Lincoln Electric IM10023 Operator'S Manual Download Page 1

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• 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 •

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0 CCO

NTTR

OLLLLEER

OPERATOR’S MANUAL

IM10023

February, 2010

For use with machines having Code Numbers:

11590

IP 23

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  READ-
ING  THIS  MANUAL  AND  THE
SAFETY  PRECAUTIONS  CON-
TAINED  THROUGHOUT.

And,

most importantly, think before
you act and be careful.

Summary of Contents for IM10023

Page 1: ...3 February 2010 For use with machines having Code Numbers 11590 Copyright Lincoln Global Inc IP 23 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 READ ING THIS MANUAL AND THE SAFE...

Page 2: ...R 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 availa...

Page 3: ...ever simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 ii SAFETY ii FUMES AND GASES can be dangerous 5 a Welding may produce fumes...

Page 4: ...s 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 touchin...

Page 5: ...s et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 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 Eloign...

Page 6: ...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 WEB SITE at www linc...

Page 7: ...d Mode Searching B 6 Multiple Arc operation B 6 Weld Sequence B 7 Start Options B 7 End Options B 8 Restrike Timer B 8 Setup Menu Features B 9 Parameter List B 10 B 14 Lockout Security B 14 Making a Weld B 15 Memory Panel Options B 16 Saving a Procedure to a Memory Location B 17 Limit Setting B 18 ________________________________________________________________________________ Accessories Section ...

Page 8: ...NPUT 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 102 mm 11 3 Kg 10 C to 40 C 40 C to 85 C When not driving a motor ...

Page 9: ...he operation of RF controlled equipment which may result in bodily injury or damage to the equipment AUXILIARY EQUIPMENT INPUT POWER 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 in the MAXsa 10 CON TROLLER controlled by two independent coil drivers The coi...

Page 10: ...ONTROLLER A 3 FIGURE A 1 MAXsa 10 CONNECTIONS 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 ...

Page 11: ...e 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 Using the Controller as a Hand held Pendant 1 Remove the 4 screws from the MAXsa 10 CON TROLLER that hold the cover See Figure A ...

Page 12: ... 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 115VA...

Page 13: ...nd 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 CR2 are connected to terminal strip blocks 10 through 15 The contacts ...

Page 14: ...sa 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 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 cir cuit is in parallel with the STOP Pushbu...

Page 15: ...tact Nozzle K2803 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 Configurations Multi Arc and Parelleled Power Sources are in the Power Wave AC DC 1000SD Operators Manual FIGURE A 6 CONNECTION DIAGRAM SINGLE ARC SYSTEM ...

Page 16: ... Do not weld on containers which have held flammable material ARC RAYS can burn Wear eye ear and body protection WARNING 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 per formance PC boards are potted in epoxy for the ultimate in out ...

Page 17: ...ng information Use it to quickly adjust weld set tings 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 inter face 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 CONTRO...

Page 18: ...L 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 PA...

Page 19: ...ING 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 con trol knob below the display while pressing either but ton FEED REVERSE Use to retract the wire from the feed mechanism FEED FORWARD...

Page 20: ...or 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 Adjusting the Balance the ratio between Positive and Negative half cycle on time changes the deposition for more efficient welding OFFSET ADJUST Press the WELD MODE selector until the MSP Display reads Offset If the se...

Page 21: ...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 Weld Mode Search is displayed This will appear in between the highest and the lowest weld mode number Once Weld Mode Searc...

Page 22: ...he weld parameters The transition is linear and may be up or down depending on the relationship between the start and weld settings 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...

Page 23: ...ng restrike the WFS and outputs are driven in an attempt to re establish the arc A restrike time of 1 to 2 seconds is sufficient in most applications A restrike time of 0 seconds allows the 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 Tim...

Page 24: ...ton to edit the select ed preference 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 simultane ously or select P 0 and press the Left Button Sixty seconds of inactivity will automatically exit the Setup Menu Note If a pr...

Page 25: ...After selecting the function press the Left Button to save the func tion 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 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 ...

Page 26: ...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 neces sary to disable the inputs on the pendent Panel Remote All pendent buttons are enabled default Panel Locked T...

Page 27: ...ss the Left Button to exit this option 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 thi...

Page 28: ...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...

Page 29: ...trols and all rele vant 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 l...

Page 30: ...begin moving as prescribed in the P 12 Parameter set ting 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 mov ing 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 t...

Page 31: ...tion 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 mes sage will be displayed Up to eight different weld pro ced...

Page 32: ... for longer than 5 sec onds will enter the Limits Mode 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 dis plays 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 CONTROLL...

Page 33: ...dly The MSP Display will read 2 After 2 seconds the display will change to show the following items Memory Value High Limit Low Limit Parameter Name 3 The Parameter Name on the MSP Display will flash to indicate it is ready to be changed If no lim its 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 t...

Page 34: ...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 MAXsa 10 CONTROLLER ...

Page 35: ... 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 but ton 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 ...

Page 36: ...SIBLE 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 Auth...

Page 37: ... 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 Uti...

Page 38: ...re to reduce the current draw The welding proce dure may exceed the capacity of the power source 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 power source reconnect pa...

Page 39: ...See the power source Instruction Manual 1 Power source overheating Verify duty cycle is correct Ensure ade quate airflow around power source 1 The power source has exceeded the output 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 1 Verify the power source recon nect ...

Page 40: ... 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 been exceeded Typically indicates mechanical overload of system If problem continues c...

Page 41: ...gged 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 Error Code 213 215 247 274 275 276 277 278 281 282 Source User Interface UI Text Power Source is Off Line Feeder Board is Off Line N A N A N A N A N A N A Varies based on the error type and who caused the err...

Page 42: ...l 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 Typical User Interface 3 digit error codes not blinked on the status LED Error Code 283 285 612 Source User Interface UI Text Varies based on the error type and who caused the error ...

Page 43: ...olls and or inner wire guide Verify the prop er 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 1 The wire feeder gear setting is not properly set Verify that the software setting matches the gear mou...

Page 44: ...y 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 ...

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: ... 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 moja da Aislese del trabajo y de la tierra 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 Elektrod...

Page 47: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing 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 co...

Page 48: ...s 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 ...

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