Lincoln Electric STT-10 Service Manual
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Lincoln Electric STT-10 Service Manual

Lincoln Electric STT-10 Service Manual

Head & controls boom mount or bench models
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STT-10 Head & Controls Boom Mount or Bench Models
For use with machines having Code Numbers:
STT-10 Control - Boom Mount Code 10447, 10832
10 Series Wire Drive - Boom Mount Code 10443, 10763, 10818
STT- Boom Package Code 10448
Synergic 7F Wire Drive Code 10190, 10191
STT-10 - Bench Model Code 10446, 10766, 10821
STT-10 - Zipline Boom Package Code 10499, 10500, 10773
SERVICE MANUAL
SVM243-A
| Issue D ate 14-Mar
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. STT-10 Head & Controls Boom Mount or Bench Models For use with machines having Code Numbers: STT-10 Control - Boom Mount Code 10447, 10832...
  • Page 2 Service and repair should be performed by only exhaust at the arc, or both, to keep Lincoln Electric Factory Trained Personnel. Unauthorized the fumes and gases from your breathing zone and the general area. repairs performed on this equipment may result in danger...
  • Page 3 American Welding Society, P.O. Box 351040, Miami, Florida 33135 MAGNETIC FIELDS MAY or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 STT-10 SAFETY 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 electrically “hot” when the welder is on. Do plates to protect your eyes from sparks and the rays of the arc not touch these “hot”...
  • Page 5 STT-10 SAFETY 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. and properly operating regulators designed for If this is not possible, cover them to prevent the gas and pressure used.
  • Page 6 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding equipment, in metallic conduit or equivalent. Shielding should be Equipment. It is for use with other Lincoln Electric equipment. It is electrically continuous throughout its length. The shielding should be designed for industrial and professional use.
  • Page 7 STT-10 SAFETY Ventilation As a rule of thumb, for many mild steel electrode, if the air is visibly clear and you are comfortable, then the ventilation is generally There are many methods which can be selected by the user to adequate for your work.
  • Page 8 TLV and PEL values are as of April 2006. Always check Material Know Act of 1986 and of 40CFR 370 and 372. Safety Data Sheet (MSDS) with product or on the Lincoln Electric website at http://www.lincolnelectric.com (b) The PEL for chromium (VI) is .005 milligrams per cubic meter as an 8 hour time weighted average.
  • Page 9 STT-10 TABLE OF CONTENTS MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ....................................ii-viii Installation .................................Section A Operation..................................Section B Accessories ................................Section C Maintenance ................................Section D Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F Electrical Diagrams ..............................Section G...
  • Page 10 STT-10 THEORY OF OPERATION TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory Of Operation ......................Section E Input Receptacles, Control Board And Operator Controls ......E-2 Wire Feed Head And Receptacle .
  • Page 11 KEYPAD INPUT RECEPTACLES, CONTROL BOARD AND OPERATOR CONTROLS The 42 VAC input voltage is applied to the STT-10 through a 9-pin amphenol type receptacle. The trigger leads are also accessed through this 9-pin receptacle. The remote control is accessed through the 6-pin receptacle.
  • Page 12 STT-10 THEORY OF OPERATION Figure E.3 - Wire feed head and receptacle SOLENOID TO GUN TRIGGER DUAL PROCEDURE WIRE WIRE DRIVE DRIVE RECEPTACLE MOTOR OPTIONAL OPTIONAL ROBOTIC TACH FEEDBACK REMOTE INTERFACE CONTROL KIT MODULE INPUT CABLE CURRENT SENSING RECEPTACLE REED SWITCH...
  • Page 13 GROUNDING LEAD PROTECTOR The STT-10 has solid-state overload protection of the wire drive The frame of the STT-10 control is grounded to the frame of the motor. If the wire drive motor becomes overloaded for an extended power source by a lead in the control cable. An overload protector...

  • Page 14: Table Of Contents

    STT-10 TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ....................Section F How to Use Troubleshooting Guide ..........F-2 PC Board Troubleshooting Procedures .

  • Page 15: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only 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.

  • Page 16: Pc Board Troubleshooting Procedures

    STT-10 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES 4. Test the machine to determine if the failure symptom has been WARNING corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

  • Page 17: Troubleshooting Guide

    3. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 18 3. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 19 4. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 20 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 21 STT-10 at the input receptacle terminals A and B. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 22 3. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 23 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F-10...
  • Page 24 2. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F-11...
  • Page 25 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F-12...
  • Page 26 5. The power source may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F-13...
  • Page 27 STT-10 NOTES F-14...

  • Page 28: Wire Drive Motor Test

    WIRE DRIVE MOTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 29 (-) lead and one white (+) lead). Do not disconnect the leads. See Figure F.2. See Wiring Diagram. 4. Apply the correct input power (42 VAC) to the STT-10. Activate the gun trigger. With the motor running, check the armature voltage at the black lead #541 (-) and white lead #539 (+).
  • Page 30 STT-10 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR TEST (continued) Figure F.2 – Wire drive motor test (+)WHITE LEAD (-)BLACK LEAD F-17...
  • Page 31 STT-10 NOTES F-18...

  • Page 32: Tach Adjustment And Feedback Test

    TACH ADJUSTMENT AND FEEDBACK TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 33 3. Locate the three hall effect leads (blue, red and black). See Figure F.4. See Wiring Diagram. 4. Apply the correct input power (42 VAC) to the STT-10. 5. Check for approximately 12 VDC from red lead #512 (+) to black lead #500 (-).
  • Page 34 TACH ADJUSTMENT PROCEDURE Proper positioning of the module is critical to the proper operation the STT-10 wire feeder. If the device is not screwed in far enough the motor speed could be unstable or run at full speed with no control. If screwed in too far, it will rub a moving part inside the gearbox.
  • Page 35 STT-10 NOTES F-22...

  • Page 36: Keypad Resistance Test

    KEYPAD RESISTANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 37 CASE FRONT MOUNTING SCREWS PROCEDURE 1. Remove input power to the STT-10 unit. 2. Using a 5/16” nutdriver, remove the two mounting screws from the top of the case front. See Figure F.5. 3. Using a small slotted screwdriver, gently pry the top of the case front open.
  • Page 38 STT-10 TROUBLESHOOTING AND REPAIR KEYPAD RESISTANCE TEST (continued) Table F.1 – Keypad resistance test TEST POINTS MAXIMUM ALLOWABLE RESISTANCE FROM PIN TO PIN KEY PRESSED (TYPICAL RESISTANCE) 1J10 2J10 CONTROL 100 OHMS (50 OHMS TYPICAL) 1J10 3J10 TIMER 100 OHMS (50 OHMS TYPICAL)
  • Page 39 STT-10 NOTES F-26...

  • Page 40: Encoder Pc Board Test

    ENCODER PC BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 41 Diagram. Do not remove the plug from the control board. 10. Using a 5/16” nutdriver, attach the two mounting screws securing 5. Apply the correct input power (42 VAC) to the STT-10 unit. the case front. See Figure F.6. 6. Carefully check for the presence of 5 VDC from 5J2 (lead #505) to 4J2 (lead #500).

  • Page 42: Gas Solenoid Test

    GAS SOLENOID TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 43 3. Locate the gas solenoid and lead connection. See Figure F.8. See Wiring Diagram. Do not disconnect the leads. 4. Apply the correct input power (42 VAC) to the STT-10 unit. 5. While pressing the gas purge button or activating the gun trigger, check for approximately 10 VDC at the solenoid leads.
  • Page 44 STT-10 TROUBLESHOOTING AND REPAIR GAS SOLENOID TEST (continued) Figure F.8 – Gas solenoid and lead locations GAS SOLENOID LEAD SOLENOID NOTE: WIRE FEEDER SHOWN WITH DRIVE MOTOR ASSEMBLY REMOVED FOR CLARITY F-31...
  • Page 45 STT-10 NOTES F-32...

  • Page 46: Display Board Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 47 CASE FRONT MOUNTING SCREWS REMOVAL PROCEDURE 1. Remove input power to the STT-10 unit. 2. Using a 5/16” nutdriver, remove the two mounting screws from the top of the case front. See Figure F.9. 3. Using a small slotted screwdriver, gently pry the top of the case front open.
  • Page 48 STT-10 TROUBLESHOOTING AND REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Connect the previously removed plug J10 to the new display board. See Wiring Diagram. 2. Carefully attach the display board to the six mounting pins. 3. Connect the previously removed plug J11 to the new display board.
  • Page 49 STT-10 NOTES F-36...

  • Page 50: Gas Solenoid Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 51 5. Using a 5/16” socket, remove the two screws securing the mounting bracket to the rear panel of the wire feeder. See Figure F.11. 6. Remove the gas solenoid and mounting bracket from the STT-10 unit. See Figure F.11. 7. Using a phillips screwdriver, remove the two screws securing the gas solenoid to the mounting bracket.
  • Page 52 STT-10 TROUBLESHOOTING AND REPAIR GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.11 – Gas solenoid removal GAS SOLENOID CLAMP MOUNTING BRACKET SCREWS (2) MOUNTING BRACKET GAS SOLENOID SCREWS (2) HOSE NOTE: WIRE FEEDER SHOWN WITH DRIVE MOTOR ASSEMBLY REMOVED FOR CLARITY REPLACEMENT PROCEDURE 1.
  • Page 53 STT-10 NOTES F-40...

  • Page 54: Encoder Pc Board Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 55 CASE FRONT MOUNTING SCREWS REMOVAL PROCEDURE 1. Remove input power to the STT-10 unit. 2. Using a 5/16” nutdriver, remove the two mounting screws from the top of the case front. See Figure F.12. 3. Using a small slotted screwdriver, gently pry open the case front.
  • Page 56 STT-10 TROUBLESHOOTING AND REPAIR ENCODER PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Connect previously removed harness plug J17 into the new encoder PC board. See Wiring Diagram. 2. Carefully position new encoder pc board into machine. 3. Using 1/2” deep well socket, attach the nut and washer to the control shaft securing the encoder pc board to the machine.
  • Page 57 STT-10 NOTES F-44...

  • Page 58: Wire Drive Motor And Gear Box Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 59 See Figure F.14. Note 3. Carefully remove the wire drive assembly from the gear box washer placement for reassembly. The motor, gear box and feed assembly. head assembly are now free from the STT-10 unit. Note RTV sealant placement for reassembly. F-46...
  • Page 60 STT-10 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.14 – Wire feed assembly removal MOTOR ARMATURE TACH LEADS LEADS CAP SCREW LOCK WASHER 3/4” NUT FLATWASHER LEAD #67 GAS HOSE FITTING Figure F.15 – Electrode cable location ELECTRODE 3/4”...
  • Page 61 Seal with silicone rubber RTV sealant. 8. Carefully place the entire assembly into the STT-10 unit. Align the mounting holes with wire feeder base. 9. Using a 7/16” socket wrench and extension, attach the previously removed four mounting screws, lock washers and flat washers securing the assembly to the wire feeder base.

  • Page 62: Current Sensing Reed Switch Removal And Replacement

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 63 REED SWITCH PLUG REMOVAL PROCEDURE 1. Remove input power to the STT-10 unit. 2. Disconnect the reed switch plug from the front of the machine. See Figure F.17. 3. Remove the reed switch box by pulling rearward on the box until it is free from the machine.
  • Page 64 STT-10 TROUBLESHOOTING AND REPAIR CURRENT SENSING REED SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Position the new reed switch in the copper energizer. 2. Using a slotted screwdriver, tighten the locking screw securing the reed switch to the copper energizer.

  • Page 65: Retest After Repair

    2. Press the Range key. The “Peak Max” LED above the Range key Apply the correct input power (42 VAC) to the STT-10 unit. The must light up. Keep pressing until the “WFSMIN” LED turns on.
  • Page 66 Wiring Diagram STT-10   Control........
  • Page 67 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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.
  • Page 68 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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.
  • Page 69 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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.
  • Page 70 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...
  • Page 71 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 14.71 5.25 7.81 6.55 4.44 2.42 12.74 10.40 2.25 4.08 WIRE DRIVE...

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