2. MAXsa 10 IM10023
CODE 11590
DESIGN FEATURES
EASY CONTROL OF ALL WELD PARAMETERS
8 MEMORIES FOR EASY STORAGE AND RECALL OF WELD
SCHEDULES
WELD PARAMETERS LIMIT SETTING AND LOCKOUT CAPABILITIES
DIGITAL COMMUNICATIONS FOR ACCURATE AND RELIABLE
PERFORMANCE
DESIGNED FOR POWER WAVE AC/DC 1000 SERIES OF PRODUCTS
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 READOUTS
OPTION TO CONVERT TO HAND HELD PENDANT INCLUDED
3. MAXsa 10 Controller
Main User Interface and Wire Drive Controller
for POWERWAVE AC/DC 1000 SD
Backwards compatible with POWERWAVE
AC/DC 1000
– Replaces PF-10A and Wire Drive Module
• Requires disconnection of WDM
• Functionality Based on NA-5 and PF-10
4. MAXsa 10 Controller
All Weld Parameters, Timers, Motion, Procedure
Memory, Configuration, and Diagnostics are
accessed at the MAXsa 10 Controller
Communicates using ArcLink
Versatile – Can Interface with Custom Controls
and PLC’s, Integrator Friendly, Multiple
Configurations, easy Setup, etc
5. MAXsa 10 Controller
Pendant can be removed in two easy steps
1. Remove the 4 screws from the MAXsa 10 Controller that
hold the cover
2. Remove the 2 screws that hold the pendant in the
brackets. Use the access holes shown
9. MAXsa 10 Pendant
Communication
• Pendant communicates to controller
over standard 5 pin ArcLink Cable.
Controls
• START
• STOP
• FEED (FORWARD/REVERSE)
• FLUX FILL
• TRAVEL
- ON, OFF, AUTO
Functions
START
BUTTON
STOP
BUTTON
FEED
REVERSE
FEED
FORWARD
TRAVEL
SWITCH
FLUX FILL
10. POWER UP SEQUENCE
•THE FIRST SCREEN YOU SEE IS MAXsa 10 INITIALIZING
•AFTER CONTACTOR PULLS IN ALL THE LEDs WILL LIGHT UP
•THE NEXT SCREEN SHOWS THE ARCLINC INITIALIZING
•NEXT YOU WILL SEE THE WELDING SOFTWARE VERSION
•FINALLY THE UNIT WILL POWER UP ON ITS LAST SETTINGS
•ALL OF THIS WILL TAKE AROUND 25 SECONDS
FORWARD AND REVERSE
INCH SETTINGS
•YOU HAVE THE ABILITY TO COLD FEED YOUR WIRE IN
EITHER DIRECTION
•THE WIRE FEED SPEED CAN BE ADJUSTED WHILE IN
COLD INCH
•MUST BE SET UP IN THE PARAMETER SETTINGS P.15
TOUCH SENSE ENABLE / DISABLE
•WHEN THE WIRE IS ELECTRICALLY “HOT” YOU WILL
SEE THIS SCREEN
15. SETTING WELD PARAMETERS
PRESS BOTH BUTTONS TOGETHER TO ENTER
THE PARAMETER SETTINGS
INDICATOR LED
WILL LIGHT
USE ENCODER TO
ENTER DIFFERENT
PARAMETERS
(SEE UPCOMING
SLIDES)
PRESS BOTH BUTTONS TOGETHER, OR RETURN
TO P0 AND PRESS LEFT BUTTON TO EXIT
PRESS RIGHT BUTTON TO
ENTER THE VARIOUS USER
PREFERENCES, THEN USE
THE ENCODER TO SET THE
DESIRED SETTINGS
WHEN ALL THE DESIRED SETTING ARE
COMPLETE PRESS THE LEFT BUTTON
TO MOVE TO THE NEXT PARAMETER
16. THE TRAVEL CARRIAGE CAN BE SET TO START WITH THE START SWITCH
OR WHEN THE ARC IS ESTABLISHED.
THE TRAVEL CARRIAGE CAN BE SET TO STOP WITH THE STOP BUTTON
OR WHEN THE ARC GOES OUT
21. SAVING AND STORING
MEMORIES
ALL PARAMETERS THAT WERE ACTIVE ARE
STORED (SAVED ) IN MEMORY UNTILL THEY
ARE OVER WRITTEN BY HOLDING THE
SELECTED MEMORY BUTTON DOWN FOR 2
SECONDS
MAKE ALL
PERTINENT WELD
SETTINGS THEN
PRESS AND HOLD
THE SELECTED
MEMORY BUTTON
FOR 2 SECONDS
BRIEFLY PRESS ANY MEMORY BUTTON TO
RECALL SETTINGS SET IN THAT PARTICULAR
MEMORY. THE MEMORY LED WILL LIGHT WHEN
THAT MEMORY IS SELECTED
NOTE: IF YOU HOLD THE MEMORY
BUTTON DOWN FOR MORE THEN 1
SECOND YOU COULD OVERRIDE
THE MEMORY SETTINGS.
22. SETTING LIMITS
PRESS AND HOLD ANY
MEMORY BUTTON FOR 5
SECONDS TO SET LIMITS
RED INDICATOR LIGHT COMES ON INDICATING
YOU HAVE ENTERED SETUP MODE
AFTER ALL DESIRED LIMITS ARE SET PRESS THE
MEMORY BUTTON THAT WAS ENABLED TO EXIT
THE LIMIT SETTINGS
THIS SCREEN WILL NOW
APPEAR. PRESS LEFT
BUTTON TO SAVE THE
SETTINGS
PRESS AND HOLD ANY ACTIVE MEMORY
BUTTON FOR 10 SECONDS TO DISABLE LIMITS.
THE SCREEN WILL READ ENABLE/ DISABLE FOR
AROUND 3 SECONDS. IF NEITHER IS SELECTED
IT WILL DEFAULT TO ENABLE LIMITS YES/NO.
SELECT NO TO DISABLE LIMITS
SET THE HIGH LIMIT WITH
THE ENCODER WHEN IT IS
FLASHING. THEN PRESS
LEFT BUTTON TO GO TO
THE NEXT ACTIVE SETTING
SET THE LOW LIMIT USING THE
ENCODER WHEN IT IS FLASHING.
THEN PRESS LEFT BUTTON TO GO
TO THE NEXT ACTIVE SETTING
ENCODER KNOB
ALLOWS THE
OPERATOR TO ENTER
ALL ACTIVE MODES
AND SET BOTH UPPER
AND LOWER LIMITS
THIS SCREEN WILL
NOW APPEAR
PRESS THE RIGHT
BUTTON TO ENTER THE
FLASHING LIMIT
SETTING LIMITS FOR WELDING AMPS IN
THIS EXAMPLE (NOTE; ONLY ACTIVE
MODES CAN BE SET)
25. Wire Feed Control Board (L11087 series)
Controls operation of welding
apparatus
– MAXsa Feeder
• Drive
• Tachometer Feedback
– Flux Hopper Relay
– Travel Carriage Relay via G4018
– Two Shutdown Inputs
– Remote Start and Stop
Contains hardware to drive
related peripherals
– Voltage Sense Select PC Board
Functions
O
N
J87 J86 J85
J84
J83
J82
J81
FEEDHEAD
L11087-3
26. Wire Feed Control Board (L11087 series)
Feed Head Selection
– Provides selection of new feed heads
• Can be changed with Power Wave Manger
Gear Box Selection
– Software configurable: No longer
required to change dip switches or
jumpers to select a different gear box.
• Can be changed with MAXsa 10 (P18) or
Power Wave Manager
Setup / Configuration Options
27. Not equipped with on board status indicators.
– External Status Indicator located on front panel.
If status light is not lit suspect a power problem
– Check for 40VDC supply at 3:J81 and 4:J81
– If voltage is present, and status LED circuit is intact,
reload software or replace board
If board appears functional, but will not
communicate:
– Suspect a communication problem
– Use Power Wave Manager to verify the board is
present in the system
Simplified Test Procedure
Wire Feed Control Board (L11087 series)
28. J81 – ArcLink and Input Power
J82 – ArcLink and Input Power
J83 – Motor Power, Flux Hopper
Control
J84 –Tachometer input and
feedback
J85 – External Inputs, Status
LED, Voltage Sense control
J86 – To Relay Board (SPI)
J87 – N/C
O
N
J87 J86 J85
J84
J83
J82
J81
FEEDHEAD
L11087-3
Wire Feed Control Board (L11087 series)
Connectors
3
4
J81 PINS 3 & 4
40Vdc INPUT
J82 PINS 3 & 4
40VDC TO PENDANT
3
4
3
4
2
1
J83 PINS 1 & 2 = 2 – 32 VDC
MOTOR CONTROL, 40VDC WITH OPEN
PINS 3 & 4 15VDC FLUX SOLENOID NOTE:
40VDC WITH OPEN
J83
J84 PINS 1 & 4 15VDC
TACH SUPPLY
PINS 2 & 3
TACH FEEDBACK
30Hz TO 2.5KHz
4
3
2
1
16
15
14
13
J85 PINS 13 &14 15VDC T0 VOLTAGE
SENSE BOARD @ TRIGGER
PINS 15 & 16
STADUS LED
J86 TO RELAY
DRIVE BOARD
29. ARCLINK CONNECTOR
OUT TO THE
F.R.E.D. BOARD
J2 VOLTAGE
SENSE BOARD
WIRE FEED CONTROL
BOARD INPUT J81
30. FEED MOTOR WILL NOT
RUN IF DIODE IS OPEN
2 TO 32 VDC
LEADS 845/846/67C
NOT USED
12V COIL
40V IF OPEN
J1 VOLTAGE
SENSE BOARD
MOTOR CONTROL
IPM
10=93 Hz
100=924 Hz
200=1.84KHz
31. Relay Drive Board(G4018 series)
J33
J331
J332
J333
G4018-2
REMOTE
Function
Controls relay’s for Travel Carriage
•Receives its operating voltage and commands from
the Wire Feed Control Board via J33
Supplies 12 VDC to CR2 to operate the Travel Carriage.
CR1 is a spare.
32. Terminal Strip
Provides Customer connection interface
– Remote Pendant access
– 115VAC Auxiliary power input
• TC3 Travel Carriage and Flux Hopper
– Control Relay Access
• CR1 is available on the Terminal Strip for customer use
- Mimics operation of CR2.
• CR2 – Travel Relay
• CR3 – Flux Hopper Relay
• Relays can be re-configured and used as outputs for Custom
Controls or PLC driven applications.
– Shutdown Circuits
33. 115VAC IN FROM POWER
RECEPTICAL SOURCE OR
OTHER POWER SOURCE
115VAC NEEDED TO POWER
UP THE FLUX HOPPER AND
THE TC3 TRAVEL CARRIAGE
15VDC
15VDC
Switch group # 1
Switch group # 2
Start
Stop
Inch Down
Inch Up
Flux Fill
USED FOR REMOTE
TRIGGERING
34. ALL THREE RELAYS
THE SAME
CR2 TRAVEL CARRAGE
CR1 SPARE
2 SHUT DOWN TERMINALS
BOTH NEED 115VAC
TO OPERATE
CR3 FLUX HOPPER
COIL RATING 12VDC
RESISTANCE 86 OHMS
N.C. 3A @ 277VAC
N.O. 30A @ 277VAC
531A
532A
531B
532B
35. Relays
Operation
– CR1 & CR2 – Travel
• ON with START or ARC ON (Configurable)
• OFF with STOP or ARC OUT (Configurable)
– CR3 – Flux Hopper
• ON with ARC ON or
depressed FLUX FILL BUTTON
• OFF with ARC OUT or
depressed FLUX FILL BUTTON
36. Shutdown Circuits
The MAXsa 10 has two, independent shutdown circuits
– Accessible on the Terminal Strip.
• The Controller is shipped with shorting jumpers between Terminal Strip
Blocks 24 & 25, and 26 & 27.
• If the customer plans to wire a shutdown input, one or both of the
shorting jumpers will need to be removed.
– The circuit is Normally Closed, and if an Open is seen by the
MAXsa 10, the entire system will shutdown.
• If a Shutdown 1 occurs, the Display will show “Err XX” & “Shutdown” and
will prompt a “Reset” by pressing the Left Mode Select Panel
Pushbutton.
- Err 83 coincides with Shutdown 1 ( At All Times )
- Err 84 coincides with Shutdown 2 ( P21 Normal Shutdown Mode )
• Err 28 ( P21 Output Disable Mode ) Overrides the “Hot Inch”
• Both shutdown circuits must be closed before the Reset will be accepted.
37. User Interface Board (G4759 series)
Used to configure output settings
Displays Output feedback
Stores 8 memory selections
Functions
FRONT BACK
39. MAXsa 10 Pendant
Troubleshooting Tips:
• No Displays
- Check 40 VDC supply (3:J31, 4:J31)
• Flashing Displays
- Check for loose wires and molex connections
• Displays Error 6
- Verify ArcLink connections and setup
• Any Other Error Displayed
- Use Power Wave Manager to troubleshoot
40. Functions
Voltage Sense Select PCB (M19540 series)
Connects the active feeder to the Electrode Voltage
sensing network.
– Appears as an ArcLink object, but is physically driven by
Feedhead Control PCB.
Protects Electrode Voltage sensing network from
transients.
49. Wire Drive Module
External I/O Connector
Shutdown jumpers required
for proper operation.
Special consideration required
for external trigger use.
– Sequencer must be properly
configured. Failure to do so will
result in unknown output.
• Typically, weld mode and
workpoint values default to
minimum.
Error 83 Shutdown Error #1
Error 84 Shutdown Error #2
50.
51. MAXsa Series
Wire Drives
Multiple speed range. (P18)
– 142:1 (default)
• 10-200 ipm
– 95:1 (conversion kit included)
• 10-300 ipm
– 57:1(conversion kit included)
• 40-500 ipm
Proven gearbox design
Robust WFS control system
– Differential tach performs at distances up to 100 ft
(K1785-xx)
– For optimal performance minimize cable distance
MAXsa 22 & 29 functions
the same but mount differently
52. MAXsa Series (K2370-2 / K2312-2)
Wire Drives
14 pin connection
standard
– K1785 Series Cable
Pin Lead # Description
A 539 Motor +
B 541 Motor -
C 521 Solenoid +
D 522 Solenoid Common
E 845 Tach 2A Differential Signal
F 847 Single Tach Input
G 841 + 15V Tach Supply
H 844 Tach Common
I 21x Work Sense (21)
J 67D Electrode Sense (67)
K 842 Tach 1A Differential Signal
L 843 Tach 1B Differential Signal
M 846 Tach 2B Differential Signal
N 67x Electrode Sense (67)
53.
54.
55. MAXsa 22 & 29 Series Set-up
Wire Drives
Changing the gear ratio
– 95:1 and 57:1 Gear Conversion Kit supplied with
feeder
• Stenciled for identification
– Gear ratio set through PC tools (P18)
Setting the Electrode Polarity
– Electrode polarity is automatically configured.
56. Wire Drives
TACHOMETER TACH SUPPLY 15V
TACH SUPPLY 15V
OVER CURRENT SHUT DOWN 9 AMPS 20 SEC.
20 AMPS ½ SEC. TAKES 45 SEC TO RESET
1 TO 2 OHMS
WIRE FEED
CONTROL BOARD
2 TO 32 VDC
831 TO 832
2 TO 32 VDC
550 TO 551
Differential Tach Output 93Hz to 1.84 KHz
Motor off 2.5 - 3.0VDC
Motor on 0 - .5VDC
Tach Sensor Output 93Hz to 1.84KHz
Motor off 0 or 15VDC
Motor on 5.5 to 6.5VDC any speed
Differential Tach Output 93Hz to 1.84 KHz
Motor off 2.5 - 3.0VDC
Motor on 0 - .5VDC
57. Remote Arc Voltage Sensing
Wire Drives
Provide most accurate info. to control the arc
– Best performance
Electrode Sense lead built into Control Cable
– Shielded for maximum noise immunity
Work Sense Lead not accessible on Wire Drive
Work Voltage Sense lead must connect at Power
Source (4 pin connector)
– Work Sense lead internal to motor control box
• Can be brought out for K2344-1 &2 installations
( AC/DC 1000 )
67
X
21
58. Arc Voltage Sense Leads
Cables and Connections
Position the sense leads out of the path of the weld
current. No less then 12 inches, 300 mm.
– Especially any current paths common to adjacent arcs.
Current from adjacent arcs can induce voltage into each
others current paths that can be misinterpreted by the power
sources, and result in arc interference.
– Use Plastic Cable Trays
– Use wooden blocks as spacers on top of metal trays.
– Do not run cables through metal trays that can support a
magnetic field.
Always route separate from Work and Electrode
59. Multiple Arcs
Cables and Connections
For circumferential applications,
connect all work leads on one
side of the weld joint, and all of
the work voltage sense leads on
the opposite side, such that they
are out of the current path
60. Multiple Arcs
Cables and Connections
For longitudinal applications,
connect all work leads at one end
of the weldment, and all of the
work voltage sense leads at the
opposite end of the weldment.
Perform welding in the direction
away from the work leads and
toward the sense leads.
CONNECT ALL SENSE
LEADS AT THE END
OF THE WELD
CONNECT ALL
WORK LEADS AT
THE BEGINNING OF
THE WELD
DIRECTION
OF TRAVEL
61. Control Cables
Cables and Connections
Guidelines
– Do Not coil excess cable
– Route separate from current carrying conductors
(Especially Work and Electrode Cables)
– Guidelines apply to all communication cables
including Wire Feeder Control Cable, and optional
DeviceNet and Ethernet cables.
62. Do not coil Ethernet cables.
Do not route the control
cables with the weld
cables.
63. Output Cables
Cables and Connections
Use the largest cable size practical
– Note minimum cable sizes listed in Instruction Manual
Minimize cable inductance
– Route Work and Electrode together if possible
TABLE 1 - Output Cable Guidelines
Total Cable Length ft (m)
Electrode and Work Combined
Duty Cycle
Number of
Parallel Cables
Cable Size
Copper
0 (0) to 250 (76.2) 80% 2 4/0 (120 mm2)
0 (0) to 250 (76.2) 100% 3 3/0 (95 mm2)
64.
65. Steel needs eight times the surface
area to conduct the same amount
of current as copper.
69. Cables and Connections
DISTANCE ELECTRODE
AND WORK ARE
SEPERATED
POWER
SOURCE
TOTAL CABLE LENGTH =
DISTANCE FROM ELECTRODE STUD TO FEEDER
+ DISTANCE THROUGH WORKPIECE
+DISTANCE FROM WORK TO WORK STUD
Loop area is defined as the total length of
electrode cable plus workpiece plus work
cable.
70.
71. Cable and Connections
An existing process is set up using a 50 Hz
balanced waveform running 500 Amps and 35
Volts. The welding setup uses three 3/0 cables
that run 100 feet from the electrode stud on the
welder to the feeder, a workpiece that is 10 feet
long , and three 3/0 cables that run 90 feet from
the end of the workpiece back to the work stud
on the welder. The electrode cables are
separated from the work cables by 5 feet. The
machine is connected to a 460 Volt input line.
72. Cable and Connections
What is the inductance of the system?
– Total cable length = 100 feet of electrode cable + 10 feet of workpiece
+ 90 feet of work cable = 200 feet
– Separation distance= 5 feet
– Based off of the chart the inductance should be approximately 47 uH.
73.
74. Based on this chart you will
not be able to achieve 1000
Amps
2350
How Does My Input Voltage Effect My Ability To
Achieve Desired Weld Amperage?
75. 2350
How Does My Input Voltage Effect My Ability To
Achieve Desired Weld Amperage?
76. Based on this chart you can see
that 1000 Amps is easily attained
with an input voltage of 575 Volts.
2350
How Does My Input Voltage Effect My Ability To
Achieve Desired Weld Amperage?
77. 28uH x 50Hz = 1400 uH Hz
JUST BY DECREASING THE DISTANCE BETWEEN THE WORK AND ELECTRODE
CABLES GIVES YOU THE ABILITY TO ACHIEVE THE DESIRED OUTPUT CURRENT.
