Operator Manual English
Contents
1. X B5 B8 5 B6 B7 B8 LED1 ur add WA l lo AnA STT STATUS a o E OUTPUT INPUT POWER 40 VDC 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 E 5 POWER WAVE STT 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 2 Improper Weld Procedure requiring out 2 Reduce output current duty cycle or put levels in excess of machine rating both 3 Major physical or electrical damage is 3 Contact your local authorized Lincoln evident in the power source when the Electric Field Service facility for techni sheet metal covers are removed cal assistance Machine will not power up no lights on 1 No Input Power 1 Make sure input supply disconnect has power source STT Module or Wire Feeder been turned ON Check input fuses Make certain that the Power Switch on the powe2. LIE 988 M qau u 5 xov18 8 3009 30105 Sulvd aaLSIML 3199143934 351 INAS 3NIHOVIA V3 9 9 8 1IV L5I LLL 908 21 05 29 00 NI LLS WYO 2 006 wyo 2 006 1 0 11005 4410 319943934 1IV15I XMII V M93 9 03 031 SNLYLS c8 JINGOW LLS 3AVM 83M Od INVH9VIG F 1 POWER WAVE STT MODULE DIAGRAMS LINCOLN ELECTRIC 2277 772777 115814 2 F 2 POWER WAVE STT MODULE NOTES F 3 POWER WAVE STT MODULE NOTES F 4 CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equipment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask 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 a
3. Section F 2 Wiring Diagram and Dimension gt __ _V parts lincolnelectric com Content details may be changed or updated without notice For most current Instruction Manuals go to parts lincolnelectric com GENERAL DESCRIPTION GENERAL DESCRIPTION General Physical Description The POWER WAVE STT 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 series Power Wave power sources such as the 5350 The module itself is a low profile pedestal designed to seamlessly integrate with compatible power sources and water cool ers General Functional Description The POWER WAVE STT MODULE is essentially a high speed high capacity output switch connected in series with the positive output of the power source It communicates module status and identification information to the power source via the ArcLink protocol and receives a high speed synchronized switching command via a dedi cated digital link POWER WAVE STT MODULE INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE STT MODULE K2902 1 STT Module Input Voltage and Current Voltage Input Amperes STT Module Output Current Capacity Duty Cycle Wes 750A Peak Max Defines capability of the output switch The actual output current is suppl
4. SYMPTOMS COURSE OF ACTION BASIC MACHINE PROBLEMS Thermal error indication on STT Module 1 Improper fan operation 1 Check for proper fan operation Fans error 36 typically run whenever output power is on Check for material blocking intake or exhaust louvers or for excessive dirt clogging cooling channels in machine 2 After machine has cooled reduce load 2 STT Switch PC board thermostat duty cycle or both Check for material blocking intake or exhaust louvers and heat sink fins 3 Open thermostat circuit 3 Check for broken wires open connec tions or faulty thermostat in the STT Module WELD AND ARC QUALITY PROBLEMS General degradation of weld performance 1 Wire feed problem 1 Check for feeding problems Check actu al WFS vs preset Verify proper wire drive and gear ratio has been selected 2 Cabling problems 2 Check for bad connections excessive loops in cable etc NOTE The presence of heat in the exter nal welding circuit indicates poor con nections or undersized cables 3 Loss of or improper Shielding Gas 3 Verify gas flow and type are correct 4 Verify weld mode is correct for process 4 Select the correct weld mode for the application 5 Machine calibration 5 Verify the calibration of the power source output current and voltage 6 STI Process ONLY Excessive cable 6 Excessive cable inductance or STT inductance or STT snubber malfunction snubber malfunction can cause
5. but not limited to SMAW GMAW GMAW P GMAW STT PROCESS LIMITATIONS The POWER WAVE STT MODULE is unaffected by the voltage at the load and therefore processes are only limited by the current and duty cycle ratings listed in the specifications for the product The POWER WAVE STT MODULE is designed to protect itself from the excessive transient voltages associated with highly inductive weld circuits These high inductance circuits may result in unsatisfactory performance but will not damage the module Ithough the STT Module can be configured to support negative elec trode polarity processes such as Innershield the STT process must be configured to use positive electrode polarity EQUIPMENT LIMITATIONS The POWER WAVE STT MODULE is intended for use with com patible medium range S series POWER WAVE power sources such as the 5350 POWER WAVE STT MODULE OPERATION COMMON EQUIPMENT PACKAGES BASIC PACKAGE STT Module 2823 1 Power Wave 5350 2370 2 OWER FEED 10M K1543 xx ArcLink Cable 5 pin connects wire feeder to power source K2536 POWER FEED 25M STT MODULE CE CASE FRONT NS SS LALLA CASE FRONT DESCRIPTIONS 1 Status LED Provides ArcLink status of Power Wave STT Module Note During normal power up the LED
6. will flash green up to 60 seconds as the equipment performs self tests LED condition Steady green System okay The power source and wire feeder are communicating normally Blinking green Occurs during a reset and indicates the power source is identifying each component in the system This is normal for the first 60 seconds after power up or if the system configuration is changed during operation Alternating green Non recoverable system fault If the power source or wire feeder status LED is flashing any combination of red and red and green errors are present in the system Read the error code before the machine is turned off 2 STT INPUT Connects directly to the Positive output of the power source 3 STT OUTPUT Connects directly to the wire feeder torch or electrode B 2 POWER WAVE STT MODULE OPERATION STT MODULE CASE BACK eru V7ZT7TT7ZZZZK CASE BACK DESCRIPTIONS 1 ArcLink Pigtail Connects directly to the ArcLink Out receptacle on the rear of the power source 2 Differential 1 0 Pigtail Connects directly to the Differential 1 0 output receptacle on the rear of the power source 3 Differential 1 0 Sync Tandem Output Supports Synchronized Tandem MIG Welding with other compatible power sources Note This f
7. GURE A 3 4 POWER WAVE STT MODULE INSTALLATION REMOTE SENSE LEAD CONNECTIONS Voltage Sensing Overview The STT welding process requires the use of remote voltage sense leads to more accurately monitor the conditions of the arc These leads originate in the power source and are connected and configured external to the STTe Module Consult the power source instruction manual for detailed information Note Other processes run through the STT Module do not necessarily require sense leads but will benefit from their use Consult the power source instruction manual for recommendations General Voltage Sensing Considerations for Multiple Arc Systems Special care must be taken when more than one arc is welding simultaneously on a single part The placement and configura tion of remote work voltage sense leads is critical to the proper operation of multiple arc 5 applications RECOMMENDATIONS Position the sense leads out of the path of the weld cur rent Especially any current paths common to adjacent arcs Current from adjacent arcs can induce voltage into each oth ers current paths that can be misinterpreted by the power sources and result in arc interference For longitudinal applications connect all work leads at one end of the weldment and all of the work voltage sense leads at the opposite end of the weldment Perform welding in the direction away from the work leads and toward th
8. Operator s Manual LINCOLN ELECTRIC POWER WAVE STT MODULE Cana Register your machine www lincolnelectric com register LINCOLN MUN PARTS Authorized Service and Distributor Locator www lincolnelectric com locator Save for future reference For use with machines having Code Numbers 11690 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 Date Purchased no later than the following business day For Service outside the USA Code ex 10859 Email globalservice lincolnelectric com Serial ex U1060512345 IM 1 0058 Issue Date Mar 15 Lincoln Global Inc All Rights Reserved THE LINCOLN ELECTRIC COMPANY 22801 St Clair Avenue e Cleveland OH 44117 1199 U S A Phone 1 216 481 8100 www lincolnelectric com THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELECTRIC 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 SAFETY DEPENDS ON YOU Lincoln arc welding and cutting equipment is des
9. S A 6 POWER WAVE STT MODULE INSTALLATION CONNECTION DIAGRAM SYSTEM STT MODULE CONNECTION DIAGRAM FIGURE A 5 K1543 XX FROM FEEDER ELECTRODE REFER TO OUTPUT CABLE GUIDELINES FOR RECOMMENDED CABLE SIZE K2230 1 Power Feed 10M K1543 XX M22497 TO STTe MODULE POWER WAVE STT MODULE OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine 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 WARNING POWER UP SEQUENCE The POWER WAVE STT MODULE will be powered up at the same time as the power source The status light will blink green for about a minute while the system is configuring After this time the status lights will turn a steady green indicating the machine is ready The fan in the POWER WAVE STT MODULE will run only when the power source fan is activated DUTY CYCLE The POWER WAVE STT MODULE is rated at 450 amps at a 100 duty cycle It is further rated to support 500 amps at a 6096 duty cycle and 550 amps at a 4096 duty cycle The duty cycle is based a ten minute period 60 duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period Note The POWER WAVE ST
10. STT Module Status PC Board If cycling the input power on the machine does not clear the error contact the Service Department A 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 E 4 POWER WAVE STT MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual ON BOARD LED S FOR THE STT SWITCH PC BOARD STT SWITCH PC BOARD MACHINE LED1 LED2 LED3 INDICATION OUTPUT GATE STATUS 15V ON OFF Normal Condition STT Switch is ON OFF Normal Condition STT Switch has been commanded OFF Note During normal STT operation the OFF state of the LED may only be detectable as a slight dimming external STTe Module Status LED Most likely caused by weld cable misconnec tion reverse polarity ON OFF Status Failure constantly Should be accompanied by Error 99 on the external 5 Module Status LED Most likely caused by the on board power supply under voltage lockout Verify input voltage to the STTe Switch board Status Failure only when triggered Should be accompanied Error 99 on the 6 A Saree B4 B1 B2 B3 O B9 B1 SNUBBER
11. T MODULE is capable of withstanding a peak output current of 750 amps The allowable maximum aver age output current is time dependant and ultimately limited by the host power source COMMON WELDING PROCEDURES MAKING A WELD Choose the electrode material electrode size shielding gas and process GMAW GMAW P GMAW STT etc appropriate for the material to be welded Select the weld mode that best matches the desired welding process 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 B 1 To make a weld the power source needs to know the desired weld ing parameters Set the parameters on the user interface typically located on the wire feeder The user interface sends the parameters arc voltage wire feed speed UltimArc value etc to the power source via the ArcLinke communication protocol through the control cables The power source controls the POWER WAVE STT MOD ULE based on the selected weld mode For a more detailed description and specific operating instructions consult the power source Instruction Manual RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The POWER WAVE STT MODULE is recommended for all process supported by the host power source including
12. T TO BE USED FOR STT PROCESS TO WORK FEEDER A CAUTION Negative electrode polarity operation may require reconfig uration of the power source voltage sense leads See the Remote Sense Lead section in the power source instruction manual for further details For additional Safety information regarding the electrode and work cable set up See the standard SAFETY INFORMATION located in the front of the Instruction Manuals POWER WAVE STT MODULE INSTALLATION TABLE A 1 OUTPUT CABLE GUIDELINES Percent Duty COPPER RATED 75 C Amperes 60 CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES RUBBER COVERED 200 to 250 Ft Tabled values are for operation at ambient temperatures of 40 C and below Applications above 40 C may require cables larger than recommended or cables rated higher than 75 C GENERAL GUIDELINES Select the appropriate size cables the Output Cable Guidelines See Table A 1 Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance Always use the largest welding cables electrode and work that are practi cal and be sure all connections are clean and tight Note Excessive heat in the weld circuit indicates undersized cables and or bad connections Route all cables directly to the work and wire feeder avoid excessive lengths and do not coil excess cabl
13. ady Red Not applicable Blinking Red Not applicable 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 E 3 POWER WAVE STT 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 5 MODULE 36 Thermal error Indicates over temperature Usually accompanied by Thermal LED Check fan opera tion Be sure process does not exceed duty cycle limit of the machine 39 Misc hardware fault Unknown glitch has occurred on the fault interrupt circuitry Sometimes caused by primary over current fault or intermittent connections in the thermostat circuit 99 STT Status error Error reported by the STT Switch PC Board Generally caused by misconnection of welding leads reverse polarity May also be caused by loss of input voltage or board failure Observe diagnostic LED s on the STT Switch PC Board to determine the exact cause A complete list of error codes is available in the Power Wave Manager Utility avail able at www powerwavesoftware com Error codes that contain three or four digits are defined as fatal errors These codes generally indicate internal errors on the
14. and with proper grade of filter plate See ANSI 749 1 PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing flame proof apron and gloves leather leggings and high boots PROTECT others from splatter flash and glare with protective screens or barriers IN SOME AREAS protection from noise may be appropriate BE SURE protective equipment is in good condition Also wear safety glasses in work area AT ALL TIMES SPECIAL SITUATIONS DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned This is extremely dangerous DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken They can release highly toxic fumes or gases Additional precautionary measures PROTECT compressed gas cylinders from excessive heat mechanical shocks and arcs fasten cylinders so they cannot fall BE SURE cylinders are never grounded or part of an electrical circuit REMOVE all potential fire hazards from welding area ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT SECTION A WARNINGS CALIFORNIA PROPOSITION 65 WARNINGS Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Gasoline Engines 14 The engine ex
15. e Route the electrode and work cables in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit Always weld in a direction away from the work ground con nection See Table A 1 for copper cable sizes recommended for different currents and duty cycles Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop CABLE INDUCTANCE AND ITS EFFECTS ON WELDING Excessive cable inductance will cause the welding performance to degrade There are several factors that contribute to the over all inductance of the cabling system including cable size and loop area The loop area is defined by the separation distance between the electrode and work cables and the overall welding loop length The welding loop length is defined as the total of length of the electrode cable A work cable B work path C see Figure A 3 below To minimize inductance always use the appropriate size cables and whenever possible run the electrode and work cables in close proximity to one another to minimize the loop area Since the most significant factor in cable inductance is the welding loop length avoid excessive lengths and do not coil excess cable For long work piece lengths a slid ing ground should be considered to keep the total welding loop length as short as possible FI
16. e OSHA PEL and ACGIH TLV limits 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 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 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 Also see item 1 b WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION 2 7 ME 6 a Remove fire hazards from the welding area If 6 b 6 c 6 d 6 e 6 f 6 0 6 h 6 1 6 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 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 info
17. e sense leads See Figure A 4 FIGURE A 4 DIRECTION OF e A 7 LINCOLN ELECTRIC CONNECT ALL SENSE LEADS AT THE END OF THE WELD INGOLNI ELECTRIC CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD POWER WAVE STT 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 BAD CURRENT FLOW FROM ARC 1 AFFECTS SENSE LEAD 2 Work 1 Sense 1 CURRENT FLOW FROMARC 2 AFFECTS SENSE LEAD 1 NEITHER SENSE LEAD PICKS UP THE CORRECT WORK VOLTAGE CAUSING STARTING AND WELDING ARC INSTABILITY D dg D SENSE LEAD 1 IS ONLY AFFECTED BY CURRENT FLOW FROM ARC 1 O SENSE LEAD 2 IS ONLY AFFECTED BY CURRENT FLOW FROMARC 2 ue 2 DUE TO VOLTAGE DROPS ACROSS Sense 1 THE WORKPIECE ARC VOLTAGE MAY BE LOW CAUSING NEED FOR DEVIATION FROM STANDARD PROCEDURES BOTH SENSE LEADS ARE OUT OF THE CURRENT PATHS BOTH SENSE LEADS DETECT ARC VOLTAGE ACCURATELY NO VOLTAGE DROP BETWEEN ARC AND SENSE LEAD BEST STARTS BEST ARCS MOST RELIABLE RESULT
18. eature is not compatible with the STT process and is therefore disabled when using STTe weld modes 4 ArcLink Out Available on the standard model only Provides an ArcLink pass through connection for all compatible ArcLink wire feeders B 3 POWER WAVE STT 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 See additional warning information throughout this operator s manual and the Engine manual as well ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine using a low pressure air stream to remove accumu lated dust and dirt from the intake and outlet louvers and the cooling channels in the machine Also verify the STT Module fan is operational when the power source fan is activated CALIBRATION SPECIFICATION Due to the nature of its operation calibration of the STT Module is not required From a system perspective the output calibra tion of the power source and wire feeder should be performed as directed in their respective instruction manuals When calibrating the power source voltage using the Weld Manager utility the actual output voltage should be monitored directly at the output of the power source not the STT Module output T
19. f Action safely contact your local Lincoln Authorized Field Service Facility A 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 1 POWER WAVE STT MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual STT MODULE FUNCTIONAL TEST PREPARATION e Connect the STT module to a Power Wave 5350 or other compatible machine This test assumes the host power source has been calibrated Verify the latest software is loaded in the Power Wave e Short the Work to the Electrode STT Output Total Cable Length 10ft K1543 XX TO STT MODULE STT INPUT TO POSITIVE STUD STT OUTPUT TO NEGATIVE STUD TEST PROCEDURE Enable test modes on the UI of the Wire Feeder See Wire Feeder instruction manual set up menu selection P 99 Select test mode 208 5 Test Mode If mode 208 is not available with the test modes enabled the Power Source software must be updated Enable the output Pulling the trigger or turn the trim knob clockwise Read Voltage feedback displayed on the Wire Feeder Display Voltage Indication Possible Cause STT Switch Shorted e Faulty or disconnected Differential 1 0 control signal grey cable located at rear o
20. f module Verify cable connections including those internal to the 5 Switch and host power source lt 2V e STT Input tied to negative weld output Reverse Polarity typically accompanied by Error 99 Verify 5 Switch is properly connected e STT Switch Shorted typically accompanied by Error 99 Disconnect and perform 5 Switch PCB Test 5 10V Normal Operation STT Switch Open Loose or open connection Verify weld cable connections both internal and external to the module including quick connections 40V e STT Switch not closing be accompanied by Error 99 Verify status of the STT Switch board via the on board diagnostic LED s 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 E 2 POWER WAVE STT 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 tus lights Therefore prior to cycling power to the system check the power source status light for error sequences in Table E 1 TABLE E 1 Light Meaning Condition Steady Green System OK Power source is operational and is communicat
21. haust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1 g ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHIL iW DREN 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 amp Cutting ANSI Standard 749 1 from the American Welding Society 0 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 2 b FOR ENGINE POWERED A EQUIPMENT 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 23 Operate engines in open well ventilated D areas or vent the engine exhaust fumes outdoors 1 b 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
22. helter from rain and snow Do not place on wet ground or in puddles Do not mount the Power Wave 5 series power source and STT Module combination over combustible surfaces Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 060 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides TILTING The machine must be placed on a stable level surface so it will not topple over FIGURE A 1 CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at all times except where noted otherwise Lincoln cables are specifically designed for the communication and power needs of the Power Wave systems Most are designed to be connected end to end for ease of extension Generally it is recommended that the total length not exceed 100 feet 30 5 m The use of non stan dard cables especially in lengths greater than 25 feet can lead to communication problems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems Always use the shortest length of control cable possible and DO NOT coil excess cable POWER WAVE STT MODULE INSTALLATION A CAUTION Regarding cable placement best results will be obtained when control cables are routed separate from the weld cables This mini mizes the possibil
23. 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 A ARC RAYS CAN BURN 4 a 4 b 4 SAFETY 724 Use shield with the proper filter and cover plates 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 standards Use suitable clot
24. hing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 IY DINE DA 5 a 5 b 5 0 5 5 6 54 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 within applicable OSHA PEL and ACGIH TLV limits 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 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicabl
25. his is necessary because the default calibration mode senses voltage directly from the power source output studs The STT Module has no effect on the output current calibration POWER WAVE STT MODULE TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE 4 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 For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed through out 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 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symp tom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course o
26. ied by host power source PHYSICAL DIMENSIONS TEMPERATURE RANGES OPERATING TEMPERATURE RANGE Environmentally Hardened 4 F to 104 F 20C to 400 STORAGE TEMPERATURE RANGE Environmentally Hardened 40 F to 185 F 40C to 850 POWER WAVE STT MODULE INSTALLATION SAFETY PRECAUTIONS Read tnis entire installation section before you start installation WARNING ELECTRIC SHOCK can kill 9 Turn off the power source at the discon nect switch before connecting or working inside of the equipment Only a qualified electrician should install and connect the STT Module LOCATION AND MOUNTING See Figure A 1 Mount the STTe Module directly to the bottom of a compatible Power Wave S series power source utilizing the quick lock mechanism as shown The STTe Module will operate in harsh environments and can be used outdoors Even so it is important that simple preventative measures are followed in order to assure long life and reliable operation e The machine must be located where there is free circulation of clean air such that movement into and out of the louvers will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum The use of air filters on the air intake is not recommended because normal air flow may be restrict ed Failure to observe these precautions can result in exces sive operating temperatures and nuisance shutdown Keep the machine dry S
27. igned and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life AN CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment Li e Y KEEP YOUR HEAD OUT OF THE FUMES DON T get too close to the arc Use corrective lenses if necessary to stay a reasonable distance away from the arc READ and obey the Material Safety Data Sheet MSDS and the warning label that appears on all containers of welding materials USE ENOUGH VENTILATION or exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR amp BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted
28. ing Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 4 1 Route the electrode and work cables together Secure them with tape when possible Never coil the electrode lead around your body 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 Connect the work cable to the workpiece as close as pos sible to the area being welded Do not work next to welding power source 2 d 2 2 d 3 3 a 3 b 3 c 3 d 3 e 34 3 9 3 h 34 31 ELECTRIC SHOCK CAN KILL 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 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
29. ing normally with all healthy peripheral equip ment connected to its ArcLinke network Blinking Green Occurs during power up or a system reset and indicates the power source is mapping iden tifying each component in the system Normal for first 1 30 seconds after power is turned or if the system configuration is changed during operation Fast Blinking Green Under normal conditions indicates Auto mapping has failed Also used by the diagnostic utility included in the Weld Manager Utilities available at www powerwavesoftware com to identify the selected machine when con necting to a specific IP address Alternating Green and Red Non recoverable system fault If the Status lights are flashing any combination of red and green errors are present Read the error code s before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is pre sent the codes will be separated by a green light Only active error conditions will be acces sible through the Status Light Error codes can also be retrieved with the diagnostics utility included in the Weld Manager Utilities available at www powerwavesoftware com This is the preferred method since it can access historical information contained in the error log To clear the active error s turn power source off and back on to reset Ste
30. ity of interference between the high currents flowing through the weld cables and the low level signals in the control cables These recommendations apply to all communica tion cables including ArcLink connections CONNECTION BETWEEN POWER SOURCE AND STT MODULE ARCLINK AND DIFFERENTIAL 1 0 PIGTAILS The pigtail connections on the STT Module include all signal and power lines required for proper operation With the STT Module securely fas tened to the power source connect the pigtails to their respective receptacles on the back of the power source per the connection dia grams located in the Installation Section Special Instructions K2902 1 Some earlier vintage S350 power sources Code 11589 may not include a 6 pin Differential 1 0 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 528481 STT Module to ArcLink Wire Feeders K1543 or K2683 ArcLink Control Cable The 2902 1 5 Module includes ArcLink output receptacle for connection to compatible wire feeders The control cable consists of two power leads one twisted pair for digital communication and one lead for voltage sensing The 5 pin ArcLink receptacle is located on the lower rear portion of the STTe Module The control cable is keyed and polarized to prevent improper connection Best results will be obtained when control cables are rou
31. n tasas A 2 Connection between Power Source and STT Module seen 3 Electrode and Work Connections essent tenente nennen A 3 Qutput Cable Guide 1008 4 Cable Inductance and its Effects on Welding 22 4 Remote Sence lead Connections essent nnnm nnne A 5 A 6 Connection Diagram SyStem es uci ii ER E ER E A 7 Operation Section B Safety PreCautlOnSs e tide B 1 Power Up Sequence Duty Cyclo e ie Common Welding PTOCGGLr8S 2 irent ta i ac n RR ER d Recommended Processes and Limitations sesenta Equipment Limitations Commom Equipment Packaces STT Module Case Front and Description STT Module Case Back and Description sse tette tnnt LC C Safety Precautioris 3 3 e reet bre nae Routine Maintenace and Calibration Specification Troubl shooting Section E 1 Using the Status LED to Troubleshoot System Problems see E 2 Eror d M LAE E 3 On Board LED s for the STT Switch PC Board sss E 4 nnn nnne nnne E 5 Troubleshooting Guide 7 77 trae trata sain E 6 E 7
32. ompressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY POWERED EQUIPMENT Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information eon Welding Safety T Interactive Web Guide n for mobile devices Get the free mobile app at http gettag mobi TABLE CONTENTS Page General Description 52 7 Installation eene Section A 1 Safety 0 inenen n A 2 Electromagnetic Compatibility _ 0 _ _ lt 2 Location and Ventilation rt tte a A 2 Control Cable Connection eese nnne rnnt nnne nnn nnne nnne nnne nennt nennt t
33. r source is in the ON position No Status Light on STT Module 1 40VDC input not present at STT Module 1 Check ArcLink cable Verify 40VDC per wiring diagram II wire feeder is functional and con nected through the 5115 Module sus pect connection issue in STT Module Verify condition of LED s on STT Switch PCB viewable through rear and left side louvers 2 Malfunctioning Status LED 2 Verify status LED is properly installed and has not disengaged from the lens Machine won t weld when attached to 1 STT Status Error 1 Make certain the polarity of the SIT STT Module Module is correct per the connection dia gram Positive to STT Input f polarity is correct verify condition of LED s on STT Switch PCB viewable through rear and left side louvers 2 STT Thermal Error 2 See Thermal error indiction section 3 40VDC input not present at STT Module 3 See No Status Light on STT section 4 Internal open circuit 4 Check for loose or broken connection in STT Module weld circuit A 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 E 6 POWER WAVE STT MODULE TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED
34. rmation for the equipment being used 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 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Al
35. so see item 1 Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing 7 a 7 b 7 0 7 0 711 7 2 8 8 b 8 c SAFETY CYLINDER MAY EXPLODE IF DAMAGED 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of C
36. spilled wipe it up and do not start engine until fumes have been eliminated 1 d To avoid scalding do not remove the radiator 2 8 2 C 2 d SAFETY 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 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 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 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 pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS 23 N 353 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before weld
37. t 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 We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information LINCOLN THE LINCOLN ELECTRIC COMPANY 22801 St Clair Avenue Cleveland OH 44117 1199 U S A Phone 1 216 481 8100 www lincolnelectric com
38. ted separate from the weld cables especial ly in long distance applications The recommended combined length of the ArcLink control cable network should not exceed 200ft ELECTRODE AND WORK CONNECTIONS Connect the electrode and work cables per the connection diagrams included in this document Size and route the cables per the following Positive Electrode Polarity Most welding applications run with the electrode being positive For those applications connect the electrode cable between the wire drive feed plate and the output stud on the STTe Module Connect a work lead from the negative power source output stud to the work piece per the Connection Diagram See Figure A 5 Negative Electrode Polarity The STT process CANNOT be run using negative electrode polarity However for processes other than STTe requiring negative polarity such as some Innershield applications the electrode and work connections should be reversed at the load NOT at the input to the STT Module Connect the electrode cable to the nega tive stud of the power source and work cable to the output stud of the STTe Module per the Negative Polarity Connection Diagram See Figure A 2 WARNING Never reverse the polarity to the input of the STT Module DO NOT connect the negative stud of the power source to input stud of the STT Module This may result in damage to the STT Module FIGURE A 2 NEGATIVE POLARITY CONNECTION NO
39. the tran sient voltage to exceed the safe operating threshold on the STT Switch PC board Under these conditions the STT switch turns ON to protect itself Follow recommended cable guidelines to minimize the inductance and inspect the snubber resistor circuit for damage A 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 E 7 DIAGRAMS POWER WAVE STT MODULE 96v ccIN 16513 9 STOSWAS 199119573 IN3NOdWOD 1 NOlldO S3NIHOVIN TIY QN3931 3015 E N SLIHM 3002 NOWINOO V SIN3NOdWOO L9VX3 IHL MOHS LON SIHL 09V09 31314102 V 40 ALFTIBV3ONVHOHINI 19344 LNOHLIM 39NVHO AVI Q8 VOS 1I I 0931MI9 V 30 HO SLNINOdINOD 32 5 SALON MOTT3A A Jequinu JUaWINbS BAIN 1uaureoe daJ e 101 jusuede 92196 34 01 ajgiBej 51 JI aJnso 2ua y 10 auo uo BUIYIEW pajsed si ICII1 I1I60 e 40 22906 00 jenueui siy Aq paJaAo9 5 je 10 9peJn93e aq 11 I00 92u9J9J9J 10 S LIICI6I0 SIUL 310N NMOH8
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