Page 2 - OPERATOR’S MANUAL; SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
OPERATOR’S MANUAL FOR ENGINEpowered 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 exhau...
Page 3 - ii
ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resist...
Page 4 - iii; Refer to
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manua...
Page 7 - TABLE OF CONTENTS
vi vi TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation .......................................................................................................................Section A Technical Specifications ..........................
Page 8 - INSTALLATION; MAXsaTM 10 CONTROLLER; TECHNICAL SPECIFICATIONS: MAXsa; INPUT VOLTAGE & CURRENT
A-1 INSTALLATION MAXsa™ 10 CONTROLLER A-1 TECHNICAL SPECIFICATIONS: 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...
Page 9 - SAFETY PRECAUTION
A-2 INSTALLATION MAXsa™ 10 CONTROLLER A-2 SAFETY PRECAUTION WELDING VOLTAGE Wire feed parts are electrically live while welding and while inching wire (with Touch Sense feature selection). The electrically live parts are listed below: Electrode Electrode Reel Wire Drive Motor Drive Rolls Gear Box Cr...
Page 11 - INTERFACING TO THE MAXsaTM 10 CON-; Using the Controller as a Hand-held Pendant
A-4 INSTALLATION 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 Front View Cover removed Access Hole 1 3 2 INTERFACING TO THE MAXsa™ 10 CON- TROLLER The MAXsa™ 10 CONTROLLER is a versatile...
Page 13 - CONTROLLING NON-LINCOLN AUXILIARY
A-6 INSTALLATION MAXsa™ 10 CONTROLLER A-6 S W IT C H G R O U P # 2 S U P P L Y 3-PIN FLUX RECEPTACLE A B C TERMINAL STRIP C R 3 I N P U T # 8 8 5 2 8 5 5 8 5 8 8 5 9 C R 3 N O # 2 C R 3 N O # 6 C R 3 N C # 3 C R 3 I N P U T # 4 C R 1 I N P U T # 8 C R 1 N O # 2 C R 1 N O # 6 C R 1 N C # 3 F L U X G ...
Page 14 - Shorting
A-7 INSTALLATION 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...
Page 16 - OPERATION; SAFETY PRECAUTIONS
B-1 OPERATION 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. • Alw...
Page 18 - CC AC
B-3 OPERATION B-3 MAXsa™ 10 CONTROLLER FIGURE B.1 - INPUT AND OUTPUT 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 TRAVEL SWITCH (AUTO / OFF / MANU...
Page 19 - WIRE FEEDER SETUP; Setup Menu; ELECTRODE HOT; Welding Software
B-4 OPERATION 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...
Page 20 - CHANGING AND SETTING WELD MODES; FREQUENCY ADJUST; Hz; percent
B-5 OPERATION B-5 CHANGING AND SETTING WELD MODES T o s e l e c t a w e l d m o d e , p r e s s t h e W E L D M O D E 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 par...
Page 21 - MULTIPLE ARC CONFIGURATION; WELD MODE SEARCHING
B-6 OPERATION B-6 MULTIPLE ARC CONFIGURATION Power Wave ® AC/DC 1000 SD / MAXsa™ systems can be used in multiple arc set ups with up to six arcs. To minimize magnetic interaction between the arcs, it is imperative that they be phased correctly. Phasing is essentially a time offset between the wavefo...
Page 22 - WELD SEQUENCE; START OPTIONS; Repeated pressing of the; Arc Start/End Options; , while on a parameter; OFF; Arc Delay Time
B-7 OPERATION 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. START OPTIONS The delay, strike, start and upslope parameters are used at the beginning of the weld sequence to estab- lish a ...
Page 23 - END OPTIONS; Downslope Time
B-8 OPERATION 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: • D O W N S L O P E d e t e r m i n e s t h e a m o u n t o f t i m e i t takes to ramp from the weld parameters to the...
Page 24 - SETUP MENU FEATURES; Exit; PARAMETER
B-9 OPERATION 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 FEATURES ACCESSING THE SETUP MENU 1. ACCESS To access the Setup Menu, Pre...
Page 25 - Yes
B-10 OPERATION 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 f...
Page 27 - another log. Press the Left Button again to exit this option.
B-12 OPERATION 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 th...
Page 29 - TOUCH SENSE; Parameter
TOUCH SENSE The Touch Sense option, when enabled, allows the operator to feed the wire forward until it touches the workpiece. When contact to the work is made, the wire will stop and the flux hopper (if used) will activate to put flux around the wire and fill the flux feed sys- tem. The flux hopper...
Page 30 - CC DC; MAKING A WELD
B-15 OPERATION B-15 Press the START BUTTON to begin welding. The ARC ESTABLISHED INDICATOR will ‘ flash’ as the wire feeds towards the work piece to show that OCV is present and switch to ON when the arc is lit. If “Start” parameters have been set they will be in effect for the specified time and th...
Page 31 - NAMING A SAVED PROCEDURE; NOTE: This can only be done with Memory loca-; USING THE MEMORY OPTION
B-16 OPERATION 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 SAVED PROCEDURE P...
Page 32 - SAVING A PROCEDURE TO A MEMORY
B-17 OPERATION B-17 SAVING A PROCEDURE TO A MEMORY LOCATION Once the parameters have been set: • P r e s s a n d H o l d t h e 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...
Page 33 - OPTIONAL LIMIT SETUP; Weld Amps
B-18 OPERATION 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, e v e n i f t h e W e l d M o d e i s t h e s a m e . F o r e x a m p l e : Memory Locatio...
Page 34 - ACCESSORIES; OPTIONS AND ACCESSORIES; are; field type E9.181 and click on the; Search; On the Results page, scroll down to the; Equipment; All of the information for the PowerWave System
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 cl...
Page 35 - MAINTENANCE; • Check weld cables, control cables and gas hoses
D-1 MAINTENANCE D-1 ROUTINE MAINTENANCE • Check weld cables, control cables and gas hoses for cuts. PERIODIC MAINTENANCE • N/A CALIBRATION SPECIFICATION All calibration is factory set on the MAXsa™ 10 CON- TROLLER. MAXsa™ 10 CONTROLLER SAFETY PRECAUTIONS S e e a d d i t i o n a l w a r n i n g i n f...
Page 36 - TROUBLESHOOTING; MAXsTM 10 CONTROLLER; CAUTION; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
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 Troublesho...
Page 37 - cycling power to the system, check the power source status light
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 trouble...
Page 38 - Observe all Safety Guidelines detailed throughout this manual; PROBLEMS; ARCLINK SYSTEM ERROR CODES
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 Sa...
Page 42 - OUTPUT PROBLEMS
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 trouble...
Page 44 - DIAGRAMS; Enhanced Diagram
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 diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service D...
Page 45 - DIMENSION PRINT
F-2 DIMENSION PRINT F-2 MAXsa™ 10 CONTROLLER 5. 89 .2 0 11 .3 0 13 .2 5 12 .2 5 11 .6 8 O .6 6 O .2 8 14 .4 0 .8 7 7. 75 8. 90 7. 07 1. 64 1. 50 S C A LE = 1 : 4 P E N D AN T L 1 3 4 4 4
