Lincoln Electric MAXsa 10 User manual

Ope ato ’s Manual
MAXsa™10 CONTROLLER
Registe you machine:
www.lincolnelectric.com/register
Autho ized Se vice and Dist ibuto Locato :
www.lincolnelectric.com/locator
IM10232 | Issue D ate Mar-15
© Lincoln Glo al, Inc. All Rights Reserved.
For use with machines having Code Num ers:
12416
Save fo futu e efe ence
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
incoln 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 READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN 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 de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
EAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 06/15/2016

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel En ines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline En ines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
ARC ELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN A AY.
PACEMAKER EARERS SHOULD CONSULT ITH
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 available from the incoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
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.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
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 the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 06/15/2016

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never 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 It ems 6.c. and 8.
ARC RAYS CAN BURN.
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 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 and gases
hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. hen welding hardfacing
(see instructions on container or SDS) or on lead
or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep
exposure as low as possible and within applicable
OSHA PEL and ACGIH TLV limits using local
exhaust or mechanical ventilation unless exposure
assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
respirator may also be required. Additional
precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PE and
ACGIH T V limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 06/15/2016

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. 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
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current 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 thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED 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
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 06/15/2016

6
TABLE OF CONTENTS
PRODUCT MODEL
Page
Product Description......................................................................................................................7
General Function Description...........................................................................................7
Definitions of Welding Modes, Common Welding Abbreviations......................................7
Graphic Symbols ..............................................................................................................7
Design Features, Recommended Processes and Equipment..........................................8
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Installation.......................................................................................................................Section A
Technical Specifications................................................................................................A-1
Safety Precautions........................................................................................................A-2
Welding Voltage, Mechanical Hazards .........................................................................A-2
Location and Mounting..................................................................................................A-2
High Frequency Protection............................................................................................A-2
Auxiliary Equipment nput Power Connection...............................................................A-2
nterfacing to the MAXsa™ 10 CONTROLLER......................................................A-3 thru A-4
MAXsa™ 10 Connections.............................................................................................A-3
Using the Controller as a Hand-held Pendant...............................................................A-4
Controlling Non-Lincoln auxillary Equipment..........................................................A-5 thru A-6
Shutdown and Stop nputs............................................................................................A-7
Connection Diagram.............................................................................................................A-8
nstallation nstructions with K2803 using 9SS30221...........................................A-9 thru A-10
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions...............................................................................................................B-1
nput, Output Connections............................................................................................B-2
Case Front Controls and Description...................................................................................B-2
Power-Up Sequence .....................................................................................................B-3
nch Wire Feed Speed Settings....................................................................................B-3
Changing Weld Modes..................................................................................................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
________________________________________________________________________________
Accessories .....................................................................................................Section C
General Options / Accessories..............................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine ..................................................................................................................D-1
Periodic..................................................................................................................D-1
Calibration Specification........................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ............................................................................E-2 thru E-8
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagrams.......................................................................................F-1 thru F-2
Dimension Print......................................................................................................F-3
________________________________________________________________________
Parts ists...............................................................................................................P-616
________________________________________________________________________

7
PRODUCT DESCRIPTION
MAXSA™ 10 CONTROLLER
P ODUCT DESC IPTION
GE ERAL PHYSICAL DESCRIPTIO
• The MAXsa™ 10 CONTROLL R is a user interface and a feeder
controller. The control is used to set all welding parameters
and control any travel mechanisms. High-speed digital cables
connect the control, wire drive, and the Power Wave power
source together.
• The MAXsa™ 10 CONTROLL R is a self-contained control box
designed to control the entire weld arc at one location.
• The user interface utilizes alphanumeric displays for advanced
text messaging providing the end user with an intuitive inter-
face allowing for easy set up and real-time control of all weld-
ing parameters.
• An eight button memory section has been included which pro-
vides easy storage and recall of stored welding parameters.
• The user interface can be removed from the control box and
connected as a Pendant for remote control near the arc.
GE ERAL FU CTIO AL DESCRIPTIO
• The MAXsa™ 10 CONTROLL R is one of the most versatile
user interfaces ever created. asy to use features make it a
snap to adjust the arc for specific preferences.
• 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
accurate and reliable operation possible.
• When the MAXsa™ 10 CONTROLL R is coupled to the Power
Wave®AC/DC 1000 SD welding power source, the result is a
welding system with the best arc performance on the market.
DEFI ITIO S OF WELDI G MODES
O -SY ERGIC WELDI G MODES
• A Non-synergic welding mode requires all welding process
variables to be set by the operator.
SY ERGIC WELDI G MODES
• A Synergic welding mode offers the simplicity of single knob
control. The machine will select the correct voltage and
amperage based on the wire feed speed (WFS) set by the oper-
ator.
• See the Power Wave® AC/DC 1000 SD Operator’s Manual for
available weld modes.
COMMO WELDI G ABBREVIATIO S
SAW
• Submerged Arc Welding
WIRE FEEDER
F UX HOPPER
CONNECTOR
TRAVE
CARRIAGE
CONNECTOR
GRAPHIC SYMBO S THAT APPEAR ON
THIS MACHINE OR IN THIS MANUA
CONTRO ER
ARC INK INPUT
CONNECTOR
PENDENT
ARC INK
CONNECTOR

8
PRODUCT DESCRIPTION
DESIG FEATURES
• asy 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 performance.
• PC boards are potted in epoxy for the ultimate in outdoor protec-
tion.
• Connectors are filled with environmental protective grease.
• Designed for the Power Wave®AC/DC 1000 SD series of prod-
ucts for the best arc in the industry.
• Wire feed speed accuracy calibrated to within 2%.
• Digital display of voltage and wire feed speed.
• 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 1000 SD
• K2370-x MAXsa™ 22 Wire Drive
• K2814-x MAXsa™ 10 CONTROLLER / User
nterface
• K2683-xx Control Cable (5 pin – 5 pin) - power
source to MAXsa™ 10.
• K1785-xx Control Cable (14 pin – 14 pin) -
MAXsa™ 10 to Wire Drive.
Optional kits
• K2312-x MAXsa™ 29 Wire Drive (for fixture
builders).
• K2311-1
Motor Conversion Kit (to convert existing
NA-3/NA-4/NA-5 wire feeder gear
boxes).
MAXSA™ 10 CONTROLLER

A-1
INSTALLATIONMAXSA™ 10 CONTROLLER
TECHNICA SPECIFICATIONS: MAXsa™10 CONTRO ER
INPUT VO TAGE & CURRENT PHYSICA 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

A-2
INSTALLATIONMAXSA™ 10 CONTROLLER
SAFETY PRECAUTIO
WELDI G 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:
lectrode lectrode Reel
Wire Drive Motor Drive Rolls
Gear Box Cross-seam Adjuster
Wire Straightener Welding Nozzle
Welding Cables Welding Cable Terminal
• 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.
MECHA ICAL HAZARDS
• Welding fixture or wire feeder will move during
welding or inching. Keep away from pinch
points.
• Electrode reel and drive rolls turn during weld-
ing or inching. Keep gloved hands away from
areas that may catch the glove.
--------------------------------------------------------------------
LOCATIO A D MOU TI G
The MAXsa™ 10 CONTROLL R will operate in harsh environments
and can be used outdoors with an IP 23 rating. ven so, it is impor-
tant that simple preventative measures are followed in order to
assure long life and reliable operation. The MAXsa™ 10 CON-
TROLL R must be mounted in the vertical(upright) position and
located where there is little risk of impacts to the Controller.
ELECTRIC SHOCK can kill.
• Only a qualified electrician should connect
the MAXsa™ 10 CO TROLLER. Installation
should be made in accordance with the
appropriate ational Electrical Code, the
local codes and the information in this
manual.
• Turn off the input power to the power
source at the disconnect switch or fuse
box before working on this equipment.
Turn off the input power to any other
equipment connected to the welding sys-
tem at the disconnect switch or fuse box
before working on this equipment.
• Do not touch electrically hot parts.
-------------------------------------------------------------------------------
This equipment is for industrial use only and it is not intended for use in
residential locations where the electrical power is provided by the pub-
lic low-voltage supply system. There can be potential difficulties in resi-
dential locations due to conducted as well as radiated radio-frequency
disturbances. The MC or RF classification of this equipment is Class A.
HIGH FREQUE CY PROTECTIO
Locate the MAXsa™ 10 CONTROLL R away from radio controlled
machinery. The normal operation of the MAXsa™ 10 CONTROLL R
may adversely affect the operation of RF controlled equipment, which
may result in bodily injury or damage to the equipment.
AUXILIARY EQUIPME T I PUT POWER CO ECTIO
The MAXsa™ 10 CONTROLL R 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 CONTROLL R, controlled by two independent coil dri-
vers. The coils of CR1 and CR2 are in parallel, therefore, they must
turn ON and OFF at the same time. The CR1 and CR2 relays are des-
ignated for driving travel motors to control motion. CR3 is driven sep-
arately, and is designated to control flux hopper operation.
MAXsa™ 10 CONTROLL R Relay Ratings:
Coil: 12Vdc, resistance = 86 ohms at 25° C
Normally Closed (N.C.) Contacts: 3A @ 277VAC
Normally Open (N.O.) Contacts: 30A @ 277VAC
The MAXsa™ 10 CONTROLL R does not provide the input power to
feed any equipment, other than the MAXsa 22 or the MAXsa 29 feed-
ers. Therefore a separate power feed must be provided by the end
user. The MAXsa™ 10 CONTROLL R has been shipped standard with
all of the wiring and connectivity to operate the Lincoln K325 TC-3
Travel Carriage (4-pin cable connector) and the Lincoln K219
Automatic Flux Hopper (3-pin cable connector). The CR2 Relay is
wired to the 4-pin travel connector, and the CR3 Relay is wired to the
3-pin flux connector, both located on the bottom of the MAXsa™ 10
CONTROLL R.
If either of these is to be used with the MAXsa™ 10 CONTROLL R,
the end-user must provide the 115VAC input power to the terminal
strip located inside the MAXsa™ 10 CONTROLL R. Access to the ter-
minal strip may be obtained via one of the two .875” dia. (22.2mm)
access holes in the bottom of the MAXsa™ 10 CONTROLL R. These
access holes are shipped with plug buttons installed. Remove the
plug button and install a suitable strain relief to protect the wires.
See Figure A.1
Although input power to MAXsa™ 10 CO TROLLER is turned off,
the customer installed auxiliary input may be energized! Ensure
that all input power to the MAXsa™ 10 CO TROLLER is turned
off before opening the cover.
-------------------------------------------------------------------------------------
WARNING
CAUTION
WARNING

A-3
INSTALLATIONMAXSA™ 10 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

A-4
INSTALLATIONMAXSA™ 10 CONTROLLER
FIGURE A.2 - HA D HELD PE DA T
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
I TERFACI G TO THE MAXsa™ 10 CO TROLLER
The MAXsa™ 10 CONTROLL R is a versatile controller. The User
Interface can be removed and used as a hand-held pendant. Most
circuits can be 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 CONTROLL R that
hold the cover. See Figure A.2.
2. Remove the 2 screws that hold the pendant in the brackets.
Use the access holes shown.
3. xtend the control cable as needed with an Arc Link cable of
appropriate length. See Figure A.2

A-5
INSTALLATIONMAXSA™ 10 CONTROLLER
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 the input power leads.
3. Strip off 1/4”(6.4mm) of insulation from the leads and route
them through the strain relief
4. Locate the 4-terminal blocks, numbered #48, #49, and #50.
These are to be used to bring in auxiliary power. Terminal
block #50 is used for the input ground connection. This termi-
nal block is color-coded green and yellow for easy identifica-
tion. Terminal blocks #48 and #49 are to be used to connect
the input power circuit. (See Figure A.3).
5. Using a flat-head screwdriver with a blade dimension of
0.137"(3.5mm) x 0.020"(.51mm), insert the screwdriver into
the square hole next to the mounting hole to be used on the ter-
minal strip. The screwdriver should be inserted until it bottoms
out. This opens the screwless cage clamping style wire inser-
tion port. With the cage clamp opened insert the wire into the
round port until it bottoms out. While holding the lead securely,
remove the screwdriver from the terminal block. This closes the
cage clamp onto the lead holding it securely. Any open port on
blocks #48, #49, and #50 may be used.
Terminal 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 CON-
TROLL R. 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 to the terminal strip
is all that is required to power the devices.
OTE: The contacts of CR1 are not connected to terminals #48
and #49 when shipped. Applying power to the #48 and #49
terminals will not transfer voltage to the CR1 relay.
Connect leads from the #48 terminal to the #4 terminal and
from the #49 terminal to the #3 terminal to supply power to
the common contacts of the relay.
Once input power is applied to the terminal strip, this voltage is
always on terminal strip blocks #3, #4 (if connected), #11, #17,
and #18. These are the inputs to the solid-state relay contacts.
Input voltage is also present on terminal strip blocks #7, #8 (if
connected), #15, #21, and #22 due to the N.C. contacts on the
relays. When the CR1 relay is energized, input power is trans-
ferred to terminal strip blocks #5 and #6 (if connected). When the
CR2 relay is energized, input power is transferred to terminal strip
block #13. When the CR3 relay is energized, input power is trans-
ferred to terminal strip blocks #19 and #20. CR1 and CR2 will be
turned ON and OFF at the same time.
FIGURE A.3
INSERT
WIRE HERE
INSERT SCREW
DRIVER HERE
# 1
# 3
REMOVE SCREW
DRIVER FROM CAGE
CLAMP HOLE.
# 2
CAGE CLAMP
VAC IN
NEUTRAL (31)
VAC IN
LINE (32)

A-6
INSTALLATIONMAXSA™ 10 CONTROLLER
CO TROLLI G O -LI COL AUXILIARY EQUIPME T
Custom motion control and/or other auxiliary equipment can be pow-
ered using the terminal strip and relays. To use non-Lincoln motion
control and/or flux hoppers, follow instructions below. See Figure A.4.
1. Remove all input power to the MAXsa™ 10 CONTROLL R including
any auxiliary power supplies.
2. Remove the wire duct cover to gain access to the leads on the right
side of the terminal strip.
3. Remove a plug button from one of the .875” (22.2mm) access
holes on the bottom of the MAXsa™ 10 CONTROLL R control box.
Install a suitable strain relief to protect the leads. See Figure A.1.
4. Remove the leads going from the terminal strip to the correspond-
ing connectors, i.e. terminal strip blocks #11, #13, and #16 for the
4-pin TC-3 Travel Carriage or terminal strip blocks #19, #20, and
#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 nor-
mally 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 for CR3 are connected to terminal strip
blocks #17 through #22. See Figure A.3.
CR1 and CR2 relay coils are in parallel and are BOTH turned ON
and OFF as determined by the Travel Options setting (P12 in the
Set-up Menu) as long as the TRAV L MOD is set to AUTO. CR3
turns ON with the START command and OFF with the STOP
Command.
7. The supply voltage to power the devices is provided by the end
user. As shipped, the MAXsa™ 10 has the auxiliary supply blocks
(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.
OTE: 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 relay ratings listed earlier.
8. Connect input supply voltage per the Auxiliary Input Power
Connection Instructions listed earlier.
9. The relays can also be used to provide contact closure for any
interfacing signals out using the normally open contacts. An exter-
nal auxiliary supply voltage would not be necessary to use the
relays as hard contact closure out signals.
OTE: The CR1 relay as shipped does not have AUX leads connect-
ed to it. This relay operates as described above and has two
normally open / normally closed contacts that could be used
as a signal out when interfacing to PLC’s or custom controls.
SWITCH GROUP #2 SUPPLY
3-PIN FLUX
RECEPTACLE
A
B
C
TERMINAL
STRIP
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
FLUX FILL
GND IN
CR1 NC #7
TRAVEL #1 GND
531B-48
4-PIN TRAVEL
RECEPTACLE
A
B
C
D
CR2 INPUT #8
CR2 NO #2
CR2 NO #6
CR2 NC #3
CR2 INPUT #4
CR2 NC #7
TRAVEL #2 GND
GND
1
2
5 6
7 8 9
10 11 12
13 14 15
16 17
18
19
20
21 22 23
24
25
26
27
28
29 30
31
32
33 34
35
36
37
38 39
40
41
42
43 44 45
49 50
3 4
47
48
46
851
8510
859
CR1-4 CR1-8
CR1-2 CR1-6
CR1-3
CR1-7
GND-B
CR3-4
CR3-8
CR3-2
CR3-6
CR3-3
CR3-7
GND-A
CR2-4
CR2-8
CR2-2
CR2-6
CR2-3
CR2-7
531A-48
532A-49
GND-C
8511 SHUTDOWN #2
853
856
857
STOP
INCH FORWARD
INCH REVERSE
Numbers Refer to
Relay Terminals
CR1, CR2 CR3
Relays
FIGURE A.4 - CONTRO ING NON- INCO N EQUIPMENT

A-7
INSTALLATIONMAXSA™ 10 CONTROLLER
SHUTDOW I PUTS
The MAXsa™ 10 CONT OLLE has two shutdown inputs avail-
able on the terminal strip. These are independent, 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 blocks #24 and #25.
Shutdown #2 is located on terminal strip blocks #26 and #27.
1. emove all input power to the MAXsa™ 10 CONT OLLE
including any auxiliary power supplies.
2. emove the wire duct cover to gain access to the leads on
the right side of the terminal strip.
3. emove one of the plug buttons located on the bottom of the
MAXsa™ 10 CONT OLLE control box and install a box con-
nector to provide strain relief for the auxiliary control leads.
4. Connect the external shutdown circuit to either of the shut-
down terminal blocks, #24 & #25, and/or #26 & #27. A nor-
mally closed circuit must be connected – the MAXsa™ 10
CONT OLLE will recognize an open circuit as a shutdown
command.
5. emove the shorting jumpers imbedded in the center of the
terminal strip with a small screwdriver for the shutdown cir-
cuits to be used.
When a shutdown input is received, all welding will stop and an
error message will be displayed on the MAXsa™ 10 CON-
T OLLE . 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 I PUT
The MAXsa™ 10 CONT OLLE 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
Pushbutton located on the Switch Panel. Unlike the Shutdown
Inputs, which completely shutdown all welding and auxiliary
equipment, the STOP Input will allow all welding and auxiliary
motion to continue based on the END OPTIONS configurations in
the MAXsa™ 10 CONT OLLE . See Figure A.5.
1. emove all input power to the MAXsa™ 10 CONT OLLE
including any auxiliary power supplies.
2. emove the wire duct cover to gain access to the leads on
the right side of the terminal strip.
3. emove one of the plug buttons located on the bottom of the
MAXsa™ 10 CONT OLLE control box and install a box con-
nector to provide strain relief for the control leads.
4. Connect the external Stop Input circuit to terminal blocks #39
and #41.
OTE: The STOP circuit only needs a momentary closure to be
recognized by the MAXsa™ 10 CONT OLLE .
FIGURE A.5 - SHUTDOW A D STOP I PUTS
859
FLUX GND
CR3 NC #7
SHUTDOWN #2 SUPPLY
SHUTDOWN #1
SHUTDOWN #1 SUPPLY
22 23
24
25
26
27
8510
859
CR3-7
GND-C
8511 SHUTDOWN #2
Shorting
Jumper
Connect STOP
Input Here
39 41
40
SWITCH GROUP #1 SUPPLY
START
STOP

A-8
INSTALLATIONMAXSA™ 10 CONTROLLER
K1543-XX
or K2683-XX
Arclink Cable
67 Lead
K1785-XX
14-Pin Cable
Work
K231-XX
Contact Nozzle
Power Wave®AC/DC 1000SD
K2370-X
MAXsa™22
K1811-XX
Sense Lead
Electrode
Weld Cable
Work
Weld Cable
Connection Diagrams for Additional
Congurations (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

A-9
INSTALLATIONMAXSA™ 10 CONTROLLER
Notes:
DO NOT DISTURB ANY OTHER HARNESS, LEAD, OR EXISTING GROUND
CONNECTIONS DURING INSTALLATION.
• Turn the supply power OFF at the disconnect switch before working on this equipment.
• Do not touch 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-[ ] (L11087-[ ]) board.
ELECTRIC SHOCK can kill.

A-10
INSTALLATIONMAXSA™ 10 CONTROLLER
3- Remove J331 from the G4018-[ ] board.
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.

B-1
OPERATION
MAXSA™ 10 CONTROLLER
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
E ECTRIC 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 not use AC welder if your cloth-
ing, gloves or work area is damp or
if working on, under or inside work-
piece.
Use the following equipment:
-DC manual (stick) welder.
-AC welder with reduced voltage
control.
• Do not operate with panels
removed.
• Disconnect input power before ser-
vicing.
------------------------------------------------------------------------
ON Y QUA IFIED PERSONS SHOU D INSTA ,
USE OR SERVICE THIS EQUIPMENT. READ AND
FO OW THE MANUFACTURERʼS INSTRUC-
TIONS, EMP OYERʼS SAFETY PRACTICES AND
MATERIA SAFETY DATA SHEETS (MSDS) FOR
CONSUMAB ES.
------------------------------------------------------------------------
READ THIS WARNING, PROTECT YOURSE F &
OTHERS.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc,
or both,to keep fumes and gases
from your breathing zone and gener-
al area.
WE DING SPARKS can cause fire
or explosion.
• Do not weld near flammable material.
• Do not weld on containers which have
held flammable material.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
------------------------------------------------------------------------
WARNING

B-2
OPERATION
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 or29
WIRE DRIVE CONNECTOR (14-PIN)
STATUS
LIGHT
TRAVEL SWITCH
(AUTO / OFF / MANUAL)
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 PANEL
CONTROL
MODE SELECT
PANEL (MSP)
DISPLAY
200 ----
4
Steel 1/8”
CC AC
FIGURE B.2 - PENDANT CONTRO S