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IM10023
™
February, 2010
M MA AX Xs sa a 1 10 0 C CO ON NT TR RO OL LL LE ER R
For use with machines having Code Numbers: 11590
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 importantl
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Linco
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vi vi TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation.......................................................................................................................Section A Technical Specifications................................................................................................A-1 Safety Precautions ........................................................................................................
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A-1 A-1 INSTALLATION ™ 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 -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
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A-2 A-2 INSTALLATION SAFETY PRECAUTION HIGH FREQUENCY PROTECTION WARNING Locate the MAXsa™ 10 CONTROLLER away from radio controlled machinery. The normal operation of the ELECTRIC SHOCK can kill. MAXsa™ 10 CONTROLLER may adversely affect the • Only a qualified electrician should operation of RF controlled equipment, which may result in connect the MAXsa™ 10 CON- bodily injury or damage to the equipment. TROLLER. Installation should be made in accordance with the appropriate National Electric
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A-3 A-3 INSTALLATION FIGURE A.1 - MAXsa™ 10 CONNECTIONS STATUS LIGHT PENDANT CONNECTOR MAXsa™ 22 or 29 WIRE DRIVE CONNECTOR (14-PIN) POWER WAVE® AC/DC 1000 SD ARCLINK CONNECTOR FLUX HOPPER CONNECTOR ACCESS TC-3 TRAVEL CARRIAGE HOLES CONNECTOR MAXsa™ 10 CONTROLLER
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A-4 A-4 INSTALLATION Using the Controller as a Hand-held Pendant: INTERFACING TO THE MAXsa™ 10 CON- TROLLER 1. Remove the 4 screws from the MAXsa™ 10 CON- TROLLER that hold the cover. See Figure A.2. The MAXsa™ 10 CONTROLLER is a versatile con- 2. Remove the 2 screws that hold the pendant in the troller. The User Interface can be removed and used brackets. Use the acccess holes shown. as a hand-held pendant. Most circuits can be accessed 3. Extend the control cable as needed with an Arc Link t
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A-5 A-5 INSTALLATION Auxiliary Input Power Connection Instructions Terminal blocks 48 and 49 are shipped connected to the contacts of CR2 and CR3 by leads 531 and 532. Use the appropriate size leads, at least 14 AWG – 2 These relay contacts are also connected to the 4-pin wire with ground. Travel connector and the 3-pin Flux connector located on the bottom of the MAXsa™ 10 CONTROLLER. 1. Remove two Phillips Head screws on right side of CR1 is available for a separate customer connection, fron
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A-6 A-6 INSTALLATION FIGURE A.4 - CONTROLLING NON-LINCOLN EQUIPMENT 3-PIN FLUX 4-PIN TRAVEL RECEPTACLE RECEPTACLE CR1, CR2 CR3 Relays Numbers Refer to Relay Terminals TERMINAL STRIP CR1 and CR2 relay coils are in parallel and are BOTH CONTROLLING NON-LINCOLN AUXILIARY turned ON and OFF as determined by the Travel Options EQUIPMENT setting (P12 in the Set-up Menu) as long as the TRAVEL MODE is set to AUTO. CR3 turns ON with the START Custom motion control and/or other auxiliary equipment command
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A-7 A-7 INSTALLATION FIGURE A.5 - SHUTDOWN AND STOP INPUTS Shorting Jumper Connect STOP Input Here SHUTDOWN INPUTS STOP INPUT The MAXsa™ 10 CONTROLLER has two shutdown The MAXsa™ 10 CONTROLLER has a Stop Input inputs available on the terminal strip. These are inde- available on the terminal strip. The Stop Input will pendent, normally closed inputs that can be used for work just like pressing the STOP Pushbutton. This cir- limit switches, PLC inputs, etc, in order to shut down cuit is in paralle
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A-8 A-8 INSTALLATION FIGURE A.6 - CONNECTION DIAGRAM - SINGLE ARC SYSTEM K2803-1 Power Wave® AC/DC 1000SD K1543-XX or K2683-XX Arclink Cable K2814-1 MAXsa™ 10 K1785-XX 14-Pin Cable K2370-2 MAXsa™ 22 67 Lead Electrode K231-XX Weld Cable Contact Nozzle K1811-XX Sense Lead Work Weld Cable Work Connection Diagrams for Additional Con!gurations (Multi- Arc and Parelleled Power Sources) are in the Power Wave® AC/DC 1000SD Operators Manual MAXsa™ 10 CONTROLLER
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B-1 B-1 OPERATION SAFETY PRECAUTIONS DESIGN FEATURES Read this entire section of operating instructions • Easy control of all weld parameters. before operating the machine. • 8 Memories for easy storage and recall of weld schedules. WARNING • Weld parameter limit setting and lockout capabilities. ELECTRIC SHOCK can kill. • Digital communications for accurate and reliable per- formance. • Do not touch electrically live parts • PC boards are potted in epoxy for the ultimate in out- or electrodes w
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B-2 B-2 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON GENERAL FUNCTIONAL DESCRIPTION THIS MACHINE OR IN THIS MANUAL • The MAXsa™ 10 CONTROLLER is one of the most versatile user interfaces ever created. Easy to use features make it a snap to adjust the arc for specific PENDENT preferences. ARCLINK CONNECTOR • The user interface brightly displays essential weld- ing information. Use it to quickly adjust weld set- tings, arc starting parameters, arc end parameters and set-up information. WIRE FEEDE
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STATUS LIGHT PENDANT CONNECTOR MAXsa™ 22 or 29 WIRE DRIVE CONNECTOR (14-PIN) POWER WAVE® AC/DC 1000 SD ARCLINK CONNECTOR FLUX HOPPER CONNECTOR ACCESS TC-3 TRAVEL CARRIAGE HOLES CONNECTOR B-3 B-3 OPERATION FIGURE B.1 - INPUT AND OUTPUT CONNECTIONS FIGURE B.2 - PENDANT CONTROLS AMPS/WFS MODE SELECT VOLTS DISPLAY PANEL (MSP) DISPLAY DISPLAY WFS VOLTS AMPS/WFS VOLTS AMPS INDICATOR INDICATOR CONTROL CONTROL INDICATOR START TRAVEL SWITCH BUTTON (AUTO / OFF / MANUAL) FLUX FILL 200 ---- WELD OUTPUT
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B-4 B-4 OPERATION FIGURE B.4.- FEED CONTROLS FIGURE B.3 - POWER UP 25 ---- ---- MAXsa Feed Cold Initializing. . . Feedhead 1 SETTING FEED FORWARD/REVERSE POWER-UP SEQUENCE While pressing either the FEED FORWARD or FEED When power is first applied to the machine the MODE REVERSE pushbutton the MSP Display will read as SELECT Display reads “MAXsa™ Initializing...”. Once shown in Figure B.4 and the preset wire feed speed the PowerWave AC/DC has intialized (20 to 60 sec- will be displayed on
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B-5 B-5 OPERATION BALANCE ADJUST CHANGING AND SETTING WELD MODES Press the WELD MODE selector until the MSP To select a weld mode, press the WELD MODE Display reads “Balance”. If the selected mode allows SELECTOR button until the WELD MODE indicator for balance adjustment, the Control Knob can be used comes ON (it may already be lit by default at power to select the desired wave balance through a range of up). Turn the control knob to select the desired mode. 25% to 75%. After about 1 second, th
