Lincoln Electric IM10021 User Manual

MAXsa™19 CONTROLLER

IM10021-A

RETURN TO MAIN MENU

For use with machines having Code Numbers:

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 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.

August, 2012

11614, 11778

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

IP 23

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN 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 & 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 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

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 spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. 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.

____________________________________________________

1.e. 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.

___________________________________________________

1.f. 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.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. 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.

___________________________________________________

1.g. 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.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare

gloves to insulate hands.

3.b. 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 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.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water 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.

skin or wet clothing. Wear dry, hole-free

ARC RAYS can burn.

4.a. 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
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. 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.

FUMES AND GASES
can be dangerous.

5.a. 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

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.

5. b. 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 applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. 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.

ventilation and/or exhaust at the arc to keep

vapors

to

5.e. 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.

5.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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 cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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.

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.

6.I. 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.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.

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. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés 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, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

v

Thank You

v

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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 at 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.

CUSTOMER ASSISTANCE POLICY

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.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially 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

Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

MAXsa™ 19 CONTROLLER

vi

TABLE OF CONTENTS

Page

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Installation.......................................................................................................................Section A

Technical Specifications................................................................................................A-1

Safety Precautions ........................................................................................................A-2

Welding Voltage, Mechanical Hazards .........................................................................A-2

Location and Mounting..................................................................................................A-2

High Frequency Protection............................................................................................A-2

Component Description.................................................................................................A-3

Interfacing to the MAXsa™ 19 Controller......................................................................A-4

Connection Diagrams................................................................................................A-4

External I/O Connector..............................................................................................A-5

Status Light ...............................................................................................................A-5

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Design Features ...................................................................................................................B-1

Common Welding Abbreviations...................................................................................B-1

Product Description.......................................................................................................B-2

Recommended Processes and Equipment...................................................................B-2

_______________________________________________________________________________

Accessories .....................................................................................................Section C

General Options / Accessories..............................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine ..................................................................................................................D-1

Periodic..................................................................................................................D-1

Calibration Specification........................................................................................D-1

________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-6

________________________________________________________________________

Diagrams ..........................................................................................................Section F

Wiring Diagram ......................................................................................................F-1

Dimension Print......................................................................................................F-2

________________________________________________________________________

Parts Lists...............................................................................................................P-617

________________________________________________________________________

vi

MAXsa™ 19 CONTROLLER

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS: MAXsa™ 19 CONTROLLER

A-1

INPUT VOLTAGE & CURRENT

Model Voltage* Input Amps* Height Width Depth Weight Operating Storage

K2626-2

* When not driving a motor.

40VDC 1.0 8.8 in. 10.38 in 3.12 in. 7 Lbs 14°F to 104°F -40°F to 185°F

(224 mm) (264 mm) (80 mm) (3.2 Kg.) (-10°C to 40°C)

PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

(

-40°C to 85°C)

MAXsa™ 19 CONTROLLER

A-2

INSTALLATION

A-2

SAFETY PRECAUTION

WARNING

ELECTRIC SHOCK can kill.

• Only a qualified electrician should
connect the MAXsa™ 19 Controller.
Installation should be made in
accordance with the appropriate
National Electrical Code, the local
codes and the information in this
manual.

• Turn off the input power to the
power source at the disconnect
switch or fuse box before working
on this equipment. Turn off the
input power to any other equipment
connected to the welding system at
the disconnect switch or fuse box
before working on this equipment.

• Do not touch electrically hot parts.

----------------------------------------------------------------------------------------

WELDING VOLTAGE

Wire feed parts are electrically live while welding and
while feeding wire (with Touch Sense feature select­ed). The electrically live parts are listed below:

Electrode Electrode Reel
Wire Drive Motor Drive Rolls
Gear Box Cross-seam Adjuster
Wire Straightener Welding Nozzle
Welding Cables Welding Cable Terminal

LOCATION AND MOUNTING

The MAXsa™ 19 Controller will operate in harsh envi­ronments and can be used outdoors with an IP 23 rat­ing. Even so, it is important that simple preventative
measures are followed in order to assure long life and
reliable operation. The MAXsa™ 19 Controller must be
located where there is little risk of impacts to the
Controller
.

HIGH FREQUENCY PROTECTION

Locate the MAXsa™ 19 Controller away from radio
controlled machinery. The normal operation of the
MAXsa™ 19 Controller may adversely affect the opera­tion of RF controlled equipment, which may result in
bodily injury or damage to the equipment.

CONTROL CABLE CONNECTIONS

GENERAL GUIDELINES

These guidelines apply to all communications
cables including optional DeviceNet and Ethernet
connections.

• Genuine Lincoln control cables should be used
at all times (except as noted otherwise). Lincoln

cables are specifically designed for the communica­tion and power needs of the Power Wave/ MAXsa™
systems. Most are designed to be connected end to
end for ease of operation.

CAUTION

• Do not touch electrically live parts or
electrodes with your skin or wet cloth­ing.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

MECHANICAL HAZARDS

• Welding fixture or wire feeder will
move during welding or inching. Keep
away from pinch points.

• Electrode reel and drive rolls turn during weld­ing or inching. Keep gloved hands away from
areas that may catch the glove.

------------------------------------------------------------------------------------------

• Always use the shortest cable lengths possible.
DO NOT coil excess cable. It is recommended that
the total length of control cable does not exceed
100ʼ (30.5M). The use of non-standard cables in
excess of 25ʼ (7.5M) can lead to communication
problems (system shutdowns), poor motor accelera­tion (poor arc starting), and low wire driving force
(wire feeding problems).

• Best results will be obtained when the 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.

MAXsa™ 19 CONTROLLER

A-3

INSTALLATION

INTERFACING TO THE MAXsa™ 19 CON­TROLLER

A-3

The MAXsa™ 19 is a versatile controller designed to
operate in a Power Wave

®

AC/DC 1000 SD system
and is responsible for relaying wire feed commands to
a MAXsa™ 29 Wire Drive. It is connected to the Power

®

Wave

AC/DC 1000 SD by a K2683-xx ArcLink Cable
and to the Wire Drive by a K1785-xx 14 Pin Control
Cable.

FIGURE A.1 - CONNECTION DIAGRAM

K1543-XX
K2683-XX

K2626-2
MAXsa

™ 19

Arclink Cable

The MAXsa™ 19 is required whenever a customer
supplied user interface is used in place of a MAXsa™
10 Controller.

or

K2803-1
Power Wave

® AC/DC 1000 SD

K1785-XX

14-Pin Cable

K1811-XX

Sense Lead

(For Codes 11778 and above)

K2312-2
MAXsa

Work

Configurations (Multi-Arc and Parellel Power Sources)

are in the Power Wave

™ 29

67 Lead

K231-XX
Contact Nozzle

Connection Diagrams for Additional

® AC/DC 1000 SD Operators Manual

MAXsa™ 19 CONTROLLER

Electrode
Weld Cable

Work
Weld Cable

A-4

FIGURE A.2 - MAXsa™ 19 COMPONENT DESCRIPTION CODE 11614

External

I/O Connector

INSTALLATION

A-4

Status

14 Pin Connector

To Wire Drive

ArcLink Connector

To Power Source

FIGURE A.2a - MAXsa™ 19 COMPONENT DESCRIPTION CODE 11778

External

LED

I/O Connector

14 Pin Connector

To Wire Drive

ArkLink Connector

Status

LED

ArcLink Connector

5 Socket

To Power Source

MAXsa™ 19 CONTROLLER

A-5

INSTALLATION

A-5

EXTERNAL I/O CONNECTOR

The MAXsa™ 19 is equipped with a terminal strip for
making simple input signal connections.(See Figure
A.3)

FIGURE A.3 - EXTERNAL I/O

1

2

3

4

5

6

7

8

9

11

10

12

The terminal strip is divided into three groups:

Group #1 - START / STOP

Group # 2 - FEED FORWARD/REVERSE

Group #3 - SHUTDOWN INPUTS

When the Power Wave AC/DC 1000 SD is controlled
via DeviceNet, the “Start/Stop” and “Feed” groups can
interfere with the welding sequence and should not be
used.

All inputs use "normally open" logic except the shut­down group. The shutdown inputs use "normally
closed" logic, and are always enabled. Unused shut­downs must be tied to the +15V supply for the shut­down group. Machines are shipped from the factory
with jumpers installed on both shutdown inputs. See
Figure A.4 for input Identification.

NOTES

1. Activating the “Start/Stop” or “Feed” group inputs
on a system without a user interface or other
means of configuring the Weld Sequencer will
result in default values for Weld Mode, WFS and
Work point settings.

2. “Start/Stop” and “Feed” group inputs may be rede­fined as "Weld Profile Selections" by Production
Monitoring software (see Production Monitoring
Literature for details).

STATUS LIGHT

The Status Light is a two color LED that indicates the
system condition. Normal operation is steady green.
Flashing green or red/green indicates a system error.
See the Troubleshooting Section.

SELECTING A WIRE DRIVE
AND GEAR RATIO

The MAXsa™ 19 can accommodate a number of wire
drives including the MAXsa™ 22 and MAXsa™ 29.
The feeder control system must be configured for both
the wire drive and the gear ratio. This can be accom­plished with the Weld Manager Utility. This utility is on
the Power Wave Submerged Arc Utilities CD, or avail­able at www.powerwavesoftware.com.

+15VDC - Group #1

1

A

FIGURE A.4

Shutdown 2 Input

START

STOP

4

3

2

+15VDC - Group #2

5

Feed Forward

6

Feed Reverse

78

C

B

DF

Shutdown 1 Input

+15VDC - Group #3

910

E

11

12

MAXsa™ 19 CONTROLLER

B-1

SAFETY PRECAUTIONS

OPERATION

DESIGN FEATURES

B-1

Read this entire section of operating instructions
before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

• Do not use AC welder if your cloth­ing, gloves or work area is damp or
if working on, under or inside work­piece.

Use the following equipment:

-DC manual (stick) welder.

-AC welder with reduced voltage
control.

• Do not operate with panels removed.

• Disconnect input power before ser­vicing.

---------------------------------------------------------------------

ONLY QUALIFIED PERSONS SHOULD INSTALL,
USE OR SERVICE THIS EQUIPMENT. READ AND
FOLLOW THE MANUFACTURERʼS INSTRUC­TIONS, EMPLOYERʼS SAFETY PRACTICES AND
MATERIAL SAFETY DATA SHEETS (MSDS) FOR
CONSUMABLES.

• Digital communications for accurate and reliable per­formance.

• PC boards are potted in epoxy for the ultimate in out­door protection.

• Connectors are filled with environmental protective
grease.

• Designed for the Power Wave
series of products for the best arc in the industry.

• Wire feed speed accuracy calibrated to within 2%.

®

AC/DC 1000 SD

COMMON WELDING ABBREVIATIONS

SAW

• Submerged Arc Welding

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

INPUT POWER

WIRE FEEDER

--------------------------------------------------------------------

READ THIS WARNING, PROTECT YOURSELF AND
OTHERS.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust at the arc,
or both,to keep fumes and gases
from your breathing zone and gener­al area.

WELDING SPARKS can cause fire or
explosion.

• Do not weld near flammable material.

• Do not weld on containers which have
held flammable materia

ARC RAYS can burn.

• Wear eye, ear, and body protection.

-----------------------------------------------------------------------

MACHINE STATUS

CONTROLLER
ARCLINK INPUT
CONNECTOR

MAXsa™ 19 CONTROLLER

B-2

PRODUCT DESCRIPTION

GENERAL PHYSICAL DESCRIPTION

OPERATION

B-2

The MAXsa™ 19 is a versatile controller designed to

®

operate in a Power Wave

AC/DC 1000 SD system
and is responsible for relaying wire feed commands to
a MAXsa™ Wire Drive. It is connected to the Power

®

Wave

AC/DC 1000 SD by a K2683-xx ArcLink Cable
and to the Wire Drive by a K1785-xx 14 Pin Control
Cable

RECOMMENDED PROCESSES AND
EQUIPMENT

• The MAXsa™ 19 Controller is intended for sub­merged arc welding only with the Power Wave
AC/DC 1000 SD, and the MAXsa™ Feed Head.

• SAW

COMMON BASIC EQUIPMENT PACKAGES

Basic Package

®

• K2803-1 Power Wave

• K2312-2 MAXsa™ 29 Wire Drive

AC/DC 1000 SD

®

• K2626-2 MAXsa™ 19 Controller

• K2683-xx Control Cable (5 pin – 5 pin) - power

source to MAXsa™ 19.

• K1785-xx Control Cable (14 pin – 14 pin) -

MAXsa™ 19 to Wire Drive.

MAXsa™ 19 CONTROLLER

C-1

ACCESSORIES

OPTIONS AND ACCESSORIES are

available at www.lincolnelectric.com

Follow these steps:

1. Go to www.lincolnelectric.com

2. In the Search field type E9.181 and click on the
Search icon (or hit ʻEnterʼ on the keyboard).

3. On the Results page, scroll down to Literature
Request in the list and click on it.

4. On the Literature Request page scroll down to
E9.181 and view or download the PDF file.

All of the information for the PowerWave System and
accessories can be found in this document.

C-1

MAXsa™ 19 CONTROLLER

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
such as output terminals or internal
wiring.

• When inching, electrode and drive
mechanism are “hot” to work and
ground and could remain energized
several seconds after the inch button
is released.

• Turn OFF input power at welding power source
before installation or changing drive roll and/or guide
tubes.

• Welding power source must be connected to system
ground per the National Electrical Code or any
applicable local codes.

• Only qualified personnel should perform mainte­nance work.

ROUTINE MAINTENANCE

• Check weld cables and control cables for cuts.

PERIODIC MAINTENANCE

• N/A

CALIBRATION SPECIFICATION

All calibration is factory set on the MAXsa™ 19
Controller.

See additional warning information

throughout this operatorʼs manual and
the Engine manual as well.

MAXsa™ 19 CONTROLLER

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed 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 throughout this manual.

__________________________________________________________________________

E-1

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 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.

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.

MAXsa™ 19 CONTROLLER

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

USING THE STATUS LED TO TROUBLESHOOT
SYSTEM PROBLEMS

The MAXsa™ 19 is equipped with a Status Light. If a problem occurs it
is important to note the condition of the status lights. Therefore, prior

to cycling power to the system, check the power source status
light for error sequences as noted below.

Included in this section is information about the power source and
Wire Drive Module Status LEDʼs, and some basic troubleshooting
charts for both machine and weld performance.

The STATUS LIGHTS are dual-color LEDʼs that indicate system
errors. Normal operation for each is steady green. Error conditions
are indicated in the following Table E.1.

TABLE E.1

E-2

Light

Condition

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

Meaning

System OK. Power source is operational, and is communicating normally with all healthy
peripheral equipment connected to its ArcLink network.

Occurs during power up or a system reset, and indicates the POWER WAVE
is mapping (identifying) each component in the system. Normal for first 1-10
seconds after power is turned on, or if the system configuration is changed
during operation.

Under normal conditions indicates Auto-mapping has failed.
Also used by the Weld Manager Utility (included on the POWER WAVE
Submerged Arc Utilities and Service Navigator CDʼs or available at www.pow­erwavesoftware.com) to identify the selected machine when connecting to a
specific IP address.

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 present, the codes will be separated by a
green light. Only active error conditions will be accessible through the Status
Light.

Error codes can also be retrieved with the Weld Manager Utility (included on
the POWER WAVE
available at www.powerwavesoftware.com). This is the preferred method,
since it can access historical information contained in the error log.

®

Submerged Arc Utilities and Service Navigator CDʼs or

®

®

To clear the active error(s), turn power source off, and back on to reset.

Steady Red

Blinking Red

Not applicable.

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.

MAXsa™ 19 CONTROLLER

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

ARCLINK SYSTEM ERROR CODES

TROUBLESHOOTING

POSSIBLE

CAUSE

E-3

RECOMMENDED

COURSE OF ACTION

Err 81 Motor Overload (long

term)

Err 82 Motor overload, short

term.

1. The wire drive motor has over­heated. Check that the electrode
slides easily through feed system.

2. Remove tight bends from the
feed conduit

3. Check that the wire reel brake is
not too tight.

4. Verify a high quality electrode is
being used.

5. Wait for the error to reset and the
motor to cool (approximately 1
minute).

6. Long term average motor current
limit has been exceeded.
Typically indicates mechanical
overload of system. If problem
continues consider higher torque
gear ratio (lower speed range).

1. The wire drive motor current draw
has exceeded limits, usually
because the motor is in a locked
rotor state. Check that motor can
turn freely when idle arm is open.

2. Verify that the gears are free of
debris and dirt.

3. Check items listed for long term
overload (Err 81).

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

Err 83 Shutdown #1 is open.

1.This refers to the ʻgreenʼ I/O con-

nector on the bottom of the con­troller.

If not being externally
accessed, verify the integrity of
the connector and jumper.

If accessed through a remote
circuit, verify the integrity of that
circuit

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.

MAXsa™ 19 CONTROLLER

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

ARCLINK SYSTEM ERROR CODES

TROUBLESHOOTING

POSSIBLE

CAUSE

E-4

RECOMMENDED

COURSE OF ACTION

Err 84 Shutdown #2 is open.

Err 6311 Unstable or “noisy” wire

feed speed (WFS) feed­back signal.

1.This refers to the ʻgreenʼ I/O con­nector on the bottom of the con­troller.

If not being externally
accessed, verify the integrity of
the connector and jumper.

If accessed through a remote
circuit, verify the integrity of that
circuit.

1. Check the cables and connec­tions to the Wire Drive.

2. Check the Wire Drive control
cable routing (see Control Cable
Connection- General Guidelines).

3. Check the Tachometer Interface
Board.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

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.

MAXsa™ 19 CONTROLLER

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

OUTPUT PROBLEMS

The feeder does power up but there
is no wire feed.

TROUBLESHOOTING

POSSIBLE

CAUSE

1. The control cable may be loose
or damaged. Tighten, repair or
replace the control cable.

2. Check for the proper command
information from the customer
supplied user interface.

E-5

RECOMMENDED

COURSE OF ACTION

Inconsistent wire feeding or wire not
feeding but drive rolls turning.

1. The electrode is rusty or dirty.
Use only clean electrode. Use
quality electrode, like L-50 or L­56 from Lincoln Electric.

2. The contact tip is partially melted
or has spatter. Replace the con­tact tip.

3. Improper tip, drive rolls and/or
inner wire guide. Verify the prop­er parts are installed.

4. Incorrect tension arm pressure on
the drive rolls. Adjust the tension
arm per the Instruction Manual.
Most electrodes feed well at a
tension arm setting of "3".

5. Worn drive roll. Replace the

drive rolls if worn or filled with
dirt.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.

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.

MAXsa™ 19 CONTROLLER

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

OUTPUT PROBLEMS

Wire feed speed consistently oper­ates at the wrong value.

TROUBLESHOOTING

POSSIBLE

CAUSE

1. The wire feeder gear setting is
not properly set. Verify that the
software setting matches the gear
mounted. See the Instruction
Manual for setting the gear ratio.

E-6

RECOMMENDED

COURSE OF ACTION

Variable or "hunting" arc.

1. Wrong size, worn and/or melted
contact tip. Replace the contact
tip.

2. Worn work cable or poor work
connection. Verify all work and
electrode connections are tight
and that the cables are in good
condition. Clean/replace as nec­essary.

3. Wrong polarity. Adjust polarity to
the recommended procedure.
Verify DIP switch #7 setting
matches the electrode polarity.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.

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.

MAXsa™ 19 CONTROLLER

F-1

ENHANCED DIAGRAM

DIAGRAMS

F-1

MAXsa™ 19 CONTROLLER

NOTE: This diagram is for reference only. It may 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.

F-2

3.12

DIAGRAMS

7.83

F-2

L13500

.97

10.38

9.38

8.14

O .28

5.50

O .66

MAXsa™ 19 CONTROLLER

NOTES

MAXsa™ 19 CONTROLLER

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch 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 moja­da.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 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 Elektroden mit Ihrem
Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

 Keep your head out of fumes.
 Use ventilation or exhaust to

remove fumes from breathing zone.

 Turn power off before servicing.

 Do not operate with panel open or

guards off.

WARNING

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

 Gardez la tête à l’écart des fumées.
 Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.
 Use ventilação e exhaustão para

remover fumo da zona respiratória.

 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 öff­nen; Maschine anhalten!)

 Não opere com as tampas removidas.
 Desligue a corrente antes de fazer

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

 Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com