Lincoln Electric MAXsa 10 Operator'S Manual Download Page 1

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Operator’s Manual

MAX

™

10 CONTROLLER

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Authorized Service and Distributor Locator:

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IM10232

| Issue D ate Mar-15

For use with machines having Code Numbers:

12416

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Summary of Contents for MAXsa 10

Page 1: ...c com register Authorized Service and Distributor Locator www lincolnelectric com locator IM10232 Issue Date Mar 15 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12416 Save for future reference Date Purchased Code ex 10859 Serial ex U1060512345 ...

Page 2: ...N 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 develop 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...

Page 3: ...ers 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 th...

Page 4: ...m 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 an...

Page 5: ...ent 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 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...

Page 6: ...odes B 4 Frequency Balance Control B 4 Weld Mode Searching B 5 Multiple Arc Configuration B 5 Weld Sequence B 6 Start Options B 6 End Options B 7 Setup Menu Features B 8 Parameter List B 9 thru B 13 Touch Sense B 13 Lockout Security B 13 Making a Weld B 14 Using the Memory Option B 15 Saving a Procedure to a Memory Location B 16 Recalling a Procedure from a Memory Location B 16 Limit Setting B 17 ...

Page 7: ...eferences The user interface brightly displays essential welding informa tion Use it to quickly adjust weld settings arc starting para meters 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 mul tiple levels of limits and lockouts Digital communications to the power source provide the most ac...

Page 8: ...Tachometer controlled wire drive motor Flux Fill Switch Bright high intensity digital read outs Option to convert to hand held pendant included RECOMMENDED PROCESSES AND 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 x Power Wave AC DC 1...

Page 9: ...VOLTAGE CURRENT PHYSICAL SIzE TEMPERATURE RATING Dimensions Model Voltage Input Amps Height Width Depth Weight Operating Storage K2814 3 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 IP 23 ...

Page 10: ...pment is Class A HIGH FREQUENCY PROTECTION Locate the MAXsa 10 CONTROLLER away from radio controlled machinery The normal operation 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 AUXILIARY EQUIPMENT INPUT POWER CONNECTION The MAXsa 10 CONTROLLER has the ability to control auxiliary equipment such...

Page 11: ... CONTROLLER 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 12: ...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 CONTROLLER that hold the cover See Figure A 2 2...

Page 13: ...ocks 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 CON TROLLER 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 ...

Page 14: ...terminal strip blocks 48 and 49 connected to the CR2 relay and CR3 relay inputs respectively When the end user connects a sup ply 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 terminal strip blocks the customer must connect power to this relay if it is to be used See rel...

Page 15: ... 10 CON TROLLER The shutdown circuit must be closed before resetting the Controller To reset the system the Mode Select Panel dis play 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 circuit is in parallel with the STOP Pushbut...

Page 16: ...ontact Nozzle Power Wave AC DC 1000SD K2370 X 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 K2814 X MAXsa 10 FIGURE A 6 CONNECTION DIAGRAM SINGLE ARC SYSTEM ...

Page 17: ...electrically hot parts Only qualified personnel should install use or service this equipment Follow all national and local safety procedures Wear the appropriate Personal Protective Equipment INSTALLATION INSTRUCTIONS FOR MAXsa 10 BEING USED WITH POWER WAVE AC DC 1000 SD USING 9SS30221 WARNING 1 Open control box and locate S27981 L11087 and G4018 boards 2 Remove J86 connector from the S27981 L1108...

Page 18: ...d 4 G4018 is no longer needed It can stay or be removed 5 Replace S27981 L11087 board with the S30221 G6752 board 6 Reconnect the J331 connector to J88 on the S30221 G6752 board then reconnect the rest of the connectors 7 Reconnect the input power and assure proper output ...

Page 19: ...oltage control Do not operate with panels removed Disconnect input power before ser vicing ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR SERVICE THIS EQUIPMENT READ AND FOLLOW THE MANUFACTURER S INSTRUC 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 Use vent...

Page 20: ...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 PANE...

Page 21: ... the Setup Menu 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 mech...

Page 22: ...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 selec...

Page 23: ... the final selection is made the MAXsa 10 will automati cally change to the weld mode found by the Weld Mode Search process Earlier products may not have this feature To activate this fea ture a software update may be needed from www power wavesoftware com 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 ...

Page 24: ...transi tion is linear and may be up or down depending on the rela tionship 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 exit the Start param...

Page 25: ...nd 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 func tion 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 sho...

Page 26: ...ton to edit the selected preference 3 PREFERENCE CHANGE Scroll through the preference options by rotating the Control Knob Change the preference setting by pressing 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 produ...

Page 27: ...ob to select either starting or end ing 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 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 ...

Page 28: ... Only the machine connected to the MAXSA 10 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 neces sary to disable the inputs on the pendent...

Page 29: ... 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 this option P ...

Page 30: ...ions 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 un...

Page 31: ...e 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 moni tored 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 ...

Page 32: ...gin moving as pre scribed in the P 12 Parameter setting 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 pre scribed 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...

Page 33: ...ion 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 locations 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 dif ferent weld procedure...

Page 34: ...or longer than 5 seconds 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 proce dure information will show in the displays The LED will remain ON until another location is selected NOTE Holding the button for longer than 1 second will re enter the Save Mode MAXSA 10 CONTROLLER F...

Page 35: ...for that location begins to blink rapidly 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 limits were previously set the High and Low values are the limits of the Power Source Press the Arc Start End Options ...

Page 36: ...B 18 NOTES MAXSA 10 CONTROLLER ...

Page 37: ... 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 Power Wave System accessories can be found in this document MAXSA 10 CONTROLLER ...

Page 38: ...LECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching electrode and drive mecha nism 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...

Page 39: ...ct 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 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 fo...

Page 40: ...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 Util...

Page 41: ...e 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 pan...

Page 42: ...r 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 power source reconnect panel wiring matches the input power 2 See the power source Instruction Manual 1 Power source overheating Verify duty cycle is correct Ensure ade quate airflow around power source 1 ...

Page 43: ...he 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 con...

Page 44: ...ed 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 error...

Page 45: ...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 N ...

Page 46: ...ls 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 mount...

Page 47: ...E 9 NOTES MAXSA 10 CONTROLLER ...

Page 48: ...6 G 842 R 843B R 841 W 832 831 COMMON MOTOR SHIELDED CABLE TACH 15VDC TACH 1A DIFF IN TACH COMMON 842 R 5 PIN ARCLINK PLUG MOTOR J31 1 2 3 4 540D 500E 542D 541D 1 2 3 4 5 6 8513 AUTO MANUAL 328A PENDANT P C BOARD PENDANT CONNECTOR 1 2 3 4 J2 67B 328C S1 S2 S3 B1 67F START STOP S4 1 2 3 4 324 5 6 7 8 327 326 J32 1 2 3 4 323 5 6 7 8 325 328 1 2 J1 328B 8511 8510 67A 67 5 PIN ARCLINK RECEPTACLE ELECT...

Page 49: ...F 2 DIAGRAMS 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 50: ...F 3 NOTES MAXSA 10 CONTROLLER ...

Page 51: ...ation 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 ...

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