Lincoln Electric INVERTEC IM904 Operator'S Manual Download Page 31

F-2

DIAGRAMS

F-2

INVERTEC STT II (CE)

NOTE:  This diagram is for reference only.   It may not be accurate for all machines covered by this manual.  The specific diag

ram for a particular code is pasted inside

the machine on one of the enclosure panels.  If the diagram is illegible, write to the Service Department for a replacement.  G

ive the equipment code number.

+

-

ELEC

TR

ICA

L SY

M

B

OLS

 PER E

1537

12

34

1

3

4

6

1

61

0

5

{

1

4

8

5

H1

T1

 FAN MO

TO

R

G

F

E

J

A

I

K

C

D

M

L

B

N

H

75

76

77

31

32

41

42

2

4

81

82

21

GND

SPA

R

E

42

VA

C

T3

  CUR

RE

NT

TR

AN

SF

OR

ME

R

1

4

T2 MA

IN

TR

A

N

S

FO

R

M

E

R

R3

OFF

ON

H1

TP

1

TP

3

TP

2

I

I

5

8

D1

D2

D3

CH

O

K

E

L3

CO

N

TRO

L

BOARD

10K 2W

R1

1

30

7

30

8

30

9

31

0

30

2

30

3

30

4

PO

W

E

R

BO

A

R

D

(V

IE

W

ED FROM COMPONENT

 SI

DE OF

 BO

ARD)

NOTE

S:

TR

IGGER

}

INP

UT

PE

R

N.A.

PO

W

E

R

S1

1

}

2

3

1

7 8

}

}

J7

J6

CB

1

504

43A

 AUXI

LI

A

R

Y

TR

A

N

S

FO

R

M

E

R

2 4 5 6 1 3

N.E.

C

W

 (M

AX)

9

10

F

F

S

S

S

TOP OUTS

ID

E

BOT

TOM

IN

S

ID

E

S

S

S

F

F

TOP

TOP IN

S

ID

E

BOT

TOM

OUTS

ID

E

7

6 8

4

5

C

O

NT

RO

L

211A

212

B

15

0 5

W

FA

N

TH

ERM

OS

TA

T

H2

H3

H4

F BOT

TOM

F

212A

W

V

U

H1

212

0V

24

V

42V

18

V

1

4

2

3

.001/

40

0

COLOR C

O

DE:

R =

 RED

6

H5

2

3

6

4

7

8

5

502

Y

301

D4

D5

1

7

8

14

D1

1

D10

D9

D8

D7

N.E.

21

0

6AM

P

H2

H3

H4

A

9C

W

B

G

A

FOR THR

E

E

 PH

A

SE INPU

T:

 CON

NECT GREEN LEAD TO 

GR

OUN

D PER NATIONAL EL

EC

TR

IC

 CODE.

CON

NECT B

LAC

K

, R

E

D & W

H

ITE

 LEADS TO 

SU

PPL

Y

 CIR

CUIT.

W

R

AP R

E

D

 L

EAD

 W

IT

H

 TAPE 

TO PROVIDE 600

V. INSU

LA

TION.

FOR THR

E

E

 PH

A

SE INPU

T:

 GROU

ND

 M

A

CH

IN

E PE

R

 NAT

ION

AL

 AN

D LOCAL EL

EC

TR

IC

AL

 C

O

DES.

CON

NECT T

E

RM

INALS U, V &

 W

 TO SUPPLY C

IRCU

IT

.

CON

NECT T

E

RM

INALS U & W

 T

O

 SUPPLY

 CIRC

UIT

.

N.D

.  PLACE "A"

 LEAD ON APPROPR

IAT

E CON

NECTION FOR

 IN

PUT

 VOLTA

GE.

C

O

NNEC

TI

ON SH

OW

N IS FOR 380-415

V OPERATION.

CON

NECT B

LAC

K

 & W

H

IT

E LEA

D

S

 T

O

 SUPPLY

 CIRC

UIT

.

FOR SIN

GL

E PHASE INPU

T:

 CON

NECT GREEN LEAD T

O

 GR

OUN

D PER NATIONAL E

LECTRIC

 C

O

DE.

FOR SIN

GL

E PHASE INPU

T:

 GROU

ND M

A

CHIN

E P

E

R

 NAT

ION

AL

 AN

D LOCAL EL

EC

TR

IC

AL

 C

O

DES.

W =

 WH

IT

E

B =

 BL

AC

K

G =

 GREEN

Y

 =

 YELLOW

H6

N.

D.

R

H1

+ ARC

- ARC

10 2W

C4

.001/

400

9D

H1

H3

H3

415

V

200- 208V

380-

R2

C3

10 2W

YY

30

5

1 2 3 4

}

J1

4

31

1

313

A

4 AM

P

SLOW BLOW

N.A.

N.B.  SINCE C

O

MPONEN

TS

 OR C

IRCU

IT

RY

 OF A PRIN

TE

D C

IRCU

IT

 BOARD M

A

Y

 C

H

AN

GE

 W

ITHOU

T AFFEC

TING

N.E.  D1 T

H

RU D

5 OU

TP

UT DIODES ARE A M

A

TCH

ED SET

.

N.F.  R1, R9 BLEEDER R

E

SISTORS ARE A MATCHED

 SET.

N.G.  C1, C2 CAPACITORS ARE A MATCHED S

E

T.

N.H

.  PLACE SW

IT

C

H

 IN APPROPR

IAT

E POSI

TION FOR

 INPUT V

O

LT

AGE.

THE INT

ER

CH

A

N

GEABI

LITY OF A C

O

MPLET

E BOARD

, THIS DIAGRAM

 MAY

 NOT 

SH

OW

 T

H

E E

XACT

C

O

M

P

O

N

E

N

TS

 O

R

 CI

RC

UI

TR

Y H

A

V

IN

G

 A

 CO

M

M

O

N

 C

O

DE

 N

U

MB

E

R

.

D

7 THRU

 D11 OUT

PU

T DIOD

ES

 AR

A M

A

TC

H

E

D SET

.

CON

NECTION SHOW

N IS FOR 380-41

5V OPERATION.

12

D

  IN

P

U

T

R

E

C

TIFIE

R

   D

13

10K 2W

C

W

 (M

AX)

C

O

NT

RO

L

BAC

KGR

OUND

ME

TE

R

ME

TE

R

1

}

J2

11

8

10

4

9

3

2

7

13

12

6

14

5

BA

C

K

GR

OUND

BOARD

}

4

}

3 1

2

4 2

1

3

CURR

EN

T

SEN

SE

J1

J1

8

IG

B

T

MO

D

U

LE

IG

B

T

BO

A

R

D

DR

IV

E

J1

3

G

E

1

2 3

6

4

5

J1

2

J5

J3

9 10

1

2

3

4

5 6

1. FOR M

A

CHIN

E

S

 SU

P

P

LIED W

ITH INPU

T CABLE

2. FOR M

A

CHIN

E

S

 N

O

T SUPPLIED W

ITH INPUT CABLE

1 2 3 4

VOL

TAGE

SE

N

S

E

CO

N

N

E

C

TI

O

N

J1

9

1

18

V

18

V

 AUXI

LI

AR

Y

TR

AN

SF

ORM

ER

115

V

10

V

18

V

R

W

R

B

B

U

U

E

C

D7

U =

 B

LU

E

21

2A

21

2

501 504

T4

27

5

35

1

35

0

35

2

35

3

35

4

35

5

35

6

35

7

35

8

358

35

9

35

9

360

360

361

361

36

2

36

2

36

3

363

29

0

291

J2

1

2

9

3

4

12

13

N

O

1 2

4

3

6 7

5

8

10

9

R1

2

J18

, J3

7

J6, J2

7, J3

3

1

8

9

16

J19

1

4

2

3

J15, J

35

210A

22

4

20/

400

C8

287

28

8A

288

B

289

A

28

9B

364 36

5

366

36

8

369

37

2

376

N O

O =

 OR

A

N

GE

N =

 BR

OW

N

1 2 3 4 5 6

1 2 3 4 5 6

35

4

35

5

35

6

35

7

10K 2W

C

W

 (M

AX)

C

O

NT

RO

L

HO

T S

T

A

R

T

R1

3

WI

R

E

 S

IZ

E

WI

R

E

FEED

ER

CB

2

BOARD

+

12

C1

R4

R5 25 25

W

25 25

W

9

5

8

+

12

m

25 25W

25 25

W

9

C2

R6

R7

4

1

R1

7500 25

W

9A

308

307

40

2,

 40

4

40

1,

 40

3

4,

5

1,

 8

R

R

W

R

W

401

, 403

1,

 8

4,

 5

402,

 4

04

SWIT

CH

+

-

+

-

SWIT

CH

DR

IVER

BOARD

4
1

63

J10

25

BOARD

1

2

3

4

52

14

51

53

14

J8

PROTEC

TI

ON

52

22

00 F

45

0V

N.G.

N.

F.

N.

G.

2200

F

450V

(LEFT)

BOARD (RI

GH

T)

12B

9B

9B

R9

9A

53

12

A

H5

7500 25

W

52

1

2

3

4

5

6

314 31

5

317

J15

N.

F.

12A

12B

51

4

1

3

2

J11

7

3

2

1

8

12

13

14

}

J16

9D

3

6

4

1

J9

2

5

12B

12D

501

115

V

11

10

371

371

A

374

A

374

J2

2

240

241

242

243

244

245

246

O

O

18

V

6V

N

N

24

0

241 242

3

4

5

6

12 13

7 14

1

2

8

9

10

11

303 302 30

4

27

5

371

A

374

A

243 244

}

J2

7

11 12

J4

37

4

370 37

1

36

7

}

J2

8

}

371 374

1

}

}

2 3 4

15 16

36

4

36

5

36

6

(+)

(-)

367

368

369

367

A

367

A

WI

R

E

 T

Y

P

E

ST

A

IN

LESS

MI

LD

J B C G A D F H E I

TR

IG

G

E

R

GND

}

.045

.035

BG

PB

10

K

10

K

OPT

IO

N

A

L

RE

MO

TE

INT

ERF

A

C

E

1

6

7

12

{

{

115

VAC

3

2

5

4

1

U

W

R

R

Y

N

Y

2

1

32

33

32C

33C

32A

32B

33A

33B

7

8

15

16

J2

2

2

S

300W

28

9

288

2

S  300W

J3

3

}

22

3

7

J3

4

}

33C

1

2

3

4

5

6

43B

31

A

}

J3

5

42

33D

6A

M

P

J3

6

1

2 3 4

}

J3

7

J3

0

J3

1

503

A

R14

8

2 1

6 7

3

4

5

37

2

37

6

374

37

0

37

1

6 2 3

7 1

8

5 4

10

9

6 1

5

8

4

3 2

J2

4

J2

3

J2

6

J2

5

353 352

35

1

350

1 2 3 4 5 6

1 2 3 4 5 6

42

VAC

11

5

VA

C

}

J3

9

1

2

4

3

6

7

5

8

10

9

11

12

}

50

2

21

0

223

Y

305 24

5

211A 21

2C

Y

24

6

301

J1

7

}

503

503A

212C 43

A

21

2B

32C

3

1

2

10 9

12 4 11

14

6

13

5

16

8

15

7

J3

8

503

RE

MO

TE

PR

OT

EC

TI

ON BOARD

S2

S3

(-)

(+)

THE

R

M

A

L

OVE

R

LOAD

IN

DI

C

A

TO

R

R13

J1

0, J

13,

J1, J8,

J3, J9,

J5,

 J7,

 J3

4

J2, J3

6

A

D

B

C

E

F

G

H

I

J

J38

A

D

B

C

E

F

G

H

I

K

J39

L

M

N

J

P

INOUT O

F FRON

T PANE

L CONNECTORS

 (REAR 

VI

EW

)

12

34

1
2

3
4

P30

J30

12

3

4

5

2
3

4

5

6

1

6

P29,

 P31

J29. J

31

12

3

4

5

2
3

4

5

6

1

6

P21

J21

12

3

9

10

2
3

10

11

1

45678

12

13

14

15

16

P22

J22

IN

LI

NE CONNEC

TOR

 CAV

IT

Y NUMBER

ING SEQU

ENCE

(V

IE

W

ED FROM 

W

IRE S

IDE OF

 CONNECTOR)

4
5
6
7
8

9

11
12
13
14
15
16

J23

J24

J25

J26

P.C.

 BO

ARD CONNECTOR C

A

VI

TY

 NUMBER

ING SEQU

ENCE

MET

ER P

INOUT (

VI

E

W

ED FROM B

ACK O

F ME

TER)

1

1

6

6

B

W

W

B

R

W

B

B W

R

W

R

B

B

PE

AK

CURR

E

N

T

PEA

K

CURR

EN

T

B

W B

R

N.I.      

    DEN

OT

ES A T

W

ISTE

D

 W

IRE PAIR OR GR

OUP.

N.

J.

R
WW

52

31

6

311 313

14

309

310

CR

1

9A

9A

9A

9A

53

9D

N.

H.

9C

12

C

9B

12A

9B

12

A

9B

S7

RE

CO

N

N

E

C

T

9D

12C

12

D

309

A

310

A

309 310

CR

2

30

9A

310

A

12D

52

9B

12

B

51

12

B

12B 12

B

12B

12

B

14

6

22

4

503

A

224

A

J2

2

TH

ERM

OST

AT

D

A

R

LINGT

ON

HE

A

TS

IN

K

W

W

C

B

A

C

B

A

D

F

C

B

A

503

B

J11

, J12

, J1

4

J4, J1

7

J16, J

28

401

402

403

40

4

405

40

6

407

40

8

409

410

411

412

41

3

414

415

416

C

B

A

C

B

A

LOAD

LINE

PO

W

E

R

 L

IN

E

FILT

ER

ASSEM

BLY

N.L.

N.

K

.

N

.K

.  NO

T PRESENT ON EUR

OP

EAN

 V

E

R

S

IONS.

N.L.  P

R

ESENT

 ON

 EUROPEAN VER

S

ION

S.

N

.J. 

 N

O

T PRESENT ON EUR

OPEA

N

 VERSIONS.

TO

R

O

ID

A

L

CO

RE

N.L.

 A.01

W

IRI

NG

 DI

A

G

RA

M

  -

  I

N

VE

RTE

C

 S

TT I

I  (CE)  (FOR CODE 11367)

G4557

Summary of Contents for INVERTEC IM904

Page 1: ...PERATE 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 For use with machines having Code...

Page 2: ...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...

Page 3: ...er for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both...

Page 4: ...vent 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...

Page 5: ...i s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan t...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...ing Controls B 2 Design Features and Advantages B 2 Welding Capability B 2 Limitations B 2 Operational Features and Controls B 3 Welding Operation B 4 Welding Parameters and Guidelines B 5 Welding Pro...

Page 8: ...UIT AWG IEC SIZES AWG IEC SIZES 200 50 60 40 33 220 50 60 40 30 10 6 mm2 10 6 mm2 380 50 60 30 18 415 50 60 30 17 440 50 60 30 16 HEIGHT WIDTH DEPTH WEIGHT 23 2 in 13 2 in 24 4 in 100 lbs 589 mm 336 m...

Page 9: ...COPPER SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE IN CONDUIT IN CONDUIT AWG IEC SIZES AWG IEC SIZES 200 50 60 40 36 208 50 60 40 34 380 50 60 30 20 10 6 mm2 10 6 mm2 400 50 60 30 19 415 50 60 30 18 HEIGH...

Page 10: ...al codes SUPPLY CONNECTIONS Be sure the voltage phase and frequency of the input supply is as specified on the rating plate Input Power supply line entry in provided on the case back of the machine Se...

Page 11: ...try access hole at the right rear of the machine 3 Route the cable through the cable hangers located along the lower right inside edge of the machine up to the power switch located on the front panel...

Page 12: ...66 access door on wraparound 2 Move input voltage switch to Voltage 380 460V position 3 Move lead A to 380 415 Terminal 380 400 or 415 VAC 1 Open reconnect panel Codes 11367 access door on wraparound...

Page 13: ...out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustible...

Page 14: ...ls Digital meters for procedure settings are standard Automatic Inductance or Pinch Control Solid state circuitry for extra long component life Current feedback ensures that original procedure setting...

Page 15: ...EAK CURRENT DISPLAY METER This is a digital meter for displaying the preset Peak Current This meter displays in 1 amp increments This meter does not indicate actual welding current only the preset cur...

Page 16: ...r connection instructions 11 ARC SENSE RECEPTACLE This is a four pin MS type connector for WORK and ELECTRODE sense leads The STT requires a WORK sense and ELECTRODE sense lead for proper operation Th...

Page 17: ...level should be set greater than in a cor responding application using a gas blend with a high percentage of Argon Longer initial arc lengths with 100 CO2 are required to reduce spatter BACKGROUND CUR...

Page 18: ...Electrode size mm 0 035 0 045 0 045 0 9 1 1 1 1 WFS min m min 100 100 120 2 5 2 5 3 0 Peak Current 225 270 310 Background Current 40 65 70 Tailout setting 8 4 6 Average Amperage 70 110 130 Travel Spe...

Page 19: ...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...

Page 20: ...e wire feeder control cable between the LN 742 or STT 10 and the 14 pin Wire Feeder Receptacle on the STT II For the STT 10 Wire Feeder Connect the second wire feeder control cable between the STT 10...

Page 21: ...ELDING ARC WORK LEAD WIRE FEEDER WIRE FEEDER CONTACT ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON THE BLOCK STT 10 WIRE FEEDER WARNING Turn off input power to the Welding Power sourc...

Page 22: ...with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 5 Locate the two capacitor terminals large hex head cap screws shown in Figure D 1 6 Use safety glasses electrically insulated gloves and in...

Page 23: ...ted circuit boards Power Switch Main Transformer Input Rectifier Heat Sink Fins Input Filter Capacitors Output Terminals Lower base compartment 4 Examine capacitors for leakage or oozing Replace if ne...

Page 24: ...IBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause genera...

Page 25: ...able between the feeder and the STT II unit Make sure the 2 and 4 leads are intact 2 Put a jumper wire between Pins C and D on the 14 pin MS connector If normal open circuit voltage 85VDC is restored...

Page 26: ...again con tact your local Lincoln Authorized Field Service Facility 1 The over current sensor is being activated indicating that too much output current is being drawn from the machine Reduce weld ing...

Page 27: ...oltages fuses and input voltage reconnect proce dures See Installation section 2 If high input voltage 380VAC or higher is applied the capacitors may need conditioning Let the unloaded machine idle fo...

Page 28: ...rift or output power is low POSSIBLE CAUSE 1 Check the Arc Sense leads for loose or faulty connections 2 Make sure the Arc Sense WORK lead is as close as pos sible to the welding arc 3 Make sure the m...

Page 29: ...ir currents 2 Check gun and nozzle for leaks or obstructions 3 Make certain machine and wire feed settings are correct for process 1 One or more of the machine set tings may be wrong Check the Backgro...

Page 30: ...ALS U W TO SUPPLY CIRCUIT FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES N B SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING COMPONE...

Page 31: ...ARY TRANSFORMER 115V 10V 18V R W R B B U U E C D7 U BLUE 212A 212 501 504 T4 275 351 350 352 353 354 355 356 357 358 358 359 359 360 360 361 361 362 362 363 363 290 291 J21 2 9 3 4 12 13 N O 1 2 4 3 6...

Page 32: ...F 3 DIAGRAMS F 3 INVERTEC STT II CE 13 19 20 75 23 25 13 21 24 50 1 9 98B M18706 DIMENSION PRINT 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: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 37: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 38: ...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 World s Leader in Welding and Cutting Pr...

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