Lincoln Electric IM586 User Manual
IM586-B
STT-10 Control - Boom Mount Code 10447, 10832
10 Series Wire Drive - Boom Mount Code 10443, 10763, 10818
STT-10 Boom Package Code 10448
Synergic 7F Wire Drive Code 10190, 10191
STT-10 - Bench Model Code 10446, 10766, 10821
STT-10 - Zipline Boom Package Code 10499, 10500, 10773
RETURN TO MAIN MENU
For use with:
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 READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
STT-10 Head & Controls
Boom Mount or Bench Models
August, 2007
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. 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 & 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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
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 vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
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.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
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.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
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
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
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.
___________________________________________________
1.g. 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.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
ii
SAFETY
ii
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) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
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. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other 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.
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.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5. b. 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 specific 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.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. 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.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
vapors
AUG 06
to
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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.
6.b. 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.
6.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.
6.d. Do 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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
6.g. 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 circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan, 07
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular 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 such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
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 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
“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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications.......................................................................................................A-1
General Description..............................................................................................................A-2
Recommended Processes and Equipment ..........................................................................A-2
Installation of the STT-10 Boom Mount Wire Feeder Components......................................A-2
Mounting the 10 Series Wire Drive Unit ........................................................................A-2
Mounting Synergic 7F Wire Drive Unit ..........................................................................A-3
Mounting the STT-10 Control Box ................................................................................A-3
Connecting Wire Drive Unit to Control Box ...................................................................A-3
Electrode Routing..........................................................................................................A-4
Wire Drive Speed Range Selection......................................................................................A-4
Control Speed Range Setting .......................................................................................A-4
10 Series Wire Drive Ratio Selection ............................................................................A-4
Wire Feed Drive Roll Kits .....................................................................................................A-5
Procedure to Install Drive Roll and Guide Tubes .................................................................A-5
Synergic 7F Wire Drive 4-Roll Kits (KP655 and KP656)...............................................A-5
10 Series Wire Drive Roll Kit Installation (KP1505) ......................................................A-5
Gun Connection-General .....................................................................................................A-6
Gun and Cable Assemblies with Standard Connection........................................................A-6
GMAW Guns .................................................................................................................A-6
Gun Cable Connection with Standard Connection........................................................A-6
Gun and Cable Assemblies with Fast-Mate Connection ......................................................A-6
GMAW Guns .................................................................................................................A-6
Gun Cable Connection with Fast-Mate Connection ......................................................A-7
Water Connections (For Water Cooled Guns) .....................................................................A-7
10 Series Wire Drives ...................................................................................................A-7
Synergic 7F Drives (K679) ............................................................................................A-7
GMAW Shielding Gas ...................................................................................................A-7
Gas Guard Regulator ....................................................................................................A-7
Electrical Installation.............................................................................................................A-8
Input Cable: STT-10 Control to Power Source..............................................................A-8
Work Cable ...................................................................................................................A-8
Optional Features Installation...............................................................................................A-9
Boom and Bench Conversions............................................................................................. A-9
vi
Operation ............................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
Duty Cycle ............................................................................................................................B-1
STT-10 Control DIP Switch Setup........................................................................................B-1
Keypad and Display Operation.............................................................................................B-4
Wire Reel Loading................................................................................................................B-6
Feeding Electrode and Brake Adjustment............................................................................B-7
Drive Roll Pressure Setting ..................................................................................................B-7
Procedure for Setting Angle of Feedplate ............................................................................B-8
Gas Guard Regulator Setting ...............................................................................................B-8
Making a Weld......................................................................................................................B-8
Wire Reel Changing .............................................................................................................B-9
Wire Feed Overload Protection ............................................................................................B-9
Grounding Lead Protector ....................................................................................................B-9
Explanation of Prompting and Error Messages....................................................................B-9
Accessories.....................................................................................................Section C
Drive Roll and Guide Tube Kits............................................................................................C-1
Other Optional Features.........................................................................................C-2 thru C-4
Maintenance ....................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Avoiding Wire Feeding Problems.........................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Procedure for Removing Feedplate from Wire Feeder ........................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions ...............................................................................................................E-1
Troubleshooting Guide ...........................................................................................E-2 thru E-6
Procedure for Replacing PC Boards ................................................................................... E-7
vii vii
Diagrams ..........................................................................................................Section F
Wiring (STT-10 Control).........................................................................................F-1
Wiring (10 Series Wire Drive) ..........................................................................F-2, F3
Dimension Prints ......................................................................................F-4 thru F-6
Parts List................................................................................................P312 Series
TABLE OF CONTENTS
Page ......
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS – STT-10 Heads & Controls
WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER
SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO
K1563-1∆, 10 Series 35-500 IPM .025 - 3/32 in. .030 - .120 in
K1563-3 Boom Mount (0.89-12.7 m/m) (0.6 - 2.4 mm) (0.8 - 3.0 mm)
K679-1 Synergic 7F* 50 - 770 IPM .025 - 1/16 in. .035 - 5/64 in.
Std Drive
K679-2 Synergic 7F* --- --- --- 80 - 1200 IPM .025 - .045 in. .035 - .045 in.
Hi-Speed
Boom Mount (1.27 - 19.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm)
Boom Mount (2.00 - 30.5 M/M) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
Speed Solid Cored Speed Solid Cored
Wire Size Wire Size
K1560-1,-2 STT-10 35-500 IPM .025 - 3/32 in. .030 - .120 in.
Bench Model (0.89-12.7 m/m) (0.6 - 2.4 mm) (0.8 - 3.0 mm)
CONTROLS, HEADS AND COMPLETE UNITS
SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING
K1565-1∆ 40-42 Vac ± 10%
Controls STT-10 4.0 Amps 50/60 Hz 14.80 “ 14.20 “ 4.20 “ 18.0 Lbs
K1565-2 Controls 40-42 Vac ± 10% (375.9 mm) ( 360.7mm) (106.7 mm) (8.2 Kg)
Controls 6.0 Amps 50/60 Hz
K1568-1∆ 10 Series 7.81 “ 14.71 “ 11.00“ 25.0Lbs
Std Drive Boom Mount (198.4 mm) (373.6 mm) (27.94 mm) (11.3 Kg)
K679-1,-2 Synergic 7F* 11.5“ 7.16“ 8.06“ 16.5 Lbs -20°C -40°C
Std Drive Boom Mount ( 285.8mm) (181.9 mm) (204.7mm) (7.5 Kg.)
K1560-1 40-42 Vac ± 10%
Std Feeder
STT-10 20.46 “ 14.43 “ 30.35 “ 65.0 Lbs
K1560-2 Bench Model 40-42 Vac ± 10% (519.7 mm) (366.5 mm) (770.9 mm) (29.5 Kg)
Std Feeder
• Excluding Wire Reel
∆ Included with K1568-Series STT-10 Boom Package
*Synergic 7F drives use 4-roll drives with 2 driven rolls(Drive roll kits not common with 10 Series heads)
4.0 Amps 50/60 Hz
6.0 Amps 50/60 Hz
Height Width Depth Weight Operating Storage
Dimensions
+40°C +40°C
to to
GENERAL DESCRIPTION
The STT-10 is a modular line of 42VAC input 4-roll wire
feeders. A single control with dual procedure presettability
Also, 4 selectable, presettable timers for each procedure;
preflow, postflow, burnback and spot weld time.
of wire feed speed (in IPM or M/min), peak current, and
background current is used with the STT-II power source.
Arc starting can be optimized for each procedure with 5
selectable wire feed acceleration rates, and independent
Preset Ranges can be set independently for each procedure
control of slower run-in procedure.
for peak current, background current, and wire feed speed.
A gas purge key is provided, as well as cold feed forward
The STT-10 models have controls providing keypad or
and reverse keys with adjustable forward feed speed setting.
remote selectability of either of two procedures.
Allot these features are selected with a tactile-feel keypad,
The units offer 4 independently selectable gun trigger
modes for each procedure; cold feed, 2 step and 4-step trigger and spot weld mode.
and are set independently using one of two rotating knob
encoders, setting levels are displayed on one of two digital
LED displays.
STT-10
A-2
2.25
INSTALLATION
A-2
The 10 Series Wire Drive assemblies include a heavy duty
head with an externally changeable gear ratio and 4 driven
roll drives housed together in a single combination mounting
and connection box. Gun adapters are available to permit
use with a variety of standard welding guns.
Available Models:
The STT-10 Wire Feeder system is available configured in
both Bench and Boom models.
Bench Models consists of an STT-10 control and a 10
Series wire drive assembly premounted on a platform
with a 2" O.D. spindle mounting.
INSTALLATION OF THE STT-10
BOOM MOUNT WIRE FEEDER
COMPONENTS
Boom Models consist of a STT-10 control and a wire drive
SAFETY PRECAUTIONS
designed to be mounted separately and joined by available
head to control cable assemblies.
The head to control cable assemblies are available as
stated below:
K1567-”L”
K681-”L” Same as above but does not include
STT-10 Boom Package (K1568-Series) is also available which includes:
• STT-10 Control Box
• 10 Series Wire Drive
• Appropriate length Control and Weld Cables to
connect Control to Wire Drive
• Accessories specific to the Boom package
ordered
Includes a control cable with a 14-pin
ms style connection on each end, and
a weld cable. Available in lengths “L”
of 16, 20 or 25 ft. (4.9, 6.1 or 7.6 m)
weld cable available in lengths “L” of
12, 16 or 25 ft. (3.6, 4.9 or 7.6 m).
Mounting the 10 Series Wire Drive Unit
Mount the 10 Series wire drive unit to the boom or
structure using the four 5/16-18 threaded mounting
holes located on the bottom of the drive connection
box. See Figure A.1 for the size and location of the
mounting holes. The feed plate and cover assembly is
electrically "hot" when the gun trigger is pressed.
Therefore, make certain the feed plate and cover do
not come in contact with the structure on which the
unit is mounted.
The wire drive unit should be mounted so that the
drive rolls are in a vertical plane so dirt will not collect
in the drive roll area. Pivot the feed plate so it will
point down at an angle so the wire feed gun cable will
not be bent sharply as it comes from the unit. See
“Procedure for setting angle of Feed Plate” in the
OPERATION section of this manual.
5/16-18 THREAD
ELECTRIC SHOCK can
kill.
• Turn the input power off at the power source
disconnect switch before attempting to connect
the input power to the STT-10 Control.
• Only qualified personnel should perform this installation.
----------------------------------------------------------------------------------------
2.25
RECOMMENDED PROCESSES
AND EQUIPMENT
GMAW is the only process supported by the STT-10.
It is similar to “short-circuiting transfer” or “short arc”
welding in that metal transfer is by physical contact.
Non-shorting modes such as axial spray and pulse
welding are not supported by STT technology.
The wire type and size range for the wire drive used,
and speed range, are given in the Technical
Specifications.
The STT-10 requires a STT-II Power Source.
STT-10
6.00
11.00
FEED PLATE
3.00
BOTTOM FRONT
10.50
14.50
DOOR OPEN
5.00
FIGURE A.1
The boom wire drive speed selection must be set to
match the STT-10 control. See “Wire Drive Speed Range
Selection” section.
A-3
2
2.62
CONTROL BOX AND REED SWITCH
INSTALLATION
A-3
Mounting Synergic 7F Wire Drive Unit
Mount the wire feed unit by means of the insulated mounting
bracket attached to the bottom of the gearbox. Reference
L9777 (included with Drive unit) to find the size and location
of the mounting holes. The gearbox assembly is electrically
“hot” when the gun trigger is pressed. Therefore, make certain the gearbox does not come in contact with the structure
on which the unit is mounted.
The wire feed unit should be mounted so that the drive rolls
are in a vertical plane so dirt will not collect in the drive roll
area. Position the mechanism so it will point down at about
a 45° angle so the wire feed gun cable will not be bent
sharply as it comes from the unit.
Note: The K1565-1 Control Box must be used with the
K679 drives.
Mounting the STT-10 Control Box (K1565-2)
(Boom Model)
The STT-10 Boom Model has two keyhole slots and one
bottom slot for mounting. See Figure A.2 for the size and
location of these slots. Mount the box at some convenient
location close to the wire drive unit which will enable the
desired control cable to reach between the control box and
the drive unit.
.62
Mounting the STT-10 Control Box (K1565-2)
(Removed from the wire drive unit.) (See Figure A.3)
Remove reed switch energizer assembly which includes:
4-pin connections, energizer spacer, insulation, mounting
screws and washers from reel stand.
Mount the reed switch energizer assembly on the mounting
bracket (G2868) as shown In Figure A.3. Then install
mounting bracket G2868 to the rear of STT-10 control box.
Secure it on the sides of box with (4) # 10-3/8” long screws.
FIGURE A.3
ENERGIZER ASSEMBLY REMOVE
FROM REEL STAND AND ADDED TO
MOUNTING BRACKET G2868
BOLT PATTERN FOR
SWITCH ENERGIZER
ASSEMBLY, DRILL (4)
HOLES IN MOUNTING
BRACKET
FIGURE A.2
14.50
2.63
10.50
2.63
5.25
.50
13.75
12.75
CLEARANCE
FOR 1/4 BOLT
14.00
CLEARANCE
FOR 1/4 BOLT
10.00
a) Drill the required holes in the mounting surface, partially
Install 1/4-20 screws.
b) Mount the box.
c) Tighten the screws.
a) Drill the required holes in the mounting surface, partially Install
1/4-20 screws.
b) Mount the box.
c) Tighten the screws.
Connecting Wire Drive Unit to Control Box.
One K1567-“L” head to control cable is needed to connect between
the control box and the wire drive.
K1567-“L” Includes a control cable with 14-pin MS style connection on each end, and a weld cable (rated 300 amps, 60% duty
cycle) to route between the wire drive and the control box.
Avaialble in lengths “L” of 16,20 or 25 ft. (4.9, 6.1m or 7.6m).
a) Making certain the cables are protectedfrom any sharp corners
which may damage their jackets, mount the cable assembly
along the boom so the end with the female amphenol connector
pins is at the wire feed unit.
b) Take the cables and connect the 14 pin cable between the 14 pin
receptacles on the wire drive unit and 14 pin receptacle on the
STT-10 Control Box.
c) Take electrode cable thatʼs part of the cable and connect one end
of the ½ connection bolt on the front of wire drive and the other
end to one side of
the energizer assembly.
STT-10
A-4
INSTALLATION
Electrode Routing
The electrode supply may be either from reels, ReadiReels, spools, or bulk packaged drums or reels.
Observe the following precautions:
a) The electrode must be routed to the wire drive unit
so that the bends in the wire are at a minimum,
and also that the force required to pull the wire
from the reel into the wire drive unit is kept at a
minimum.
The electrode is "hot" when the gun trigger is pressed
b)
and must be insulated from the boom and structure.
c) If more than one wire feed unit shares the same
boom and are not sharing the some power source
output stud, their wire and reels must be insulated
from each other as well as insulated from their
mounting structure.
WIRE DRIVE SPEED RANGE
SELECTION
The rated speed and wire size range for each wire
drive head is shown in the SPECIFICATIONS in the
front of this section.
A-4
2) Remove the Phillips head screw retaining the pin-
ion gear to be changed and remove the gear. If
the gear is not easily accessible or difficult to
remove, remove the feedplate from the gearbox.
To remove feedplate:
a) Loosen the clamping collar screw using a 3/16"
Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.
b) Loosen the retaining screw, which is also
accessed from bottom of feeder, using a 3/16"
Allen wrench. Continue to loosen the screw
until the feedplate can be easily pulled off of the
wire feeder.
3) Loosen, but do not remove, the screw on the lower right
face of the feedplate with a 3/16" Allen wrench.
4) Remove the screw on the left face of the feedplate. If
changing from high speed (larger gear) to low speed
(smaller gear), line the lower hole on the left face of the
feedplate with the threads on the clamping collar. Line
the upper hole with the threads to install larger gear for
high speed feeder. If feedplate does not rotate to allow
holes to line up, further loosen the screw on right face of
feedplate.
Control Speed Range Setting
The STT-10 Control is factory set for the 10 Series
low speed ratio wire drives. If using the Synergic 7F
wire drive, the speed range must be set up to match
this wire feed head by properly setting the switch (S1)
code on the control board inside the control box. See
OPERATION “Setting the DIP Switch” for setting
instructions.
10 Series Wire Drive Ratio Selection
The STT-10 Bench and Boom model packages come
with a 1" dia. gear only.
The K1563-1,-3 10 Series type Boom model wire drive
includes two external gear sizes; a 1"(25.4mm) dia.
gear and a 1-1/2"(38.1mm) dia. gear. The smaller
gear provides the desired low speed range ratio,
appropriate for the STT process per the SPECIFICATIONS in the front of this section.
The following procedure is for changing ratio of the 10
Series Boom wire drive (K1563-1,-3):
1) Pull open the Pressure Door.
5) Install the smaller, 1.00”(25.4mm) dia., gear onto output
shaft and secure with flat washer, lock washer, and
Phillips head screw which were previously removed.
6) Tighten the screw on lower right face of feedplate.
7) Install gear onto output shaft and secure with flat washer,
lock washer, and Phillips head screw which were previously removed.
8) Re-attach feedplate to wire feeder if removed in Step 2.
9 Feedplate will be rotated out-of-position due to the gear
change. To re-adjust angle of feedplate:
a) Loosen the clamping collar using a 3/16" Allen
wrench. The clamping collar screw is accessed
from the bottom of the feedplate. It is the screw
which is perpendicular to the feeding direction.
b) Rotate feedplate to the desired angle and tight-
en clamping collar screw.
10) Make sure to properly set the switch (S1) code on the
control board inside the control box for the new gear
size installed. See OPERATION “Setting the
Switch” for setting instructions.
DIP
STT-10
A-5
INSTALLATION
A-5
WIRE FEED DRIVE ROLL KITS
NOTE: The maximum rated solid and cored wire
sizes for each wire drive head and selected
drive ratio is shown on the SPECIFICATIONS
in the front of this section.
The electrode sizes that can be fed with each roll and
guide tube are stenciled on each part. Check the kit
for proper components.
Synergic 7F Wire Drives (K679) use 4-Roll drive roll
kits with 2 driven rolls, per Table C.1 in ACCESSORIES. These kits are common with those used for
the 4-Roll LN-7 GMA and LN-9 GMA Lincoln Wire
Feeders, but are not common with those used with the
10 Series wire drive units. Installation instructions are
included with the kits.
10 Series Wire Drives use 4-Roll drive roll kits with 4
driven rolls, per Table C1 in ACCESSORIES.
3) Remove clamping screw & clamping collar from
the drive shaft closest to the incoming side of the
feeder.
4) Install drive roll onto keyed shaft. (Do not exceed
the maximum wire size rating of the wire drive.)
Replace collar and tighten clamping screw.
5) Back out the set screw for the middle guide tube.
Install the middle guide tube and slide it up against
the drive roll. DO NOT TIGHTEN THE MIDDLE
GUIDE AT THIS TIME.
6) Install the outgoing drive roll following the same
procedure as steps 3 & 4.
7) Center the middle guide between the two drive
rolls and tighten in place.
8) Back out the screws for the incoming and outgoing
guide tubes.
9) Install the longer guide tube in the rear hole near
the incoming drive roll. Slide the tube in until it
almost touches the roll. Tighten in place.
PROCEDURE TO INSTALL DRIVE
ROLL AND WIRE GUIDES
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
•
When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
Synergic 7F 4-Roll Kits (KP655 and KP656)
1) Turn OFF welding power source.
10) Install the remaining guide tube in the front hole.
Be certain that the proper plastic insert is used.
Fine wire chisel point tube must have largest
radius next to drive roll. Tighten in place.
11) Re-latch both quick release levers.
12) To start new electrode, straighten the first 6"
(150mm) and cut off the first 1" (25 mm). Insert
free end through the incoming tube. Press gun
trigger and push wire into the drive roll.
TO SET IDLE ROLL PRESSURE, see “Idle Roll
Pressure Setting” in OPERATION.
10 Series Wire Drive - Drive Roll Kit
Installation (KP1505 and KP1507)
1) Turn OFF Welding Power Source.
2) Pull open Pressure Door to expose rolls and wire
guides.
3) Remove Outer Wire Guide by turning knurled
thumb screws to unscrew from Feedplate.
4) Remove drive rolls, if any are installed, by pulling
straight off shaft. Remove inner guide.
2) Release both quick release levers by sliding the
levers sideways into the open positions.
5) Insert inner Wire Guide, groove side out, over the
two locating pins in the feedplate.
STT-10
A-6
INSTALLATION
A-6
6) Install each drive roll by pushing over shaft until it
butts up against locating shoulder on the drive roll
shaft. (Do Not exceed maximum wire size rating of
the wire drive).
7) Install Outer Wire Guide by sliding over locating
pins and tightening in place.
8) Engage upper drive rolls if they are in the “open”
position and close Pressure Door.
TO SET IDLE ROLL PRESSURE, see “Idle Roll
Pressure Setting” in OPERATION.
GUN CONNECTIONS - GENERAL
4-roll feed plates are equipped with a brass connector
bar at the gun-end of the feed plate to allow a bolted
brass-to-brass electrical connection to be made directly to either standard or Fast-mate gun adapter bushings. Use a 1/4” inch allen key on the factory-installed
socket head cap screw to insure that the connector
bar is securely tightened to the adapter bushing.
GUN AND CABLE ASSEMBLIES
WITH STANDARD CONNECTION
Gun Cable Connection with Standard
Connection
1. Check that the drive rolls and guide tubes are
proper for the electrode size and type being used.
If necessary, change them per “Wire Drive Roll
Kits” in this section.
2. Lay the cable out straight. Insert the connector on
the welding conductor cable into the brass conductor block on the front of the wire drive head. Make
sure it is all the way in and tighten the hand clamp.
Keep this connection clean and bright. Connect
the trigger control cable polarized plug into the
mating 5 cavity receptacle on the front of the wire
drive unit.
3. For GMA Gun Cables with separate gas fitting (10
Series Wire Drive using K1500-1 Gun Adapter),
connect the 3/16" I.D. gas hose from the wire drive
unit to the gun cable barbed fitting.
GUN AND CABLE ASSEMBLIES
WITH FAST-MATE CONNECTION
(Requires K489-2 Fast Mate™ Adapter Kit used with
the K1500-1 Gun Adapter)
The 10 Series Wire Drive Head requires a K1500 Gun
Adapter installed See “Gun Adapters” in ACCESSORIES section. The K1500-2 Gun Adapter and
Trigger Cable for Magnum 200-400 guns are factory
included with the STT-10.
GMAW Guns
An expanding line of Magnum gun and cable assemblies are available to allow welding with solid and
cored electrodes using the GMAW process. See the
appropriate Magnum literature for descriptions of the
200 to 550 ampere air cooled gun and cables that are
available. Gun cable lengths range from 10 ft. (3.0 m)
to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6
mm) to 3/32" (2.4 mm). The entire line of Magnum
Fast-Mate gun and cable assemblies can also be
used by installing a K489-2 Fast-Mate adapter kit.
See “Gun and Cable Assemblies with Fast-Mate
Connection” in this section for details.
GMAW Guns
An expanding line of Magnum Fast-Mate™ air cooled
and water cooled gun and cable assemblies are available to allow welding with solid and cored electrodes
using the GMAW process. See the appropriate
Magnum literature for descriptions of the 200 to 400
ampere air cooled gun and cables that are available
as well as the Magnum “Super Cool” 450 ampere
water cooled gun and cable. Gun cable lengths range
from 10 ft. (3.0 m) to 25 ft. (7.6 m) and feed electrode
sizes .025" (0.6 mm) to 5/64" (20 mm).
An expanding line of Magnum X-Tractor gun and
cable assemblies provides fume extraction capability
for welding with solid and cored electrodes using the
GMAW process. See the appropriate Magnum literature for descriptions of the 250 to 400 ampere air
cooled gun and cables that are available. Gun cable
lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) and
feed electrode sizes .035" (0.9 mm) to 1/16" (1.6 mm).
These guns require the use of either the K173-1 or
K184* vacuum units.
* Requires S14927-8 connector hose and an S20591
hose adapter.
STT-10
A-7
INSTALLATION
A-7
Gun Cable Connection with Fast-Mate
Connection
1. Check that the drive rolls, feeder guide tubes and
gun connector guide tube are appropriate for the
electrode size being used. If necessary, change
them per “Wire Drive Roll Kits” in this section.
2. Connect gun to gun connector making sure all pins
and gas tube line up with appropriate holes in connector. Tighten gun by turning large nut on gun
cable clockwise.
WATER CONNECTIONS
(FOR WATER COOLED GUNS)
10 Series Wire Drives: must have a K590-4
Water Connection Kit installed for each water cooled
gun. (See ACCESSORIES).
Using male quick-connect fittings, connect the water
hoses to the coolant inlet and outlet on the back of the
wire drive. Connect the other ends of these hoses to
the appropriate ports on the water cooling units.
In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the wire drive, male quickconnects (L.E. Part No. S19663) are provided in the
Kit for installation on 3/16" (5 mm) I.D. hose
(Customer to provide appropriate clamps). The feeder connectors self seal when disconnected.
Synergic 7F Wire Drives (K679)
Must have a K682-2 Water Connection Kit installed.
(See ACCESSORIES).
Using hose clamps provided with the K682-2 kit, connect appropriate water hoses to the coolant inlet and
outlet fittings on the back of the K682-2 Kit. Connect
the other ends of these hoses to the appropriate ports
on the water cooling units.
GMAW Shielding Gas
WARNING
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to
support.
• Keep cylinder away from areas where
it may be damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live electrical circuits.
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply when not
in use.
SEE AMERICAN NATIONAL STANDARD Z-49.1,
“SAFETY IN WELDING AND CUTTING” PUBLISHED
BY THE AMERICAN WELDING SOCIETY.
------------------------------------------------------------------------
Customer must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve, and a hose
from the flow valve to the gas inlet fitting of the wire
drive unit.
Connect a supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on the
back panel of the wire drive or, if used, on the inlet of
the Gas Guard regulator. (See Below).
Gas Guard Regulator - The Gas Guard Regulator is
an optional accessory (K659-1) on these models.
Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the wire
drive. Secure fitting with flow adjuster key at top.
Attach gas supply to 5/8-18 female inlet of regulator
per instructions above.
In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the K682-2 Kit male quickconnects are provided with the kit for installation on
3/16 (5 mm) I.D. hose (Customer to provide appropriate clamps). The feeder connectors self seal when
disconnected.
STT-10
Loading...