RETURN TO MAIN MENU IM10024-A MAXsa™ 22 & 29 WIRE DRIVES For use with machines having Code Numbers: March 2013 11615, 11616, 11815, 11816 11615 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS The engine exhaust from this product contains Diesel engine exhaust and some of its constituents chemicals known to the State of California to cause are known to the State of California to cause cancancer, birth defects, or other reproductive harm. cer, birth defects, and other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
ii ii SAFETY 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.
iii iii SAFETY 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.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v Thank You v 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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi vi TABLE OF CONTENTS Page Installation ..........................................................................................................Section A Product Description .....................................................................................................................A-1 Recommended Processes ..........................................................................................................A-1 Process Limitations ..........................................................
A-1 PRODUCT DESCRIPTION PRODUCT SUMMARY The MAXsa™ series of Automatic Wire Drives are designed for hard automation, submerged arc welding. The heavy-duty gearbox and feed plate have many years of proven reliability while a new permanent magnet motor has been added. The MAXsa™ 22 & 29 WIRE DRIVES consist of a high torque motor and gearbox assembly with a heavy-duty feed plate housing knurled drive rolls for positive, accurate wire feeding of heavy welding wire.
A-2 A-2 GENERAL INFORMATION DESIGN FEATURES - MAXsa™ 22 • Closed-loop speed control. • Knurled drive rolls. • Heavy cast aluminum gearbox housing and feed plate assembly. • Wire straightener. • Cross Seam Adjuster • Flux Hopper (not shown) • Mounting Hardware for accessories • 32Vdc permanent magnet, high torque motor. • Gears included to change speed range. FIGURE A.
A-3 A-3 INSTALLATION DESIGN FEATURES - MAXsa™ 29 • Closed-loop speed control. • Knurled drive rolls. • Heavy cast aluminum gearbox housing and feed plate assembly. • Wire straightener. • 32Vdc permanent magnet, high torque motor. • Gears included to change speed range. FIGURE A.
A-4 A-4 INSTALLATION DESIGN FEATURES - MAXsa™ 22 • Closed-loop speed control. • Knurled drive rolls. • Heavy cast aluminum gearbox housing and feed plate assembly. • Wire straightener. • Cross Seam Adjuster • Flux Hopper (not shown) • Mounting Hardware for accessories • 32Vdc permanent magnet, high torque motor. • Gears included to change speed range. FIGURE A.
A-5 A-5 INSTALLATION DESIGN FEATURES - MAXsa™ 29 • Closed-loop speed control. • Knurled drive rolls. • Heavy cast aluminum gearbox housing and feed plate assembly. • Wire straightener. • 32Vdc permanent magnet, high torque motor. • Gears included to change speed range. FIGURE A.
A-6 A-6 SPECIFICATIONS TECHNICAL SPECIFICATIONS - MAXsa™ 22 & 29 WIRE DRIVES Spec. Type 142:1 Speed Ratio Speed K2370-2 MAXsa™ 22 10-200 K2312-2 MAXsa™ 29 95:1 Speed Ratio Wire Size Solid Cored Speed 7/32 5/32 10-300 57:1 Speed Ratio Wire Size Solid Cored 1/8 5/32 Speed Wire Size Solid Cored 40-500 1/16 3/32 Wire Feeders - Input Voltage and Current Voltage Input Amperes 32V DC 7 Amps (max.) PHYSICAL DIMENSIONS MODEL K2312-2 K2370-2 K2311-1 WIDTH 14.0in (355mm) 14.0in (355mm) 6.
A-7 INSTALLATION SAFETY PRECAUTIONS Read this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF 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 system at the disconnect switch or fuse box before working on the equipment. • Do not touch electrically hot parts.
A-8 A-8 INSTALLATION POWER WAVE® AC/DC 1000 SD SUBARC SYSTEM CONNECTIONS (See Figure A.3) Diagram shown is for a single arc system. Refer to the power source manual for additional connection options (Multi-arc and/or parallel machines). Mounting Dimensions The MAXsa™ Wire Drive can be mounted by using the four 3/8-16 tapped holes or the two 0.562 through holes. See mounting hole locations (See Figure A.4). FIGURE A.
A-9 A-9 INSTALLATION CHANGING THE WIRE DRIVE CONFIGURATION 5. Carefully disconnect the Motor leads from the harness by pulling the quick-connect terminals apart. The MAXsa™ 22 & 29 WIRE DRIVES can be reconfigured to fit in any hard automation application. 6. Reverse the motor leads and reconnect the quickconnect terminals (see the Wiring Diagram). As shipped, the MAXsa™ 22 & 29 WIRE DRIVES Drive Rolls rotate clockwise to feed the wire down. Reconfiguring the Wire Drive per Figure A.
A-10 A-10 INSTALLATION WIRE FEED MECHANISM 4. Pull the gear from the shaft using the screws as a pulling device. All MAXsa™ Wire Drive units are shipped with 142:1 ratio gears. Gears are included to change to either 95:1 or 57:1 ratio depending on wire size to be used. 5. Be certain woodruff key is properly located on the shaft. Screw the adapter plate and motor assembly mounting screws into the new fiber input helical gear from the stenciled side and place the gear on the shaft.
A-11 A-11 INSTALLATION TABLE A.1 - DRIVE ROLL KITS KP1899 DRIVE ROLL KIT Drive Roll Kit Number Wire Sizes & Types KP1899-1 KP1899-2 KP1899-3 KP1899-4 3/32-7/32” 1/16-3/32” .035-.052” .045-.052” INCLUDED WITH KIT Drive Roll Incoming Part Number No. required Guide Wires Wires Solid Wire Cored Wire KP1885-1 KP1886-1 KP1887-1 KP1892-1 2 2 1 2 KP2116-2 KP2116-1 KP1967-1 KP1967-1 Outgoing Guide KP1963-1 KP2097-2 KP2097-1 KP2097-1 NOTE: Twinarc drive rolls are included with the Twinarc kits.
A-12 A-12 INSTALLATION K325 - TC-3 TRAVEL CARRIAGE The TC-3 travel carriage is available in two models. Both are “High Capacity” and suitable for multiple arc welding. FIGURE A.5 K325HC-S (Standard - 952:1 ratio) 5” to 70”/min (127mm to 1.88M/mim) 19” (483mm) K325-HC-F (High Speed - 254:1 ratio) 15” to 270”/min (381mm to 6.
A-13 A-13 INSTALLATION INSTALLATION The TC-3 comes factory assembled to fit an 8” (203mm) beam. See print G1458 for instructions to use it on 10” (254mm) or 12” (305mm) beams. The Carriage Release Handle, the Wire Reel Support Bracket and the Wire Drive Support Bracket are not factory mounted. They should be mounted to the carriage before it is placed on the beam per the following instructions. 1.
A-14 A-14 INSTALLATION INCLINED OPERATION OF TC-3 1. The beam should have a Knurled Drive Flange and the TC-3 should have the straight toothed Drive Gear (T13586 - ordered separately). CAUTION When the carriage is used in an inclined application the unit is free to move whenever the Carriage Release Handle is pulled down. This may happen even if a counter balance weight is used.
A-15 A-15 INSTALLATION FIGURE A.7 - DRIVE GEAR TRACKING Incorrect ADD Shims Shims Drive Gear Full Face Contact .88” Incorrect REMOVE Shims Beam Drive Rail DRIVE GEAR TRACKING FIGURE A.8 - BEARING TRACKING The TC-3 is shimmed at the factory so that the drive gear sits flat against a .88” (22mm) flange when the release handle is in the up position. If the flange dimension is other than .88” (22mm) the shims under the TC-3 gear box mounting will have to be changed accordingly. See Figure A.7.
B-1 OPERATION B-1 ROUTINE OPERATION Once the procedures and parameters are properly set at the controller the operator should be able to make production welds without changing those settings. A typical weld sequence is as follows: 1. Before starting, make sure that: a. There is enough wire on the reel(s) to finish the weld. b. The flux hopper is filled with new or properly screened flux. 2. Energize the power source and wait for it to stabilize (all Status LED’s Green). 3.
B-2 B-2 OPERATION FIGURE B.1 - FEED HEAD ADJUSTMENT The Cross Seam Adjuster Can Be Mounted to the Top or Bottom of the Gear Box Loosen this Socket Head Screw to Adjust Faceplate Angle 5/16” Allen Wrench Face-plate Rotates 360° Around the Drive Roll Shaft Feed Head Rotates 360° Around the Motor Axis FIGURE B.
C-1 ACCESSORIES 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 click on E9.181. All of the information for the Power Wave System accessories can be found in this document.
C-2 C-2 ACCESSORIES SUBMERGED ARC CONTACT ASSEMBLIES Connect the lug on the electrode cables from the power source to the tab on the contact nozzle and tighten the bolt and nut. See Figure C.1. K231-[X/XX] CONTACT NOZZLE The K231- [x/xx] is used for submerged arc welding with currents generally under 600 amps. Higher currents can be used but result in somewhat faster tip wear. The outer flux cone deposits flux around the arc for full coverage with minimum flux consumption.
C-3 C-3 ACCESSORIES K226 CONTACT ASSEMBLY Maintenance - Rusty or dirty wire and/or excessively high welding currents increase wear on the contact jaws. When arcing occurs or the electrode becomes loose in the jaws, remove the jaws and ‘dress’ them with a file. When necessary, the jaw inserts should be replaced. The K226 assemblies are used for welding at currents from 600 to 1000 amps. Model K226-T - (2 tapered jaws) 3/32” and 1/8” (2.4 and 3.
C-4 C-4 ACCESSORIES K148 CONTACT NOZZLE AND K149 Linc-Fill LONG STICKOUT EXTENSION TM This nozzle is available in three models and can be used for Innershield® or submerged arc processes. K148-A - For 3/32” and 1/8” (2.4 - 3.2mm) wire. K148-B - For 5/32” and3/16” (4.0 - 4.8mm) wire. K148-C - For 1/16” to 5/64” (1.6 to 2.0mm) wire. 7. Slide the center guide (G) up out of the pivot body until the tang is above the window. 8.
C-5 C-5 ACCESSORIES 10. Line up the lower spot in the center guide tube (G) with the 3/8” (9.5 mm) set screw (H) and tighten the screw securely. 11. Replace the brass thread protecting collar (E). It is important that this protecting collar be pulled up against its locating shoulder, otherwise the tip locking nut will not clamp the tip securely. 12. Replace the contact tip and its clamping nut (D) and tighten securely. 13.
C-6 C-6 ACCESSORIES To install a new contact tip proceed as follows: K285 Installation to the K148 1. Clip the end of the electrode and inch it up until it is free of the tip. 1. Remove the tension on the center guide tube using a “C” clamp as shown in Figure C.8. Apply only enough clamping force to relieve the tang pressure from the contact tip. 2. Remove the contact tip locking nut. 3. Relieve the spring pressure of the contact tip against the steel tang in the hole of the contact tip.
C-7 C-7 ACCESSORIES K285 Installation with K149 K285 installation with the K129 1. Install the K149 to the K148 per the instructions. 1. Unscrew the hose clamps enough so they can slip over the tip holder clamping nut. 2. Loosen the hose clamps of the K285 entirely, place them around the nozzle and tighten them so that the stationary part of the K285 is directly opposite the K149 arm. See Figure C.10. NOTE: The lower hose clamp must be positioned so it does not touch the arm of the K149. 2.
C-8 ACCESSORIES C-8 K285 Used in Horizontal Fillet Applications 1. With K148 or K148/K149 combination - After the K285 has been attached to the nozzle body: a. Set the head and nozzle to the desired electrode angle. b. Loosen the two hold down screws that hold the nozzle to the faceplate and rotate the entire assembly 40 to 45° and retighten the screws. c. Loosen the K285 hose clamps and rotate the flux cone unit about 40 to 45° and retighten the clamps. d.
C-9 ACCESSORIES C-9 K29 VERTICAL HEAD ADJUSTER Automatic welding applications frequently require raising and/or lowering of the feed head assembly. The K29 provides an easy method of accomplishing this task by simply turning a crank handle. A height variation of 4” (102mm) is possible with this attachment. FIGURE C.13 - K29 4. Slide the Head Adjustment Lock (A) over the end of the Mounting Bracket (M). 5.
C-10 C-10 ACCESSORIES K96 HORIZONTAL HEAD ADJUSTER The K96 provides an easy means of moving the Feed Head in a horizontal direction by simply turning a crank handle. It provides 2” (51mm) of travel and can be mounted directly to the Head Support or to a K29 Vertical Lift Adjuster. Installation (See Figure C.14) 1. If the Feed Head is already mounted, make sure that the Lock Nut (H) on the Feed Head Draw Bolt (J) is tight and drive out the Roll Pin (G) with a 5/16” punch. 2.
C-11 C-11 ACCESSORIES FIGURE C.16 - K129 TINY TWINARC® COMPONENTS 1 D A F 7 6 2 E C 3 3 5 B 4 4 1 - Nozzle Assembly 2 - Guide Tubes 3 - Locking Collar 4 - Contact Tip(s) 5 - Tip Holder 6 - Connection Tab 7 - Mounting Block A - Drive Rolls B - Guide Tubes C - Idle Roll Arm D - Incoming Wire Guide E - Drive Roll Spacer F - Key K129 TINY TWINARC® KIT INSTALLATION Twin arc welding is a process where two wires of the same size are fed through a nozzle by a single wire drive.
C-12 ACCESSORIES B. For 3/32 (2.4mm) Wire 1. Remove the items listed in Step “A” plus: • The drive roll key. • The drive roll spacer. NOTE: The set screw that holds the drive roll spacer in place is accessible once the idle roll assembly is removed. 2. Oil or grease the O.D. of the new shorter drive roll spacer (E) and place it on the output shaft. Push it back as far as it will go and tighten the set screw. C-12 5.
C-13 C-13 ACCESSORIES FIGURE C.18 - K225 TWINARC® COMPONENTS 1 A E F 2 9 D C B 3 5 A - Drive Rolls B - Guide Tubes C - Idle Roll Arm D - Drive Roll Spacer E - Key F - Nozzle Assembly 7 8 6 4 K225 SUBMERGED ARC TWINARC® KIT Twin arc welding is a process where two wires of the same size are fed through a nozzle by a single wire drive. The K225 Twinarc Kit can be used to weld with 5/64”, 3/32” or 1/8” (2.0, 2.4 or 3.2mm) electrodes. Both wires must be the same size.
C-14 C-14 ACCESSORIES Nozzle Installation (See Figure C.18) 1. install the new idle roll arm (C) using the pin and set screw from the original assembly. IMPORTANT Make sure that the mating surface (8) between the Center Block (4) and the Copper Bar (2). is bright, clean and smooth. This junction carries the full weld current. 2. Replace the tension spring and screw and adjust the tension screw to the proper line on the indicator plate. FIGURE C.20 3.
C-15 C-15 ACCESSORIES K281 SOLID WIRE STRAIGHTENER FOR TINY TWINARC® The K281 wire straightener can be used to straighten .045” through 3/32” (1.0-2.4mm) wiress. It is recommended for applications requiring long stickout and/or where accurate wire placement is essential. The following table shows the recommended maximum electrical stick-out (ESO). ESO - Standard ESO - K281 Wire Size (mm) Wire Guide (mm) Straightener (mm) .045” (1.0) 3/8” (9.5) 5/8” (16.0) .052” (1.3) 1/2” (12.5) 3/4” (19.
D-1 MAINTENANCE SAFETY PRECAUTIONS SENSE LEAD FUSE There should never be any current flowing through the sense leads! The sensing lead circuit is current protected in the Power Wave® AC/DC 1000 SD. WARNING ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • D-1 Do not touch electrically hot parts.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Drive rolls turn, but wire will not feed or wire feeding is rough or uneven. 1. Wire jammed or kinked on route through wire drive. Remove wire from wire drive, then feed in new wire. Note any obstruction. RECOMMENDED COURSE OF ACTION 2. Incorrect drives rolls and/or guide tubes, or incorrect pressure setting.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2 DIMENSION PRINT MAXsa™ 22 & 29 WIRE DRIVES F-2
23.42 13.50 11.14 20.64 10.88 .35 CENTERLINE OF WIRE 8.90 5.53 5.15 4.35 11.21 7.39 17.39 7.43 . 1.438 2.
6.15 MAXsa™ 22 & 29 WIRE DRIVES 10.73 3.50 5.11 2.59 5.19 CENTERLINE OF WIRE 12.04 4.22 5.37 .21 2.82 7.70 3/8-16 TAPPED HOLE (4 PLACES) .62 14.11 .96 . .560 (2 HOLES) CENTERLINE OF WIRE 2.69 .40 2.50 .50 2.50 .
NOTES MAXsa™ 22 & 29 WIRE DRIVES
Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Keep flammable materials away. Wear eye, ear and body protection. Mantenga el material combustible Protéjase los ojos, los oídos y el electrode with skin or wet clothing. Insulate yourself from work and ground. No toque las partes o los electrodos bajo carga con la piel o ropa mojada. Aislese del trabajo y de la tierra.
Keep your head out of fumes. Use ventilation or exhaust to Turn power off before servicing. Do not operate with panel open or guards off. remove fumes from breathing zone. Los humos fuera de la zona de res- piración. Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. Gardez la tête à l’écart des fumées. Utilisez un ventilateur ou un aspira- Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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