Lincoln Electric IM10126 User Manual

Operator’s Manual
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MAXsa™ 19 MSA
For use with machines having Code Numbers:
11886
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
© Lincoln Global, Inc. All Rights Reserved.
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you
act and be careful.
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.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use
corrective lenses if necessary to stay a reasonable distance away from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your
face.
If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate (See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.
PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
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.
SAFETY
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
1.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.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is
hot.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
FOR ENGINE POWERED EQUIPMENT.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
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.
3
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 clothing. Wear dry, 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 must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage
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.
between the
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 welding
with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
4
cause
SAFETY
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 the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER MAY EXPLODE IF DAMAGED.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected to physical damage.
A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
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.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety Interactive Web Guide for mobile devices
5
vi
TABLE OF CONTENTS
Page
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Installation.......................................................................................................................Section A
Technical Specifications................................................................................................A-1
Safety Precautions ........................................................................................................A-2
Welding Voltage, Mechanical Hazards .........................................................................A-2
Location and Mounting..................................................................................................A-2
High Frequency Protection............................................................................................A-2
Component Description.................................................................................................A-3
Interfacing to the MAXsa™ 19 MSA .............................................................................A-4
Connection Diagrams................................................................................................A-4
Status Light ...............................................................................................................A-5
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Design Features ...................................................................................................................B-1
Common Welding Abbreviations...................................................................................B-1
Product Description.......................................................................................................B-2
Recommended Processes and Equipment...................................................................B-2
_______________________________________________________________________________
Accessories .....................................................................................................Section C
General Options / Accessories..............................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine ..................................................................................................................D-1
Periodic..................................................................................................................D-1
Calibration Specification........................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-6
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print......................................................................................................F-2
________________________________________________________________________
Parts Lists...............................................................................................................P-703
________________________________________________________________________
vi
MAXsa™ 19 MSA
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS: MAXsa™ 19 MSA
A-1
INPUT VOLTAGE & CURRENT
Model Voltage* Input Amps* Height Width Depth Weight Operating Storage
K3172-1
* When not driving a motor.
40VDC 1.0 8.8 in. 10.38 in 3.12 in. 7 Lbs 14°F to 104°F -40°F to 185°F
(224 mm) (264 mm) (80 mm) (3.2 Kg.) (-10°C to 40°C)
PHYSICAL SIZE• TEMPERATURE RATING
Dimensions
(
-40°C to 85°C)
IP 23
MAXsa™ 19 MSA
A-2
INSTALLATION
A-2
SAFETY PRECAUTION
WARNING
ELECTRIC SHOCK can kill.
• Only a qualified electrician should connect the MAXsa™ 19 MSA. Installation should be made in accordance with the appropriate National Electrical Code, the local codes and the information in this manual.
• Turn off the input power to the power source at the disconnect switch or fuse box before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
----------------------------------------------------------------------------------------
WELDING VOLTAGE
Wire feed parts are electrically live while welding and while feeding wire (with Touch Sense feature select­ed). The electrically live parts are listed below:
Electrode Electrode Reel Wire Drive Motor Drive Rolls Gear Box Cross-seam Adjuster Wire Straightener Welding Nozzle Welding Cables Welding Cable Terminal
CAUTION
• Do not touch electrically live parts or electrodes with your skin or wet cloth­ing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
MECHANICAL HAZARDS
• Welding fixture or wire feeder will move during welding or inching. Keep away from pinch points.
• Electrode reel and drive rolls turn during weld­ing or inching. Keep gloved hands away from areas that may catch the glove.
------------------------------------------------------------------------------------------
LOCATION AND MOUNTING
The MAXsa™ 19 MSA will operate in harsh environ­ments and can be used outdoors with an IP 23 rating. Even so, it is important that simple preventative mea­sures are followed in order to assure long life and reli­able operation. The MAXsa™ 19 MSA must be located where there is little risk of impacts to the Controller .
HIGH FREQUENCY PROTECTION
Locate the MAXsa™ 19 MSA away from radio con­trolled machinery. The normal operation of the MAXsa™ 19 MSA may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.
CONTROL CABLE CONNECTIONS
GENERAL GUIDELINES
These guidelines apply to all communications cables including optional DeviceNet and Ethernet connections.
Genuine Lincoln control cables should be used at all times (except as noted otherwise). Lincoln
cables are specifically designed for the communica­tion and power needs of the Power Wave/ MAXsa™ systems. Most are designed to be connected end to end for ease of operation.
Always use the shortest cable lengths possible. DO NOT coil excess cable. It is recommended that the total length of control cable does not exceed 100ʼ (30.5M). The use of non-standard cables in excess of 25ʼ (7.5M) can lead to communication problems (system shutdowns), poor motor accelera­tion (poor arc starting), and low wire driving force (wire feeding problems).
Best results will be obtained when the control
cables are routed separate from the weld cables.
This minimizes the possibility of interference between the high currents flowing through the weld cables and the low level signals in the control cables.
MAXsa™ 19 MSA
A-3
INSTALLATION
INTERFACING TO THE MAXsa™ 19 MSA
A-3
The MAXsa™ 19 MSA is a versatile controller designed to operate in a Power Wave
®
AC/DC 1000 SD system and is responsible for relaying wire feed commands to a MAXsa™ 29 Wire Drive. It is connect-
®
ed to the Power Wave
AC/DC 1000 SD by a K2683-xx ArcLink Cable and to the Wire Drive by a K1785-xx 14 Pin Control Cable.
FIGURE A.1 - CONNECTION DIAGRAM
K2803-1
POWERWAVE
AC/DC 1000 SD
M22383
BOTTOM EDGE
OF PLATE
2.00
.25
27°
5.00
2.00
2.00
K2683-XX
ARCLINK CABLE
K1785-XX
14-PIN CABLE
K1811-XX
SENSE LEAD
K2814-1
MAXsa 10
K3172-1
MAXsa 19 MSA
K2814-1
MAXsa 10
K1785-XX
14-PIN CABLE
67 Lead
K2683-XX
ARCLINK CABLE
K2803-1
POWERWAVE
AC/DC 1000 SD
K2803-1
POWERWAVE
AC/DC 1000 SD
N.A.
WORK
COPPER
BUS BAR
ELECTRODE
WELD CABLE
K148-XX
WORK WELD CABLE
CONTACT NOZZLE
WORK
TO MASTER CABLE, AND MA STER TO SLAVE CABLE IS
NOT TO EXCEED 200 FEET
K1811-XX
SENSE LEAD
NOTES:
N.A. 67 LEAD OF CENT ER TORCH NOT TO BE CONNECTED
N.C. THE MAX IMUM DISTANCE OF ARCLINK CABLE, M ASTER
MAXsa™ 19 MSA
A-4
External
I/O Connector
INSTALLATION
FIGURE A.2 - MAXsa™ 19 MSA COMPONENT DESCRIPTION
Status
A-4
14 Pin Connector
To Wire Drive
ArcLink Connector
To Power Source
COLD INCH SWITCH
Cold inch will feed @ MAXsa™ 10 speed.
STATUS LIGHT
The Status Light is a two color LED that indicates the system condition. Normal operation is steady green. Flashing green or red/green indicates a system error. See the Troubleshooting Section.
SELECTING A WIRE DRIVE AND GEAR RATIO
LED
The MAXsa™ 19 MSA can accommodate a number of wire drives including the MAXsa™ 22 and MAXsa™ 29. The feeder control system must be con­figured for both the wire drive and the gear ratio. This can be accomplished with the Weld Manager Utility. This utility is on the Power Wave Submerged Arc Utilities CD, or available at
www.powerwavesoftware.com.
MAXsa™ 19 MSA
B-1
ArcLink
ArcLink
SAFETY PRECAUTIONS
OPERATION
DESIGN FEATURES
B-1
Read this entire section of operating instructions before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
• Do not use AC welder if your cloth­ing, gloves or work area is damp or if working on, under or inside work­piece.
Use the following equipment:
-DC manual (stick) welder.
-AC welder with reduced voltage control.
• Do not operate with panels removed.
• Disconnect input power before ser­vicing.
---------------------------------------------------------------------
ONLY QUALIFIED PERSONS SHOULD INSTALL, USE OR SERVICE THIS EQUIPMENT. READ AND FOLLOW THE MANUFACTURERʼS INSTRUC­TIONS, EMPLOYERʼS SAFETY PRACTICES AND MATERIAL SAFETY DATA SHEETS (MSDS) FOR CONSUMABLES.
• Digital communications for accurate and reliable per­formance.
• PC boards are potted in epoxy for the ultimate in out­door protection.
• Connectors are filled with environmental protective grease.
• Designed for the Power Wave series of products for the best arc in the industry.
• Wire feed speed accuracy calibrated to within 2%.
®
AC/DC 1000 SD
COMMON WELDING ABBREVIATIONS
SAW
• Submerged Arc Welding
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
WIRE FEEDER
--------------------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF AND OTHERS.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc, or both,to keep fumes and gases from your breathing zone and gener­al area.
WELDING SPARKS can cause fire or explosion.
• Do not weld near flammable material.
• Do not weld on containers which have held flammable materia
ARC RAYS can burn.
• Wear eye, ear, and body protection.
-----------------------------------------------------------------------
MACHINE STATUS
INPUT CONNECTOR
OUTPUT CONNECTOR
MAXsa™ 19 MSA
B-2
PRODUCT DESCRIPTION
GENERAL PHYSICAL DESCRIPTION
OPERATION
B-2
The MAXsa™ 19 MSA is a versatile controller
®
designed to operate in a Power Wave
AC/DC 1000 SD system and is responsible for relaying wire feed commands to a MAXsa™ wire drive. It is connected to the Power Wave
®
AC/DC 1000 SD by a K2683-xx ArcLink cable and to the wire drive by a K1785-xx 14 pin control cable
RECOMMENDED PROCESSES AND EQUIPMENT
• The MAXsa™ 19 MSA is intended for modified series arc welding only with the Power Wave AC/DC 1000 SD, and the MAXsa™ Feed Head.
COMMON BASIC EQUIPMENT PACKAGES
Basic Package
• K2803-1 Power Wave
• K2312-2 MAXsa™ 29 Wire Drive
• K2626-2 MAXsa™ 19 MSA
®
AC/DC 1000 SD
®
• K2683-xx Control Cable (5 pin – 5 pin) - power
source to MAXsa™ 19 MSA, or MAXsa™ 19 MSA to MAXsa 10.
• K1785-xx Control Cable (14 pin – 14 pin) -
MAXsa™ 19 MSA to Wire Drive.
MAXsa™ 19 MSA
C-1
ACCESSORIES
OPTIONS AND ACCESSORIES are
available at www.lincolnelectric.com
Follow these steps:
1. Go to www.lincolnelectric.com
2. In the Search field type E9.181 and click on the Search icon (or hit ʻEnterʼ on the keyboard).
3. On the Results page, scroll down to Literature Request in the list and click on it.
4. On the Literature Request page scroll down to E9.181 and view or download the PDF file.
®
All of the information for the Power Wave accessories can be found in this document.
System and
C-1
MAXsa™ 19 MSA
D-1
MAINTENANCE
D-1
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as output terminals or internal wiring.
• When inching, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the inch button is released.
• Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes.
• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.
• Only qualified personnel should perform mainte­nance work.
ROUTINE MAINTENANCE
• Check weld cables and control cables for cuts.
PERIODIC MAINTENANCE
• N/A
CALIBRATION SPECIFICATION
All calibration is factory set on the MAXsa™ 19 MSA.
See additional warning information
throughout this operatorʼs manual and the Engine manual as well.
MAXsa™ 19 MSA
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAXsa™ 19 MSA
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS
The MAXsa™ 19 MSA is equipped with a Status Light. If a problem occurs it is important to note the condition of the status lights.
Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.
Included in this section is information about the power source and Wire Drive Module Status LEDʼs, and some basic troubleshooting charts for both machine and weld performance.
The STATUS LIGHTS are dual-color LEDʼs that indicate system errors. Normal operation for each is steady green. Error conditions are indicated in the following Table E.1.
TABLE E.1
E-2
Light
Condition
Steady Green
Blinking Green
Fast Blinking Green
Alternating Green and Red
Meaning
System OK. Power source is operational, and is communicating normally with all healthy peripheral equipment connected to its ArcLink network.
Occurs during power up or a system reset, and indicates the POWER WAVE is mapping (identifying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation.
Under normal conditions indicates Auto-mapping has failed. Also used by the Weld Manager Utility (included on the POWER WAVE Submerged Arc Utilities and Service Navigator CDʼs or available at www.pow­erwavesoftware.com) to identify the selected machine when connecting to a specific IP address.
Non-recoverable system fault. If the Status lights are flashing any combination of red and green, errors are present. Read the error code(s) before the
machine is turned off.
Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits are flashed in red with a long pause between digits. If more than one code is present, the codes will be separated by a green light. Only active error conditions will be accessible through the Status Light.
Error codes can also be retrieved with the Weld Manager Utility (included on the POWER WAVE available at www.powerwavesoftware.com). This is the preferred method, since it can access historical information contained in the error log.
®
Submerged Arc Utilities and Service Navigator CDʼs or
®
®
To clear the active error(s), turn power source off, and back on to reset.
Steady Red
Blinking Red
Not applicable.
Not applicable.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAXsa™ 19 MSA
E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
ARCLINK SYSTEM ERROR CODES
TROUBLESHOOTING
POSSIBLE
CAUSE
E-3
RECOMMENDED
COURSE OF ACTION
Err 81 Motor Overload (long
term)
Err 82 Motor overload, short
term.
1. The wire drive motor has over­heated. Check that the electrode slides easily through feed system.
2. Remove tight bends from the feed conduit
3. Check that the wire reel brake is not too tight.
4. Verify a high quality electrode is being used.
5. Wait for the error to reset and the motor to cool (approximately 1 minute).
6. Long term average motor current limit has been exceeded. Typically indicates mechanical overload of system. If problem continues consider higher torque gear ratio (lower speed range).
1. The wire drive motor current draw has exceeded limits, usually because the motor is in a locked rotor state. Check that motor can turn freely when idle arm is open.
2. Verify that the gears are free of debris and dirt.
3. Check items listed for long term overload (Err 81).
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAXsa™ 19 MSA
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 6311 Unstable or “noisy” wire
feed speed (WFS) feed­back signal.
1. Check the cables and connec­tions to the Wire Drive.
2. Check the Wire Drive control cable routing (see Control Cable Connection- General Guidelines).
3. Check the Tachometer Interface Board.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAXsa™ 19 MSA
E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
OUTPUT PROBLEMS
The feeder does power up but there is no wire feed.
TROUBLESHOOTING
POSSIBLE
CAUSE
1. The control cable may be loose or damaged. Tighten, repair or replace the control cable.
2. Check for the proper command information from the customer supplied user interface.
E-5
RECOMMENDED
COURSE OF ACTION
Inconsistent wire feeding or wire not feeding but drive rolls turning.
1. The electrode is rusty or dirty. Use only clean electrode. Use quality electrode, like L-50 or L­56 from Lincoln Electric.
2. The contact tip is partially melted or has spatter. Replace the con­tact tip.
3. Improper tip, drive rolls and/or inner wire guide. Verify the prop­er parts are installed.
4. Incorrect tension arm pressure on the drive rolls. Adjust the tension arm per the Instruction Manual. Most electrodes feed well at a tension arm setting of "3".
5. Worn drive roll. Replace the
drive rolls if worn or filled with dirt.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAXsa™ 19 MSA
E-6
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
OUTPUT PROBLEMS
Wire feed speed consistently oper­ates at the wrong value.
TROUBLESHOOTING
POSSIBLE
CAUSE
1. The wire feeder gear setting is not properly set. Verify that the software setting matches the gear mounted. See the Instruction Manual for setting the gear ratio.
E-6
RECOMMENDED
COURSE OF ACTION
Variable or "hunting" arc.
1. Wrong size, worn and/or melted contact tip. Replace the contact tip.
2. Worn work cable or poor work connection. Verify all work and electrode connections are tight and that the cables are in good condition. Clean/replace as nec­essary.
3. Wrong polarity. Adjust polarity to the recommended procedure. Verify DIP switch #7 setting matches the electrode polarity.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAXsa™ 19 MSA
F-1
DIAGRAMS
F-1
MAXsa™ 19 MSA
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
3.12
DIAGRAMS
7.83
F-2
L13500
.97
10.38
9.38
8.14
O .28
5.50
O .66
MAXsa™ 19 MSA
NOTES
MAXsa™ 19 MSA
NOTES
MAXsa™ 19 MSA
F-5
NOTES
F-5
MAXsa™ 19 MSA
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 vêtements
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 alimentación
de poder de la máquina antes de ini­ciar cualquier servicio.
Débranchez le courant avant l’entre-
tien.
Strom vor Wartungsarbeiten abschal-
ten! (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.
CUSTOMER ASSISTANCE POLICY
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.
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