Lincoln Electric STT-10 Operator'S Manual Download Page 1

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STT-10 Head & Controls

Boom Mount or Bench Models

OPERATOR’S MANUAL

IM586-B

August, 2007

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 thought-
ful operation on your part.

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.

For use with: STT-10 Control - Boom Mount Code 10447, 10832

10 Series Wire Drive - Boom Mount Code 10443, 10763, 10818

STT-10 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

• 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

• World's Leader in Welding and Cutting Products •

Summary of Contents for STT-10

Page 1: ...NS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with STT 10 Control Boom Mount Code 10447 10832 10 Series Wire Drive Boom Mount Code 10443 10763 10818 STT 10 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 Sales and Service through Subsidiaries and D...

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 Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availab...

Page 3: ...ter 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 welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produ...

Page 4: ... 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 wel...

Page 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6...

Page 6: ...important when identifying the correct replacement parts On Line Product Registration 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 For On Line Registration Go to our WEB SITE at www linc...

Page 7: ...on A 7 Water Connections For Water Cooled Guns A 7 10 Series Wire Drives A 7 Synergic 7F Drives K679 A 7 GMAW Shielding Gas A 7 Gas Guard Regulator A 7 Electrical Installation A 8 Input Cable STT 10 Control to Power Source A 8 Work Cable A 8 Optional Features Installation A 9 Boom and Bench Conversions A 9 Operation Section B Safety Precautions B 1 Duty Cycle B 1 STT 10 Control DIP Switch Setup B ...

Page 8: ...TABLE OF CONTENTS Page Diagrams Section F Wiring STT 10 Control F 1 Wiring 10 Series Wire Drive F 2 F3 Dimension Prints F 4 thru F 6 Parts List P312 Series vii vii ...

Page 9: ...to to K679 1 2 Synergic 7F 11 5 7 16 8 06 16 5 Lbs 20 C 40 C Std Drive Boom Mount 285 8mm 181 9 mm 204 7mm 7 5 Kg K1560 1 40 42 Vac 10 Std Feeder 4 0 Amps 50 60 Hz STT 10 20 46 14 43 30 35 65 0 Lbs K1560 2 Bench Model 40 42 Vac 10 519 7 mm 366 5 mm 770 9 mm 29 5 Kg Std Feeder 6 0 Amps 50 60 Hz GENERAL DESCRIPTION The STT 10 is a modular line of 42VAC input 4 roll wire feeders A single control with...

Page 10: ...al transfer is by physical contact Non shorting modes such as axial spray and pulse welding are not supported by STT technology The wire type and size range for the wire drive used and speed range are given in the Technical Specifications The STT 10 requires a STT II Power Source SAFETY PRECAUTIONS INSTALLATION OF THE STT 10 BOOM MOUNT WIRE FEEDER COMPONENTS Mounting the 10 Series Wire Drive Unit ...

Page 11: ...s energizer spacer insulation mounting screws and washers from reel stand Mount the reed switch energizer assembly on the mounting bracket G2868 as shown In Figure A 3 Then install mounting bracket G2868 to the rear of STT 10 control box Secure it on the sides of box with 4 10 3 8 long screws FIGURE A 3 a Drill the required holes in the mounting surface partially Install 1 4 20 screws b Mount the ...

Page 12: ...hanged and remove the gear If the gear is not easily accessible or difficult to remove remove the feedplate from the gearbox To remove feedplate a Loosen the clamping collar screw using a 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feedplate It is the screw which is perpendicular to the feeding direction b Loosen the retaining screw which is also accessed from bo...

Page 13: ... Back out the screws for the incoming and outgoing guide tubes 9 Install the longer guide tube in the rear hole near the incoming drive roll Slide the tube in until it almost touches the roll Tighten in place 10 Install the remaining guide tube in the front hole Be certain that the proper plastic insert is used Fine wire chisel point tube must have largest radius next to drive roll Tighten in plac...

Page 14: ...le Connection with Standard Connection 1 Check that the drive rolls and guide tubes are proper for the electrode size and type being used If necessary change them per Wire Drive Roll Kits in this section 2 Lay the cable out straight Insert the connector on the welding conductor cable into the brass conduc tor block on the front of the wire drive head Make sure it is all the way in and tighten the ...

Page 15: ... of these hoses to the appropriate ports on the water cooling units In the event the water line fittings on your water cooled gun are incompatible with the female quick connects on the front of the K682 2 Kit male quick connects are provided with the kit for installation on 3 16 5 mm I D hose Customer to provide appropri ate clamps The feeder connectors self seal when disconnected GMAW Shielding G...

Page 16: ...box 4 Slip the current sensor cover off enough to expose the input connector stud Connect the electrode cable from the power source to this stud with the nut provided then reclose the current sensor cover Work Cable Connect a work lead of sufficient size and length per the following table between the proper output termi nal on the power source and the work Be sure the connection to the work makes ...

Page 17: ...botics Interface Module The module plugs directly into the STT 10 control board and pro vides an interface to a properly equipped Fanuc robot ArcTool software and an additional process I O board are needed When installed and properly configured the K1561 1 Robotics Interface Module allows complete control of the welding process from the robot controller The Lincoln Electric Companyʼs Automation Ce...

Page 18: ...ROL DIP SWITCH SETUP Initial set up of the STT 10 control for the system components being used and for general operator preferences is done using an 8 pole DIP switch locat ed inside the STT 10 control box Setup DIP Switch Access 1 Shut off the input power to the STT 10 control by turning off the power at the welding power source it is connected to 2 Remove the two screws on the top of the STT 10 ...

Page 19: ...time then gas postflow time 4 Reopening Trigger stops gas flow if or when post flow time is over Security Mode Selection The STT 10 Control is set up for Security Mode See Security Mode in this section by setting S1 DIP Switch 6 Labeled S Head M 4 S R S1 ON S1 1 2 3 4 5 6 7 8 L Head M 4 S R S1 ON S1 1 2 3 4 5 6 7 8 L Head M 4 S R S1 ON S1 1 2 3 4 5 6 7 8 L Head M 4 S R S1 ON S1 1 2 3 4 5 6 7 8 L H...

Page 20: ...stored it will automatically return all settings to the state they were in when power was removed The operator may over write any or all of these settings following power up recall Operation Keys Current Lights Indicates whether the top display controls peak current or background current setting Procedure Lights Indicate which procedure A or B is selected The Procedure select key selects A or B or...

Page 21: ...s are selected the current display shows the time setting in seconds as indicated by SEC displayed on the speed display The times are set using the top encoder knob When Run in WFS is selected the WFS display shows the Run in WFS setting in in min or m min Top Light indicates Run in WFS is being displayed Speed encoder knob can adjust Run in speed between minimum Rated speed and up to the Weld spe...

Page 22: ...de optimum starting of various processes and proce dures the wire feed acceleration of the STT 10 can be set to five levels 1 thru 5 for each procedure 1 is the slowest accel eration and 5 is the fastest Factory set to 4 To change acceleration hold the Gas Purge Key closed then press the Range key The top display shows Acc indicating acceleration set ting 1 thru 5 is displayed on the bottom Speed ...

Page 23: ...k to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi Reel Cage in place Retaining Spring must rest on the cage not the welding elec trode ___________________________________________ 9 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not rem...

Page 24: ...n the spindle FIGURE B 2 FEEDING ELECTRODE AND BRAKE ADJUSTMENT 1 Turn the Reel or spool until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end and straighten the first 6 150 mm Cut off the first 1 25 mm If the electrode is not proper ly straightened it may not feed or may jam causing a birdnest 3 Insert the free end through the incoming guide ...

Page 25: ...red trigger mode for each procedure Refer to Trigger Mode Selection in this section 4 Use Control Select and encoder knobs to set desired Weld feed speed and current then Run in speed to optimize arc starting Set for each procedure if using front panel or optional dual procedure switch Refer to Operation Keys and Display Control Keys in this section 5 Adjust the wire feed acceleration if desired f...

Page 26: ...rounding lead fault occurs the WFS display will show GLP with blank Voltage display and the trigger circuit will be disabled To reset the circuit release the trigger make sure that the electrode is not touching the wire feeder frame and then either press any key on the keypad or close the trigger When the GLP circuit is reset the GLP display is removed and the wire feeder is returned to normal ope...

Page 27: ...ode 0 023 0 025 0 6 mm KP1505 030S KP655 025S 0 030 0 8 mm KP1505 030S KP655 030S 0 035 0 9 mm KP1505 035S KP655 035S 0 040 1 0 mm KP1505 040S KP655 035S 0 040 1 0 mm KP1505 045S KP655 035S 0 045 1 2 mm KP1505 045S KP655 052S 0 045 Cored 1 2 mm KP1505 045C KP655 052C 0 052 1 4 mm KP1505 052S KP655 052S C 1 ACCESSORIES C 1 STT 10 ...

Page 28: ...e closed to enable the feeder welding operation Also the Module provides for interface connection of external equipment fume extractor etc to the Moduleʼs isolated relay contacts which actuate when the feeder welding gas solenoid is activated repre senting welding operation in process K1561 1 ROBOTICS INTERFACE MODULE The module plugs directly into the STT 10 control board and provides an interfac...

Page 29: ...nd install a K1500 3 gun connection kit to the wire feeder LINCOLN INNERSHIELD AND SUB ARC GUNS All of these guns can be connected to the STT 10 by using the K1500 1 Adapter Kit LINCOLN FUME EXTRACTION GUNS The K556 250XA and K566 400XA guns require that a K489 7 Fast Mate adapter kit be installed K206 K289 and K309 require only the installation of a K1500 1 connector in the STT 10 wire feeder NON...

Page 30: ...es are equipped with a Fast Mate connector They can be used with 10 Series wire feed models by installing a K489 2 Fast Mate adapter kit and a K1500 1 Lincoln Gun adapter K684 Magnum Super Cool FM water cooled GMAW gun and cable assemblies are rated 450 amps 100 duty cycle CO2 Consult sales specifi cations for appropriate models K498 Magnum 200 FM GMAW gun and cable assemblies are rated for 200 am...

Page 31: ... wire feeder MAINTENANCE Safety Precautions Routine Maintenance Drive Rolls and Guide Tubes After feeding every coil of wire inspect the drive roll section Clean it as necessary Do not use a solvent for cleaning the idle roll because it may wash the lubricant out of the bearing The driver roll and guide tubes are stamped with the wire sizes they will feed If a wire size other than that stamped on ...

Page 32: ...ontribute to the machine symptom 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 of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE ...

Page 33: ... 4 Drive rolls may not be seated properly 5 Gun cable dirty 6 Worn drive roll 7 Worn nozzle or cable liner 8 Partially flashed or melted contact tip 9 Incorrect drive roll pressure 10 Improper liner contact tip or inner outer wire guides 11 Incorrect wire drive or gear ratio selection on the control p c board 1 Wrong size worn and or melted contact tip 2 Worn work cable or poor work connection 3 L...

Page 34: ...e overloaded Hxx will be dis played on the WFS display where xx is the number of sec onds until the wire drive attempts to run again 2 A jumper plug or K1558 1 Remote Switch Interface Module must be properly installed into connector J5 3 Damaged wiring in the trigger cir cuit 4 Control p c board failure 1 Damaged leads to the drive motor 2 Damaged wire drive motor 3 Damaged control p c board 1 Dam...

Page 35: ...s lit or in acceleration setting mode 2 The connector from the control p c board to the display p c board or the connector from the display p c board to the keypad are loose or improperly inserted 3 Damaged keypad 4 Damaged display p c board 5 Damaged control p c board 1 The connector from the control p c board to the display p c board or the connector from the display p c board to the keypad are ...

Page 36: ... that the DIP switches on the control p c board are not set for security mode 2 The connector from the control p c board to the display p c board or the connector from the display p c board to the keypad are loose or improperly inserted 3 Damaged keypad 4 Damaged display p c board 5 Damaged control p c board 1 The display is in a mode that can only use one encoder 2 The connector from the control ...

Page 37: ...d cur rent 1 The connectors from the control p c board to the display p c board are loose or improperly inserted 2 Damaged display p c board 3 Damaged control p c board 1 Damaged control p c board 1 STT 10 control not properly set for using a dual procedure switch at the gun 2 Disconnected or damaged wiring between the wire drive and con trol box 3 Damaged wiring in the STT 10 wire drive 4 Damaged...

Page 38: ...anical damage to any of its components and conductors on the back of the board a If there is no visible damage to the PC board install a new one and see if this remedies the problem If the problem is remedied reinstall the old PC board to see if the problem still exists If it does no longer exist with old PC board 1 Check the PC board harness connector pins for corrosion contamination or looseness...

Page 39: ...ay 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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 40: ...ay 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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 41: ...ay 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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 42: ...F 4 CONNECTION DIAGRAMS F 4 STT 10 ...

Page 43: ...F 5 DIAGRAMS F 5 STT 10 DIMENSION PRINT 3 00 6 00 2 42 12 74 7 81 6 55 14 71 4 44 5 16 18UNC 2B 4 PLACES 5 25 11 00 2 25 4 08 10 40 WIRE DRIVE DIMENSION PRINT M18904 7 2000 ...

Page 44: ...F 6 DIAGRAMS F 6 STT 10 DIMENSION PRINT M 18903 7 2000 1 5 3 0 3 0 3 5 2 0 4 6 1 4 4 3 5 2 5 1 0 6 6 BENCH MODEL DIMENSION PRINT ...

Page 45: ...G R A P H I C S S H O W N R E P R E S E N T M 1 7 8 6 9 1 3 YEAR WARRANTY 4 5 8 4 2 7 5 2 5 2 8 0 R 1 4 1 3 S L O T S 1 0 9 2 1 3 7 5 2 6 3 1 0 1 0 1 2 7 5 1 4 6 7 1 4 6 5 5 2 97 M18299 Boom Model Control Box Dimension Print DIMENSION PRINT ...

Page 46: ...NOTES STT 10 ...

Page 47: ...NOTES STT 10 ...

Page 48: ...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 de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 49: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 50: ...s 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 Products ...

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