Lincoln Electric POWER WAVE STT Operator's Manual
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- Operator's manual (64 pages) ,
- Specification sheet (168 pages) ,
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Operator's Manual
POWER WAVE
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10249
| Issue D ate July-15
© Lincoln Global, Inc. All Rights Reserved.
®
®
STT
MODULE
For use with machines having Code Numbers:
12461
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
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Table of Contents
Related Manuals for Lincoln Electric POWER WAVE STT
Summary of Contents for Lincoln Electric POWER WAVE STT
- Page 1 Operator’s Manual ® ® POWER WAVE MODULE For use with machines having Code Numbers: 12461 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
- Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
- Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
- Page 4 S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
- Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
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Page 6: Table Of Contents
TABLE OF CONTENTS Page General Description ..............................7 Installation ..............................Section A Technical Specifications..........................A-1 Safety Precautions............................A-2 Electromagnetic Compatibility.......................A-2 Location and Ventilation........................A-2 Control Cable Connection........................A-2 Connection between Power Source and STT ® Module ................A-3 Electrode and Work Connections......................A-3 Output Cable Guide Lines........................A-4 Cable Inductance and its Effects on Welding ..................A-4 Remote Sence lead Connections......................A-5, A-6 Connection Diagram System .........................A-7... -
Page 7: General Description
GENERAL DESCRIPTION GENERAL DESCRIPTION General Physical Description The POWER WAVE ® ® MODULE is an accessory enabling compati- ble power sources to perform the STT ® function without limiting the normal multi-process rating of the host machine. It is intended for use with medium range “S”–... -
Page 8: Installation
POWER WAVE ® ® MODULE INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE ® ® MODULE (K2902-2) Module - Input Voltage and Current ® Voltage Input Amperes Notes 40Vdc Module - *Output Current Capacity ® Duty Cycle Amperes Notes 100% 750A Peak (Max.) * Defines capability of the output switch. -
Page 9: Safety Precautions
POWER WAVE ® ® MODULE INSTALLATION SAFETY PRECAUTIONS Read FIGURE A.1 this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. • Turn off the power source at the discon- nect switch before connecting or working inside of the equipment. •... -
Page 10: Control Cable Connection
Some earlier vintage S350 power sources (Code 11589) may not include a 6-pin Differential I/O receptacle. If the receptacle is not pre- sent on the host power source, contact the Lincoln Electric Service Department to obtain an S350/STT Retrofit Kit (S28481). -
Page 11: Output Cable Guidelines
POWER WAVE ® ® MODULE INSTALLATION TABLE A.1 OUTPUT CABLE GUIDELINES Percent CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES (RUBBER COVERED Duty COPPER - RATED 75°C)** Amperes Cycle 0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. -
Page 12: Remote Sence Lead Connections
POWER WAVE ® ® MODULE INSTALLATION REMOTE SENSE LEAD CONNECTIONS RECOMMENDATIONS: • Position the sense leads out of the path of the weld cur- Voltage Sensing Overview rent. Especially any current paths common to adjacent arcs. The STT welding process requires the use of remote voltage ®... - Page 13 POWER WAVE ® ® MODULE INSTALLATION • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path.
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Page 14: Connection Diagram System
POWER WAVE ® ® MODULE INSTALLATION CONNECTION DIAGRAM SYSTEM MODULE CONNECTION DIAGRAM ® FIGURE A.5... -
Page 15: Safety Precautions
The standard weld set shipped with the host power source encompasses a wide range of common processes that will meet most needs. If the STT modes are not available, or if a special weld mode is desired, visit www.powerwavesoftware.com or contact the local Lincoln Electric sales representative. -
Page 16: Commom Equipment Packaces
MODULE (CE) CASE FRONT CASE FRONT DESCRIPTIONS 1. Status LED – Provides ArcLink ® status of Power Wave STT Module. ® Note: During normal power-up, the LED will flash green up to 60 seconds as the equipment performs self tests. - Page 17 POWER WAVE ® ® MODULE OPERATION ® MODULE CASE BACK CASE BACK DESCRIPTIONS 1. ArcLink ® Pigtail – Connects directly to the ArcLink ® Out receptacle on the rear of the power source. 2. Differential I/O Pigtail – Connects directly to the Differential I/O output receptacle on the rear of the power source. 3.
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Page 18: Routine Maintenance
POWER WAVE ® ® MODULE MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Disconnect input power before servicing. • Do not operate with covers removed. • Do not touch electrically live parts. • Only qualified persons should install, use or service this equipment. -
Page 19: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs per- formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. - Page 20 POWER WAVE ® ® MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual MODULE FUNCTIONAL TEST ® PREPARATION • Connect the STT module to a Power Wave S350 or other compatible machine. ® (This test assumes the host power source has been calibrated.) •...
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Page 21: Error Codes
POWER WAVE ® ® MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The STT Module is equipped with a Status Light. If a problem occurs it is important to note the condition of the sta- ®... - Page 22 POWER WAVE ® ® MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE STT ® MODULE The following is a partial list of possible error codes for the STT ® MODULE. ® MODULE Indication Error Code # Thermal error Indicates over temperature.
- Page 23 POWER WAVE ® ® MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual ON BOARD LED’S FOR THE STT SWITCH PC BOARD ® SWITCH PC BOARD ® MACHINE LED1 LED2 LED3 INDICATION OUTPUT (GATE) (STATUS) (+15V) ON/OFF Normal Condition – STT ®...
- Page 24 POWER WAVE ® ® MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION BASIC MACHINE PROBLEMS Input fuses keep blowing 1. Improperly sized input fuses. 1. Make sure fuses are properly sized. See installation section of this manual for rec- ommended sizes.
- Page 25 POWER WAVE ® ® MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION BASIC MACHINE PROBLEMS 1. Improper fan operation. 1. Check for proper fan operation. (Fans Thermal error indication on STT ®...
- Page 26 POWER WAVE ® ® MODULE DIAGRAMS...
- Page 27 POWER WAVE ® ® MODULE DIAGRAMS...
- Page 28 POWER WAVE ® ® MODULE NOTES...
- Page 29 POWER WAVE ® ® MODULE NOTES...
- Page 30 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.