Lincoln Electric INVERTEC IM904 Operator's Manual

INVERTEC ®

For use with machines having Code Numbers:

S T T

11366, 11367

® II (CE)

IM904

July, 2006

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation

... and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And, most importantly, think before you act and be careful.

ISO/IEC 60974-1

OPERATOR’S MANUAL

Copyright © 2006 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

i 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

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

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.

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.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running.

Stop the engine and allow it to cool before refueling to prevent spilled fuel from 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.

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 i

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.

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.

SAFETY

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 applica ti on 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 vapors coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors to 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 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 ii

iii SAFETY

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.

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 though they have been “cleaned”. For information, purchase “Recommended

Safe Practices for the Preparation for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a welding area.

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.

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.

iii

Mar ‘95

iv 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: iv

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.

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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.

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.

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.

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.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

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.

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.

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.

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

v

Thank You

v

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!

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 WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

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

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

vi

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

DUTY CYCLE

60% Duty Cycle

100% Duty Cycle

CURRENT RANGE

225

33/30/18/17/16

RATED OUTPUT

AMPS VOLTS AT RATED AMPS

29

28 200

OUTPUT

OPEN CIRCUIT VOLTAGE AUXILIARY POWER

Peak Current 1 0 - 450 Amps

Background 0 - 125 Amps

85 VDC Maximum 115 2 VAC @ 4 Amps

42 VAC @ 4 Amps

A-1

I NPUT VOLTAGE

AND FREQUENCY

200/50/60

220/50/60

380/50/60

415/50/60

440/50/60

HEIGHT

23.2 in

589 mm

RECOMMENDED INPUT WIRE AND FUSE SIZES

FUSE(SUPER LAG)

OR BREAKER

SIZE

INPUT AMPERE

RATING ON

NAMEPLATE

TYPE 75°C

COPPER

SUPPLY WIRE

IN CONDUIT

AWG (IEC) SIZES

40

40

30

30

30

33

30

18

17

16

10 (6 mm2)

WIDTH

PHYSICAL DIMENSIONS

DEPTH

13.2 in.

336 mm

24.4 in.

620 mm

TYPE 75°C

COPPER

GROUND WIRE

IN CONDUIT

AWG (IEC) SIZES

10 (6 mm2)

WEIGHT

100 lbs.

46 kg

1 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.

2 115 VAC not present on European Models.

INVERTEC STT II (CE)

A-2

INSTALLATION

A-2

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

DUTY CYCLE

60% Duty Cycle

100% Duty Cycle

RATED OUTPUT

AMPS

225

200

OUTPUT

OPEN CIRCUIT VOLTAGE

VOLTS AT RATED AMPS

29

28

CURRENT RANGE AUXILIARY POWER

Peak Current 0 - 450 Amps

Background 0 - 125 Amps

I NPUT VOLTAGE

AND FREQUENCY

88 VDC Maximum 115 1 VAC @ 4 Amps

42 VAC @ 4 Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES

FUSE(SUPER LAG)

OR BREAKER

SIZE

INPUT AMPERE

RATING ON

NAMEPLATE

TYPE 75°C

COPPER

SUPPLY WIRE

IN CONDUIT

AWG (IEC) SIZES

TYPE 75°C

COPPER

GROUND WIRE

IN CONDUIT

AWG (IEC) SIZES

200/50/60

208/50/60

380/50/60

400/50/60

415/50/60

40

40

30

30

30

36

34

20

19

18

10 (6 mm2) 10 (6 mm2)

HEIGHT

23.2 in

589 mm

WIDTH

PHYSICAL DIMENSIONS

DEPTH

13.2 in.

336 mm

24.4 in.

620 mm

WEIGHT

100 lbs.

46 kg

1 115 VAC not present on European Models.


A-3

INSTALLATION

Read and understand entire Installation Section before starting installation.

A-3

MACHINE GROUNDING AND HIGH

FREQUENCY INTERFERENCE

PROTECTION

WARNING


• Only qualified personnel should perform this installation.

• Turn the input power OFF at the disconnect switch or fuse box before installing this equipment.

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:

• Turn the power switch on the Invertec

STT “OFF” before connecting or disconnecting input power lines, output cables, or control cables.

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.

• Do not touch electrically hot parts.

• Always connect the ground terminal to a good electrical earth ground.

Provide proper electrical ground to the machine per local and national electrical codes.

SELECT SUITABLE LOCATION

INPUT CONNECTIONS

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.

FAILURE TO FOLLOW THESE INSTRUCTIONS

CAN CAUSE IMMEDIATE FAILURE OF COMPO-

NENTS WITHIN THE WELDER.

Turn the input power off at the disconnect switch before attempting to connect the input power lines.

Connect the green lead of the power cord to ground per local and national electrical codes.

SUPPLY CONNECTIONS

STACKING

The INVERTEC STT II (CE) cannot be stacked.

TILTING

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

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 INSTALLA-

TION AND CONNECTION”.


A-4

INSTALLATION

CASE BACK

A-4

INPUT CABLE

ENTRY ACCESS

& CABLE STRAIN RELIEF

RATING PLATE

FIGURE A.1 CASE BACK

INPUT CABLE INSTALLATION AND CON-

NECTION

A cable strain relief is provided at the supply line entry and is designed to accommodate cable diameters of

.310 - 1.070 in. (7.9 - 27.2 mm). On European models the strain relief is designed to accommodate cable diameters of .709 - 1.000 in. (18.0 - 25.4 mm). Refer to “Technical Specifications” at the beginning of this section for the proper input cable sizes. Refer to

Figure A.1 and perform the following steps:

1. Remove the wraparound cover of the

INVERTEC STT II (CE).

2.

Feed the input cable through the input cable entry access hole at the right rear of the machine.

3. Route the cable through the cable hangers, located along the lower right inside edge of the machine, up to the power switch located on the front panel.

4. Strip away 102 mm (4 in.) of the outer jacket.

Trim fillers and strip conductor jackets to connect to the power switch.

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).


A-5

ACCESS DOOR

LOCATION

To Operate at

460 or 440 VAC

(Code 11366)

380-415

OR

OR

200-208

Procedure

INSTALLATION

4A

* (NOT PRESENT ON ALL MODELS)

*

*

FIGURE A.2 RECONNECT PANEL

INPUT VOLTAGE RECONNECT

PROCEDURE

As shipped from the factory, multiple voltage machines are internally configured for the highest input voltage (440-460 VAC), for Code 11366 and

(380-415 VAC), for Code 11367.

1. For Connections to 440 or 460 VAC verify the internal configurations to the procedures shown below and refer to Figure A.2.

2. For Connections to 200,208,220,230,380,400 or

415 VAC follow the procedure shown below and refer to figure A.2.

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.

------------------------------------------------------------------------

1. Open reconnect panel access door on wraparound.

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

380 or 415 VAC

(Codes 11366)

380,400 or 415 VAC

(Codes 11367)

220 or 230 VAC

(Codes 11366)

200 or 208 VAC

(Codes 11366)

200 or 208 VAC

(Codes 11367)



3. Move lead “ A ” to 380-415

Terminal.



3. Move lead “ A ” to 380-415

Terminal.


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

3. Move lead “ A ” to 220-230

Terminal.



3. Move lead “ A ” to 200-208

Terminal.



3. Move lead “ A ” to 200-208

Terminal.

A-5

OUTPUT CONNECTIONS

WIRE FEEDER OUTPUT CONNECTIONS

3. Move lead “ A ” to 440-460

Terminal.

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).


B-1 OPERATION

OPERATING INSTRUCTIONS

Read and understand entire section before operating machine.

GENERAL WARNINGS

SAFETY PRECAUTIONS

WARNING


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

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• 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.

B-1


B-2

GENERAL DESCRIPTION

OPERATION

• High temperature Class H insulation.

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.

B-2

• 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.

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.

DESIGN FEATURES AND ADVANTAGES

• 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.

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).


B-3 OPERATION

OPERATIONAL FEATURES AND CONTROLS

B-3

All operator controls are located on the case front of the INVERTEC STT II (CE). Refer to Figure B.1 for locations.

4 5

6

7

10

9

11

14

3

8

2

1

13

15

12

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.

V

ON

OFF

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.

3B. PEAK CURRENT DISPLAY METER: This 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.

A

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.

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.

A

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.

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.


B-4 OPERATION

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.

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).

9. REMOTE RECEPTACLE: This is a 10 pin MStype 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 CON-

TROL 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 connection is the negative output terminal for connecting a work cable and clamp to the workpiece.

15. ELECTRODE TERMINAL: This twistmate 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

Features and Controls of these switches.

11. ARC SENSE RECEPTACLE: This is a four pin

MS-type connector for WORK and ELECTRODE sense leads. The STT requires a WORK sense and ELECTRODE sense lead for proper operation.

The ELECTRODE sense lead is bolted together with power source electrode lead at the wire feeder gun block. The WORK sense lead is furnished with an “ alligator ” type clip for connection to the work piece. Refer to the LN 742 or STT-10 wire feeder connection instructions in the Accessories section of this manual for proper connection of these leads.

12. 42V AUXILIARY POWER CIRCUIT BREAKER:

The 42 VAC supply is protected from excessive current draws with a 6 amp circuit breaker. When the breaker “ trips ” its button will extend. Depressing this button will reset the breaker.


”

“ Operational

in this section for the function

B-5 OPERATION

WELDING PARAMETERS AND GUIDE-

LINES

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.

Adjust Bead Shape using Background Current

Note: Background Current levels for applications using

100% CO

2 is less than similar procedures involving gas blends with high percentages of Argon. This is a result of the greater heat generated in the 100% CO

2 arc. (100% CO

2 is 35 volts/cm and 100% Argon is 20 volts/cm. 75% Argon, 25% CO

2 is about 24 volts/cm.

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.

Contact Tip to Work Distance

PEAK CURRENT

The Peak Current control acts similar to an “ arc pinch ” control. Peak current serves to establish the arc length and promote good fusion. Higher peak current levels will cause the arc to broaden momentarily while increasing the arc length. If set too high, globular type transfer will occur. Setting this level to low will cause instability and wire stubbing. In practice, this current level should be adjusted for minimum spatter and puddle agitation.

Adjust Arc Length with Peak Current

Note: In 100% CO

2 shielding gas applications the peak current level should be set greater than in a corresponding application using a gas blend with a high percentage of Argon. Longer initial arc lengths with

100% CO2 are required to reduce spatter.

BACKGROUND CURRENT

The Background Current provides the control for the overall heat input to the weld. Adjusting this level too high will cause a large droplet to form and globular type transfer to occur resulting in increased spatter.

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.


B-6 OPERATION

WELDING PROCEDURES FOR STT II -

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

(Stainless Steel) Horizontal Fillet

(See Table B.3 and B.4)

DIRECTION

OF

TRAVEL

75

°

DIRECTION

OF

TRAVEL

B-6

75

°

45

°

TOP VIEW

DIRECTION

OF

TRAVEL

75 °

45

°

TOP VIEW

DIRECTION

OF

TRAVEL

75 °

END VIEW FRONT VIEW

Table B.1

100% CO

2

Gas Shield (Set for Steel Mode)

Plate Thickness “ (mm) 20 ga

(0.9)

Electrode size “ (mm) 0.035

(0.9)

WFS “ /min (m/min)

Peak Current

Background Current

Tailout setting

Average Amperage

Travel Speed “ /min

(m/min)

Gas Flow cfh (L/min)

Electrical Stickout “

(mm)

100

(2.5)

220

30

3

60

12

(0.3)

14 ga 10 ga

(2.0) (3.25)

0.045

0.045

(1.1) (1.1)

100

(2.5)

260

40

170

(4.2)

280

65

7

105

12

(0.3)

25 (12)

1/4 - 3/8

(6.4 - 10)

5

120

12

(0.3)

Table B.2

75% CO

2

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


(0.9)


(0.9)


Peak Current

Background Current

Tailout setting

Average Amperage


(m/min)



(mm)

100

(2.5)

225

40

8

70

12

(0.3)

14 ga 10 ga

(2.0) (3.25)

0.045

0.045

(1.1) (1.1)

100

(2.5)

270

65

4

110

12

(0.3)

25 (12)

1/4 - 3/8

(6.4 - 10)

120

(3.0)

310

70

6

130

12

(0.3)


END VIEW FRONT VIEW

Table B.3

90% He, 7.5% Ar, 2.5% CO

2

Gas Shield (Set for Steel Mode)


(0.9)


(0.9)


Peak Current

Background Current

Tailout setting

Average Amperage


(m/min)



(mm)

100

(2.5)

165

35

7

40

12

(0.3)

14 ga 10 ga

(2.0) (3.25)

0.045

0.045

(1.1) (1.1)

130

(3.3)

210

60

170

(4.2)

250

85

7

95

16

(0.4)

25 (12)

1/4 - 3/8

(6.4 - 10)

4

120

16

(0.4)

Table B.4

98% Ar, 2% O

2

Gas Shield (Set for Stainless Steel Mode)


(0.9)


(0.9)


Peak Current

Background Current

Tailout setting

Average Amperage


(m/min)



(mm)

100

(2.5)

145

45

7

60

12

(0.3)

14 ga 10 ga

(2.0) (3.25)

0.045

0.045

(1.1) (1.1)

130

(3.3)

190

95

170

(4.2)

280

95

8

120

12

(0.3)

25 (12)

1/4 - 3/8

(6.4 - 10)

7

150

12

(0.3)

C-1

OPTIONS / ACCESSORIES

ACCESSORIES

K940 SENSE LEADS: These leads are used to accurately 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.

C-1

STT control board to accept PEAK and BACK-

GROUND inputs on this connector rather than from the front panel controls. If this short is removed, the front panel controls will be active. 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 ” )

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)

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

+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.

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.

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

4. The trigger switch is connected between pins “ D ” and “ F ” . These connections are in parallel with the trigger switch from the wire feeder.

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

5. The digital meters for PEAK and BACKGROUND currents will show preset values in both local and remote operation.

REMOTE

PROTECTION BOARD

+ ARC

290

291

J19

- ARC

J37

1

2

3

4

3

4

1

2

(+)

(-)

VOLTAGE

SENSE

CONNECTION

212C

43A

33C

32C

212B

6

1

4

8

5

3

2

7

J38

10

9

12

4

11

3

2

1

J38

A

D

F

H

E

I

C

G

J

B

TRIGGER

GND

BG

10K

PB

10K

223

OPTIONAL

REMOTE

INTERFACE

290A

8

WIRE

FEEDER

J39

N ELECTRODE SENSE LEAD

PORTION OF G3136 WIRING DIAGRAM

REFER TO ACTUAL DIAGRAM PASTED INSIDE YOUR MACHINE


C-2 ACCESSORIES

LN-742 or STT-10 WIRE FEEDER

CONNECTION INSTRUCTIONS

C-2

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

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.

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


• Only qualified personnel should perform this installation.

• Turn the input power OFF at the disconnect switch or fuse box before connecting the wire feeder

NOTE: For best welding performance make this connection as close as possible to the welding arc.

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.

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.

REMOTE RECEPTACLE

WORK LEAD

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.

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

CONTROL, ELECTRODE, ARC SENSE "ELECT"

AND ARC SENSE "WORK" CABLES SHOULD

BE TAPED TOGETHER.

WIRE FEEDER

LN 742

LN7 GMA

LN9 GMA

NA5R

NA5

WIRE FEEDER

CONTROL CABLE

ELECTRODE LEAD

ARC SENSE LEAD

'ELECT"

WORK

ARC SENSE LEAD "WORK"

(SHOULD BE LOCATED

AS CLOSE AS POSSIBLE

TO THE WELDING ARC.)

CONNECT ELECTRODE LEAD AND "ELECT"

ARC SENSE LEAD TOGETHER TO ELECTRODE

TERMINAL OF WIRE FEEDER.

CRM after 6-10-96

M17657

FIGURE C.2 LN-742 to STT II CONNECTION


C-3

WIRE FEEDER

REMOTE

WORK LEAD

ACCESSORIES

CONNECTION DIAGRAM - INVERTEC STT II

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.

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

C-3

CABLES AND LEADS SHOULD

BE TAPED TOGETHER.

WIRE FEEDER

STT-10

ELECTRODE LEAD

ELECTRODE LEAD

ELECTRODE SENSE LEAD

IS BOLTED TOGETHER WITH

ELECTRODE LEAD ON THE

WIRE FEEDER CONTACT

BLOCK

WIRE

FEEDER

REMOTE

WORK

ARC SENSE LEAD "WORK"

(SHOULD BE LOCATED

AS CLOSE AS POSSIBLE

TO THE WELDING ARC)

4-9-99

M17657-3

FIGURE C.3 STT-10 to STT II CONNECTION


D-1

WARNING

MAINTENANCE D-1

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

D.1.

Failure to follow this capacitor discharge procedure can result in electric shock.

INPUT FILTER CAPACITOR

DISCHARGE PROCEDURE

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.

1. Turn off input power or disconnect input power lines.

7. Repeat discharge procedure for capacitor on other side of machine.

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.

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.

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.

FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.


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.


E-1 TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

E-1

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.

Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical

Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions.

Simply follow the three-step procedure listed below.

Step 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.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “ PROBLEM (SYMP-

TOMS) ” . This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

If you do not understand or are unable to perform the

Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

Step 2. POSSIBLE CAUSE.

The second column labeled “ POSSIBLE CAUSE ” lists the obvious external possibilities that may contribute to the machine symptom.

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.



Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

Major physical or electrical damage is evident

OUTPUT PROBLEMS

1. Contact your local Lincoln

Authorized Field Service

Facility.

RECOMMENDED

COURSE OF ACTION

E-2

Machine has no open circuit voltage.

Wire feeds ok.

1. Check the control cable between the feeder and the STT II unit.

Make sure the #2 and #4 leads are intact.

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

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.

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

Contact your local Lincoln


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






PROBLEMS

(SYMPTOMS)

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

POSSIBLE

CAUSE

OUTPUT PROBLEMS inspect input leads for possible shorts or grounds or misconnections.

RECOMMENDED


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

Field Service Facility.

E-3

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.

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.




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






PROBLEMS

(SYMPTOMS)

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

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Check input voltages, fuses and input voltage reconnect procedures. See Installation section.

RECOMMENDED


2. If high input voltage (380VAC or higher) is applied, the capacitors may need conditioning. Let the

“ unloaded ” machine idle for 30 minutes.

E-4

Machine loses output while welding.

The thermal indicator light is lit.

Normal welding output returns after about 10 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.




Facility.

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

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

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






E-5

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

Excessive weld spatter. Arc sounds and looks like a standard MIG process.

OUTPUT PROBLEMS

1. Check the Arc Sense leads for loose or faulty connections.

RECOMMENDED


“ 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.

The wire burns back to the tip.

Poor welding, weld settings drift or output power is low.

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.




Facility.

CAUTION






PROBLEMS

(SYMPTOMS)

Porosity in the weld

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.

RECOMMENDED


2. Check gun and nozzle for leaks or obstructions.

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

E-6

Weld bead appears “ cold ” .

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.




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




F-1 DIAGRAMS

1 2

1 4 5 3 8 9 4 6

}

43B 42

3 4 5 6 11 2 44 5 6

357 35

6 7

3 1 7 5 6 8 2 4

3 4 5 7 8 9

7 14

244 303

2 1 16 10 7 14

11 3 1 12 6 7 4 10

Y 30

245 22

2 5

365 366

4 3

4 5

10 2W

}

314 31

9B 9B

R5 25 25

9B 9B

200- 208V

UT PE


F-1

F-2 DIAGRAMS

1 2 3 4

2 3 4

J B C G A D F H E I

10 9 12 4 11

6 1 3 2

212C 43

}

5 4 6 2 3 7 1

W B

1 2 3 4 5 6

1 2 3 4 5 6

353 352

1 2 3 4 5 6

1 2 3 4 5 6

10K 2W 10K 2W 10K 2W

370 37

6 7 2 1

4 2

B W

9 10 1 2

241 242

6 7

7 14

243 244 303 302 30

11 12

12 13

15 16

305 24 211A 21

364 36

5 6

3 1

2 3 4

2 3

371 374 N O

6 8

7 8 2 4 5 6 1 3 1 2 3 4

501 504

10 2W

F BOT

T2 MA TOP OUTS

10 2W

TOP IN

BOARD (RI

25 25W 25 25

309 310

311 313

314 31

R5 25 25

25 25

R9

7500 25

7500 25

12B 12 SLOW BLOW

200- 208V

FAN MO


F-2

F-3 DIAGRAMS F-3


NOTES


NOTES


NOTES


Chinese

Korean

Arabic

WARNING

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATEN ÇÃ O

●

●

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.

●

●

Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension.

Isolez-vous du travail et de la terre.

● Gardez à l’écart de tout matériel inflammable.

● Protégez vos yeux, vos oreilles et votre corps.

●

●

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 electrodos com a pele ou roupa molhada.

Isole-se da peça e terra.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guardados.

● Tragen Sie Augen-, Ohren- und Körperschutz!

● Use proteção para a vista, ouvido e corpo.

Japanese

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 HER-

STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

●

●

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 respiración.

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 aspirateur pour ôter les fumées des zones de travail.

● Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entretien.

● No operar con panel abierto o guardas quitadas.

● N’opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés.

●

●

Vermeiden Sie das Einatmen von

Schweibrauch!

Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in

Betrieb setzen!

●

●

Mantenha seu rosto da fumaça.

Use ventilação e exhaustão para remover fumo da zona respiratória.

●

●

●

Não opere com as tampas removidas.

Desligue a corrente antes de fazer serviço.

Não toque as partes elétricas nuas.

●

●

Mantenha-se afastado das partes moventes.

Não opere com os paineis abertos ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATEN ÇÃ O

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.

• 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

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