Lincoln Electric IM10023 User Manual

IM10023

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MMAAXXssaa™1100 CCOONNTTRROOLLLLEERR

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with saf ety in mind. How ever,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your par t. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think bef ore
you act and be careful.

February, 2010

11590

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

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

i

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 fue l near an open f lame
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 s ome cas es it may be neces sary to rem ove s afety

gu a r d s to perf o r m r equir e d m ainten a n c e. Rem o v e
guards only when necessary and replace them when the
ma i n t e nance re q uirin g th eir re m o v a l is c o m p lete.
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 a ny c onductor cause s
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF field s may int erfer e with some pacemak ers, 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. Nev er coil the e lectrod e 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.

Mar ‘95

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
skin or wet cloth in g. W ea r dr y, hole-free

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
mu s t be p e rformed under elec t rically hazar d ous
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 sem ia ut om at ic
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. Ne ver s imu ltane ous ly touch ele ctr ica lly “ hot ” par ts 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.

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
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

we l ding with e lectrod e s wh i ch r e quire special
ve n tilati on s uch as s tainles s or hard facing (se e
instru ctio ns on container or MSDS ) o r o n l ead 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 circum­st a nces, outd oors, a r espira tor may be r equired .
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

caus e injur y or dea th. Alw ays use e nough v entilat ion,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t e r i al s a f e ty d a t a shee t (MSDS) an d fo llow yo u r
employer’s safety practices. MSDS forms are available from
yo u r weld i n g di s t r ibuto r or fr om th e ma n u f actur e r .

5.f. Also see item 1.b.

Jan ‘09

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

Re m e m b er t h a t we l d i n g s p a r ks a n d hot
materials from welding can easily go through small cracks
an d o pen i ngs to adja cen t a r eas . A voi d w eldi ng nea r
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
Co n t a i ners and Piping That Have Held Haza r d o u s
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 t he w el di ng 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 s pa rks fro m startin g a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e o n ly com p r e ssed g a s c ylind e r s
containing the correct shielding gas for the
pr o c e s s used a n d p r operl y o p e ratin g
re g u l a tors d e signe d f or t h e gas a n d

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Alwa ys keep cyl inder s in an upr ight posit ion sec urely
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. Re ad and f oll ow the inst ruc tio ns on com pre sse d g as
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 accord ance with the U.S. National
Electrical Code, all local code s 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.

Jan ‘09

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 L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode 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 s’isoler 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 l’eau 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 s’applicuent 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 n’importe 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 l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. U n cour t- ci rcuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
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 d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils 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
d’o pérations de d égraissage, nettoyage ou pist olage. La
chaleur ou les rayons de l’arc 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 d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Proté ge r l’autre p er sonnel travaillant à p roximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gout tes de laitier en fusion sont émises d e l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, 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
l’électricité 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, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

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

Mar. ‘93

Thank You

vv

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

Registration”. 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 “Quick Links” and then “Product

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.

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

Auxiliary Equipment Input Power Connection ...............................................................A-2

Interfacing to the MAXsa™ 10 CONTROLLER ......................................................A-3 thru A-4

Controlling Non-Lincoln auxillary Equipment...................................................A-5 thru A-6

Shutdown and Stop Inputs ............................................................................................A-7

Connection Diagram.............................................................................................................A-8

________________________________________________________________________________

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

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

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

Definitions of Welding Modes........................................................................................B-1

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

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

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

Locating Front Panel Controls and Input, Output Connections.....................................B-3

Case Front Controls and Description

Power-Up Sequence .....................................................................................................B-4

Inch Wire Feed Speed Settings ....................................................................................B-4

Changing Weld Modes..................................................................................................B-5

Frequency/Balance Control...........................................................................................B-5

Weld Mode Searching...................................................................................................B-6

Multiple Arc operation ...................................................................................................B-6

Weld Sequence.............................................................................................................B-7

Start Options .............................................................................................................B-7

End Options ..............................................................................................................B-8

Restrike Timer...........................................................................................................B-8

Setup Menu Features....................................................................................................B-9

Parameter List ..............................................................................................B-10, B-14

Lockout/Security.....................................................................................................B-14

Making a Weld .......................................................................................................B-15

Memory Panel Options...........................................................................................B-16

Saving a Procedure to a Memory Location ............................................................B-17

Limit Setting ...........................................................................................................B-18

________________________________________________________________________________

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-7

________________________________________________________________________

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

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

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

________________________________________________________________________

Parts Lists...............................................................................................................P-616

________________________________________________________________________

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS: MAXsa™10 CONTROLLER

A-1

INPUT VOLTAGE & CURRENT

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

K2814-1

* When not driving a motor.

40VDC 1.0 15.0in. 13.0 in 4.0 in. 25 Lbs 14°F to 104°F -40°F to 185°F

(381 mm) (259 mm) (102 mm) (11.3 Kg.) (-10°C to 40°C) (-40°C to 85°C)

PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

MAXsa™ 10 CONTROLLER

A-2

INSTALLATION

A-2

SAFETY PRECAUTION

WARNING

ELECTRIC SHOCK can kill.

• Only a qualified electrician should
connec t th e MA X s a™ 10 CON­TROLLER. Installation should be
made i n a cc o r da n c e w i th th e
appropri a t e Natio n a l Elect r i c a l
Code, the local codes and the infor­mation in this manual.

• Tu r n off the i n put po wer to the
power source at the disconnect
switch or fuse box before working
on thi s equipment. Turn off t he
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 inching wire (with Touch Sense feature selection).
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

CAUTION

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

• In s u l a t e yourself from the w o r k 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 fr o m areas th at may ca t c h the
glove.

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

LOCATION AND MOUNTING

HIGH FREQUENCY PROTECTION

Locate the MAXsa™ 10 CONTROLLER away from radio
co ntrolled machinery. The norma l op erati on of the
MAXsa™ 10 CONTROLLER may adversely affect the
operation of RF controlled equipment, which may result in
bodily injury or damage to the equipment.

AUX IL IARY EQU IPME NT IN PUT P OW ER
CONNECTION

The MAXsa™ 10 CONTROLLER has the ability to control
auxiliary equipment such as feeders, flux hoppers and
travel motors using solid state relays. There are three
relays (CR1,CR2 &CR3) i n the MA X s a ™ 10 CO N ­TROLLER, controlled by two independent coil drivers. The
coils of CR1 and CR2 are in parallel, therefore, they must
turn ON and OFF at the same time. The CR1 and CR2
relays are designated for driving travel motors to control
motion. CR3 is driven separately, and is designated to
control flux hopper operation.

MAXsa™ 10 CONTROLLER Relay Ratings:

Coil: 12Vdc, resistance = 86 ohms at 25° C
Normally Closed (N.C.) Contacts: 3A @ 277VAC
Normally Open (N.O.) Contacts: 30A @ 277VAC

The MAXsa™ 10 CONTROLLER does not provide the
input power to feed any equipment, other than the MAXsa
22 or the MAXsa 29 feeders. Therefore a separate power
feed must be provided by the end user. The MAXsa™ 10
CONTROLLER has been shipped standard with all of the
wiring and connectivity to operate the Lincoln K325 TC-3
Travel Carriage (4-pin cable connector) and the Lincoln
K219 Automatic Flux Hopper (3-pin cable connector). The
CR2 Relay is wired to the 4-pin travel connector, and the
CR3 Relay is wired to the 3-pin flux connector, both locat­ed on the bottom of the MAXsa™ 10 CONTROLLER.

If either of these is to be used with the MAXsa™ 10 CON­TROLLER, the end-user must provide the 115VAC input
power to the terminal strip located inside the MAXsa™ 10
CONTROLLER. Access to the terminal strip may be
obtained via one of the two .875” dia. (22.2mm) access
holes in the bottom of the MAXsa™ 10 CONTROLLER.
The s e acces s holes are shipped with plug bu t t ons
installed. Remove the plug button and install a suitable
strain relief to protect the wires. See Figure A.1

The MAXsa™ 10 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™ 10 CONTROLLER
must be mounted in the vertical(upright) position and
loc a t e d whe r e ther e is l i t tle ri s k of i m pacts to the
Controller.

MAXsa™ 10 CONTROLLER

WARNING

Although input power to MAXsa™ 10 CONTROLLER is
turned off, the customer installed auxiliary input may
be energized! Ensure that all input power to the
MAXsa™ 10 CONTROLLER is turned off before open­ing the cover

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

A-3

ACCESS

HOLES

TC-3 TRAVEL CARRIAGE

CONNECTOR

FLUX HOPPER

CONNECTOR

POWER WAVE® AC/DC 1000 SD

ARCLINK CONNECTOR

PENDANT

CONNECTOR

MAXsa™ 22 or 29

WIRE DRIVE CONNECTOR (14-PIN)

STATUS

LIGHT

INSTALLATION

FIGURE A.1 - MAXsa™ 10 CONNECTIONS

A-3

MAXsa™ 10 CONTROLLER

A-4

Cover Screws

(4 places)

Pendant

Screws

( 2 Places)

K1543-xx

or K2683-xx

Arclink Cable

(Optional)

Cover

F

ront View

Cover removed

Access

Hole

1

3

2

INSTALLATION

INTERFACING TO THE MAXsa™ 10 CON­TROLLER

The MAXsa™ 10 CONTROLLER is a versatile con­troller. The User Interface can be removed and used
as a hand-held pendant. Most circuits can be accessed
through the screwless terminal strip. The auxiliary
relays can control standard Lincoln equipment, or they
can be used to control any other auxiliary equipment
custom controls. PLC interfacing to control starting,
stopping, motion, etc, can be accomplished with ease.

FIGURE A.2 - HAND HELD PENDANT

A-4

Using the Controller as a Hand-held Pendant:

1. Remove the 4 screws from the MAXsa™ 10 CON­TROLLER that hold the cover. See Figure A.2.

2. Remove the 2 screws that hold the pendant in the
brackets. Use the acccess holes shown.

3. Extend the control cable as needed with an Arc Link
cable of appropriate length. See Figure A.2

MAXsa™ 10 CONTROLLER

A-5

INSERT
WIRE HERE

INSERT SCREW
DRIVER HERE

# 1

# 3
REMOVE SCREW
DRIVER FROM CAGE
CLAMP HOLE.

# 2

CAGE CLAMP

VAC IN
NEUTRAL (31)
VAC IN
LINE (32)

Auxiliary Input Power Connection Instructions

Use the appropriate size leads, at least 14 AWG – 2
wire with ground.

1. Remove two Phillips Head screws on right side of
front panel of hinged door to access terminal strip.

2. Remove a plug button and install a box connector

to provide strain relief for the input power leads.

INSTALLATION

A-5

Terminal blocks 48 and 49 are shipped connected to
the contacts of CR2 and CR3 by leads 531 and 532.
These relay contacts are also connected to the 4-pin
Travel connector and the 3-pin Flux connector located
on the bottom of the MAXsa™ 10 CONTROLLER.
CR1 is available for a separate customer connection,
but it will turn ON and OFF with CR2. Therefore, if
Lincoln auxiliary equipment is to be used, connecting
115VAC to the terminal strip is all that is required to
power the devices.

3. Strip off 1/4”(6.4mm) of insulation from the leads

and route them through the strain relief

4. Locate the 4-terminal blocks, numbered #48, #49,

and #50. These are to be used to bring in auxiliary
power. Terminal block #50 is used for the input
ground connection. This terminal block is color­coded green and yellow for easy identification.
Terminal blocks #48 and #49 are to be used to con­nect the input power circuit. (See Figure A.3).

5. Using a flat-head screwdriver with a blade dimen-

sion of 0.137"(3.5mm) x 0.020"(.51mm), insert the
screwdriver into the square hole next to the mount­ing hole to be used on the terminal strip. The
screwdriver should be inserted until it bottoms out.
This opens the screwless cage clamping style wire
insertion port. With the cage clamp opened insert
the wire into the round port until it bottoms out.
While holding the lead securely, remove the screw­driver from the terminal block. This closes the cage
clamp onto the lead holding it securely. Any open
port on blocks #48, #49, and #50 may be used.

FIGURE A.3

NOTE: The contacts of CR1 are not connected to ter-

minals #48 and #49 when shipped. Applying
power to the #48 and #49 terminals will not
transfer voltage to the CR1 relay. Connect
leads from the #48 terminal to the #4 terminal
and from the #49 terminal to the #3 terminal to
supply power to the common contacts of the
relay.

Once input power is applied to the terminal strip, this
voltage is always on terminal strip blocks #3, #4 (if
connected), #11, #17, and #18. These are the inputs
to the solid-state relay contacts. Input voltage is also
present on terminal strip blocks #7, #8 (if connected),
#15, #21, and #22 due to the N.C. contacts on the
relays. When the CR1 relay is energized, input power
is transferred to terminal strip blocks #5 and #6 (if
connected). When the CR2 relay is energized, input
power is transferred to terminal strip block #13. When
the CR3 relay is energized, input power is transferred
to terminal strip blocks #19 and #20. CR1 and CR2
will be turned ON and OFF at the same time.

MAXsa™ 10 CONTROLLER

A-6

SWITCH GROUP #2 SUPPLY

3-PIN FLUX

RECEPTACLE

A

B

C

TERMINAL

S

TRIP

CR3 INPUT #8

852

855

858

859

CR3 NO #2

CR3 NO #6

CR3 NC #3

CR3 INPUT #4

CR1 INPUT #8

CR1 NO #2

CR1 NO #6

CR1 NC #3

FLUX GND

CR1 INPUT #4

CR3 NC #7

SHUTDOWN #2 SUPPLY

SHUTDOWN #1

SHUTDOWN #1 SUPPLY

532B-49

SWITCH GROUP #1 SUPPLY

START

FLUX FILL

GND IN

CR1 NC #7

TRAVEL #1 GND

531B-48

4-PIN TRAVEL
RECEPTACLE

A

B

C

D

CR2 INPUT #8

CR2 NO #2

CR2 NO #6

CR2 NC #3

CR2 INPUT #4

CR2 NC #7

TRAVEL #2 GND

GND

1

2

5

6

789

101112

131415

16

17

181920

212223

24

25

262728

29

30

31

32

33

34

35

36

37

38

39

404142

434445

49

50

3

4

47

48

46

851

8510

859

CR1-4

CR1-8

CR1-2

CR1-6

CR1-3

CR1-7

GND-B

CR3-4

CR3-8

CR3-2

CR3-6

CR3-3

CR3-7

GND-A

CR2-4

CR2-8

CR2-2

CR2-6

CR2-3

CR2-7

531A-48

532A-49

GND-C

8511

SHUTDOWN #2

853

856

857

STOP

INCH FORWARD

INCH REVERSE

Numbers Refer to

Relay Terminals

CR1, CR2 CR3

Relays

INSTALLATION

FIGURE A.4 - CONTROLLING NON-LINCOLN EQUIPMENT

A-6

CONTROLLING NON-LINCOLN AUXILIARY
EQUIPMENT

Custom motion control and/or other auxiliary equipment
can be powered using the terminal strip and relays. To
use non-Lincoln motion control and/or flux hoppers, fol­low instructions below. See Figure A.4.

1. Remove all input power to the MAXsa™ 10 CON­TROLLER including any auxiliary power supplies.

2. Remove the wire duct cover to gain access to the
leads on the right side of the terminal strip.

3. Remove a plug button from one of the .875” (22.2mm)
access holes on the bottom of the MAXsa™ 10 CON­TROLLER control box. Install a suitable strain relief to
protect the leads. See Figure A.1.

4. Remove the leads going from the terminal strip to the
corresponding connectors, i.e. terminal strip blocks
#11, #13, and #16 for the 4-pin TC-3 Travel Carriage
or terminal strip blocks #19, #20, and #23 for the 3-pin
Automatic Flux Hopper. See the Wiring Diagram.

5. These loose leads can be taped and secured in the
wire duct.

.

6. Any custom or non-Lincoln equipment can be powered
by the normally open contacts from relays CR1, CR2,
or CR3. The contacts for CR1 are connected to the
terminal strip blocks #3 through #8. The contacts for
CR 2 are con nected t o te rminal s trip blocks #10
through #15. The contacts for CR3 are connected to
terminal strip blocks #17 through #22. See Figure A.3.

CR1 and CR2 relay coils are in parallel and are BOTH
turned ON and OFF as determined by the Travel Options
setting (P12 in the Set-up Menu) as long as the TRAVEL
MODE is set to AUTO. CR3 turns ON with the START
command and OFF with the STOP Command.

7. The supply voltage to power the devices is provided
by the end user. As shipped, the MAXsa™ 10 has the
auxiliary supply blocks (terminal strip blocks #48 and
#49) connecte d to the CR2 relay and CR3 relay
inputs, respectively. When the end user connects a
supply to the AUX blocks #48 and #49, this voltage will
be jumpered to the CR2 and CR3 relay inputs on ter­minal strip blocks #11, #17, and #18.

NOTE: The CR1 relay is not connected to the AUX

8. Connect input supply voltage per the Auxiliary Input
Power Connection Instructions listed earlier.

9. The relays can also be used to provide contact closure
for any interfacing signals out using the normally open
contacts. An external auxiliary supply voltage would
not be necessary to use the relays as hard contact clo­sure out signals.

NOTE: The CR1 relay as shipped does not have AUX

leads connected to it. This relay operates as
described above and has two normally open /
normally closed contacts that could be used as

MAXsa™ 10 CONTROLLER

a signal out when interfacing to PLC’s or cus­tom controls.

terminal strip blocks; the customer must con­nect power to this relay if it is to be used. See
relay ratings listed earlier.

A-7

859

FLUX GND

CR3 NC #7

SHUTDOWN #2 SUPPLY

SHUTDOWN #1

SHUTDOWN #1 SUPPLY

22

23

24

25

26

27

8510

859

CR3-7

GND-C

8511

SHUTDOWN #2

Shorting

Jumper

Connect STOP
Input Here

39

41

40

SWITCH GROUP #1 SUPPLY

START

STOP

INSTALLATION

FIGURE A.5 - SHUTDOWN AND STOP INPUTS

A-7

SHUTDOWN INPUTS

The MAXsa™ 10 CONTROLLER has two shutdown
inputs available on the terminal strip. These are inde­pendent, normally closed inputs that can be used for
limit switches, PLC inputs, etc, in order to shut down
the welding operation for any reason. Shutdown #1 is
located on term i n al stri p bloc k s #2 4 and #25.
Shutdown #2 is located on terminal strip blocks #26
and #27.

1. Remove all input power to the MAXsa™ 10 CON­TROLLER including any auxiliary power supplies.

2. Remove the wire duct cover to gain access to the
leads on the right side of the terminal strip.

3. Remove one of the plug buttons located on the bot­tom of the MAXsa™ 10 CONTROLLER control box
and install a box connector to provide strain relief
for the auxiliary control leads.

4. Connect the external shutdown circuit to either of
the shutdown terminal blocks, #24 & #25, and/or
#26 & #27. A normally closed circuit must be con­nected – the MAXsa™ 10 CONTROLLER will rec­ognize an open circuit as a shutdown command.

5. Remove the shorting jumpers imbedded in the cen­ter of the terminal strip with a small screwdriver for
the shutdown circuits to be used.

STOP INPUT

The MAXsa™ 10 CONTROLLER has a Stop Input
available on the terminal strip. The Stop Input will
work just like pressing the STOP Pushbutton. This cir­cuit is in parallel with the STOP Pushbutton located on
the Switch Panel. Unlike the Shutdown Inputs, which
completely shutdown all welding and auxiliary equip­ment, the STOP Input will allow all welding and auxil­iary motion to continue based on the END OPTIONS
configurations in the MAXsa™ 10 CONTROLLER.
See Figure A.5.

1. Remove all input power to the MAXsa™ 10 CON­TROLLER including any auxiliary power supplies.

2. Remove the wire duct cover to gain access to the
leads on the right side of the terminal strip.

3. Remove one of the plug buttons located on the bot­tom of the MAXsa™ 10 CONTROLLER control box
and install a box connector to provide strain relief
for the control leads.

4. Connect the external Stop Input circuit to terminal
blocks #39 and #41.

NOTE: The STOP circuit only needs a momentary

closure to be recognized by the MAXsa™ 10
CONTROLLER.

When a shutdown input is received, all welding will
stop and an error message will be displayed on the
MAXsa™ 10 CONTROLLER. The shutdown circuit
must be closed before resetting the Controller. To
reset the system, the Mode Select Panel display will
prompt the user to press the left Mode Select Panel
Pushbutton.

MAXsa™ 10 CONTROLLER

A-8

K1543-XX
or K2683-XX
Arclink Cable

67 Lead

K1785-XX
14-Pin Cable

Work

K231-XX
Contact Nozzle

K

2803-1

Power Wave

® AC/DC 1000SD

K2814-1

MAXsa™ 10

K2370-2
MAXsa™ 22

K1811-XX
Sense Lead

Electrode
Weld Cable

Work
Weld Cable

Connection Diagrams for Additional
Congurations (Multi- Arc and Parelleled Power Sources)
are in the Power Wave® AC/DC 1000SD Operators Manual

INSTALLATION

FIGURE A.6 - CONNECTION DIAGRAM - SINGLE ARC SYSTEM

A-8

MAXsa™ 10 CONTROLLER