Lincoln Electric MAXsa 29 WIRE DRIVE Operator's Manual
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Lincoln Electric MAXsa 29 WIRE DRIVE Operator's Manual

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Operator's Manual
MAXsa
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10265
| Issue D ate June-15
© Lincoln Global, Inc. All Rights Reserved.
TM
29 WIRE DRIVE
For use with machines having Code Numbers:
12424

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Summary of Contents for Lincoln Electric MAXsa 29 WIRE DRIVE

  • Page 1 Operator’s Manual MAXsa 29 WIRE DRIVE For use with machines having Code Numbers: 12424 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10265 | Issue D ate June-15 ©...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Installation ......................Section A Product Description ........................A-1 Recommended Processes ......................A-1 Process Limitations ........................A-1 Equipment Limitations .........................A-1 Common Equipment........................A-1 Specifications ..........................A-2 Safety Precautions........................A-3 Non-Safety Standard Equipment..................A-3 Input and Ground Connections ....................A-3 Location and Mounting ......................A-3 High Frequency Protection....................A-3 Power Wave ®...

  • Page 7: Product Description

    PRODUCT DESCRIPTION PRODUCT SUMMARY The MAXsa™ series of Automatic Wire Drives are designed for hard automation, submerged arc weld- ing. The heavy-duty gearbox and feed plate have many years of proven reliability while a new perma- nent magnet motor has been added. The MAXsa™...
  • Page 8 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.2 - LOCATION OF MAXsa™...
  • Page 9 INSTALLATION DESIGN FEATURES - MAXsa™ 29 • 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 •...
  • Page 10 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.2a - LOCATION OF MAXsa™...

  • Page 11: Specifications

    SPECIFICATIONS TECHNICAL SPECIFICATIONS - MAXsa™ 29 WIRE DRIVE Spec. Type 142:1 Speed Ratio 95:1 Speed Ratio 57:1 Speed Ratio Wire Size Wire Size Wire Size Speed Solid Cored Speed Solid Cored Speed Solid Cored 10-200 7/32 5/32 10-300 5/32 40-500 1/16 3/32 K2312-3 MAXsa™...

  • Page 12: Safety Precautions

    INSTALLATION HIGH FREQUENCY PROTECTION SAFETY PRECAUTIONS Locate the MAXsa™ Wire Driveaway from radio con- Read this entire installation section before you trolled machinery. start installation. WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • Turn the input power OFF at the dis- connect switch or fuse box before working on this equipment.

  • Page 13: Power Wave

    INSTALLATION POWER WAVE AC/DC 1000 SD SUBARC Mounting Dimensions ® SYSTEM CONNECTIONS ( See Figure A.3) The MAXsa™ Wire Drive can be mounted by using the four 3/8-16 tapped holes or the two 0.562 through Diagram shown is for a single arc system. Refer to the holes.

  • Page 14: Changing Wire Drive Configuration

    INSTALLATION CHANGING THE WIRE DRIVE 5. Carefully disconnect the Motor leads from the har- CONFIGURATION ness by pulling the quick-connect terminals apart. The MAXsa™ 29 WIRE DRIVE can be reconfigured to 6. Reverse the motor leads and reconnect the quick- fit in any hard automation application. connect terminals (see the Wiring Diagram).

  • Page 15: Wire Feed Mechanism

    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 5. Be certain woodruff key is properly located on the ratio gears. Gears are included to change to either 95:1 shaft.
  • Page 16 A-10 A-10 INSTALLATION TABLE A.1 - DRIVE ROLL KITS KP1899 DRIVE ROLL KIT INCLUDED WITH KIT Drive Roll Drive Roll Incoming Outgoing Kit Number Wire Sizes & Types Part Number No. required Guide Guide KP1899-1 3/32-7/32” Wires KP1885-1 KP2116-2 KP1963-1 KP1899-2 1/16-3/32”...
  • Page 17 A-11 A-11 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 FIGURE A.5 welding. K325HC-S (Standard - 952:1 ratio) 5” to 70”/min (127mm to 1.88M/mim) 19”...
  • Page 18 A-12 A-12 INSTALLATION INSTALLATION NOTE: To install a MAXsa™ 29 Wire Drive order a The TC-3 comes factory assembled to fit an 8” Mounting Bracket (M6769) and the appropri- (203mm) beam. See print G1458 for instructions to ate Head Support (K29 or M8232). use it on 10”...
  • Page 19 A-13 A-13 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.
  • Page 20 A-14 A-14 INSTALLATION FIGURE A.7 - DRIVE GEAR TRACKING Incorrect ADD Shims Shims Full Face Incorrect Beam Drive Gear .88” Contact REMOVE Shims 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”...

  • Page 21: Operation

    Wire Drive head stationary and the wire not touch- to any weld position. The most often used adjust- ing the workpiece. ments are available on the MAXsa 29 Wire drive. See Figure B.1 a. Always cut the end of the wire to a sharp point.
  • Page 22 OPERATION FIGURE B.1 - FEED HEAD ADJUSTMENT The Cross Seam Adjuster Can Be Mounted to the Loosen this Socket Top or Bottom of the Head Screw to Adjust Gear Box Faceplate Angle 5/16” Allen Feed Head Rotates Wrench Face-plate Rotates 360°...

  • Page 23: Options And Accessories Website

    ACCESSORIES OPTIONS AND ACCESSORIES 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.
  • Page 24 ACCESSORIES Connect the lug on the electrode cables from the SUBMERGED ARC CONTACT power source to the tab on the contact nozzle ASSEMBLIES and tighten the bolt and nut. See Figure C.1. K231-[X/XX] CONTACT NOZZLE Operation - DO NOT completely straighten the The K231- [x/xx] is used for submerged arc weld- electrode.
  • Page 25 ACCESSORIES K226 CONTACT ASSEMBLY Maintenance - Rusty or dirty wire and/or exces- The K226 assemblies are used for welding at currents sively high welding currents increase wear on the from 600 to 1000 amps. contact jaws. When arcing occurs or the elec- trode becomes loose in the jaws, remove the Model K226-T - (2 tapered jaws) jaws and ‘dress’...
  • Page 26 ACCESSORIES 7. Slide the center guide (G) up out of the pivot body K148 CONTACT NOZZLE AND K149 Linc-Fill LONG STICKOUT EXTENSION until the tang is above the window. This nozzle is available in three models and can be 8. Place the Linc-Fill guide assembly into the nozzle window, and then lower the center guide tube (G) used for Innershield or submerged arc processes.
  • Page 27 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 Operation screw securely. The same contact tip, S13763, is used for 3/32” (2.4 11. Replace the brass thread protecting collar (E). It is mm) through 3/16”...
  • Page 28 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 1. Remove the tension on the center guide tube using free of the tip. a “C”...
  • Page 29 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 2.
  • Page 30 ACCESSORIES K285 Used in Horizontal Fillet Applications c. Loosen the K285 hose clamps and rotate the flux 1. With K148 or K148/K149 combination - After the cone unit about 40 to 45° and retighten the K285 has been attached to the nozzle body: clamps.

  • Page 31: Vertical Head Adjuster

    ACCESSORIES K29 VERTICAL HEAD ADJUSTER 4. Slide the Head Adjustment Lock (A) over the end Automatic welding applications frequently require rais- of the Mounting Bracket (M). ing and/or lowering of the feed head assembly. The K29 provides an easy method of accomplishing this 5.

  • Page 32: Horizontal Head Adjuster

    C-10 C-10 ACCESSORIES K96 HORIZONTAL HEAD ADJUSTER FIGURE C.14 - K96 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.

  • Page 33: K129 Tiny Twinarc Kit

    C-11 C-11 ACCESSORIES FIGURE C.16 - K129 TINY TWINARC COMPONENTS ® 1 - Nozzle Assembly A - Drive Rolls 2 - Guide Tubes B - Guide Tubes 3 - Locking Collar C - Idle Roll Arm 4 - Contact Tip(s) D - Incoming Wire Guide 5 - Tip Holder E - Drive Roll Spacer...
  • Page 34 C-12 C-12 ACCESSORIES B. For 3/32 (2.4mm) Wire 5. Insert the two long insulated wire guides (2) into 1. Remove the items listed in Step “A” plus: the Twinarc nozzle (1) making sure that they are • The drive roll key. seated in the holes in the mounting block (7).
  • Page 35 C-13 C-13 ACCESSORIES FIGURE C.18 - K225 TWINARC COMPONENTS ® A - Drive Rolls B - Guide Tubes C - Idle Roll Arm D - Drive Roll Spacer E - Key F - Nozzle Assembly K225 SUBMERGED ARC TWINARC ® NOTE: The idle roll arm pivot pin is held in place by a set screw that is accessed from the outgoing Twin arc welding is a process where two wires of the...
  • Page 36 C-14 C-14 ACCESSORIES Nozzle Installation (See Figure C.18) IMPORTANT Make sure that the mating surface (8) between the 1. install the new idle roll arm (C) using the pin and Center Block (4) and the Copper Bar (2). is bright, set screw from the original assembly.

  • Page 37: K281 Solid Wire Straightener For Twinarc

    C-15 C-15 ACCESSORIES 4. Insert one wire through each of the guide block K281 SOLID WIRE STRAIGHTENER FOR holes. TINY TWINARC ® 5. Push both wires through and between the rollers The K281 wire straightener can be used to straighten and down through the guide tube until they touch .045”...

  • Page 38: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS SENSE LEAD FUSE There should never be any current flowing through WARNING the sense leads! The sensing lead circuit is current protected in the Power Wave AC/DC 1000 SD. ® If the MAXsa™ 29 WIRE DRIVE are used in an older ELECTRIC SHOCK can kill.

  • Page 39: Troubleshooting

    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.
  • Page 40 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Drive rolls turn, but wire will not 1. Wire jammed or kinked on route feed or wire feeding is rough or through wire drive.
  • Page 41 DIAGRAMS MAXsa™ 29 WIRE DRIVE...
  • Page 42 DIMENSION PRINT MAXsa™ 29 WIRE DRIVE...
  • Page 43 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 44 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 45 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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