Lincoln Electric MAXsa 29 Operator'S Manual Download

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• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

MAXsa

™

22 & 29 WIRE DRIVES

OPERATOR’S MANUAL

IM10024

July(R2), 2009

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 thought-
ful operation on your part.

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.

For use with machines having Code Numbers:

11615, 11616

Summary of Contents for MAXsa 29

Page 1: ... 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 thought ful 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 For u...

Page 2: ... WEARERS SHOULD CONSULT WITH 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 availab...

Page 3: ...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 Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fumes...

Page 4: ...o 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 cir...

Page 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6...

Page 6: ...important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www linc...

Page 7: ...___________________________________________________ Accessory Section C Options and Accessories Website C 1 Motor Conversion Kit For 142 1 NA Style Wire Drives C 1 Sub Arc Contact Assemblies C2 thru C 8 Vertical Head Adjuster C 9 Horizontal Head Adjuster C 10 K129 Tiny TwinArc Kit C 11 K225 Sub Arc TwinArc Kit C 13 K281 Solid Wire Straightener for TwinArc C 15 _____________________________________...

Page 8: ... used the MAXsa has many axes of rotation for ease of fixturing and locating RECOMMENDED PROCESSES The MAXsa series of wire drive packages are best suited for submerged arc welding PROCESS LIMITATIONS MIG welding Robotic applications EQUIPMENT LIMITATIONS The MAXsa series of wire drives cannot be used with the NA3 NA 4 or NA 5 series of Lincoln Automatics COMMON EQUIPMENT PACKAGES Basic Package K2...

Page 9: ...rbox housing and feed plate assembly Wire straightener Cross Seam Adjuster Flux Hopper not shown Mounting Hardware for accessories 32Vdc permanent magnet high torque motor Conversion kits included to change speed range Connection Box Gear Box Drive Rolls Cross Seam Adjuster Mounting Hardware Drive Motor FIGURE A 1 LOCATION OF MAXsa 22 COMPONENTS ...

Page 10: ...rled drive rolls Heavy cast aluminum gearbox housing and feed plate assembly Wire straightener 32Vdc permanent magnet high torque motor Conversion kits included to change speed range FIGURE A 2 LOCATION OF MAXsa 29 COMPONENTS Connection Box Wire Straightener Gear Box Drive Rolls Mounting Drive Motor ...

Page 11: ... 0lbs 36 3kg 10 0lbs 4 5kg Input Amperes 7 Amps max OPERATING TEMPERATURE RANGE 4 F to 104 F 20 C to 40 C STORAGE TEMPERATURE RANGE 40 F to 185 F 40 C to 85 C WELDING PROCESSES Spec Type 142 1 Speed Ratio 95 1 Speed Ratio 57 1 Speed Ratio Process SAW Electrode Diameter Range 045 7 32 1 2 5 6 mm Output Range Amperes 200 2000 with paralleled machines Wire Feed Speed Range 10 500 ipm 25 11 43 m minut...

Page 12: ...king on the equip ment Do not touch electrically hot parts NON STANDARD SAFETY INFORMATION The PF 10S series of wire drives may be at weld ing voltage potential when the output of the power source is active INPUT AND GROUND CONNECTIONS Only a qualified electrician should connect the MAXsa 22 29 WIRE DRIVES Wire Drive Installation should be made in accordance with the appropriate National Electrica...

Page 13: ...ive 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 3 CONNECTION DIAGRAM FIGURE A 4 MOUNTING DIMENSIONS K2683 XX Arclink Cable 67 Lead K1795 XX 14 Pin Cable Work K231 XX Contact Nozzle K2803 1 Power Wave AC DC 1000 K2814 1 MAXsa 10 K2370 2 MAXsa 22 K1811 XX Sense Lead Electrode Weld Cable Work Weld Cable K1543 ...

Page 14: ... 5 Carefully disconnect the Motor leads from the har ness by pulling the quick connect terminals apart 6 Reverse the motor leads and reconnect the quick connect terminals see the Wiring Diagram 7 Carefully replace the wire harness back into the Connection Box and place back onto the Motor housing locating over the Motor lead grommet Ensure that the tachometer leads are completely covered by the Ch...

Page 15: ...e 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 Replace plain washer tighten the hex nut and remove the adapter plate and motor assembly mounting screws from the gear 6 Support the pinion properly and with the proper size punch drive the roll pin that holds the pinion out of the shaft P...

Page 16: ...e excessive leading to poor welding characteristics if undersized welding cables are used REMOTE SENSE LEAD SPECIFICATIONS The MAXsa 22 29 Wire Drives has an ELEC TRODE sense lead extending from the connection box that is mounted to the motor This sense lead is critical to the accuracy of the Power Wave welding process A ring terminal is provided at the end of the lead This lead must be extended a...

Page 17: ... other equipment to the TC 3 Travel Carriage that there is a minimum of overhung weight The Wire Drive mount ings are to be such that the heads are within 19 483mm from the front of the carriage as shown in Figure A 5 TABLE A 2 MAXIMUM EQUIPMENT LOAD FOR TC 3 MULTIPLE ARC OPERATION TANDEM TWINARC Two MAXsa Wire Drives and Controls Three MAXsa Wire Drives and Controls Two MAXsa Wire Drives and Cont...

Page 18: ...g Bracket that is sup plied with the MAXsa 22 using the hardware and insulators provided See Figure A 6 NOTE To install a MAXsa 29 Wire Drive order a Mounting Bracket M6769 and the appropri ate Head Support K29 or M8232 5 Use an ohmmeter to be sure that the Wire Reel shaft and the Wire Drive Mounting Bracket are electrically isolated from the TC 3 frame With the release handle all the way down set...

Page 19: ... is used With a prop er counterbalance and if the flux hopper and wire reel s are mounted off of the carriage this free wheeling is less likely to occur since the changing weight will not affect the counterbalance 2 With a tilt of 5 or less a counterbalance is typical ly not required see CAUTION 3 A tilt in excess of 5 will require a counter weight as shown in Figure A 10 The amount of coun teweig...

Page 20: ...he 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 NOTE TC 3 units are shipped with a helical tooth drive wheel that is suitable for use on a smooth drive rail A straight tooth gear T13586 is available for use on a drive rail with a straight cut knurl CARRIAGE BEARING TRACKING Bearing tracking can be checked by pl...

Page 21: ...ting the weld after the travel begins to get a scratch start Normally this type of starting requires the use of a ʻrun onʼ tab to insure proper weld deposition at the beginning of the weld a Use the Set Up Menue of the MAXsa 10 to set the travel to start with the START button b Follow the Hot Starting procedure Cold Starting refers to starting the weld with the Wire Drive Head stationary and the e...

Page 22: ...late Angle 5 16 Allen Wrench Face plate Rotates 360 Around the Drive Roll Shaft Feed Head Rotates 360 Around the Motor Axis The Cross Seam Adjuster Can Be Mounted to the Top or Bottom of the Gear Box FIGURE B 3 VERTICAL ADJUSTMENT With Standard Mounting M6767 or K29 Vertical Adjuster Loosen to Rotate Entire Head Around Mounting Axis With K29 Loosen Screw K29 Clamps Can Be Set to Restrict In and Ou...

Page 23: ...bly 2 Remove existing Adapter Plate and Motor Assembly 3 The Conversion Kit Motor is shipped configured for a 142 1 gear ratio The existing gearbox must be con figured for a 142 1 gear ratio for the Conversion Kit to assemble correctly If both assemblies are not con figured for the same gear ratio this must be done before continuing See Gear Ratio Conversion Kit instructions 4 Cover the teeth of t...

Page 24: ...ug 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 Operation DO NOT completely straighten the electrode A slight curvature is required in the electrode to insure good electrical contact inside the contact tip Maintenance Replace the contact tip when it no longer provides accurate wire location or good electrical contact Rus...

Page 25: ...assembly See Figure C 3 Maintenance Rusty or dirty wire and or exces sively high welding currents increase wear on the contact jaws When arcing occurs or the elec trode becomes loose in the jaws remove the jaws and ʻdressʼ them with a file When neces sary the jaw inserts should be replaced NOTE Units made prior to 1979 did not have inserts The replacement jaws will have them The contact jaws must ...

Page 26: ... to 1 gallon 1 9 to 3 8L of tap water per minute K149 Installation See Figure C 5 1 Install the K149 attachment before mounting the K148 nozzle on the welder 2 Place a small C clamp on the spring supporting members A and B in such a manner that the spring can be compressed Look up into the hole in the end of contact tip and tighten the C clamp until the tang lifts off the surface of the tip 3 Remo...

Page 27: ... diameter electrodes S16388 is used for 062 1 6 mm and 5 64 2 0 mm electrode Loading of Wire Straighten the start end of the coil for at least eight inch es pass the end down through the appropriate wire straightener Inch the wire through the wire feeder and the nozzle When using 062 1 6 mm or 5 64 2 0 mm Innershield electrode with a K148 C nozzle make sure that the wire is in the vee groove of th...

Page 28: ... nozzle body K285 Concentric Flux Cone The K285 Concentric Flux Cone is designed to fit on a K148 with or without the K149 attachment or on a K129 Tiny Twin Arc nozzle This attachment deposits the flux so that it surrounds the electrode s NOTE If using a K149 extension the electrical stick out will be limited to 4 102mm The K285 consists of two pieces that are electrically isolated from each other...

Page 29: ...allation with the K129 1 Unscrew the hose clamps enough so they can slip over the tip holder clamping nut 2 Position the stationary portion of the K285 as shown in Figure C 11 and tighten the clamps 3 Position the moveable section to the desired flux height and tighten the wing nut 4 Due to the 7 angle of the tips it may be necessary to pivot the cone as shown Remove the outermost screws from each...

Page 30: ...e head and nozzle to the desired electrode angle b Feed the electrode theough the tips to the proper stickout and place the nozzle into the welding position c Loosen the K285 hose clamps and rotate the flux cone unit about 40 to 45 and retighten the clamps d Slide the K285 flux cone dowm to about 1 8 3 0mm away from both the vertical and horizon tal plates and tigten the wing screw See Figure C 12...

Page 31: ...the hole of the Head Adjustnent Lock with the groove in the Mounting Bracket and drive in the 1 4 Roll Pin B 6 Using the 1 2 x 2 75 Locking Screw tighten the Head Adjustment Lock with the open slot in the up position 7 Slide the Vertical Head Lift Adjuster E into the Mounting Bracket M and tighten the Draw Bolt Nut K 8 Install the two Clamps D one on each side of the Head Adjustment Lock with the ...

Page 32: ...d Head NOTE If a K29 Vertical Head Adjuster is to be used install it now per the instructions provided 3 With the Draw Bolt A in place fit the K96 Horizontal Adjuster D over the shaft of the Head Support E or the K29 Eʼ if used 4 Drive in the 1 4 Roll Pin that comes with the K96 5 With the Draw Bolt J and the Lock Nut H in place raise the Feed Head in to position on the shaft of the Horizontal Adj...

Page 33: ... 1 6mm Wires K129 5 64 5 64 2 0mm Wire K129 3 32 3 32 2 4mm Wire NOTE For 045 or 052 wire order KP1901 1 Wire Drive Kit for use with the K129 1 16 kit INSTALLATION A For 045 through 5 64 1 0 2 0mm Wires 1 Remove the following items from the standard Feed Head The wire straightener The nozzle assembly Both upper and lower guide tubes The drive rolls The idle roll assembly The tension spring assembl...

Page 34: ...les Lock it securely in place with the lock ing collar 3 See Figure C 16 NOTE For applications that require staggered or cross seam wire placement rather than in line the contact tip or tip holder may be rotated Re adjust the head position to maintain the proper wire to work angle For overlay applications a special side by side tip holder part S17728 that accepts standard contact tips is available...

Page 35: ... electrical stick out E S O It also helps to maintain acceptable noz zle temperatures during welding INSTALLATION 1 Remove the following items from the standard Feed Head The wire straightener The nozzle assembly Both upper and lower guide tubes The drive rolls The idle roll assembly NOTE The idle roll arm pivot pin is held in place by a set screw that is accessed from the outgoing surface of the ...

Page 36: ...ed 6 Connect the weld cables of the proper size and number to the copper bar 2 If using multiple cables use both sides of the bar 7 Route the flux hose from the flux hopper to the clip 3 on the K225 nozzle 8 Spacing between the electrodes is maintained by the center block which comes in three sizes The 50 and 625 center blocks come with the kit A 375 block is also available See the parts list for ...

Page 37: ...e the easier to load 4 Insert one wire through each of the guide block holes 5 Push both wires through and between the rollers and down through the guide tube until they touch the drive roll s Press the Cold Inch to start the wires through the wire drive 6 Replace the upper guide block making sure that each wire is in its respective groove of both rollers Tighten the thumb screw 7 Turn the adjusti...

Page 38: ... in min 2 54m min and provide a COLD FEED Signal Measure the actual wire feed speed with a calibrated wire feed speed tachometer K283 The measured wire feed speed should be within 2 of the set value NOTE If a K283 is not available feed wire for 15 sec onds and measure the wire Repeat several times to get an average measurement It should be 25 635mm 2 SENSE LEAD FUSE There should never be any curre...

Page 39: ...POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln A...

Page 40: ...uide tubes or incorrect pres sure setting Ensure drive rolls and or guide tubes are stamped with wire diameter being used Replace if necessary Check for proper pressure setting 3 Worn drive rolls Replace or reverse if split type 4 Partially flashed or melted con tact tip Replace contact tip 1 Contact tip worn or incorrect size Replace contact tip 2 Worn or undersized work cables or poor connection...

Page 41: ...nly 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 ...

Page 42: ... 2 MAXsa 22 29 WIRE DRIVES 3 50 6 16 2 48 4 22 9 82 2 60 5 19 6 16 12 04 2 82 13 56 21 7 70 4 70 4 24 62 2 50 41 2 69 96 50 2 50 50 O 562 2 HOLES 3 8 16 TAPPED HOLE 4 PLACES CENTERLINE OF WIRE CENTERLINE OF WIRE A 01 L13370 ...

Page 43: ...electrically live parts or 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 moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 44: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 45: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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