Lincoln Electric INVERTEC IM904 Operator's Manual
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Lincoln Electric INVERTEC IM904 Operator's Manual

Lincoln Electric INVERTEC IM904 Operator's Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
IM904
INVERTEC
®
S T T
®
II (CE)
July, 2006
11366, 11367
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT 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

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Summary of Contents for Lincoln Electric INVERTEC IM904

  • Page 1 RETURN TO MAIN MENU IM904 INVERTEC ® S T T ® II (CE) July, 2006 11366, 11367 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Fumes And Gases

    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.
  • Page 4 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.
  • Page 5 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - 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.

  • Page 7: Table Of Contents

    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...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS –INVERTEC STT II (CE) (For Code 11366) STANDARD VOLTAGE 200/220/380/415/440/3/50/60 HZ DUTY CYCLE 60% Duty Cycle 100% Duty Cycle CURRENT RANGE Peak Current 0 - 450 Amps Background 0 - 125 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES NPUT VOLTAGE FUSE(SUPER LAG) AND FREQUENCY...
  • Page 9 TECHNICAL SPECIFICATIONS –INVERTEC STT II (CE) (For Code 11367) STANDARD VOLTAGE 200/208/380/400/415/3/50/60 HZ DUTY CYCLE 60% Duty Cycle 100% Duty Cycle CURRENT RANGE Peak Current 0 - 450 Amps Background 0 - 125 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES NPUT VOLTAGE FUSE(SUPER LAG) AND FREQUENCY...

  • Page 10: Location

    INPUT CONNECTIONS 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.

  • Page 11: Rating Plate

    INPUT CABLE ENTRY ACCESS & CABLE STRAIN RELIEF 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.

  • Page 12: Input Voltage Reconnect Procedure

    ACCESS DOOR LOCATION 380-415 200-208 (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.

  • Page 13: Operation

    OPERATING INSTRUCTIONS Read and understand entire section before operating machine. GENERAL WARNINGS SAFETY PRECAUTIONS Observe additional Safety Guidelines detailed in the beginning of this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.

  • Page 14: General Description

    GENERAL DESCRIPTION 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 con- ventional short circuiting GMAW.

  • Page 15: Operational Features And Controls

    OPERATIONAL FEATURES AND CONTROLS All operator controls are located on the case front of the INVERTEC STT II (CE). Refer to Figure B.1 for locations. FIGURE B.1 CASE FRONT CONTROLS 1. POWER SWITCH: Turns output power ON and OFF. This switch also controls auxiliary power available through the 14-pin Wire Feeder Receptacle.

  • Page 16: Welding 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 perfor- mance of smaller diameter wires at higher wire feed speeds.

  • Page 17: Welding Parameters And Guidelines

    WELDING PARAMETERS AND GUIDE- LINES The INVERTEC STT II (CE) is neither a constant cur- rent (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”).
  • Page 18 WELDING PROCEDURES FOR STT II - (Steel) Horizontal Fillet (See Table B.1 and B.2) DIRECTION DIRECTION 45° END VIEW Table B.1 100% CO Gas Shield (Set for Steel Mode) Plate Thickness “ (mm) 20 ga (0.9) Electrode size “ (mm) 0.035 (0.9) WFS “/min (m/min)

  • Page 19: Options & Accessories

    OPTIONS / ACCESSORIES K940 SENSE LEADS: These leads are used to accu- rately sense arc voltage. One set is required for each STT II power source. A 10 ft and 25 ft set are provid- ed as standard with the machine. Additional sets are available in 10 ft (K940-10), 25 ft (K940-25) and 50 ft (K940-50) lengths.

  • Page 20: Ln-742 Or Stt-10 Wire Feeder Connection Instructions

    LN-742 or STT-10 WIRE FEEDER CONNECTION INSTRUCTIONS The LN-742 or STT-10 is the recommended wire feed- er 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.
  • Page 21 CONNECTION DIAGRAM - INVERTEC STT II WIRE FEEDER REMOTE WORK LEAD ELECTRODE LEAD ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON THE WIRE FEEDER CONTACT BLOCK FIGURE C.3 STT-10 to STT II CONNECTION ACCESSORIES ELECTRIC CAN KILL CABLES AND LEADS SHOULD BE TAPED TOGETHER.

  • Page 22: Maintenance

    WARNING Failure to follow this capacitor discharge procedure can result in electric shock. INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1. Turn off input power or disconnect input power lines. 2. Remove hex head screws from side and top of machine and remove wrap-around machine cover. 3.

  • Page 23: Preventive Maintenance

    PREVENTIVE MAINTENANCE 1. Perform the following preventive maintenance pro- cedures 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 per- form the input filter capacitor discharge procedure (detailed at the beginning of this chapter).

  • Page 24: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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.
  • Page 25 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident Machine has no open circuit voltage. Wire feeds ok. Machine has no welding output (no open circuit voltage) and the wire feeder does not feed wire when the gun trigger is pulled.
  • Page 26 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) No output. Main fuses open, indicat- ing excessive current draw. Machine loses output when gun trig- ger is pulled or arc is struck. Machine output returns after a few seconds and trigger is pulled again.
  • Page 27 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) No output or reduced output the first time power is applied to the machine. Machine loses output while welding. The thermal indicator light is lit. Normal welding output returns after about 10 minutes.
  • Page 28 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Excessive weld spatter. Arc sounds and looks like a standard MIG process. The wire burns back to the tip. Poor welding, weld settings drift or output power is low. 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.
  • Page 29 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Porosity in the weld Weld bead appears “cold”. Molten weld puddle appears exces- sively “violent”. 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.

  • Page 30: Diagrams

    DIAGRAMS INVERTEC STT II (CE)
  • Page 31 DIAGRAMS INVERTEC STT II (CE)
  • Page 32 DIAGRAMS INVERTEC STT II (CE)
  • Page 33 NOTES INVERTEC STT II (CE)
  • Page 34 NOTES INVERTEC STT II (CE)
  • Page 35 NOTES INVERTEC STT II (CE)
  • Page 36 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 37 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 38 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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Invertec stt ii ce

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