IM10024
MAXsa™22 & 29 WIRE DRIVES
RETURN TO MAIN MENU
IM10024-A
March 2013
For use with machines having Code Numbers:
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. And,
most importantly, think before
you act and be careful.
IP2X
11615, 11616, 11815, 11816
11615
11616
CCC COMPLIANCE
11815
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
11816
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 •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered 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.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ii
SAFETY
ii
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
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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Ne ver simult aneously 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.
skin or wet clothing. Wear dry, hole-free
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
ventilation and/or exhaust at the arc to keep
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
iii
SAFETY
iii
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
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. 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
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use on ly c omp re sse d ga s c yli nders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
iv
SAFETY
iv
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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Thank You
vv
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!
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. On occasion, purchasers may ask 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. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially 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
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi
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
General Information.....................................................................................................................A-2
Design Features ...................................................................................................................A-2
Location of Components ......................................................................................................A-2
Specifications ..............................................................................................................................A-3
Safety Precautions. .....................................................................................................................A-4
Non-Safety Standard Equipment..........................................................................................A-4
Input and Ground Connections ............................................................................................A-4
Location and Mounting .........................................................................................................A-4
High Frequency Protection...................................................................................................A-4
Power Wave
Mounting Dimensions...........................................................................................................A-5
Connection Diagram.............................................................................................................A-5
Changing Wire Drive Configuration .............................................................................................A-6
Wire Feed Mechanism.................................................................................................................A-7
Gear Ratio Conversion Kits .........................................................................................................A-7
Electrode Connectios ..................................................................................................................A-8
Remote Sense Lead Specifications.............................................................................................A-8
TC-3 Travel Carriage...................................................................................................................A-9
Installation............................................................................................................A-10 thru A12
________________________________________________________________________________
Operation ...........................................................................................................................Section B
Routine operation ........................................................................................................................B-1
Starting Techniques .............................................................................................................B-1
Head Positioning ..................................................................................................................B-2
________________________________________________________________________________
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
________________________________________________________________________________
Maintenance........................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Engine Maintenance ...........................................................D-1
Calibration Specification........................................................................................D-1
________________________________________________________________________________
Troubleshooting .................................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
________________________________________________________________________________
Wiring Diagrams and Dimension Print .............................................................Section F
________________________________________________________________________________
Parts List.............................................................................................P-623, P-697, P-101
________________________________________________________________________________
®
AC/DC1000 SD Systems Connections ................................................................A-5
vi
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.
Depending on which options are 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
A-1
• 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
• K2803-1 Power Wave
• K2814-1 MAXsa™ 10 Controller/Feed Head
• K2370-2 MAXsa™ 22 Wire Drive
Basic Package with optional kits:
• K2803-1 Power Wave
®
AC/DC 1000 SD
®
AC/DC 1000 SD
• K2311-1 MAXsa™ Motor Retrofit Kit
• K2312-2 MAXsa™ 29 Wire Drive
• K2626-2 Wire Drive Controller (for fixture
builders that do not require the
MAXsa™ 10 Controller).
MAXsa™ 22 & 29 WIRE DRIVES
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.1 - LOCATION OF MAXsa™ 22 COMPONENTS CODE 11615
Connection
Box
A-2
Gear Box
Cross Seam
Adjuster
Drive Rolls
Mounting
Hardware
Drive Motor
MAXsa™ 22 & 29 WIRE DRIVES
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.2 - LOCATION OF MAXsa™ 29 COMPONENTS CODE 11616
Connection
Box
A-3
Gear Box
Wire Straightener
Mounting
Drive Motor
Drive Rolls
MAXsa™ 22 & 29 WIRE DRIVES
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.1a - LOCATION OF MAXsa™ 22 COMPONENTS CODE 11815
Connection
Box
A-4
Gear Box
Cross Seam
Adjuster
Drive Rolls
Mounting
Hardware
Drive Motor
MAXsa™ 22 & 29 WIRE DRIVES
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.2a - LOCATION OF MAXsa™ 29 COMPONENTS CODE 11816
Connection
Box
A-5
Gear Box
Wire Straightener
Mounting
Drive Motor
Drive Rolls
MAXsa™ 22 & 29 WIRE DRIVES
A-6
SPECIFICATIONS
TECHNICAL SPECIFICATIONS - MAXsa™ 22 & 29 WIRE DRIVES
Spec. Type 142:1 Speed Ratio 95:1 Speed Ratio 57:1 Speed Ratio
A-6
K2370-2
K2312-2
MODEL
K2312-2
K2370-2
K2311-1
Process
SAW
Wire Size
Speed Solid Cored
MAXsa™ 22
MAXsa™ 29
10-200 7/32 5/32
Wire Feeders - Input Voltage and Current
Voltage
32V DC
PHYSICAL DIMENSIONS
HEIGHT
12.0 in. (305 mm)
8.0 in. (203 mm)
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-4°F to 104°F (-20°C to 40°C)
WELDING PROCESSES
Electrode Diameter Range
.045” – 7/32" (1.2 – 5.6 mm)
Output Range (Amperes)
Wire Size
Speed Solid Cored
10-300 1/8 5/32
WIDTH
14.0in (355mm)
14.0in (355mm)
6.0in (152mm)
STORAGE TEMPERATURE RANGE
-40°F to 185°F (-40°C to 85°C)
200 - 2000+
(with paralleled machines)
Wire Size
Speed Solid Cored
40-500 1/16 3/32
Input Amperes
7 Amps (max.)
DEPTH
10.0in (254mm)
10.0in (254mm)
5.0in (127mm)
Wire Feed Speed Range
10 - 500 ipm (.25 – 11.43 m/minute)
WEIGHT
35.0lbs (15.9kg)
80.0lbs (36.3kg)
10.0lbs (4.5kg)
MAXsa™ 22 & 29 WIRE DRIVES
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.
------------------------------------------------------------------------
NON-STANDARD SAFETY INFORMATION
A-7
CAUTION
The MAXsa™ series of wire drives may be at
welding 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 Electrical Code, all local codes
and the information in this manual.
LOCATION AND MOUNTING
The MAXsa™ Wire Drive will operate in harsh indoor
environments. It has an IP2X rating.
HIGH FREQUENCY PROTECTION
Locate the MAXsa™ Wire Driveaway from radio controlled machinery.
MAXsa™ 22 & 29 WIRE DRIVES
A-8
INSTALLATION
A-8
POWER WAVE®AC/DC 1000 SD SUBARC
SYSTEM CONNECTIONS (
Diagram shown is for a single arc system. Refer to the
power source manual for additional connection
options (Multi-arc and/or parallel machines).
K2814-1
MAXsa™ 10
K1785-XX
14-Pin Cable
See Figure A.3)
FIGURE A.3 - CONNECTION DIAGRAM
K1543-XX or
K2683-XX
Arclink Cable
K2370-2
MAXsa™ 22
67 Lead
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).
K2803-1
Power Wave
® AC/DC 1000
K1811-XX
Sense Lead
Work
4.70
4.24
K231-XX
Contact Nozzle
FIGURE A.4 - MOUNTING DIMENSIONS
.62 2.50
3/8-16 TAPPED HOLE
(4 PLACES)
.41
2.69
.96
Electrode
Weld Cable
Work
Weld Cable
ø
.562 (2 HOLES)
.50
2.50
.50
7.70
MAXsa™ 22 & 29 WIRE DRIVES
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