Lincoln Electric IM904 User Manual

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Page 1

INVERTEC

RETURN TO MAIN MENU

S T T

II (CE)

IM904

July, 2006

For use with machines having Code Numbers:

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.

11366, 11367

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

ISO/IEC 60974-1

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Page 2

SAFETY

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.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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 ‘95

Page 3

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) 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.

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.

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.

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.

vapors

5.e. 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.

5.f. Also see item 1.b.

AUG 06

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iii

SAFETY

iii

WELDING SPARKS can 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.

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.

Remember that welding sparks and hot

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 manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Mar ‘95

Page 5

SAFETY

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 L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode 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 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 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 l’eau 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 s’applicuent 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 n’importe 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 l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie 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 d’incendie.

8. S’assurer que la masse est connectée le plus prés 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 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 d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils 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 d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc 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 d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, 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 l’électricité 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, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

Page 6

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• 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 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.

Page 7

TABLE OF CONTENTS

Page

Safety .....................................................................................................................i-iv

Installation ......................................................................................................Section A

Technical Specifications.....................................................................................A-1,A-2

Location ....................................................................................................................A-3

Stacking ....................................................................................................................A-3

Tilting .....................................................................................................................A-3

Machine Grounding and High Frequency Interference Protection............................A-3

Input Connections .....................................................................................................A-3

Supply Connections ...........................................................................................A-3

Input Cable Installation and Connection.............................................................A-4

Ground Connection ............................................................................................A-4

Input Voltage Reconnect Procedure .........................................................................A-5

Output Connections ..................................................................................................A-5

Wire Feeder Output Connections.......................................................................A-5

Operation ........................................................................................................Section B

Safety Precautions....................................................................................................B-1

General Description ..................................................................................................B-2

Recommended Equipment .......................................................................................B-2

Operating Controls....................................................................................................B-2

Design Features and Advantages.............................................................................B-2

Welding Capability ....................................................................................................B-2

Limitations.................................................................................................................B-2

Operational Features and Controls...........................................................................B-3

Welding Operation ....................................................................................................B-4

Welding Parameters and Guidelines ........................................................................B-5

Welding Procedures for (Steel) Horizontal Fillet .......................................................B-5

Welding Procedures for (Stainless Steel) Horizontal Fillet .......................................B-6

Accessories ....................................................................................................Section C

Options/Accessories .................................................................................................C-1

LN-742 or STT-10 Wire Feeder Connection Instructions .........................................C-1

Maintenance....................................................................................................Section D

Safety Precautions .................................................................................................D-1

Input Filter Capacitor Discharge Procedure ...........................................................D-1

Preventive Maintenance.........................................................................................D-2

Troubleshooting .............................................................................................Section E

How To Use Troubleshooting Guide ......................................................................E-1

Troubleshooting Guide ..................................................................................E-2 - E-6

Diagrams .........................................................................................................Section F

Wiring Diagram............................................................................................F-1 thru F-3

Dimension Print.........................................................................................................F-4

Parts List ....................................................................................................P-540 Series

Page 8

A-1

INSTALLATION

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 33/30/18/17/16

RATED OUTPUT

DUTY CYCLE AMPS VOLTS AT RATED AMPS

60% Duty Cycle 225 29

100% Duty Cycle 200 28

OUTPUT

CURRENT RANGE OPEN CIRCUIT VOLTAGE AUXILIARY POWER

A-1

Peak Current

0 - 450 Amps 85 VDC Maximum 1152VAC @ 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

200/50/60 40 33

220/50/60 40 30 10 (6 mm2) 10 (6 mm2) 380/50/60 30 18 415/50/60 30 17 440/50/60 30 16

AWG (IEC) SIZES

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

23.2 in 13.2 in. 24.4 in. 100 lbs.

589 mm 336 mm 620 mm 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 II (CE)

Page 9

A-2

INSTALLATION

TECHNICAL SPECIFICATIONS –INVERTEC 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 AMPS VOLTS AT RATED AMPS

60% Duty Cycle 225 29

100% Duty Cycle 200 28

OUTPUT

CURRENT RANGE OPEN CIRCUIT VOLTAGE AUXILIARY POWER

A-2

Peak Current 0 - 450 Amps 88 VDC Maximum 115 Background 0 - 125 Amps 42 VAC @ 4 Amps

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

200/50/60 40 36 208/50/60 40 34

380/50/60 30 20 10 (6 mm2) 10 (6 mm2) 400/50/60 30 19 415/50/60 30 18

AWG (IEC) SIZES

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

23.2 in 13.2 in. 24.4 in. 100 lbs.

589 mm 336 mm 620 mm 46 kg

115 VAC not present on European Models.

INVERTEC STT II (CE)

Page 10

A-3

Read and understand entire Installation Section before starting installation.

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 disconnecting input power lines, output cables, or control cables.

• Do not touch electrically hot parts.

• Always connect the ground terminal to a 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 circulate 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 temperatures 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 locations. It should not be exposed to rain or snow.

A-3

MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION

The machine may not be suitable for use in an environment where high frequency is present. For example do not place the machine in close proximity to “TIG” or “PLASMA” operations. To minimize high frequency interference:

Locate the STT II 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 COMPONENTS 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

STACKING

The INVERTEC STT II (CE) cannot be stacked.

TILTING

Place the machine on a secure, level surface otherwise the unit may topple over.

INVERTEC STT II (CE)

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 case 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 INSTALLATION AND CONNECTION”.

Page 11

A-4

CASE BACK

RATING PLATE

INPUT CABLE ENTRY ACCESS & CABLE STRAIN RELIEF

INSTALLATION

A-4

FIGURE A.1 CASE BACK

INPUT CABLE INSTALLATION AND CONNECTION

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 right inside edge of the machine, up to the power switch located on the front panel.

5. Connect the three phase line conductors to the power switch terminals labeled U, V and W. Tighten the connections to 3.0 Nm. (27 in.-lb.) torque.

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).

4. Strip away 102 mm (4 in.) of the outer jacket. Trim fillers and strip conductor jackets to connect to the power switch.

INVERTEC STT II (CE)

Page 12

A-5

380-415 OR

OR 200-208

* *

(NOT PRESENT ON ALL MODELS)

ACCESS DOOR LOCATION

INSTALLATION

380 or 415 VAC 1. Open reconnect panel (Codes 11366) access door on wraparound.

380,400 or 415 VAC 1. Open reconnect panel

(Codes 11367) access door on wraparound.

A-5

2. Move input voltage switch to Voltage = 380-460V position.

3. Move lead “A” to 380-415 Terminal.

2. Move input voltage switch to Voltage = 380-415V position.

FIGURE A.2 RECONNECT P ANEL

NPUT 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.

WARNING

NOTE: Turn main power to the machine OFF before performing the reconnect procedure. Failure to do 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 1. Open reconnect panel (Code 11366) access door on wraparound.

2. Move input voltage switch to Voltage = 380-460V position.

3. Move lead “A” to 440-460 Terminal.

3. Move lead “A” to 380-415 Terminal.

220 or 230 VAC 1. Open reconnect panel (Codes 11366) access door on wraparound.

2. Move input voltage switch to Voltage = 200 -230V position.

3. Move lead “A” to 220-230 Terminal.

200 or 208 VAC 1. Open reconnect panel (Codes 11366) access door on wraparound.

2. Move input voltage switch to Voltage = 200 -230V position.

3. Move lead “A” to 200-208 Terminal.

200 or 208 VAC 1. Open reconnect panel (Codes 11367) access door on wraparound.

2. Move input voltage switch to Voltage = 200 -230V position.

3. Move lead “A” to 200-208 Terminal.

OUTPUT CONNECTIONS

WIRE FEEDER OUTPUT 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 II (CE).

INVERTEC STT II (CE)

Page 13

B-1

OPERATION

OPERATING INSTRUCTIONS

Read and understand entire section before operating machine.

GENERAL WARNINGS

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

B-1

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• 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.

ARC RAYS can burn.

• Wear eye, ear and body protection.

Observe additional Safety Guidelines detailed in the beginning of this manual.

INVERTEC STT II (CE)

Page 14

B-2

GENERAL DESCRIPTION

OPERATION

• High temperature Class H insulation.

B-2

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 superior to conventional short circuiting GMAW. The process is optimized for short-circuiting GMAW welding.

RECOMMENDED EQUIPMENT

The LN-742 or STT-10 wire feeder is recommended for use with the STT II. The LN-7 GMA, LN-9 GMA, NA-5, and NA-5R can all be used with the STT II. 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 selection and one for wire type selection.

• Protection circuits and ample safety margins prevent

damage to the solid state components from transient voltages and high currents.

• Preset welding current capability.

• STT II 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 reasonable 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)

• Suitable for indoor use only (IEC IP21S).

DESIGN FEATURES AND ADVANT AGES

• State of the art inverter technology yields high

power efficiency, excellent welding performance, lightweight and compact design.

• Twist-Mate™ output terminals.

• Digital meters for procedure settings are standard.

• 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 temperatures, or loss of air flow.

INVERTEC STT II (CE)

Page 15

B-3

OPERATION

B-3

OPERA TIONAL FEA TURES AND CONTROLS

All operator controls are located on the case front of the INVERTEC STT II (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 also controls auxiliary power available through the 14-pin Wire Feeder Receptacle.

2A. BACKGROUND CURRENT OUTPUT CON-

TROL: The output current is switched to the Background level at the conclusion of the preceding Peak Current pulse. This 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 displays in 1 amp increments. This meter does not indicate the actual welding current, only the preset current.

3A. PEAK CURRENT OUTPUT CONTROL:

The beginning portion of the welding arc is a pulse of current referred to as Peak Current. This knob allows preset adjustment of the amplitude of the peak current up to 450 amperes.

3B. PEAK CURRENT DISPLAY METER: This

OFF

INVERTEC STT II (CE)

is a digital meter for displaying the preset 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: “Hot Start” provides approximately 25% to 50% more current during the initial start of the weld for improved arc starting and bead appearance. This control adjusts the duration 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.

5. TAILOUT: Alters the current waveform to increase

deposit rate and travel speed. The Minimum setting sets STT II to the original STT waveform. As tailout is increased peak and Background current may need to be reduced to maintain optimum performance.

Page 16

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 performance of smaller diameter wires at higher wire feed speeds.

OPERATION

B-4

13. 115V AUXILIARY POWER CIRCUIT BREAKER (Not on European Models): The 115 VAC supply is protected from excessive current draws with a 6 amp circuit breaker. When the breaker “trips” its button will extend. Depressing this button will reset the breaker.

7. WIRE TYPE SELECT SWITCH: This toggle switch selects between mild or stainless steel. In the stainless position, the pulse width of the Peak Current is changed from 1 to 2 ms for better performance for stainless steel welding.

8. THERMAL SHUT-DOWN INDICATOR: This light will indicate that either the internal thermostat(s) or the FET over current sensor 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).

REMOTE RECEPTACLE: This is a 10 pin MS-

9. type connector for remote control of Peak Current and Background Current. Trigger switch connections are also provided. The presence of the mating connector is automatically sensed, disabling the front panel Peak and Background Current controls. Refer to “REMOTE CONTROL CONNECTOR” in the ACCESSORIES Section of this manual for more information.

10. WIRE FEEDER RECEPTACLE: This is 14

pin MS-type connector for the wire feeder connection. 115 and 42 VAC along with the trigger switch connections are provided. (Only 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.

14. WORK TERMINAL: This twist-mate con- nection is the negative output terminal for connecting a work cable and clamp to the workpiece.

15. ELECTRODE TERMINAL: This twist- mate connection is the positive output terminal 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 beginning 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.

11. ARC SENSE RECEPTACLE: 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 excessive current draws with a 6 amp circuit breaker. When the breaker “trips” its button will extend. Depressing this button will reset the breaker.

This is a four pin

INVERTEC STT II (CE)

Page 17

B-5

OPERATION

WELDING PARAMETERS AND GUIDELINES

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

The INVERTEC STT II (CE) is neither a constant current (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 II (CE) is a current controlled machine which is capable of changing the electrode current quickly in order to respond to the instantaneous requirements of the arc and optimize performance. By 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 currents 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 Bead Shape

Note: Background Current levels for applications using 100% CO gas blends with high percentages of Argon. This is a result of the greater heat generated in the 100% CO2 arc. (100% CO2 is 35 volts/cm and 100% Argon is 20 volts/cm. 75% Argon, 25% CO2 is about 24 volts/cm.

Contact Tip

2 is less than similar procedures involving

to Work Distance

using Background Current

Adjust Arc Length

Note: In 100% CO2shielding 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% CO2are 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.

with Peak Current

INVERTEC STT II (CE)

HOT START

The Hot Start control can be set to enhance establishing 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 concentrated on the puddle.

Page 18

B-6

45°

END VIEW

75°

FRONT VIEW

DIRECTION

TRAVEL

75°

TOP VIEW

DIRECTION

TRAVEL

45°

END VIEW

75°

FRONT VIEW

DIRECTION

TRAVEL

75°

TOP VIEW

DIRECTION

TRAVEL

OPERATION

B-6

WELDING PROCEDURES FOR STT II -

(Steel) Horizontal Fillet (See Table B.1 and B.2)

Table B.1

100% CO

Plate Thickness “ (mm) 20 ga 14 ga 10 ga Electrode size “ (mm) 0.035 0.045 0.045 WFS “/min (m/min) 100 100 170 Peak Current 220 260 280

Background Current 30 40 65 Tailout setting 3 7 5 Average Amperage 60 105 120 Travel Speed “/min 12 12 12

Gas Flow cfh (L/min) 25 (12) Electrical Stickout “ 1/4 - 3/8

75% CO

Plate Thickness “ (mm) 20 ga 14 ga 10 ga Electrode size “ (mm) 0.035 0.045 0.045 WFS “/min (m/min) 100 100 120 Peak Current 225 270 310

Background Current 40 65 70 Tailout setting 8 4 6 Average Amperage 70 110 130 Travel Speed “/min 12 12 12

Gas Flow cfh (L/min) 25 (12) Electrical Stickout “ 1/4 - 3/8

Gas Shield (Set for Steel Mode)

(0.9) (2.0) (3.25) (0.9) (1.1) (1.1) (2.5) (2.5) (4.2)

(m/min) (0.3) (0.3) (0.3)

(mm) (6.4 - 10)

Table B.2

- 25% Ar Gas Shield (Set for Steel Mode)

(0.9) (2.0) (3.25) (0.9) (1.1) (1.1) (2.5) (2.5) (3.0)

(m/min) (0.3) (0.3) (0.3)

(mm) (6.4 - 10)

(Stainless Steel) Horizontal Fillet (See Table B.3 and B.4)

Table B.3

90% He, 7.5% Ar, 2.5% CO

Gas Shield (Set for Steel Mode)

Plate Thickness “ (mm) 20 ga 14 ga 10 ga

(0.9) (2.0) (3.25)

Electrode size “ (mm) 0.035 0.045 0.045

(0.9) (1.1) (1.1)

WFS “/min (m/min) 100 130 170

(2.5) (3.3) (4.2) Peak Current 165 210 250 Background Current 35 60 85 Tailout setting 7 7 4 Average Amperage 40 95 120 Travel Speed “/min 12 16 16

(m/min) (0.3) (0.4) (0.4) Gas Flow cfh (L/min) 25 (12) Electrical Stickout “ 1/4 - 3/8

(mm) (6.4 - 10)

Table B.4

98% Ar, 2% O

Gas Shield (Set for Stainless Steel Mode)

Plate Thickness “ (mm) 20 ga 14 ga 10 ga

(0.9) (2.0) (3.25)

Electrode size “ (mm) 0.035 0.045 0.045

(0.9) (1.1) (1.1)

WFS “/min (m/min) 100 130 170

(2.5) (3.3) (4.2) Peak Current 145 190 280 Background Current 45 95 95 Tailout setting 7 8 7 Average Amperage 60 120 150 Travel Speed “/min 12 12 12

(m/min) (0.3) (0.3) (0.3) Gas Flow cfh (L/min) 25 (12) Electrical Stickout “ 1/4 - 3/8

(mm) (6.4 - 10)

INVERTEC STT II (CE)

Page 19

C-1

+ ARC

- ARC

1 2

3 4

VOLTAGE SENSE CONNECTION

J19

290

291

(+)

(-)

J B

C G A

TRIGGER

GND

10K

OPTIONAL REMOTE INTERFACE

223

J38

33C

2 3 4

J37

6 1

212C

43A

212B

32C

12 4

J38

REMOTE PROTECTION BOARD

PORTION OF G3136 WIRING DIAGRAM REFER TO ACTUAL DIAGRAM PASTED INSIDE YOUR MACHINE

ELECTRODE SENSE LEAD

290A

J39

WIRE

FEEDER

ACCESSORIES

OPTIONS / ACCESSORIES

K940 SENSE LEADS: These leads are used to accu-

rately sense arc voltage. One set is required for each STT II power source. A 10 ft and 25 ft set are provided 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 adjustment 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) current 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

3. For robotic control of the PEAK CURRENT, a 0 to

NOTE: These analog signals should be isolated from the robot circuitry to prevent interference.

4. The trigger switch is connected between pins “D”

5. The digital meters for PEAK and BACKGROUND

C-1

STT control board to accept PEAK and BACKGROUND inputs on this connector rather than from the front panel controls. If this short is removed, the front panel controls will be active. By adding a switch between pins “J” and “B” a “LOCAL/REMOTE” control switch can be created. (Switch open for “local” and closed for “remote”)

+10 volt DC signal is applied between pins “A” and “G” with + applied to pin “G”. 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.

and “F”. These connections are in parallel with the trigger switch from the wire feeder.

currents will show preset values in both local and remote operation.

INVERTEC STT II (CE)

Page 20

C-2

M17657

ARC SENSE LEAD 'ELECT"

CONNECT ELECTRODE LEAD AND "ELECT" ARC SENSE LEAD TOGETHER TO ELECTRODE TERMINAL OF WIRE FEEDER.

ELECTRODE LEAD

Only qualified persons should install, use or service this machine.

WIRE FEEDER

LN 742 LN7 GMA LN9 GMA NA5R NA5

WARNING

ELECTRIC SHOCK CAN KILL

Turn off input power to the Welding Power source using the disconnnect switch at the fuse box before connecting the wire feeder.

REMOTE RECEPTACLE

WORK

WORK LEAD

CONTROL, ELECTRODE, ARC SENSE "ELECT" AND ARC SENSE "WORK" CABLES SHOULD BE TAPED TOGETHER.

WIRE FEEDER CONTROL CABLE

ARC SENSE LEAD "WORK" (SHOULD BE LOCATED AS CLOSE AS POSSIBLE TO THE WELDING ARC.)

CRM after 6-10-96

ACCESSORIES

LN-742 or STT-10 WIRE FEEDER CONNECTION INSTRUCTIONS

The LN-742 or STT-10 is the recommended wire feeder for use with the INVERTEC STT II (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.

C-2

3. Connect the electrode lead (Twist-Mate) to (+) output terminal on STT II.

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.

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 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 II front panel.

6. Connect the ARC SENSE LEAD “WORK” (lead with alligator clip) to work piece.

NOTE: For best 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 II. 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.

FIGURE C.2 LN-742 to STT II CONNECTION

INVERTEC STT II (CE)

Page 21

C-3

CONNECTION DIAGRAM - INVERTEC STT II

4-9-99

M17657-3

CABLES AND LEADS SHOULD

ELECTRODE LEAD

BE TAPED TOGETHER.

WORK

(SHOULD BE LOCATED AS CLOSE AS POSSIBLE

FEEDER

REMOTE

ELECTRODE LEAD

TO THE WELDING ARC)

WORK LEAD

WIRE FEEDER

WIRE FEEDER CONTACT

ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON THE

BLOCK

STT-10

WIRE FEEDER

WARNING

Turn off input power to the Welding Power source using the disconnnect switch at the fuse box before connecting the wire feeder.

Only qualified persons should install,

ELECTRIC

use or service this machine.

SHOCK CAN KILL

WIRE

ARC SENSE LEAD "WORK"

ACCESSORIES

C-3

FIGURE C.3 STT-10 to STTII CONNECTION

INVERTEC STT II (CE)

Page 22

D-1

MAINTENANCE

WARNING

Failure 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.

3. 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 resistor is not supplied with machine. NEVER USE A

SHORTING STRAP FOR THIS PROCEDURE.

D-1

5. Locate the two capacitor terminals (large hex head cap screws) shown in Figure D.1.

6. Use safety glasses, electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor leads across the two capacitor terminals. Hold resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS.

7. Repeat discharge procedure for capacitor on other

side of machine.

8. Check voltage across terminals of all capacitors with 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.

INVERTEC STT II (CE)

Page 23

D-2

MAINTENANCE

D-2

PREVENTIVE MAINTENANCE

1. Perform the following preventive maintenance procedures 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.

2. Remove the machine wraparound cover and perform the input filter capacitor discharge procedure (detailed at the beginning of this chapter).

3. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following components thoroughly.

• Power Switch, Driver, Protection, and Control

printed circuit boards

• Power Switch

• Main Transformer

• Input Rectifier

• Heat Sink Fins

• Input Filter Capacitors

• Output Terminals

• Lower base compartment

4. Examine capacitors for leakage or oozing. Replace if needed.

5. 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.

6. Check electrical ground continuity. Using an ohmmeter, measure 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 properly insulated from the case. Correct insulation if needed.

7. Replace machine cover and screws.

INVERTEC STT II (CE)

Page 24

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

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.

__________________________________________________________________________

E-1

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 (SYMPTOMS)”. 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 contact 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 II (CE)

Page 25

E-2

TROUBLESHOOTING

Observe Safety Guidelines detailed in the beginning of this manual.

E-2

PROBLEMS (SYMPTOMS)

Major physical or electrical damage is evident

Machine has no open circuit voltage. Wire feeds ok.

Machine has no welding output (no open circuit voltage) and the wire feeder does not feed wire when the gun trigger is pulled.

POSSIBLE CAUSE

OUTPUT PROBLEMS

1. Contact your local Lincoln

Authorized Field Service Facility.

1. Check the control cable between the feeder and the STT II unit. Make sure the #2 and #4 leads are intact.

2. 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.

1. The 42VAC circuit breaker CB1

may be tripped. Reset if necessary.

2. Put a jumper between pins “A”

and “C” on the 5 pin MS connector located on the LN742 wire feeder. If wire feeds check the gun trigger. Repair or replace if necessary.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

3. Check for the presence of 42AC at pins “K” and “I” 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 feeder.

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)

Page 26

E-3

TROUBLESHOOTING

Observe Safety Guidelines detailed in the beginning of this manual.

E-3

PROBLEMS (SYMPTOMS)

No output. Main fuses open, indicating excessive current draw.

Machine loses output when gun trigger is pulled or arc is struck. Machine output returns after a few seconds and trigger is pulled again. The Thermal indicator light is lit.

POSSIBLE CAUSE

OUTPUT PROBLEMS

1. With input power removed inspect input leads for possible shorts or grounds or misconnections.

2. Install new fuses and reapply power. If fuses open again contact your local Lincoln Authorized Field Service Facility.

1. The over current sensor is being activated indicating that too much output current is being drawn from the machine. Reduce welding current demands or remove “fault” in welding cables.

2. Make sure that the gun tip is not “shorted” to the work surface and that the proper welding procedures are being used.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Machine is dead - no output -no fans - no display.

1. Power switch must be in the

“ON” position.

2. Check the input voltage. Make sure all three phases are applied to the machine.

3. 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 voltage being used. See Reconnect Procedure in the Installation Section.

4. With input power removed check continuity of 3 amp slow blow fuse located on reconnect panel.

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)

Page 27

E-4

TROUBLESHOOTING

Observe Safety Guidelines detailed in the beginning of this manual.

E-4

PROBLEMS (SYMPTOMS)

No output or reduced output the first time power is applied to the machine.

Machine loses output while welding. The thermal indicator light is lit. Normal welding output returns after about 10 minutes.

POSSIBLE CAUSE

OUTPUT PROBLEMS

1. Check input voltages, fuses and input voltage reconnect proce-

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.

1. Check to make sure the fans are running and operating correctly.

2. Welding application may exceed recommended duty cycle.

3. Dirt and dust may have clogged the cooling channels. Blow out unit with clean, dry compressed air.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Machine has low OCV, and loses output while attempting to weld.

4. Air intake and exhaust louvers may be blocked due to inadequate clearance around machine.

1. Check for faulty connection on plug J1 on Control Board and plug J1 on Current Sense Board.

2. 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)

Page 28

E-5

TROUBLESHOOTING

Observe Safety Guidelines detailed in the beginning of this manual.

E-5

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 possible 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.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists,

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 II (CE)

Page 29

E-6

TROUBLESHOOTING

Observe Safety Guidelines detailed in the beginning of this manual.

E-6

PROBLEMS (SYMPTOMS)

Porosity in the weld

Weld bead appears “cold”.

POSSIBLE CAUSE

OUTPUT PROBLEMS

1. Make sure proper gas type and flow rate is correct for procedure being used. Shield work from excessive outside air currents.

2. Check gun and nozzle for leaks or obstructions.

3. Make certain machine and wire feed settings are correct for process.

1. One or more of the machine settings may be wrong. Check the Background, Peak Current, Tailout and wire speed controls for proper settings. Adjust for optimum welding performance.

2. Make sure the Wire Type, and Wire Size switches are in the correct position for the electrode wire being used.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Molten weld puddle appears excessively “violent”.

1. The Wire Type switch may be in the wrong position for the electrode wire being used.

2. 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 II (CE)

Page 30

F-1

32A

32B

J22

18V

32C

43A

18V

501

504

275

311

212A

212

352

212B

503A

301

305

245

223

503

24V

351

244

CASE

BACK

PLATFORM

4 AMP

309

503A

BOTTOM

OUTSIDE

Y Y

4,5

12D

FAN

SLOW

12B

RIGHT

MOTOR

BLOW

J11

379

CR2

10K

CW (MAX)

353

362

363

CONTROL

BACKGROUND

N.L.

ASSEMBLY

INPUT

LINE

POWER

LINE

LOAD

F-

POWER

OFF

INPUT

PER

N.A.

}

FILTER

TRIGGER

CORE

12C

12D

- ARC

}

+ ARC

CURRENT

METER

VAC

12D

378

363

CW (MAX)

233

359

358

10K

R11

377

TRANSFORMER

374

NIO

CURRENT

N.E.

371

}

210

211A

502

246

212C

}

364

365

366

367

369

368

J28

J33

}

372372

371

J27

376

370

}

370

376

374

371

115V

374

33B

33A

J26

290A

367A

369

.045

502

(-)

INDICATOR

J25

115

223

357

356

355

354

CB2

J37

403

504

TRANSFORMER

AUXILIARY

N.D.

TRANSFORMER

501

220-

212A

}

150 5W

PROTECTION

RECONNECT

12B

212C

287

43A

BOARD

POWER

308

307

THERMOSTAT

HEATSINK

J22

DARLINGTON

503B

18V

359

356

358

355

354

357

352

351

360

353

361

362

244

303

242

302

371A

302

374A

304

275

305

243

301

}

240

241

12B

IGBT

12D

BOARD

J16

TOP

DRIVER

MOTOR

FAN

LEFT

MOTOR

TOP

FAN

D13

RECTIFIER

TP2

TP1

TP3

J16, J28

J34

N.K.

413

416

405

408

406

VAC

314

315

J13

ELECTRODE SENSE LEAD

}

360

367

368

367A

STAINLESS

R12

.035

INTERFACE

503

TRIGGER

MILD

378

PEAK

377

PEAK

METER

BACKGROUND

CONTROL

HOT START

WIRE TYPE

500K

TAILOUT

CONTROL

R14

N.J.

}

REMOTE

407

115

350

J35

J17

J23

J24

METER PINOUT (VIEWED FROM BACK OF METER)

ELECTRICAL SYMBOLS PER E1537

18V

J23

504A

380-

415V

230V

200-

208V

}

BACK

FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

}

10V

J24

}

18V

THERMOSTAT

COLOR CODE:

FAN

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

J26

CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

B = BLACK

CASE TRAY

G = GREEN

N = BROWN

FRONT

NOTES:

O = ORANGE

R = RED

W = WHITE

N.A.

J25

Y = YELLOW

U = BLUE

1. FOR MACHINES SUPPLIED WITH INPUT CABLE

N.M. PRESENT ON EUROPEAN VERSIONS, CODE 10383 AND HIGHER.

FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

CONNECTION SHOWN IS FOR 440-460V OPERATION.

N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.

D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.

N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.

J21

N.G. C1, C2 CAPACITORS ARE A MATCHED SET.

P21

PINOUT OF FRONT PANEL CONNECTORS (REAR VIEW)

J29. J31

CONNECTION SHOWN IS FOR 380-460V OPERATION.

N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.

N.I. DENOTES A TWISTED WIRE PAIR OR GROUP.

P29, P31

J30

P30

J22

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

N.K. NOT PRESENT ON EUROPEAN VERSIONS, CODE 10309 AND HIGHER.

N.L. PRESENT ON EUROPEAN VERSIONS, CODE 10309 AND HIGHER.

P22

765

1211

J38

J19

N.J. NOT PRESENT ON EUROPEAN VERSION.

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

J39

2 3

}

310

309

310A

310

309A

310A

224A

309

INSIDE

12B

25W

2200

BOARD

450V

(RIGHT)

1 5

307

2 36

308

J10

5252

}

J34

J36

2WR310

.001/400

N.E.

12C

12A

OUTSIDE

TOP

CHOKE

BOARD

12A

J12

N.H.

BOARD

224

310

J15

316

}

12B

401, 403

1, 8

371

J22

12B

TOP

12B

.001/400

CR1

2200

450V

25W

12A

401, 403

402, 404

(LEFT)

BOARD

SWITCH

1, 8

25W

4, 5

GND

{

FEEDER

{

J39

414

432

TRANSFORMER

288

289

R16

288A

SENSE

MAIN

289A

20/400

D11

J18

313

J14

210A

210

THERMOSTAT

CHOKE

}

FANCASE

BOTTOM

INSIDE

BOTTOM

D10

311

33C

J30

224

440-

460V

J31

42V

115V

J21

R15

300W

J38

409

412D404

CURRENT

411

291

GND

MODULE

}

DRIVE

BOARD

317

402, 404

N.G.

N.F.

25W

7500

SWITCH

SHROUD

J6, J27, J33

J2, J36

J18, J37

J11, J12, J14

J1, J8,

P.C. BOARD CONNECTOR CAVITY NUMBERING SEQUENCE

212B

32C

33C

D12

J3, J9,

IGBT

402

401

410

10K

CB1

}

6AMP

43B

242

243

241

240

374A

371A

211A

350

25W

7500

N.F.

J5, J7,

(VIEWED FROM COMPONENT SIDE OF BOARD)

J15, J35

J10, J13,

J4, J17

R13

(+)

10K22W

CW (MAX)

361

CONTROL

366

503A

WIRE SIZE

THERMAL

OVERLOAD

364

365

CONTROL

CURRENT

BOARD

415

31A

33D

6AMP

246

245

212

INLINE CONNECTOR CAVITY NUMBERI NG SEQUENCE

313

G4500

WIRING DIAGRAM - INVERTEC STT II (CE) (FOR CODE 11366)

(VIEWED FROM WIRE SIDE OF CONNECTOR)

SENSE

(-)

VOLTAGE

CONNECTION

(+)

J19

290

PROTECTION BOARD

REMOTE

288B

TOROIDAL

289B

374

}

WIRE

OPTIONAL

VAC

N.L.

N.M.

N.G.

300W

501A

DIAGRAMS

F-1

INVERTEC STT II (CE)

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 31

ELECTRICAL SYMBOLS PER E1537

1 3

610

{

FAN

MOTOR

MLB

313241422

GND

SPARE

VAC

CURRENT

TRANSF ORMER

MAIN

TRANSFORMER

OFF

TP1

TP3

TP2

CHOKE

CONTROL

BOARD

10K

R11

307

308

309

310

302

303

304

POWER

BOARD

(VIEWED FROM COMPONENT SIDE OF BOARD)

NOTES:

TRIGGER

}

INPUT

PER

N.A.

POWER

}

CB1

504

43A

AUXILIARY

TRANSFORMER

613

N.E.

CW (MAX)

TOP

OUTSIDE

BOTTOM

INSIDE

TOP

INSIDE

BOTTOM

OUTSIDE

CONTROL

211A

212B

150 5W

FAN

THERMOSTAT

BOTTOM

212A

212

24V

42V

18V

.001/400

COLOR CODE:

R = RED

785

502

301

D11

D10

N.E.

210

6AMP

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.

N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

CONNECTION SHOWN IS FOR 380-415V OPERATION.

CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

W = WHITE

B = BLACK

G = GREEN

Y = YELLOW

N.D.

+ ARC

- ARC

.001/400

415V

200-

208V

380-

305

}

J14

311

313

4 AMP

SLOW

BLOW

N.A.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.

N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.

N.G. C1, C2 CAPACITORS ARE A MATCHED SET.

N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CI RCUITRY HAVING A COMMON CODE NUMBER.

D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.

CONNECTION SHOWN IS FOR 380-415V OPERATION.

12D

INPUT

RECTIFIER

D13

10K

CW (MAX)

CONTROL

BACKGROUND

METER

}

BACKGROUND

BOARD

}

213

CURRENT

SENSE

J18

IGBT

MODULE

IGBT

BOARDDRIVE

J13

J12

1. FOR MACHINES SUPPLIED WITH INPUT CABLE

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE

VOLTAGE

SENSE

CONNECTION

J19

18V

AUXILIARY

TRANSFORMER

115V

10V

18V

U = BLUE

212A

212

501

504

275

351

350

352

353

354

355

356

357

358

359

360

361

362

363

290

291

J21

934

758

R12

J18, J37

J6, J27, J33

J19

J15, J35

210A

224

20/400

287

288A

288B

289A

289B

364

365

366

368

369

372

376

O = ORANGE

N = BROWN

234

23456

354

355

356

357

10K

CW (MAX)

CONTROL

HOT START

R13

WIRE SIZE

WIRE

FEEDER

CB2

BOARD

25W

7500

25W

308

307

402, 404

401, 403

4,5

1, 8

401, 403

1, 8

4, 5

402, 404

SWITCH

DRIVER

BOARD

J10

BOARD

123

PROTECTION

2200 F

450V

N.G.

N.F.

N.G.

2200 F

450V

(LEFT)

BOARD

(RIGHT)

12B

12A

7500

25W

314

315

317

J15

N.F.

12A

12B

J11

}

J16

12B

12D

501

115V

371

371A

374A

374

J22

240

241

242

243

244

245

246

18V

240

241

242

303

302

304

275

371A

374A

243

244

}

J27

374

370

371

367

}

J28

}

371

374

}

364

365

366

(+)

(-)

367

368

369

367A

WIRE TYPE

STAINLESS

MILD

DFH

TRIGGER

GND

}

.045

.035

10K

OPTIONAL

REMOTE

INTERFACE

{

115

VAC

RYN

32C

33C

32A

32B

33A

33B

J22

2S 300W

289

288

2S 300W

J33

}

223

J34

}

33C

345

43B

31A

}

J35

33D

6AMP

J36

}

J37

J30

J31

503A

R14

372

376

374

370

371

432

J24

J23

J26

J25

353

352

351

350

234

23456

VAC

115

VAC

}

J39

675

8109

}

502

210

223

305

245

211A

212C

246

301

J17

}

503

503A

212C

43A

212B

32C

J38

503

REMOTE

PROTECTION BOARD

(-)

(+)

THERMAL

OVERLOAD

INDICATOR

R13

J10, J13,

J1, J8,

J3, J9,

J5, J7,

J34

J2, J36

J38

J39

PINOUT OF FRONT PANEL CONNECTORS (REAR VIEW)

P30

J30

1234

P29, P31

J29. J31

1234

P21

J21

1239

145678

12 13 14 15 16

P22

J22

INLINE CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM WIRE SIDE OF CONNECTOR)

45678

111213141516

J23

J24

J25

J26

P.C. BOARD CONNECTOR CAVITY NUMBERING SEQUENCE

METER PINOUT (VIEWED FROM BACK OF METER)

RWB

PEAK

CURRENT

PEAK

CURRENT

N.I. DENOTES A TWISTED WIRE PAIR OR GROUP.

N.J.

RWW

316

311

313

309

310

CR1

N.H.

12C

12A

RECONNECT

12C

12D

309A

310A

309

310

CR2

309A

310A

12D

12B

224

503A

224A

J22

THERMOSTAT

DARLINGTON

HEATSINK

503B

J11, J12, J14

J4, J17

J16, J28

401

402

403

404

405

406

407

408

409

410

411

412

413

414

415

416

LOAD

LINE

POWER LINE

FILTER

ASSEMBLY

N.L.

N.K.

N.K. NOT PRESENT ON EUROPEAN VERSIONS.

N.L. PRESENT ON EUROPEAN VERSIONS.

N.J. NOT PRESENT ON EUROPEAN VERSIONS.

TOROIDAL

CORE

N.L.

A.01

WIRING DIAGRAM - INVERTEC STT II (CE) (FOR CODE 11367)

G4557

F-2

DIAGRAMS

F-2

INVERTEC STT II (CE)

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 32

F-3

13.19

20.75

23.25

13.21

24.50

1-9-98B

M18706

DIMENSION PRINT - STT II (CE)

DIAGRAMS

F-3

INVERTEC STT II (CE)

Page 33

NOTES

INVERTEC STT II (CE)

Page 34

NOTES

INVERTEC STT II (CE)

Page 35

NOTES

INVERTEC STT II (CE)

Page 36

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 37

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 38

• 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

Lincoln Electric IM904 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual