for the STT welding process It is neither a constant current CC nor a constant voltage CV machine It is a power source that delivers current of a desired wave form and characteristics that are supe
30. TEC STT CE LINCOLN E Jequunu epoo 1ueuudinbe y e 94 6311 5 eu sjeued y JO euo UO y CN LI LL peised s epoo 104 2112505 siy Aq je 104 eq jou u UO e2u949J8J 104 SI SIUL LON 19479 HOLVOIQNI KO 329 CH 10H ssswivis VISE SNOISN3A NO 1IN3S3Hd TN SNOISHAA NO 1435344 LON SNOISH3A NO 3534 LON HO SHIM 03151 11 V S3LON3Q NOILVH3dO 614 088 SI NMOHS NOLLOSNNOO 39 110 04 HO3 NOILISOd 31WIHdOHdAY NI HOLIMS 3OV 1d 195 G3HOLVW V SHO IOVdVO 22 10 O N LAS Q3H91VW V 01915 35 4303778 6H LH AN LAS V 9300 0 1nd 100 7186 03 01 38V 530010 1Nd1NO SQ LA NOILVH3dO SI NMOHS NOLIO3NNOO 29 1710 LNdNI NOLLO3NNOO 2171 03 NO QV31 V 20714 ON 3009 V 9NIAVH 20 LOVX3 MOHS LON WVHOVIC SIHL 2313191 03 V 40 ALITISVSONVHOMALNI ONLL9344
31. V 1 GHVOS 0212 GALNIMd 40 SIN3NOdOO 3ONIS ON 1 0 14408 OL STWNIWYAL S309 779 1 313 W901 3NIHOVIN ANNOYS INANI 3517 13 3211 11 03 LINDYID 6 OL M n STVNINYAL 193NNOO 8309 7 9 313 7 907 TWNOLLWN SSWHd 3 TONIS HO 2318 2 1014001 31194405 LON SANIHOVN Z LINDYID 74405 OL 50 37 1 L3NNOO 3009 91419373 TWNOILVN 0 66 5 OL 0 27 N3349 133002 10911 357 9 33 11 NOILYTNSNI A009 OL 3dV L 0 2 LINDUID 74408 OL 50931 211 3 03 3009 91419313 TYNOLLYN Yad 0 602 5 OL 27 LO3NNOO 1 9 3SvHd 319NIS 278 2 16 02144605 S3NIHOVW L VN 313W 30 O3M3IA LNONId a a 1 3909 Ca HO1O3NNOO 3015 31M WOH3 0 2326535 HOIO3NNOO DREI SEET 821121121121212 SEI Zd 7 Dnm 6 626 SHOLO3NNOO 7310 14053 JO au
32. VOg 40 adis IN3NOdWOO 0 301130639 ONRI3SWAN ALIAVO 012230062 4 6 noc 9 noc 4 569 9 3 ser er SE 7 9 9 vie n Arer Rasa ia e o cj eer ir or 45918 Had STOSWAS 710313 cer aus aNnouoxova ay VA 280 DIAGRAMS WA 180 co H ate C kz ot zr eo 0 ser gt gt pum um Tr VA Ue 207 0 su ET E 90 OWA ler 520 4 woen 2090 30334 K EN LOWY oz wz YIWYOJSNVYL GG D DEEN 109 az lt el SS m K ch Keen nace w 9 gt I we va vil e HI Fre TZ wes lt Ki en E vr K gE 38 Hose 0 Ge var lt aio a A vits Live e
33. ant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on
34. ase back of the machine See figure A 1 for location of the rating plate The INVERTEC STT II CE should be connected only by a qualified electrician Installation should be made in accordance with local and national codes Refer to the Technical Specifications at the beginning of this section for proper fuse sizes ground wire and input supply power cable sizes Some models come from the factory with an input power cord If your model does not include the input power cord install the proper size input cable and ground cable according to INPUT CABLE INSTALLA TION AND CONNECTION INVERTEC STT Il CE LINCOLN 5 me INSTALLATION A 4 CASE BACK INPUT CABLE ENTRY ACCESS RATING PLATE amp CABLE STRAIN RELIEF FIGURE A 1 CASE BACK INPUT CABLE INSTALLATION AND CON NECTION A cable strain relief is provided at the supply line entry and is designed to accommodate cable diameters of 310 1 070 in 7 9 27 2 mm On European models the strain relief is designed to accommodate cable diameters of 709 1 000 in 18 0 25 4 mm Refer to Technical Specifications at the beginning of this section for the proper input cable sizes Refer to Figure A 1 and perform the following steps 1 Remove the wraparound cover of the INVERTEC STT II CE 2 Feed the input cable through the input cable entry access hole at the right rear of the machine 3 Route the cable through the cable hangers located along the lower
35. asure resistance between either output stud and an unpainted surface of the machine case Meter reading should be 500 000 ohms or more If meter reading is less than 500 000 ohms check for electrical components that are not prop erly insulated from the case Correct insulation if needed Replace machine cover and screws Il CE 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to c
36. ct for procedure being used Shield work from excessive outside air currents Check gun and nozzle for leaks or obstructions Make certain machine and wire feed settings are correct for process Weld bead appears cold One or more of the machine set tings may be wrong Check the Background Peak Current it al recommended possible areas Tailout and wire speed controls of misadjustment have been for proper settings Adjust for checked and the problem persists optimum welding performance Contact your local Lincoln Authorized Field Service Make sure the Wire Type and Facility Wire Size switches are in the cor rect position for the electrode wire being used Molten weld puddle appears exces 1 The Wire Type switch may be in sively violent the wrong position for the elec trode wire being used The Peak Current setting may be too high Adjust for optimum welding performance CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC STT CE LINCOLN 5 F 1 00579 NOLVOIONI QvoTi3 o KO azs JOHLNOO LHYLS LOH 008 mem Hp KETTEN aNnouoxova KE eene aia aNnosoxova 8 01
37. d the manufacturer s recommendations Mar 95 SAFETY PR CAUTIONS DE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la mach
38. ed wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit guards to perform required 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the idler by pushing on the throttle control rods while
39. eing activated indicating that too much output current is being drawn from the machine Reduce weld ing current demands or remove fault in welding cables Make sure that the gun tip is not shorted to the work surface and that the proper welding proce dures are being used Power switch must be in the ON position Check the input voltage Make sure all three phases are applied to the machine With input power removed check that the input voltage set up switch and jumper A the reconnect auxiliary jumper are in the proper position for input volt age being used See Reconnect Procedure in the Installation Section With input power removed check continuity of 3 amp slow blow fuse located on reconnect panel CAUTION RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have 7 checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC STT CE LINCOLN 5 E 4 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION OUTPUT PROBLEMS No output or reduced output the first 1 Check
40. es and nuisance shut down of the INVERTEC STT II CE This machine carries an enclosure rating of IP21S It should not be placed in extremely damp or dirty loca tions It should not be exposed to rain or snow STACKING The INVERTEC STT II CE cannot be stacked TILTING Place the machine on a secure level surface other wise the unit may topple over INSTALLATION A 3 MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION The machine may not be suitable for use in an envi ronment where high frequency is present For exam ple do not place the machine in close proximity to TIG or PLASMA operations To minimize high fre quency interference Locate the STT power source more than 15 feet 4 5 m away from high frequency units and more than 25 feet 7 6 m separation between ground connections or welding arcs of high frequency units Provide proper electrical ground to the machine per local and national electrical codes INPUT CONNECTIONS FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE IMMEDIATE FAILURE OF COMPO NENTS WITHIN THE WELDER Turn the input power off at the disconnect switch before attempting to connect the input power lines Connect the green lead of the power cord to ground per local and national electrical codes SUPPLY CONNECTIONS Be sure the voltage phase and frequency of the input supply is as specified on the rating plate Input Power supply line entry in provided on the c
41. g Background Current Optimum Note Background Current levels for applications using 100 CO is less than similar procedures involving gas blends with high percentages of Argon This is a result of the greater heat generated in the 10096 CO2 arc 10096 CO is 35 volts cm and 10096 Argon is 20 volts cm 7596 Argon 25 CO is about 24 volts cm Contact Tip to Work Distance Short Long Optimum HOT START The Hot Start control can be set to enhance establish ing the arc and provide the capability of increasing the heat at the start of the weld to compensate for a cold work piece Hot start adjusts the time that additional current is applied during the starting of the arc Refer to Operational Features and Controls in this section for a description of this control TAILOUT The tail out provides additional heat without the molten droplet becoming too large Increase as necessary to add Heat to the arc without increasing arc length This will allow for faster travel speeds and produce improved wetting As tailout is increased the peal and or background current is usually reduced WELDING ARC PERFORMANCE For optimum spatter reduction the arc should be con centrated on the puddle INVERTEC STT Il CE LINCOLN B 6 WELDING PROCEDURES FOR STT II Steel Horizontal Fillet See Table B 1 and B 2 DIRECTION OF TRAVEL 11 TOP VIEW 1 1 DIRECTION
42. he sary Authorized Field Service gun trigger is pulled Facility Put a jumper between pins A and C on the 5 pin MS connec tor located on the LN742 wire feeder wire feeds check the gun trigger Repair or replace if necessary 3 Check for the presence of 42AC at pins and 4 on the 14 pin MS connector If the 42VAC is present and the feeder does not work the problem is in the feeder control cable s or the wire feed er CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC STT CE LINCOLN 5 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No output Main fuses open indicat ing excessive current draw Machine loses output when gun trig ger is pulled or arc is struck Machine output returns after a few seconds and trigger is pulled again The Thermal indicator light is lit Machine is dead fans no display no output no POSSIBLE CAUSE OUTPUT PROBLEMS 1 With input power removed inspect input leads for possible shorts or grounds or misconnec tions Install new fuses and reapply power If fuses open again con tact your local Lincoln Authorized Field Service Facility The over current sensor is b
43. ine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxique
44. o so will result in damage to the machine DO NOT switch the reconnect bar with machine power ON To Operate at Procedure 460 or 440 VAC Code 11366 1 Open reconnect panel access door on wraparound 2 Move input voltage switch to Voltage 380 460V pos ition 3 Move lead A to 440 460 Terminal INSTALLATION A 5 380 or 415 VAC Codes 11366 Open reconnect panel access door on wraparound Move input voltage switch to Voltage 380 460V position Move lead to 380 415 Terminal 380 400 or 415 VAC Codes 11367 Open reconnect panel access door on wraparound D Move input voltage switch to Voltage 380 415V position Move lead to 380 415 Terminal 220 or 230 VAC Codes 11366 Open reconnect panel access door on wraparound Move input voltage switch to Voltage 200 230V position Move lead A to 220 230 Terminal 200 or 208 VAC Codes 11366 Open reconnect panel access door on wraparound Move input voltage switch to Voltage 200 230V position Move lead to 200 208 Terminal 200 or 208 VAC Codes 11367 Open reconnect panel access door on wraparound Move input voltage switch to Voltage 200 230V position Move lead A to 200 208 Terminal OUTPUT CONNECTIONS WIRE FEEDER OUTPU
45. ontact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC STT CE LINCOLN 5 E 2 TROUBLESHOOTING E 2 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage 1 Contact your local Lincoln is evident Authorized Field Service Facility Machine has no open circuit voltage 1 Check the control cable between Wire feeds ok the feeder and the STT II unit Make sure the 2 and 4 leads are intact Put a jumper wire between Pins C and D on the 14 pin MS connector If normal open circuit voltage 85VDC is restored then the problem is in feeder control cable or the wire feeder all recommended possible areas BE of misadjustment have been Machine has no welding output no 1 The 42VAC circuit breaker CB1 checked and the problem persists open circuit voltage and the wire be tripped Reset if neces Contact your local Lincoln feeder does not feed wire when t
46. rations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 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 Do
47. ries vi 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS INVERTEC STT II CE For Code 11366 INPUT THREE PHASE ONLY STANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT 200 220 380 415 440 3 50 60 HZ 33 30 1 8 17 16 RATED OUTPUT AMPS VOLSATRATEDAMPS 60 Duty Cycle 225 29 100 Duty Cycle 200 28 OUTPUT CURRENT RANGE OPEN CIRCUIT VOLTAGE AUXILIARY POWER Peak Current 0 450 Amps 85 VDC Maximum 115 4 Amps Background 0 125 Amps 42 VAC 4 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT VOLTAGE FUSE SUPER LAG INPUT AMPERE TYPE 75 C TYPE 75 C AND FREQUENCY OR BREAKER RATING ON COPPER COPPER SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE IN CONDUIT IN CONDUIT AWG IEC SIZES AWG IEC SIZES 200 50 60 220 50 60 10 6 mm2 10 6 mm2 380 50 60 415 50 60 440 50 60 WEIGHT 100 Ibs 46 kg At low input voltages below 208 VAC and input voltages of 380 VAC through 415 VAC there may be a 15 reduction in Peak Current 115 VAC not present on European Models INVERTEC STT Il CE LINCOLN 5 A 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS STT II CE For Code 11367 INPUT THREE PHASE ONLY STANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT 200 208 380 400 415 3 50 60 HZ 36 34 20 19 18 RATED OUTPUT DUTY CYCLE VOLTS AT RATED AMPS 60 Duty Cycle 225 29 100 Duty Cycle 200 28 OUTPUT CURRENT RANGE OPEN CIRCUIT VO
48. rior to con ventional short circuiting GMAW The process is opti mized for short circuiting GMAW welding G RECOMMENDED EQUIPMENT The LN 742 or STT 10 wire feeder is recommended for use with the STT Il The LN 7 GMA LN 9 GMA NA 5 and NA 5R can all be used with the STT Il However these units can only be used to feed wire since these feeders have no provision for control of the STT output OPERATING CONTROLS The INVERTEC STT II CE has the following controls as standard On Off switch Peak Current adjustment Background Current adjustment Hot Start adjustment Tailout and 2 toggle switches one for wire size selec tion and one for wire type selection DESIGN FEATURES AND ADVANTAGES State of the art inverter technology yields high power efficiency excellent welding performance lightweight and compact design e Twist Mate output terminals Digital meters for procedure settings are standard e Automatic Inductance or Pinch Control Solid state circuitry for extra long component life Current feedback ensures that original procedure settings all remain constant Arc Sense lead assembly Electrode and Work connects through a 4 pin case front connector Peak Current and Background Current may be remotely controlled Thermostat and FET over current protector prevent overheating from overloads high ambient tempera tures or loss of air flow e High temperature Class H insulation e Protection circuit
49. s Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER dd TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Aut
50. s and ample safety margins prevent damage to the solid state components from tran sient voltages and high currents e Preset welding current capability e STT Il offers improvements over the previous model Approximately 40 increase in deposition rate capability and a significant increase in travel speed WELDING CAPABILITY The INVERTEC STT II CE is rated at 225 amps 29 volts at 60 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents If the duty cycle s are exceeded a thermal protector will shut off the output until the machine cools to a rea sonable operating temperature LIMITATIONS May not be suitable for use in an environment with High Frequency present See Machine Grounding and High Frequency Protection in the Installation section of this manual e Suitable for indoor use only IEC IP21S INVERTEC STT CE LINCOLN B 3 OPERATION ES OPERATIONAL FEATURES AND CONTROLS All operator controls are located on the case front of the INVERTEC STT CE Refer to Figure B 1 for locations FIGURE B 1 CASE FRONT CONTROLS 1 POWER SWITCH Turns output power ON and OFF This switch DA ON also controls auxiliary power available through the 14 pin Wire Feeder Receptacle O OFF 2A BACKGROUND CURRENT OUTPUT CON TROL The output current is switched to the Background level at the conclusion VAS the preceding Peak Current pulse This
51. this manual PROBLEMS SYMPTOMS Excessive weld spatter Arc sounds and looks like a standard MIG process The wire burns back to the tip Poor welding weld settings drift or output power is low POSSIBLE CAUSE OUTPUT PROBLEMS 1 Check the Arc Sense leads for loose or faulty connections 2 Make sure the Arc Sense WORK lead is as close as pos sible to the welding arc 3 Make sure the machine and wire feed settings are correct for the process and wire being used 1 Remove P1 from the control board if the machine noodle welds the current sense board is bad 1 Make sure machine settings are correct for welding process being used 2 Check welding cables for loose or faulty connections CAUTION RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have 7 checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC STT CE LINCOLN 5 E 6 TROUBLESHOOTING E 6 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION OUTPUT PROBLEMS Porosity in the weld Make sure proper gas type and flow rate is corre
52. to maintain optimum per formance INVERTEC STT CE LINCOLN B 4 6 WIRE SIZE SELECT SWITCH This toggle switch selects between electrode diameters of 035 1 mm and smaller or 045 1 2 mm and larger The 035 1 mm position provides improved perfor mance of smaller diameter wires at higher wire feed speeds 7 WIRE TYPE SELECT SWITCH This toggle switch selects between mild or stainless steel In the stain less position the pulse width of the Peak Current is changed from 1 to 2 ms for better performance for stainless steel welding This light will indicate that either the internal thermostat s or the FET over current sen sor has actuated Machine output will return after the internal components have returned to normal operating temperature if the thermostat s opened or after about 3 7 seconds if the FET over current sensor activated 9 REMOTE RECEPTACLE This is a 10 pin MS type connector for remote control of Peak Current and Background Current Trigger switch connec tions are also provided The presence of the mating connec tor is automatically sensed disabling the front panel Peak and Background Current controls Refer to REMOTE CON TROL CONNECTOR in the ACCESSORIES Section of this manual for more information 8 THERMAL SHUT DOWN INDICATOR E pin MS type connector for the wire feeder connection 115 and 42 VAC along with the trigger switch connections are provided Onl
53. ts are two such current outputs that can be adjusted Wire Feed Speed controls the deposition rate Peak Current controls the Arc Length Background Current controls the Bead Contour And Tailout increases Power in the Arc PEAK CURRENT The Peak Current control acts similar to an arc pinch control Peak current serves to establish the arc length and promote good fusion Higher peak current levels will cause the arc to broaden momentarily while increasing the arc length If set too high globular type transfer will occur Setting this level to low will cause instability and wire stubbing In practice this current level should be adjusted for minimum spatter and puddle agitation Adjust Arc Length with Peak Current Low Optimum High Note In 10096 CO shielding gas applications the peak current level should be set greater than in a cor responding application using a gas blend with a high percentage of Argon Longer initial arc lengths with 100 CO are required to reduce spatter BACKGROUND CURRENT The Background Current provides the control for the overall heat input to the weld Adjusting this level too high will cause a large droplet to form and globular type transfer to occur resulting in increased spatter OPERATION B 5 Adjusting this level to low will cause wire stubbing and also poor wetting of the weld metal This is similar to a low voltage setting on a standard CV machine Adjust Bead Shape usin
54. welding performance make this connection as close as possible to the welding arc 7 Connect the wire feeder control cable between the LN 742 or STT 10 and the 14 pin Wire Feeder Receptacle on the STT Il For the STT 10 Wire Feeder Connect the second wire feeder control cable between the STT 10 and the 10 pin Remote Receptacle on the STT II WARNING Turn off input power to the Welding a Power source using the disconnnect switch at the fuse box before connecting the wire feeder ELECTRIC Only qualified persons should install SHOCK use or service this machine CAN KILL WIRE FEEDER LN 742 LN7 GMA LN9 GMA NA5R NAS WIRE FEEDER CONTROL CABLE ELECTRODE LEAD ARC SENSE LEAD CONNECT ELECTRODE LEAD AND ELECT ARC SENSE LEAD TOGETHER TO ELECTRODE TERMINAL OF WIRE FEEDER ARC SENSE LEAD WORK SHOULD BE LOCATED AS CLOSE AS POSSIBLE TO THE WELDING ARC 17657 FIGURE C 2 LN 742 to STT II CONNECTION INVERTEC STT CE LINCOLN 5 C 3 ACCESSORIES C 3 CONNECTION DIAGRAM INVERTEC STT Turn off input power to the Welding Power source using the disconnnect switch at the fuse box before connecting the wire feeder ELECTRIC Only qualified persons should install SHOCK use or service this machine CAN KILL WIRE FEEDER REMOTE WORK LEAD CABLES AND LEADS SHOULD BE TAPED TOGETHER WIRE FEEDER STT 10 ELECTRODE LEAD ELECTRODE
55. y 42 VAC is available on European models There are no provisions for voltage control of the power source by the wire feeder Refer to the Accessories section of this manual for wire feeder connection instructions 10 WIRE FEEDER RECEPTACLE This is 14 6 11 ARC SENSE RECEPTACLE This is a four pin MS type connector for WORK and ELECTRODE sense leads The STT requires a WORK sense and ELECTRODE sense lead for proper operation The ELECTRODE sense lead is bolted together with power source electrode lead at the wire feeder gun block The WORK sense lead is furnished with an alligator type clip for connection to the work piece Refer to the LN 742 or STT 10 wire feeder connection instructions in the Accessories section of this manual for proper connection of these leads 12 42V AUXILIARY POWER CIRCUIT BREAKER The 42 VAC supply is protected from exces sive current draws with a 6 amp circuit break er When the breaker trips its button will extend Depressing this button will reset the breaker OPERATION B 4 13 115V AUXILIARY POWER CIRCUIT BREAKER Not on European Models The 115 VAC supply is protected from excessive current 6 draws with a 6 amp circuit breaker When the breaker trips its button will extend Depressing this button will reset the breaker 14 WORK TERMINAL This twist mate con nection is the negative output terminal fOr connecting a work cable and clamp to the workpiece
56. y operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code an
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