Lincoln Electric POWER WAVE STT User manual

IM2049
02/2013
Rev. 0
POWER WAVE STT module CE
OPERATOR’S MANUAL
ENGLISH
LINCOLN ELECTRIC EUROPE S.L
c/o Balmes, 89 – 8°2a, 08008 Barcelona, Spain
www.lincolnelectric.eu

English English
I
THE LINCOLN ELECTRIC COMPANY
EC DECLARATION OF CONFORMITY
Manufacturer and technical
documentation holder: The Lincoln Electric Company
Address: 22801 St. Clair Ave.
Cleveland Ohio 44117-1199 USA
EC Company: Lincoln Electric Europe S.L.
Address: c/o Balmes, 89 - 8
0
2a
08008 Barcelona SPAIN
Hereby declare that welding equipment: Power Wave S350 CE, including options and accessories,
Power Wave S500 CE, including options and accessories,
STT Module
Sales code: K2823, code may also contain prefixes and suffixes
K3168, code may also contain prefixes and suffixes
K2921, code may also contain prefixes and suffixes
Is in conformity with Council Directives
and amendments: EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC
Standards: EN 60974-1, Arc Welding Equipment – Part 1: Welding Power
Sources, 2005
EN 60974-10 Arc Welding Equipment – Part 10:
Electromagnetic compatibility (EMC) requirements, 2003
‘12 (K3168)
‘10 (K2823)
‘10 (K2921)
Frank Stupczy, Manufacturer Dario Gatti, European Community
Representative
Compliance Engineering Manager European Engineering Director Machines
2 November 2012 6 November 2012

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II
12/05
THANKS! For having choosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code &
Serial Number can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Safety .............................................................................................................................................................................. 1
Installation and Operator Instructions .............................................................................................................................. 2
Electromagnetic Compatibility (EMC) .............................................................................................................................. 8
Technical Specifications .................................................................................................................................................. 9
WEEE.............................................................................................................................................................................. 9
Spare Parts...................................................................................................................................................................... 9
Electrical Schematic ........................................................................................................................................................ 9

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1
Safety
11/04
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this
equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible
for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician before operating this
equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and
EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal
Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as
required by EN169 Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.

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2
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.
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. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
NOISE APPEARES DURING WELDING CAN BE HARMFUL: Welding arc can cause noise with high
level of 85dB for 8-hour week day. Welders operating welding machines are obligated to wear the
proper ear protectors /appendix No. 2 for the Decree of the Secretary of Labor and Social Policy from
17.06 1998 – Dz.U. No. 79 pos. 513/. According to the Decree the Secretary of Health and Social
Welfare from 09.07.1996 /Dz.U. No. 68 pos. 194/, employers are obligated to carry examinations and
measurements of health harmful factors.
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which can
cause serious injury. Keep your hands, body and clothing away from those parts during machine
starting, operating and servicing.
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
Location and Environment
Mount the STT Module directly to the bottom of a
compatible Power Wave “S” series power source
utilizing the quick lock mechanism as shown.
The STT 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.
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 restricted. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
Keep the machine dry. Shelter from rain and snow.
Do not place on wet ground or in puddles.
Do not mount the Power Wave “S” series power
source and STT Module combination over
combustible surfaces.
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 30,5m. The use of nonstandard
cables, especially in lengths greater than 7,6m, 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.

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3
WARNING
Regarding cable placement, best results will be
obtained when control cables are routed separate from
the weld cables. this minimizes the possibility 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
communication cables including ArcLink® connections.
Connection between Power Source and STT®
module (Arclink®and differential I/O pigtails)
The pigtail connections on the STT® Module include all
signal and power lines required for proper operation.
With the STT® Module securely fastened to the power
source, connect the pigtails to their respective
receptacles on the back of the power source per the
connection diagram located in the “Installation
Section”.
Special Instructions: K2921-1
A special ArcLink® and Differential I/O receptacle kit is
provided with the STT® Module for installation into the
host power source. Follow the instructions provided with
the kit. (reference instruction sheet M22499-1).
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 STT 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 STT 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
negative (-) stud of the power source, and work
cable to the output stud of the STT Module per the
Negative Polarity Connection Diagram. (See Figure
a.2)
WARNING
Never reverse the polarity at 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!
NEGATIVE POLARITY CONNECTION (not to be used
for STT process)
Figure A.2
1. To work;
2. To electrode (feeder).
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 overall 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
sliding ground should be considered to keep the total
welding loop length as short as possible.
Figure A.3
1. Work

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4
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 STT®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 configuration of remote work voltage sense leads is
critical to the proper operation of multiple arc STT®
applications.
RECOMMENDATIONS:
Position the sense leads out of the path of the
weld current. Especially any current paths common
to adjacent arcs. Current from adjacent arcs can
induce voltage into each others 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 the sense leads.
(See Figure a.4)
Figure A.4
1. Direction of travel.
2. Connect all sense leads at the end of the weld.
3. Connect all work leads at the beginning of the weld.
Bad connection
Current flow from Arc#1 affects Sense lead #2.
Current flow from Arc#2 affects Sense lead #1.
Neither sense lead picks up the correct work
voltage, causing starting and welding arc instability.
Better connection
Sense lead #1 is only affected by current flow from
Arc#1.
Sense lead #2 is only affected by current flow from
Arc#2.
Due to voltage drops across workpiece, Arc voltage
may be low, causing need for deviation from
standard procedures.
Best connection
Both Sense leads are out of the current paths.
Both Sense leads detect arc voltage accurately.
No voltage drop between Arc and Sense leads.
Best start, best arcs, most reliable results.
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.

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5
GENERAL DESCRIPTION
General Physical Description
The POWER WAVE® STT® MODULE (CE) is an
accessory enabling compatible 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 S350. The module itself is a
low profile pedestal, designed to seamlessly integrate
with compatible power sources and water coolers.
General Functional Description
The POWER WAVE® STT® MODULE (CE) 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 dedicated digital link.
DUTY CYCLE
The POWER WAVE® STT® MODULE (CE) is rated at
450 amps at a 100% duty cycle. It is further rated to
support 500 amps at a 60% duty cycle and 550 amps at
a 40% duty cycle. The duty cycle is based on a ten-
minute period. A 60% duty cycle represents 6 minutes of
welding and 4 minutes of idling in a ten-minute period.
Note:
The POWER WAVE® STT® MODULE (CE) is capable
of withstanding a peak output current of 750 amps. The
allowable maximum average 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.
The power source controls the POWER WAVE® STT®
MODULE (CE) based on the selected weld mode.
For a more detailed description, and specific operating
instructions, consult the power source Instruction
Manual.
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 and red
Non-recoverable system fault. If the
power source or wire feeder status
LED is flashing any combination of
red and green, errors are present in
the system. Read the error code
before the machine is turned off.
RECOMMENDED PROCESSES AND
EQUIPMENT
RECOMMENDED PROCESSES
The POWER WAVE® STT® MODULE (CE) is
recommended for all process supported by the host
power source including, but not limited to SMAW,
GMAW, GMAW-P, GMAW-STT.
PROCESS LIMITATIONS
The POWER WAVE® STT® MODULE (CE) 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 (CE) 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.
Although the STT Module can be configured to support
negative electrode polarity processes, such as
Innershield, the STT process must be configured to use
positive electrode polarity.
EQUIPMENT LIMITATIONS
The POWER WAVE® STT® MODULE (CE) is intended
for use with compatible medium range “S” – series
POWER WAVE® power sources such as the S350.
COMMON EQUIPMENT PACKAGES
Basic Package (CE)
K2921-1 STT® Module (CE)
K2823-2 Power Wave® S350 (CE)
K14072-1 LF-45
K10349-PG(W)-XX Interconnecting cable package
K3168-1 Power Wave S500 CE

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STT® MODULE (CE) CASE FRONT
CASE FRONT DESCRIPTIONS
1. Status LED – Provides ArcLink® status of Power
Wave STT Module.
Note: During normal power-up, the LED will flash green
up to 60 seconds as the equipment performs self tests.
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.
STT® MODULE (CE) CASE BACK
CASE BACK DESCRIPTIONS
1. ArcLink® Pigtail – Connects directly to the ArcLink®
Out receptacle on the rear of the power source.
2. Differential I/O Pigtail – Connects directly to the
Differential I/O output receptacle on the rear of the
power source.
3. Differential I/O (Sync Tandem) Output – Supports
Synchronized Tandem MIG Welding with other
compatible power sources. Note: This feature is not
compatible with the STT process, and is therefore
disabled when using STT weld modes.
4. Watercooler Pass Through – CE model only.
Provides a channel to conceal and protect the power
and control leads for the optional integrally mounted CE
watercooler.
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing out
the machine, using a low-pressure air stream, to remove
accumulated 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.

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CONNECTION DIAGRAM SYSTEM
STT MODULE (CE) CONNECTION DIAGRAM
Figure A.5
1. Ground cable
2. Electrode cable (to feeder)
3. Sense lead cable

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8
Electromagnetic Compatibility (EMC)
11/04
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturbances
with, if necessary, assistance from Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
Personal medical devices like pacemakers and hearing aids.
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.

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9
Technical Specifications
POWER WAVE® STT®module CE
STT® Module – INPUT VOLTAGE AND CURRENT
V
oltage Input Current
40Vdc 0.5A
STT® Module - *Output Current Capacity
Duty Cycle Amperes Notes
100% 450
750A Peak (Max)
60% 500
40% 550
* Output Current Capacity: Defines capability of the output switch. the actual output current is supplied by host power
source.
PHYSICAL DIMENSIONS
Height (mm) Width (mm) Depth (mm) Weight (kg)
292 353 630 21.3
TEMPERATURE RANGES
Operating Temperature Range (ºC) Storage Temperature Range (ºC)
-20 to +40 -40 to +85
IP23 Insulation Class
WEEE
07/06
English
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE)
and its implementation in accordance with national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an environmentally compatible recycling facility. As the
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment and human health!
Spare Parts
12/05
Part List reading instructions
Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service
Department for any code number not listed.
Use the illustration of assembly page and the table below to determine where the part is located for your particular
code machine.
Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate
a change in this printing).
First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine, that
contains a picture-descriptive part number cross-reference.
Electrical Schematic
Refer to the "Spare Part" manual supplied with the machine.