Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ʻ93 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS
Page Installation ..........................................................................................................Section A Product Description .....................................................................................................................A-1 Recommended Processes ......
Page 8 - PRODUCT DESCRIPTION; PRODUCT SUMMARY; Basic Package
A-1 PRODUCT DESCRIPTION MAXsa™ 22 & 29 WIRE DRIVES A-1 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 a...
Page 9 - GENERAL INFORMATION; DESIGN FEATURES - MAXsaTM 22; FIGURE A.1 - LOCATION OF MAXsaTM 22 COMPONENTS
A-2 GENERAL INFORMATION MAXsa™ 22 & 29 WIRE DRIVES A-2 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 acces...
Page 10 - INSTALLATION; DESIGN FEATURES - MAXsaTM 29; FIGURE A.2 - LOCATION OF MAXsaTM 29 COMPONENTS
A-3 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-3 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. • Conversion kits included to change sp...
Page 11 - SPECIFICATIONS; TECHNICAL SPECIFICATIONS - MAXsaTM 22 & 29 WIRE DRIVES; PHYSICAL DIMENSIONS
A-4 SPECIFICATIONS MAXsa™ 22 & 29 WIRE DRIVES A-4 TECHNICAL SPECIFICATIONS - MAXsa™ 22 & 29 WIRE DRIVES PHYSICAL DIMENSIONS TEMPERATURE RANGES Wire Feeders - Input Voltage and Current Voltage 32V DC HEIGHT 12.0 in. (305 mm) 8.0 in. (203 mm) MODEL K2312-2 K2370-2 K2311-1 WIDTH 14.0in (355mm) ...
Page 12 - SAFETY PRECAUTIONS; form this installation.; NON-STANDARD SAFETY INFORMATION
A-5 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-5 SAFETY PRECAUTIONS Read this entire installation section before youstart installation. 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 beforewo...
Page 13 - POWER WAVE; Mounting Dimensions
A-6 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-6 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™...
Page 15 - WIRE FEED MECHANISM
A-8 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-8 WIRE FEED MECHANISM All MAXsa™ Wire Drive units are shipped with 142:1 ratio gears. Conversion kits are included to change to either 95:1 or 57:1 ratio depending on wire size to be used. As shipped, the drive mechanism parts are designed to feed 3/...
Page 16 - ELECTRODE CONNECTIONS
A-9 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-9 ELECTRODE CONNECTIONS Because the Power Wave® AC/DC 1000 SD can pro- duce either a DC positive, DC negative or AC output the electrode and work connections do not need to be reversed for the different polarities. Additionally no DIP switch changes ...
Page 17 - MULTIPLE ARC OPERATION
A-10 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-10 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. K325HC-S (Standard - 952:1 ratio) 5” to 70”/min (127mm to 1.88M/mim) K325-HC-F (High Speed - 254:1 ra...
Page 19 - INCLINED OPERATION OF TC-3; CAUTION; Beam
A-12 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-12 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). When the carriage is used in an inclined application the unit is free to move whenev...
Page 20 - Drive Gear; FIGURE A.9 BEARING SHIMS; Shim Here; DRIVE GEAR TRACKING
A-13 INSTALLATION MAXsa™ 22 & 29 WIRE DRIVES A-13 FIGURE A.8 - BEARING TRACKING INCORRECT PATTERNS Bearing is not flat Against Drive Rail CORRECT PATTERN Full Face Bearing Contact FIGURE A.7 - DRIVE GEAR TRACKING Beam Drive Rail Shims Full Face Contact Drive Gear Incorrect ADD Shims Incorrect RE...
Page 21 - OPERATION; ROUTINE OPERATION; STARTING TECHNIQUES
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 re...
Page 23 - ACCESSORIES; OPTIONS AND ACCESSORIES; are; Search
C-1 ACCESSORIES C-1 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 ʻEnterʼ on the keyboard). 3. On the Results page, scroll down to the Equipment list and cl...
Page 24 - Installation
C-2 ACCESSORIES C-2 SUBMERGED ARC CONTACTASSEMBLIES K231-[X/XX] CONTACT NOZZLE The K231- [x/xx] is used for submerged arc weld- ing with currents generally under 600 amps. Higher currents can be used but result in some- what faster tip wear. The outer flux cone deposits flux around the arc for full ...
Page 25 - K226 CONTACT ASSEMBLY; FIGURE C.3 - K226 CONTACT NOZZLE ASSEMBLY
C-3 ACCESSORIES C-3 K226 CONTACT ASSEMBLY 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 3.2mm) electrode Model K226-R - (1 tapered and 1 rectangular jaw) 1/8” thru 7/32” (3.2 - 5.6mm) electrode Installation - Remov...
Page 26 - K 1 4 8 C O N T A C T N O Z Z L E A N D K 1 4 9 L i n c - F i l l; LONG STICKOUT EXTENSION; Current Ratings; Water Cooling Attachment
C-4 ACCESSORIES C-4 K 1 4 8 C O N T A C T N O Z Z L E A N D K 1 4 9 L i n c - F i l l T M LONG STICKOUT EXTENSION 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...
Page 27 - K148 Nozzle Installation; Too Late
C-5 ACCESSORIES C-5 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 t...
Page 28 - K285 Concentric Flux Cone
C-6 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-6 To install a new contact tip proceed as follows: 1. Clip the end of the electrode and inch it up until it is free of the tip. 2. Remove the contact tip locking nut. 3. Relieve the spring pressure of the contact tip against the steel tang in the hole...
Page 29 - IMPORTANT
C-7 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-7 K285 Installation with K149 1. Install the K149 to the K148 per the instructions. 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...
Page 30 - K285 Used in Horizontal Fillet Applications
C-8 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-8 K285 Used in Horizontal Fillet Applications 1. With K148 or K148/K149 combination - After the K285 has been attched 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 nozzl...
Page 31 - K29 VERTICAL HEAD ADJUSTER
C-9 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-9 K29 VERTICAL HEAD ADJUSTER Automatic welding applications frequently require rais- ing and/or lowering of the feed head assembly. The K29 provides an easy method of accomplishng this task by simply turning a crank handle. A height varia- tion of 4” ...
Page 32 - K96 HORIZONTAL HEAD ADJUSTER
C-10 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-10 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 Li...
Page 33 - K129 TINY TWINARC® KIT
C-11 ACCESSORIES MAXSA™ 22 & 29 WIRE DRIVES C-11 K129 TINY 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 K129-x/xx can be used for wire sizes .045” through 3/32” (1.0 - 2.4mm). The gear ratio of the MAXsa™ 22 &...
Page 34 - C. Nozzle Installation
C-12 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-12 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 assem- bly is removed. 2. Oil or grea...
Page 35 - K225 SUBMERGED ARC TWINARC
C-13 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-13 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,or3.2mm) electrodes. Both ...
Page 36 - Nozzle Installation
C-14 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-14 Nozzle Installation (See Figure C.18) 1. install the new idle roll arm (C) using the pin and set screw from the original assembly. 2. Replace the tension spring and screw and adjust the tension screw to the proper line on the indica- tor plate. 3....
Page 38 - MAINTENANCE; ELECTRIC SHOCK can kill.; • Only Qualified personnel should; ROUTINE MAINTENANCE; SENSE LEAD FUSE
D-1 MAINTENANCE D-1 MAXsa™ 22 & 29 WIRE DRIVES SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the d i s c o n n e c t s w i t c h o r f u s e b o xbefore working on this equipment. • Do not touch electrically ...
Page 39 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 MAXsa™ 22 & 29 WIRE DRIVES If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This...
Page 40 - OUTPUT PROBLEMS
E-2 TROUBLESHOOTING E-2 MAXsa™ 22 & 29 WIRE DRIVES If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION Obse...
Page 41 - DIAGRAMS
F-1 DIAGRAMS F-1 MAXsa™ 22 & 29 WIRE DRIVES 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 ...
Page 42 - DIMENSION PRINT
F-2 DIMENSION PRINT F-2 MAXsa™ 22 & 29 WIRE DRIVES 3 .5 0 6 .1 6 2 .4 8 4 .2 2 9 .8 2 2 .6 0 5 .1 9 6 .1 6 1 2 .0 4 2 .8 2 1 3 .5 6 .2 1 7 .7 0 4 .7 0 4 .2 4 .6 2 2 .5 0 .4 1 2 .6 9 .9 6 .5 0 2 .5 0 .5 0 O .5 6 2 (2 H O L E S ) 3 /8 -1 6 T A P P E D H O L E (4 P L A C E S ) C E N T E R L IN E O ...
