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Lincoln Electric IM10023 manual

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Table of contents for the manual

  • Page 1

    • 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 • World's Leader in Welding and Cutting Products • M M A A X X s s a a ™ 1 1 0 0 C C O O N N T T R R O O L L L L E E R R OPERA T OR’S MANUAL IM10023 February, [...]

  • Page 2

    OPERA T OR’S MANUAL FOR ENGINE pow ered 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. _________________________[...]

  • Page 3

    ARC R A Y S can bur n. 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[...]

  • Page 4

    FOR ELECTRIC ALL Y pow ered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electri[...]

  • Page 5

    iv SAFETY iv PRÉC A UTIONS 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits[...]

  • Page 6

    v v Thank Y ou 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pa[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation ..................................................................[...]

  • Page 8

    A-1 INST ALLA TION MAXsa™ 10 CONTROLLER A-1 TECHNICAL SPECIFICA TIONS: MAXsa ™ 10 CONTROLLER INPUT VOLTAGE & CURRENT PHYSICAL SIZE• TEMPERATURE RATING Dimensions Model Voltage* - - Input Amps* Height Width Depth Weight Operating Storage K2814-1 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) (10[...]

  • Page 9

    A-2 INST ALLA TION MAXsa™ 10 CONTROLLER A-2 SAFETY PRECAUTION WELDING VOL T AGE 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 [...]

  • Page 10

    A-3 INST ALLA TION MAXsa™ 10 CONTROLLER A-3 FIGURE A.1 - MAXsa™ 10 CONNECTIONS ACCESS HOLES TC-3 TRA VEL CARRIAGE CONNECTOR FLUX HOPPER CONNECTOR POWER W A VE® AC/DC 1000 SD ARCLINK CONNECTOR PENDANT CONNECTOR MAXsa™ 22 or 29 WIRE DRIVE CONNECTOR (14-PIN) ST A TUS LIGHT[...]

  • Page 11

    A-4 INST ALLA TION MAXsa™ 10 CONTROLLER A-4 FIGURE A.2 - HAND HELD PENDANT Cover Screws (4 places) Pendant Screws ( 2 Places) K1543-xx or K2683-xx Arclink Cable (Optional) Cover F ront View Cover removed Access Hole 1 3 2 INTERF ACING TO THE MAXsa™ 10 CON- TROLLER The MAXsa™ 10 CONTROLLER is a versatile con- troller. The User Interface can be[...]

  • Page 12

    A-5 INST ALLA TION MAXsa™ 10 CONTROLLER A-5 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 [...]

  • Page 13

    A-6 INST ALLA TION MAXsa™ 10 CONTROLLER A-6 SWITCH GROUP #2 SUPPLY 3-PIN FLUX REC EP TACLE A B C TERMINAL S TRIP CR3 INPUT #8 852 855 858 859 CR3 NO #2 CR3 NO #6 CR3 NC #3 CR3 INPUT #4 CR1 INPUT #8 CR1 NO #2 CR1 NO #6 CR1 NC #3 FLUX GND CR1 INPUT #4 CR3 NC #7 SHUTDOWN #2 SUPPLY SHUTDOWN #1 SHUTDOWN #1 SUPPLY 532B-49 SWITCH GROUP #1 SUPPLY START F[...]

  • Page 14

    A-7 INST ALLA TION MAXsa™ 10 CONTROLLER A-7 SHUTDOWN INPUTS The MAXsa™ 10 CONTROLLER has two shutdown inputs available on the terminal strip. These are inde- pendent, 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 terminal strip b[...]

  • Page 15

    A-8 INST ALLA TION MAXsa™ 10 CONTROLLER A-8 K154 3-X X or K2683-XX Arcli nk Cable 67 Lead K178 5-X X 14-Pin C ab le Wo rk K231-X X Contact Nozz le K 280 3-1 Power W ave ® AC/DC 1000SD K281 4-1 MAXs a™ 10 K237 0-2 MAXsa ™ 22 K181 1-X X Sense Lead Electrode W eld Cable Wo rk W eld Cable Connection Diagrams for A dditional Congurations (Mult[...]

  • Page 16

    B-1 OPERA TION B-1 MAXsa™ 10 CONTROLLER SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. 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 no[...]

  • Page 17

    B-2 OPERA TION B-2 MAXsa™ 10 CONTROLLER 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 mech- anisms. High-speed digital cables connect the con- trol, wire drive, and the Power Wave power source tog[...]

  • Page 18

    B-3 OPERA TION B-3 MAXsa™ 10 CONTROLLER FIGURE B.1 - INPUT AND OUTPUT CONNECTIONS ACCESS HO L ES T C- 3 T RA VEL CARRIAG E CO NNECT O R F L UX H O PPER CO NNECT O R PO W ER W A VE® AC/DC 1 000 SD ARCL INK CO NNECT O R P E N D A N T C O N N E C T O R MA X sa™ 22 o r 29 W IR E D R IV E C O N N E C T O R ( 14-P IN ) S T A T U S L IG H T TRA VEL S[...]

  • Page 19

    B-4 OPERA TION B-4 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 sec- onds) a “lamp test” is performed. • All discrete LED’s, seven segment displays and alpha numeric displays will be turned ON for 2 sec- onds • A[...]

  • Page 20

    B-5 OPERA TION B-5 CHANGING AND SETTING WELD MODES To select a weld mode, 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 adjust[...]

  • Page 21

    B-6 OPERA TION B-6 MUL TIPLE ARC CONFIGURA TION 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 dif- ferent arcs. The phase of each a[...]

  • Page 22

    B-7 OPERA TION B-7 MAXsa™ 10 CONTROLLER WELD SEQUENCE The weld sequence defines the weld procedure from beginning to end. All adjustments are made through the user interface. ST ART OPTIONS The delay, strike, start and upslope parameters are used at the beginning of the weld sequence to estab- lish a stable arc and provide a smooth transition to [...]

  • Page 23

    B-8 OPERA TION B-8 MAXsa™ 10 CONTROLLER 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 dependi[...]

  • Page 24

    B-9 OPERA TION B-9 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. MAXsa™ 10 CONTROLLER SETUP MENU FEA TURES ACCESSING THE SETUP MENU 1. ACCESS To access the Setup Menu, Press the Left Button and Right Button simultaneo[...]

  • Page 25

    B-10 OPERA TION B-10 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/minu[...]

  • Page 26

    B-11 OPERA TION B-11 Parameter Definition P .15 Hot-Inch T ouch 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[...]

  • Page 27

    B-12 OPERA TION B-12 MAXsa™ 10 CONTROLLER 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 l[...]

  • Page 28

    B-13 OPERA TION B-13 MAXsa™ 10 CONTROLLER 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 acces[...]

  • Page 29

    TOUCH SENSE The Touch Sense option, when enabled, allows the operator to feed the wi re forward until i t 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 t he flux feed sys- tem. The flux hopper will stay active until the Feed Forward button[...]

  • Page 30

    B-15 OPERA TION 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 speci fied time and then the Weld Mode parameters will take ef[...]

  • Page 31

    B-16 OPERA TION B-16 The MAXsa™ 10 has eight available memory loca- tions 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 SA VED PROCEDURE Procedures stored in memory can[...]

  • Page 32

    B-17 OPERA TION B-17 SA VING A PROCEDURE TO A MEMORY LOCA TION Once the parameters have been set: • Press and Hold the M e m o r y B u t t o n o f t h e 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 informa- tion is saved, then ret[...]

  • Page 33

    B-18 OPERA TION B-18 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[...]

  • Page 34

    C-1 ACCESSORIES C-1 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[...]

  • Page 35

    D-1 MAINTENANCE D-1 ROUTINE MAINTENANCE • Check weld cables, control cables and gas hoses for cuts. PERIODIC MAINTENANCE • N/A CALIBRA TION SPECIFICA TION All calibration is factory set on the MAXsa™ 10 CON- TROLLER. MAXsa™ 10 CONTROLLER SAFETY PRECAUTIONS See additional warning information throughout this operator ’ s manual and the Engi[...]

  • Page 36

    E-1 TROUBLESHOOTING E-1 MAXs™ 10 CONTROLLER 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. CAUTION This Troubleshootin g Gu ide is provided to help you locate and[...]

  • Page 37

    E-2 TROUBLESHOOTING E-2 MAXsa™ 10 CONTROLLER Observe all Safety Guidelines detailed throughout this manual 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. CAUTION [...]

  • Page 38

    E-3 TROUBLESHOOTING E-3 MAXsa™ 10 CONTROLLER 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. CAUTION Observe all Safety Guidelines detailed throughout this manual [...]

  • Page 39

    E-4 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE 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 35 Capacitor bank "B" overvol[...]

  • Page 40

    E-5 TROUBLESHOOTING E-5 MAXsa™ 10 CONTROLLER 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. CAUTION Observe all Safety Guidelines detailed throughout this manual [...]

  • Page 41

    E-6 TROUBLESHOOTING E-6 MAXsa™ 10 CONTROLLER Observe all Safety Guidelines detailed throughout this manual 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. CAUTION [...]

  • Page 42

    E-7 TROUBLESHOOTING E-7 MAXsa™ 10 CONTROLLER Observe all Safety Guidelines detailed throughout this manual 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. CAUTION [...]

  • Page 43

    E-8 TROUBLESHOOTING E-8 MAXsa™ 10 CONTROLLER Observe all Safety Guidelines detailed throughout this manual 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. CAUTION [...]

  • Page 44

    F-1 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 c[...]

  • Page 45

    F-2 DIMENSION PRINT F-2 MAXsa™ 10 CONTROLLER 5.89 .20 11.30 13.25 12.25 11.68 O .66 O .28 14.40 .87 7.75 8.90 7.07 1.64 1.50 SCALE = 1 : 4 PENDANT L13444[...]

  • Page 46

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PR A CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABRIC A[...]

  • Page 47

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INSTR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E AS P ARTES DE USO , E SIG A A S PRÁTIC A S DE SEGUR ANÇA DO EMPREG ADOR. • Kee p yo ur h ead out of fume s. • Use ven tila tion or exh a[...]

  • Page 48

    • 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 • World's Leader in Welding and Cutting Products •[...]