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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

IP 23

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

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.

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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

SAFETY

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

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

SAFETY

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

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.

TABLE OF CONTENTS

Page

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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

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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

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

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

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

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

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

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

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

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

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

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

Troubleshooting Guide.............................................................................E-2 thru E-7

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

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

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

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

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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.

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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.

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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

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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

ront View

Cover removed

Access

Hole

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

TERMINAL

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

CR2 INPUT #8

CR2 NO #2

CR2 NO #6

CR2 NC #3

CR2 INPUT #4

CR2 NC #7

TRAVEL #2 GND

GND

789

101112

131415

181920

212223

262728

404142

434445

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

8510

859

CR3-7

GND-C

8511

SHUTDOWN #2

Shorting

Jumper

Connect STOP Input Here

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

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

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

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 n o t operate wi t h pa ne l s removed.

• Disconnect input power before servicing.

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

ONLY QUALIFIED PERSONS SHOULD INSTALL, USE OR SERVICE THIS EQUIPMENT. READ AND FOLLOW THE MANUFACTURER’S INS T R U C TIONS, EMPLOYER’S SAFETY PRACTICES AND MATERIAL SAFETY DATA SHEETS (MSDS) FOR CONSUMABLES.

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

READ THIS WARNING, PROTECT YOURSELF & OTHERS.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

DESIGN FEATURES

• Easy control of all weld parameters.

• 8 Memories for easy storage and recall of weld schedules.

• Weld parameter limit setting and lockout capabilities.

• 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%.

• Digital display of voltage and wire feed speed.

• Tachometer controlled wire drive motor.

• Flux Fill Switch.

• Bright, high intensity digital read-outs.

• Option to convert to hand-held pendant included.

AC/DC 1000 SD

DEFINITIONS OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of single knob control. The machine will select the correct voltage and amperage based on the wire feed speed (WFS) set by the operator.

• See the Power Wave Manual for available weld modes.

AC/DC 1000 SD Operator’s

COMMON WELDING ABBREVIATIONS

• 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 material.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

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

MAXsa™ 10 CONTROLLER

SAW

• Submerged Arc Welding

B-2

OPERATION

B-2

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

PENDENT ARCLINK CONNECTOR

WIRE FEEDER

CONTROLLER ARCLINK INPUT CONNECTOR

FLUX HOPPER CONNECTOR

GENERAL FUNCTIONAL DESCRIPTION

• The MAXsa™ 10 CONTROLLER is one of the most versatile user interfaces ever created. Easy to use features make it a snap to adjust the arc for specific preferences.

• The user interface brightly displays essential welding information. Use it to quickly adjust weld settings, arc starting parameters, arc end parameters and set-up information.

• The memories allow for up to eight weld schedules to be stored and quickly recalled. The user interface allows for multiple levels of limits and lockouts.

• Digital communications to the power source provide the most accurate and reliable operation possible.

• When the MAXsa™ 10 CONTROLLER is coupled to the Power Wave power source, the result is a welding system with the best arc performance on the market.

AC/DC 1000 SD welding

TRAVEL CARRIAGE CONNECTOR

PRODUCT DESCRIPTION

GENERAL PHYSICAL DESCRIPTION

• The MAXsa™ 10 CONTROLLER is a user interface and a feeder controller. The control is used to set all welding parameters and control any travel mechanisms. High-speed digital cables connect the control, wire drive, and the Power Wave power source together.

• The MAXsa™ 10 CONTROLLER is a self-contained control box designed to control the entire weld arc at one location.

• The user interface utilizes alphanumeric displays for advanced text messaging providing the end user with an intuitive interface allowing for easy set up and real-time control of all welding parameters.

REC OM MEND ED P ROCE SSES A ND EQUIPMENT

• The MAXsa™ 10 CONTROLLER is best suited for submerged arc welding only with the Power Wave AC/DC 1000 SD, the MAXsa™ 22 or the MAXsa™ 29 Feed Heads.

• SAW

COMMON BASIC EQUIPMENT PACKAGES

Basic Package

• K2803-1 Power Wave

• K2370-2 MAXsa™ 22 Wire Drive

• K2814-1 MAXsa™ 10 CONTROLLER / User

Interface

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

source to MAXsa™ 10.

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

MAXsa™ 10 to Wire Drive.

Optional kits

AC/DC 1000 SD

• An eight button memory section has been included which provides easy storage and recall of stored welding parameters.

• The user interface can be removed from the control box and connected as a Pendant for remote control near the arc.

MAXsa™ 10 CONTROLLER

• K2312-2 MAXsa™ 29 Wire Drive (for fixture builders).

• K2311-1

Motor Conversion Kit (to convert existing NA-3/NA-4/NA-5 wire feeder gear boxes).

B-3

ACCESS

C-3 T

VEL CARRIAG

NNECTO

UX H

PPER

NNECTO

ER W

VE®

AC/DC 1

000 SD

ARCL

INK CO

NNECT

sa™

22 o

(14-

)

TRAVEL SWITCH

(AUTO / OFF / MANUAL)

FLUX FILL

SWITCH

WELD MODE

SELECTOR

WELD MODE

INDICATOR

FREQUENCY AND

BALANCE INDICATOR

AMPS

INDICATOR

WFS

INDICATOR

AMPS/WFS

DISPLAY

AMPS/WFS

CONTROL

VOLTS

CONTROL

VOLTS

DISPLAY

MEMORY

BUTTONS (8)

VOLTS

INDICATOR

START

BUTTON

WELD OUTPUT

INDICATOR

STOP

BUTTON

SET-UP MENU

INDICATOR

ARC START/END

OPTIONS SELECTOR

START OPTIONS

INDICATOR

END OPTIONS

INDICATOR

FEED

REVERSE

FEED

FORWARD

MODE SELECT PANEL

CONTROL

MODE SELECT

PANEL (MSP)

DISPLAY

200

----

Steel 1/8”

CC AC

OPERATION

FIGURE B.1 - INPUT AND OUTPUT CONNECTIONS

B-3

FIGURE B.2 - PENDANT CONTROLS

MAXsa™ 10 CONTROLLER

B-4

----

Feed Cold

Feedhead 1

----

MAXsa Initializing. . .

Feed FWD Hot!

ELECTRODE HOT

Welding Software

Zxxxxxx

FIGURE B.3 - POWER UP

OPERATION

B-4

FIGURE B.4.- FEED CONTROLS

POWER-UP SEQUENCE

When power is first applied to the machine the MODE SELECT Display reads “MAXsa™ Initializing...”. Once the PowerWave AC/DC has intialized (20 to 60 seconds) a “lamp test” is performed.

• All discrete LED’s, seven segment displays and alpha numeric displays will be turned ON for 2 seconds

• After 2 seconds all displays are turned OFF again and the MSP Display will show:

After initialization is complete,the MSP Display will show the weld mode. The upper displays will show the parameters that were selected when the machine was last powered down and the WELD MODE Indicator will be ON.

SETTING FEED FORWARD/REVERSE

While pressing either the FEED FORWARD or FEED REVERSE pushbutton the MSP Display will read as shown in Figure B.4 and the preset wire feed speed will be displayed on the left (AMPS/WFS) display.

The feed speed can be changed by adjusting the control knob below the display while pressing either button.

FEED REVERSE Use to retract the wire from

the feed mechanism.

FEED FORWARD Fe eds the wire down ward

towards the work piece.

NOTE: The MAXsa 10 has an option in the Setup

Menu (P.15) to enable the “Touch Sense” circuitry. See the Setup Menu. When P.15 is enabled and the FEED FORWARD button is pressed, the MSP Display will read:

WIRE FEEDER SETUP

Use the FEED FORWARD pushbutton to insert wire into the feed mechanism.

Prior to inserting the wire make sure that the “Touch Sense” option is disabled. (P.15 in the Setup Menu).

WARNING

This “Hot Feed” feature enables the output of the power source and there is voltage on the wire while feeding down. Avoid touching any exposed parts as defined in the SAFETY PRECAUTIONS.

MAXsa™ 10 CONTROLLER

B-5

Frequency

500

-500

-1000

1000

Increase

Decrease

Use Frequency to fine tune stability of

imbalanced waveforms and multiple arc systems

Balance

500

-500

1000

Nominal Balance

Increased Balance

More Penetration

Less Deposition

Decreased Balance

Less Penetration More Deposition

500

-500

-1000

1000

Nominal Offset

Positive Offset

More Penetration

Less Deposition

Negative Offset

Less Penetration More Deposition

percent

DC Offset

OPERATION

B-5

CHANGING AND SETTING WELD MODES

To select a weld m ode, press the WELD MODE SELECTOR button until the WELD MODE indicator comes ON (it may already be lit by default at power up). Turn the control knob to select the desired mode. After about 1 second, the parameters for the new mode will be displayed. These parameters can be adjusted with the control knobs below each display.

NOTE: CC Modes will show AMPS in the upper left

display. CV Modes will show wire feed speed and the WFS indicator will be lit.

BALANCE ADJUST

Pres s the WELD MO D E sele c t o r until the MSP Display reads “Balance”. If the selected mode allows for balance adjustment, the Control Knob can be used to select the desired wave balance through a range of 25% to 75%.

FREQUENCY/BALANCE CONTROL

FREQUENCY ADJUST

Press the WELD MODE selector until the FREQUENCY/BALANCE indicator comes ON and the MSP Display reads “Frequency”. If the selected mode allows for frequency adjustment, the Control Knob can be used to select the desired frequency between 20 and 100hz.

Adjusting the Balance (the ratio between Positive and Negative half cycle ‘on time’) changes the deposition for more efficient welding.

OFFSET ADJUST

Pres s the WELD MO D E sele c t o r until the MSP Display reads “Offset”. If the selected mode allows for offset adjustment, the Control Knob can be used to select the desired offset. The amount of offset allowed is determined by the selected weld mode.

Frequency adjustment can be used to fine tune stability of imbalanced waveforms and multiple arc system.

Independent control of the Positive and Negative cycles allows for more precise control of penetration and deposition.

MAXsa™ 10 CONTROLLER

B-6

OPERATION

B-6

WELD MODE SEARCHING

The Weld Mode Search feature allows the selection of a welding mode based on certain criteria (wire size, process type, etc.).

SEARCHING FOR A WELD MODE

To search for a mode, press and release the control knob while the WELD MODE indicator is lit. Another way to search for a mode is to turn the control knob until “W eld Mode Sear ch” is displayed. This will appear in between the highest and the lowest weld mode number.

Once “Weld Mode Search” is displayed, pressing the right pushbutton labeled “Begin” will start the search process.

During the search process, pressing the right pushbutton typically acts as a “next” button and the left pushbutton typically acts as a “back” button. Pressing the control knob also acts as a “next” button.

MULTIPLE ARC CONFIGURATION

Power Wave®AC/DC 1000 SD / MAXsa™ systems can be used in multiple arc set ups with up to six arcs. To minimize magnetic interaction between the arcs, it is imperative that they be phased correctly. Phasing is essentially a time offset between the waveforms of different arcs. The phase of each arc is set via the User Interface of the lead arc.

The ideal situation is to have adjacent arcs 90° offset as illustrated in table B.1.

TABLE B.1 - PHASE RELATIONSHIP

ARC 1 ARC 2 ARC 3 ARC 4 ARC 5 ARC 6

2 Arc

System

3 Arc

System

4 Arc

System

5 Arc

System

6 Arc

System

0° 90° X X X X

0° 90° 180° X X X

0° 90° 180° 270° X X

0° 90° 180° 270° 0° X

0° 90° 180° 270° 0° 90°

Rotate the control knob then press to select relevant welding details such as welding process, wire type, wire size, etc.

When the final selection is made, the MAXsa™ 10 will automatically change to the weld mode found by the Weld Mode Search process.

Earlier products may not have this feature. To activate this feature, a software update may be needed from www.powerwavesoftware.com

See the Power Wave

AC/DC Operator’s Manual for more information regarding the configuration of multiple arc systems.

MAXsa™ 10 CONTROLLER

B-7

Output

Strike

Upslope

eld

Downslope

Time

Arc Start

Delay

Start

Crater

Burnback

Start

Pressed

ire Be

to Feed

re T

che

End of Start

Timer

End of

Upslope

p Button

ssed

End of

Downslope

End of

Crater

Timer

End of

Burnback

OFF

Arc Delay Time

OPERATION

FGIURE B.6 - WELD SEQUENCE

B-7

WELD SEQUENCE

The weld sequence defines the weld procedure from beginning to end. All adjustments are made through

the user interface.

START OPTIONS

The delay, strike, start and upslope parameters are used at the beginning of the weld sequence to establish a stable arc and provide a smooth transition to the welding parameters. They are described in the following:

• ARC DELAY inhibits the wire feed for up to 5 seconds to prov i d e an accurate weld st a r t point. Typically used in multi-arc systems.

• STRIKE settings are valid from the beginning of the sequence (Start) until the arc is established. They control run-in (speed at which the wire approaches the workpiece) and provide the power to establish the arc. Typically output levels are increased, and WFS is reduced during the strike portion of the weld sequence.

• START values allow the arc to become stabilized once it is established. Extended start times or improperly set parameters can result in poor starting.

• UPSLOPE TIME determines the amount of time it takes to ramp from the start parameters to the weld parameters. The transition is linear and may be up or down depending on the relationship between the start and weld settings.

MAXsa™ 10 CONTROLLER

START OPTIONS OPERATION

Pressing the Arc Start/End Options pushbutton will illuminate the START OPTIONS LED and the Arc Delay Time parameter will show on the MSP Display.

Use the Mode Select Panel Control to select the desired delay time. Press the Weld Mode Selector to exit the Start parameters.

Repeated pressing of the Arc Start/End Options pushbutton will scroll through the parameters. Turning the Mode Select Panel Control, while on a parameter will change its value.

When a Start Option is set to a value other than OFF, the START OPTIONS LED will blink synchronous with the WFS or Amps and/or the volts LED located on the Dual Display Panel prompting the user to enter these parameters. The parameters that can be set by the user in the START OPTIONS will be as follows:

ARC DELAY TIME STRIKE WFS STRIKE TIME START WFS/AMPS START VOLTS START TIME UPSLOPE TIME

B-8

OFF

Downslope Time

OPERATION

B-8

END OPTIONS

The downslope, crater, and burnback parameters are used to define the end of the weld sequence. The are defined in the following:

• DOWNSLOPE determines the amount of time it takes to ramp from the weld parameters to the crater parameters. The transition is linear and may be up or down depending on the relationship between the weld and crater settings.

• CRATER parameters are typically used to fill the crater at the end of the weld and include both time and output settings.

• BURNBACK defines the amount of time the output remains on after the wire has stopped. This feature is used to prevent the wire from sticking in the weld puddle and to condition the end of the wire for the next weld. A burnback time of 0.4 second is sufficient in most applications.

• RESTRIKE TIME determines how long the system will try to re-establish the arc in the event of a poor start or if the arc goes out for any reason (short circuit or open circuit). During restrike, the WFS and outputs are driven in an attempt to re-establish the arc.

Repeated pressing of the Arc Start/End Options pushbutton will toggle through the parameters. Turning the Mode Select Panel Control while on a parameter will change its value. When the Crater Time is set to a value other than OFF, the END OPTIONS LED will blink synch r o n ou s wi t h th e WF S or Amps LED (depending on CC or CV Weld Modes) and with the Volts LED located on the Dual Display Panel prompting the user to enter these parameters. The parameters that can be set by the user in the END OPTIONS will be as follows:

DOWNSLOPE TIME CRATER WFS/AMPS CRATER VOLTS CRATER TIME BURNBACK TIME RESTRIKE TIME

• A restrike time of 1 to 2 seconds is sufficient in most applications.

• A r e s trike ti m e of 0 seconds a l l ows th e restrike function to continue indefinitely.

END OPTIONS OPERATION

Pressing the Arc Start/End Options pushbutton after scrolling through the Start Options will illuminate the END OPTIONS LED and the Downslope Time parameter will show on the MSP Display.

Use the Mode Select Panel Control to select the desired delay time. Press the Weld Mode Selector to exit the End parameters.

MAXsa™ 10 CONTROLLER

B-9

P. 0

Exit

User Prefs

Setup Menu

Indicator

Mode Select

Panel (MSP)

Left Button

Control Knob

Right Button

The Setup Menu provides access for configuring user preferences, which are generally only set at installation. The user preferences are grouped as shown in the following table.

OPERATION

SETUP MENU FEATURES

B-9

PARAMETER

P.1 through P.99 P.101 through P.199 P.501 through P.599

ACCESSING THE SETUP MENU

1. ACCESS

To access the Setup Menu, Press the Left Button and Right Bu t t on si mu l t an e o us l y . Th e Se t up Me nu Indicator will light and the lower display will read as shown below.

Note: The Setup Menu cannot be accessed during welding, or if a fault is displayed. To resume welding,

exit the Setup Menu.

2. PREFERENCE SELECTION

Scroll through the Prefer ence list by rotating the Control Knob. Press the Right Button to edit the select-

ed preference.

Secured Parameters (only accessible with Weld Manager)

DEFINITION

Unsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)

3. PREFERENCE CHANGE

Scroll through the preference options by rotating the Control Knob. Change the preference setting by press-

ing the Right Button. To cancel, press the Left Button.

4. EXIT

To exit the Setup Menu, press both buttons simultaneously or select P.0 and press the Left Button. Sixty seconds of inactivity will automatically exit the Setup Menu.

Note: If a product is missing any of the preference options listed below, a software update may be needed from www.powerwavesoftware.com.

FIGURE B.7 - SETUP MENU

MAXsa™ 10 CONTROLLER

B-10

OPERATION

USER DEFINED PARAMETERS

Parameter Definition

Exit Setup Menu

P.0 This option is used to exit the setup menu. When P.0 is displayed, press the Left Button to exit

the setup menu

P.1 Wire Feed Speed Units

This option selects which units to use for displaying wire feed speed. English = inches/minute wire feed speed units (default). Metric = meters/minute wire feed speed units.

P.2 Arc Display Mode

This option selects what value will be shown on the upper left display while welding. Amps = The left display shows Amperage while welding (default). WFS = The left display shows Wire Feed Speed while welding.

P.3 Display Energy

This option selects whether or not energy is shown on the lower display while welding. The total energy from the previous weld will persist on the lower display until another weld is started, or a user interface control is changed. This option will only show up in the list if the power source is capable of calculating energy (a power source firmware update may be necessary).

No = Energy will not be displayed (default). Yes = Energy is displayed.

B-10

P.12 Travel Carriage Start/Stop - Travel Starts

This option allows the adjustment of the start and end travel options for a travel carriage. Press the Right Button to enter the option and rotate the Control Knob to select either starting or ending options. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired function. After selecting the function, press the Left Button to save the function and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this option.

P.12 Travel Carriage Start/Stop - Travel Ends

P.13 Arc Force Adjustment Options

This option allows the adjustment of Arc Force values for Start, Weld and Crater. Press the right Mode Select Button to enter the option and rotate the Set knob to select the desired weld state to adjust. Press the right button again to adjust the value on the upper left knob. Press the left button to save the value and back out to select another weld state. Rotate the Set knob to make another selection, or press the left button to exit this option. P.13 will not appear if the presently selected weld mode does not support Arc Force.

P.14 Reset Consumable Weight

Use this option to reset the initial weight of the consumable package. Press the Right Button to reset the consumable weight. This option will only appear with systems using Production Monitoring.

MAXsa™ 10 CONTROLLER

B-11

OPERATION

USER DEFINED PARAMETERS (CONT.)

Parameter Definition

P.15 Hot-Inch Touch Sense Option

This option allows enabling or disabling touch sense when feeding wire forward. Disabled = Touch sensing is disabled when feeding the wire forward (default). Enabled = Touch sensing is active when feeding the wire forward.

When enabled and feeding wire forward, the wire is electrically "hot" and waiting to short to the plate. When a short occurs, the wire feed automatically stops and the flux hopper relay is activated until the feed forward button is released.

P.18 Wire Drive Gear Ratio

This option selects the Wire Drive Gear Ratio that will be used. This applies to the Cruiser dX Tractor and MAXsa 10 only. The possible selectable values are read from the Wire Drive on startup.

Note: Changing this value will cause the system to reset.

P.21 Shutdown 2 Function Select

This option allows selection of the Shutdown 2 input function on the control box. Normal Shutdown = The Shutdown 2 input functions as a standard shutdown input that locks out all input buttons (default) Output Disable = The Shutdown 2 input functions as a machine output lockout to disable the welding circuit but still allow cold feeding of the wire.

B-11

P.23 Trigger Fan-Out

For Sub-Arc Lead Arc machines only. Allows the Lead Arc MAXsa10 to control all machine triggers in a multi-arc system.

No = Only the machine connected to the MAXsa10 can be triggered on and off (default). Yes = All machines in the system can be triggered on and off simultaneously.

P.30 Input Control

This option allows the front panel controls of the MAXsa 10 to be enabled/disabled. The remote inputs are always functional when connected, but there may be applications where it is necessary to disable the inputs on the pendent. Panel & Remote = All pendent buttons are enabled (default). Panel Locked = The Start, Flux and feed buttons are disabled at the pendent. The pendent's Stop button is always active and cannot be disabled.

P.80 Sense From Studs

Use this option for diagnostic purposes only. When power is cycled, this option is automatically reset to False. False = Voltage sensing is automatically determined by the selected weld mode and othermachine settings (default).

True = Voltage sensing is forced to "studs".

P.99 Show Test Modes?

Most power sources contain weld modes used for calibration and test purposes. By default, the machine does not include test weld modes in the list of weld modes that are available to the operator. To manually select a test weld mode, set this option to "Yes". When the power source is turned off and back on again, the test modes will no longer appear in the mode list. Test weld modes typically require the machine output to be connected to a grid load and cannot be used for welding.

P.100 View Diagnostics?

Diagnostics are only used for servicing or troubleshooting the Power Wave system. Select "Yes" to access the diagnostic options in the menu. Additional parameters will now appear in the setup menu (P.101, P.102, etc).

MAXsa™ 10 CONTROLLER

B-12

OPERATION

USER DEFINED PARAMETERS (CONT.)

Parameter Definition

P.101 View Event Logs

Used for viewing all the system event logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired event log to read. Press the Right Button again to enter the selected log. Rotating the Control Knob will scroll through the event log, displaying the log index number, event code and some other data. Press the Left Button to back out to select another log. Press the Left Button again to exit this option.

P.102 View Fatal Logs

Used for viewing all the system fatal logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired fatal log to read. Press the Right Button again to enter that log. Rotating the Control Knob will scroll through the log, displaying the log index number and fatal code. Press the Left Button to back out to select another log. Press the Left Button again to exit this option.

P.103 View Software Version Information

Used for viewing the software versions for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the firmware version. Press the Left Button to back out to select another board. Rotate the Control Knob to select another board, or press the Left Button to exit this option.

B-12

P.104 View Hardware Version Information

Used for viewing the hardware version for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the hardware version. Press the Left Button to back out to select another board. Press the Left Button again to exit this option.

P.105 View Welding Software Information

Used for viewing the Weld Set in the Power Source. Press the Right Button to read the Weld Set version. Press the Left Button to back out and exit this option.

P.106 View Ethernet IP Address

Used for viewing the IP address of Ethernet compatible equipment. Press the Right Button to read the IP Address. Press the Left Button to back out and exit this option. The IP address cannot be changed using this option.

P.107 View Power Source Protocol

Used for viewing the type of power source the feeder is connected to. Press the Right Button to identify the power source as either LincNet or ArcLink. Press the Left Button to back out and exit this option.

P.501 Encoder Lockout

Locks one or both of the upper knobs (encoders), preventing the operator from changing wire feed speed, amps, volts or trim. The function of each upper knob depends on the selected weld mode. When a constant current weld mode is selected (e.g. Stick, TIG, Gouge), the upper right knob will always function as an on/off switch. This parameter can only be accessed using Power Wave.

MAXsa™ 10 CONTROLLER

B-13

OPERATION

USER DEFINED PARAMETERS (CONT.)

Parameter Definition

P.502 Memory Change Lockout

Determines if the memories can be overwritten with new contents.

No = Memories can be saved and limits can be configured (default). Yes = Memories cannot be changed - saving is prohibited and limits cannot be re-configured.

This parameter can only be accessed using Power Wave Manager software.

P.503 Memory Button Disable

Disables the specified memory button(s). When a memory is disabled, welding procedures cannot be restored from or saved to that memory. If an attempt is made to save or restore a disabled memory, a message will be displayed on the lower display indicating the memory number is disabled. In multi-head systems, this parameter disables the same memory buttons on both feed heads. This parameter can only be accessed using Power Wave Manager software.

P.504 Mode Select Panel Lock

Selects between several Mode Select Panel lockout preferences. When a Mode Select Panel selection is locked and an attempt is made to change that parameter, a message will be displayed on the lower display indicating the parameter is locked. All MSP Options Unlocked = All adjustable parameters on the Mode Select Panel are unlocked.

All MSP Options Locked = All knobs and buttons on the Mode Select Panel are locked. Start & End Options Locked = The Start and End parameters on the Mode Select Panel are

locked, all others are unlocked. Weld Mode Option Locked = The weld mode cannot be changed from the Mode Select Panel, all others Mode Select Panel settings are unlocked. Wave Control Options Locked = The Wave Control parameters on the Mode Select Panel are locked, all others are unlocked. Start, End, Wave Options Locked = The Start, End and Wave Control parameters on the Mode. Select Panel are locked, all others are unlocked. Start, End, Mode Options Locked = The Start, End and Weld Mode Select parameters on the Mode. Select Panel are locked, all others are unlocked. This parameter can only be accessed using Power Wave Manager software.

B-13

P.505 Setup Menu Lock

Determines if the setup parameters can be modified by the operator without entering a passcode. No = The operator can change any set menu parameter without first entering the passcode even if the passcode is non-zero (default). Yes = The operator must enter the passcode (if the passcode is non-zero) in order to change any setup menu parameters. This parameter can only be accessed using Power Wave Manager software.

MAXsa™ 10 CONTROLLER

B-14

OPERATION

USER DEFINED PARAMETERS (CONT.)

Parameter Definition

P.506 Set User Interface Passcode

Prevents unauthorized changes to the equipment. The default passcode is zero which allows full access. A nonzero passcode will prevent unauthorized: changes to memory limits, saving to memory (if P.502 = Yes), changes to setup parameters (if P.505 = Yes). This parameter can only be accessed using Power Wave Manager software.

P.509 UI Master Lockout

Locks all user interface controls, preventing the operator from making any changes. This parameter can only be accessed using Power Wave Manager software.

TOUCH SENSE

The Touch Sense option, when enabled, allows the operator to feed the wire forward until it touches the workpiece. When contact to the work is made, the wire will stop and the flux hopper (if used) will activate to put flux around the wire and fill the flux feed system. The flux hopper will stay active until the Feed Forward button is released.

B-14

WARNING

If the Touch Sense is enabled the Power Source output is ON as long as the Feed Forward button is held. Avoid touching any portion of the weld circuit while feeding down.

If the Touch Sense option is disabled, the wire is “cold” during the Feed Forward time. It will not stop when it touches the work and the flux hopper will not activate.

LOCKOUT / SECURITY

The MAXsa™ 10 can be configured to prevent the operator from changing selected User Interface panel controls. By default, the welder will be able to change the weld mode, all relevant wave controls and all relevant start and end options.

Note that when an option is locked, its value can still be monitored. For example, if start and end options are locked, the welder can still press the right Mode Select Panel Pushbutton and see the value set for Start Time. If the welder attempts to change its value, a message will briefly appear on the Mode Select Panel indicating "MSP Option is LOCKED

The lockout features are only available through the use of Power Wave Manager.

MAXsa™ 10 CONTROLLER

B-15

200

Steel 1/8”

CC DC

30.5

START

BUTTON

STOP

BUTTON

ARC ESTABLISHED

INDICATOR

OPERATION

MAKING A WELD

Once the necessary parameters have been set and the desired Weld Mode selected:

B-15

Press the START BUTTON to begin welding.

The ARC ESTABLISHED INDICATOR will ‘flash’ as the wire feeds towards the work piece to show that OCV is present and switch to ON when the arc is lit.

If “Start” parameters have been set they will be in effect for the specified time and then the Weld Mode parameters will take effect.

The two upper displays will indicate the “actual” parameters as the weld progresses.

If the TRAVEL function is selected it will begin moving as prescribed in the P.12 Parameter setting.

FIGURE B.7 - MAKING A WELD

Press the STOP BUTTON to end the weld.

If “End” parameters have been set, they will take effect for the specified time.

If the TRAVEL function is selected it will stop moving as prescribed in the P.12 Parameter setting.

The ARC ESTABLISHED INDICATOR will go OFF when the power source output is disabled (after Burnback).

The displays will return to the idle state in preparation for the next weld.

MAXsa™ 10 CONTROLLER

B-16

OPERATION

USING THE MEMORY OPTION

B-16

The MAXsa™ 10 has eight available memory locations for storing procedural information. Each location will store the following information:

• Weld Mode

• Amperage(or WFS)

• Voltage

• Frequency

• Balance

• DC Offset

• Arc Start options

• Arc End Options

NAMING A SAVED PROCEDURE

Procedures stored in memory can be given a name that the user will easily recognize such as “Root Pass”‘ “Fill Pass” or “Cap Pass’. As with the Lockout Option. this option is only available through the use of Weld Manager.

MULTI PROCEDURE WELDING

The MAXsa™ 10 CONTROLLER can do “On-The-Fly” welding changes with multiple weld procedures by using the Memory Panel. While welding, any Memory location can be accessed, and the parameters stored in that memory location will be switched in while actively welding.

NOTE: This can only be done with Memory loca-

tions that have the same Weld Mode.

While welding, any Memory location trying to be accessed with a different Weld Mode than the one currently being used will be ignored and an error message will be displayed. Up to eight different weld procedures can be used while actively welding by using all of the memory locations, as long as each location utilizes the same Weld Modes.

Memory saving can be optionally disabled using Lockout Levels. If the user attempts to save a procedure to memory location that is locked, the Mode Select Panel will briefly display "Memory Save is DISABLED!". Presently, Memory Panel Lockout Levels can only be accessed through Weld Manager.

MAXsa™ 10 CONTROLLER

B-17

200

Steel 1/8”

CC DC

30.5

MEMORY

BUTTON

LED

INDICATOR

MSP

DISPLAY

Hold for 2 Seconds

to Save

Press and Release

to Recall

Memory 1 Saved

OPERATION

B-17

SAVING A PROCEDURE TO A MEMORY LOCATION

Once the parameters have been set:

• Press an d Hol d the Me m o ry Button o f the

desired location for 2 seconds.

• The LED for that location will come ON.

• After 2 seconds the LED will go OFF

• The MSP display will show briefly that the information is saved, then return to the Weld Mode.

NOTE: Holding the button for longer than 5 sec-

onds will enter the Limits Mode.

FIGURE B.8 - MEMORY

RECALLING A PROCEDURE FROM A MEMORY LOCATION

• Press and release the desired Memory Button.

• The LED for that location will come ON and the stored procedure information will show in the displays.

• The LED will remain ON until another location is selected

NOTE: Holding the button for longer than 1 sec-

ond will re-enter the “Save” Mode.

MAXsa™ 10 CONTROLLER

B-18

Memory 1

Set Limits

200

Hi=1050 Lo= 200

Weld Amps

Set High

Limit

alue

ow Limit

Set Low

Limit

Parameter

ame

Save Limits

Yes No

OPERATION

OPTIONAL LIMIT SETUP

The Limits feature allows the operator to set minimum and maximum values for various parameters depending on the Weld Mode selected.

Each memory location may have a different set of limits, even if the Weld Mode is the same. For example: Memory Location 1 can be set for a maximum wire feed speed of 140”/min; Memory Location 2 may be set for a minimum of 100”/min and a maximum of 160”/min and Memory Location 3 may have no WFS limit set.

Parameters are constrained by the machine limitations or by memory limits. When the Memory Limits are enabled the parameter will flash if an attempt is made to set a value outside of the prescribed limit (if less than the machine capabilities). The parameter will not flash if an attempt is made to exceed the machine limits.

NOTE: Weld Modes cannot be selected through the

Limits Setup Menu. They must be chosen and saved before entering the Limits Menu.

SETTING LIMITS

1. Press and hold the desired Memory Button until

the LED for that location begins to blink rapidly.

• The MSP Display will read:

B-18

3. The Parameter Name on the MSP Display will flash to indicate it is ready to be changed. If no limits were previously set, the High and Low values are the limits of the Power Source

• Press the Arc Start/End Options button to select

that parameter.

• Use the Mode Select Panel Control to adjust the

High Limit (flashing).

• Press the Arc Start/End Options button.

• Use the Mode Select Panel Control to adjust the

Value (flashing).

• Press the Arc Start/End Options button.

• Use the Mode Select Panel Control to adjust the

Low Limit (flashing).

• Press the Arc Start/End Options button.

• Use the Mode Select Panel Control to select

another Parameter Name (flashing) and repeat the above sequence until all Limits are set.

2. After 2 seconds the display will change to show the following items:

• Memory Value

• High Limit

• Low Limit

• Parameter Name

4. Press the selected Memory when all limits are set to desired values. The MSP Display will read:

• Use the Weld Mode Select or the Arc Start/End Options button to either save (yes) or discard (no) the changes.

MAXsa™ 10 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 ‘Enter’ on the keyboard).

3. On the Results page, scroll down to the Equipment list and click on E9.181.

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

C-1

MAXsa™ 10 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, control cables and gas hoses for cuts.

PERIODIC MAINTENANCE

• N/A

CALIBRATION SPECIFICATION

All calibration is factory set on the MAXsa™ 10 CONTROLLER.

See add it iona l wa rnin g in form atio n

throughout this operator’s manual and the Engine manual as well.

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

MAXsa™ 10 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 provi des a co urse 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.

MAXs™ 10 CONTROLLER

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The MAXsa 10 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 LED’s, and some basic troubleshooting charts for both machine and weld performance.

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

TABLE E.1

Light

Condition

Meaning

E-2

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

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® i400 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 Diagnostics Utility (included on the POWER WAVE® Utilities and Service Navigator CD’s 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 Diagnostics Utility (included on the POWER WAVE ® U til ities and Service Navigator CD’s or availab le at www.powerwavesoftware.com). This is the preferred method, since it can access historical information contained in the error log.

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

Steady Red

Blinking Red

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™ 10 CONTROLLER

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

ARCLINK SYSTEM ERROR CODES

Err 31 Primary overcurrent

TROUBLESHOOTING

POSSIBLE

CAUSE

1. The power source has exceeded input current limits. Adjust the welding procedure to reduce the current draw. The welding procedure may exceed the capacity of the power source.

2. See the power source Instruction Manual.

E-3

RECOMMENDED

COURSE OF ACTION

Err 32 Capacitor bank "A" under

voltage.

Err 33 Capacitor bank "B" under

voltage.

Err 34 Capacitor bank "A" overvolt-

age.

1. The power source input power may be wired incorrectly. Verify the pow e r s ou r c e r e co n n ec t panel wiring matches the input power.

2. See the power source Instruction Manual.

1. The power source input power may be wired incorrectly. Verify the power source reconnect panel wiring matches the input power.

2. See the power source Instruction Manual.

1. The power source input power may be wired incorrectly. Verify the pow e r s ou r c e r e co n n ec t panel wiring matches the input power.

2. See the power source Instruction Manual.

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™ 10 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 35 Capacitor bank "B" overvolt-

age.

Err 36 Thermal

Err 41 Long term secondary over-

current.

Err 43 Capacitors are out of bal-

ance

1. The power source input power may be wired incorrectly. Verify the pow e r so u r ce re c on n e ct panel wiring matches the input power.

2. See the power source Instruction Manual.

1. Power source overheating. Verify

duty cycle is correct. Ensure adequate a i r fl o w a r ou n d p ow e r source.

1. The power source has exceeded

the output current limits. Adjust the welding procedure to reduce the current draw. The welding proced u r e may e xc e e d the capacity of the power source.

2. See the power source Instruction

Manual.

1. Verify the power source recon-

nect panel wiring matches the input power.

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

2. See the power source Instruction Manual.

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™ 10 CONTROLLER

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

PROBLEMS

(SYMPTOMS)

ARCLINK SYSTEM ERROR CODES

Err 44 Main CPU problem.

Err 53 Voltage sense loss.

Err 54 Short term secondary over-

current.

Err 81 Motor overload, long term.

POSSIBLE

CAUSE

1. Verify the earth ground connection to the power source is wired correctly.

2. See the power source Instruction

Manual.

1. Verify correct sense lead connection.

1. The wire drive motor has overheated. Check that the electrode slides easily through the gun and cable.

2. Remove tight bends from the gun and cable.

3. Check that the spindle 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 bee n e x c e ed e d . Typically indicates mechanical overload of system. If problem continues consider higher torque gear ratio (lower speed range).

RECOMMENDED

COURSE OF ACTION

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

Err 82 Motor overload, short term.

1. The wire drive motor current draw has exceeded limit s , us u a l ly 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.

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™ 10 CONTROLLER

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

ARCLINK SYSTEM ERROR CODES

Err 263 No usable weld modes. 1. The power source does not have

Below are errors implemented for the MAXsa™ 10.

TROUBLESHOOTING

POSSIBLE

CAUSE

any welding programs loaded.

2. See the power source Instruction Manual fo r load we l d in g programs.

E-6

RECOMMENDED

COURSE OF ACTION

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

Error Code

N/A

Typical User Interface 3 digit error codes (not blinked on the status LED).

Error Code

213

215

247

274 275

276

277

278

281

282

Source

User Interface

Feeder

Source

User Interface

“OUTPUT DISABLED”

Feeder Board is Off-Line

UI Text

" Limits Exceed "

"Gear Box Type"

" UI Shutdown 1 "

" UI Shutdown 2 "

UI Text

Power Source

is Off-Line

N/A

N/A N/A

N/A

(Varies based on the

error type and who

caused the error)

(Varies based on the

error type and who

caused the error)

When a mode is selected with a work point low limit

greater than the high WFS limit. (no event is logged)

The shutdown 2 input on the Feeder Board is open and

P.21 is selected for “Output Disable”

The shutdown 1 input on the Feeder Board is open.

The shutdown 2 input on the Feeder Board is open.

User Interface could not communicate with control board

in power source.

Either no feed head board is connected, being repro-

grammed or experiencing a fatal event.

Arc control has a latched fault. The UI will indicate a

Reset button needs to be pressed to clear the fault. Weld set change required clearing of user memory.

UI memory could not be saved. Contact Lincoln Electric

Service Department for further support.

UI memory could not be restored. Contact Lincoln

Electric Service Department for further support.

UI memories were converted due to change in number of

UI parameters. Info only.

UI limits were converted due to change in number of UI

parameters with limits. Info only.

Internal Error. Collect all displayed values and contact

Lincoln Electric Service Department.

Internal Error. Collect all displayed values and contact

Lincoln Electric Service Department.

Reason

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™ 10 CONTROLLER

E-7

Typical User Interface 3 digit error codes (not blinked on the status LED).

TROUBLESHOOTING

E-7

Error Code

283

285

612

Source

User Interface

Observe all Safety Guidelines detailed throughout this manual

(Varies based on the

error type and who

caused the error)

{" Phase Gen Init "},

{"Duplicate Arc # "}, {" Mult Lead Arcs "}, {" Missing an Arc "},

{" Too Many Arcs "},

{"Missing Lead Arc"},

{" Missing an Arc "}

PROBLEMS

(SYMPTOMS)

OUTPUT PROBLEMS

The feeder does not power up - no display, no feed.

UI Text

Internal Error. Collect all displayed values and contact

Lincoln Electric Service Department.

N/A

UI memory could not be restored. Contact Lincoln

Electric Service Department for further support.

1 = Initializing Phase Generator

7 = Trail Arc dropped communication with Lead Arc

POSSIBLE

CAUSE

1. The Power Wave power source is OFF. Turn ON the Power Wave source.

Reason

2 = Duplicate Arc #'s found

3 = Mult Lead Arcs found

4 = Missing a Trail Arc

5 = Too Many Arcs

6 = Missing Lead Arc

RECOMMENDED

COURSE OF ACTION

2. The circuit breaker for the wire feeder on power source ha s tripped. Reset the circuit breakers.

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

4. The power switch is damaged. Replace the power switch.

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™ 10 CONTROLLER

E-8

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

OUTPUT PROBLEMS

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

TROUBLESHOOTING

POSSIBLE

CAUSE

1. The electrode is rusty or dirty. Use only clean electrode. Use quality electrode, like L-50 or L-56 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".

E-8

RECOMMENDED

COURSE OF ACTION

Wire feed speed consistently operates at the wrong value.

Variable or "hunting" arc.

5. Worn dr i v e roll. Replace the

drive rolls if worn or filled with dirt.

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

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 recomm e n d ed pr o c edure. Verify DIP sw i tc h #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™ 10 CONTROLLER

F-1

Enhanced Diagram

DIAGRAMS

F-1

MAXsa™ 10 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

5.89 .20

11.30

13.25

12.25

11.68

O .66

O .28

14.40

.87

7.75

8.90

7.07

1.641.50

SCALE = 1 : 4

PENDANT

L13444

DIMENSION PRINT

F-2

MAXsa™ 10 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 electro-

dos 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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric IM10023 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual