Lincoln Electric INVERTEC IM904 Operator'S Manual Download Page 4

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode
if damaged.

7.a. 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.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

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. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. 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 information for the
equipment being used.

6.c. 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.

6.d. 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).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. 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.

6.g. 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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

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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