Lincoln Electric IM10024 User Manual

MAXsa™22 & 29 WIRE DRIVES

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IM10024

July(R2), 2009

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 IN ST ALL, OPERAT E OR
REP A I R THI S EQUIP M E NT
WIT H O UT REA D I NG THI S
MAN U A L AND THE S AFETY
PRE CAUT IONS CO NTA I NED
THR O U GHOUT . And , mos t

importantly, think before you act
and be careful.

11615, 11616

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

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

i

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 f ue l n ear an open flam e
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 s om e cases it may be necessary to re move safety

gu a rds to perfo rm requ ired main t ena n ce. Remo v e
guards only when necessary and replace them when the
ma i nten ance req uiri n g th eir rem o val is comp l ete .
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. Ele ct ric curren t flowing thr ough any cond uctor causes
local ized Ele ctric an d Magnet ic Field s (EMF). Welding
curre nt creat es EMF fi elds around welding cables and
welding machines

2.b. EMF fi el ds ma y i nt er fere 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 bo dy .

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.

Mar ʻ95

ii

SAFETY

ii

ELE CTR IC 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 clothi ng. 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.

In addition to the normal safety precautions, if welding
mu s t be p e rfo r med u nde r elec t ric a lly h aza r dou s
con ditions (in d amp location s 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,
elect rode reel, weldin g 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. Never simultan eo usly tou ch el ec tricall y “hot” part s 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.

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. Weldin g may produce fume s and gases
hazardous to health. Avoid breathing these
fumes and gases. When we ld in g, kee p
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathin g zone. When

we l ding w i th el e ctr o des wh i ch req u ire s p eci a l
ve n til atio n su c h as s tai nles s or h ard f aci ng (s ee
in str uct ion s on con tai ner or MSD S) o r on lea d or
cadmi um plate d steel and other me tals or coa tings
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 sp ac es or in so me circum­st a nce s, ou tdoo rs, a res p ira tor m ay b e req u ire d.
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.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t eria l saf ety da ta sh eet ( MSD S ) an d fol l ow yo ur
employer’s safety practices. MSDS forms are available from
yo u r w e ldi n g d i str i but o r o r fro m the man u fact urer .

5.f. Also see item 1.b.

Jan ‘09

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

Re m embe r th a t we l din g spa r ks an d ho t
materials from welding can easily go through small cracks
an d open in gs to adj acent ar eas . Avo id wel din g nea r
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
Standar d Z49. 1) and the opera ting informatio n 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
Co n tain ers and P ipi n g T hat H ave H eld H aza r dou s
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
incre ase the poss ibility of the weldin g current pa ssing
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 spa rk s from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. U se o nly comp ress ed g a s c y lin d ers
containing the correct shielding gas for the
pr o cess used a n d p rop e rly op era t ing
re g ulat ors d esig ned f o r th e ga s an d

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Al ways keep cylinders in an upright pos ition sec ur el y
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 foll ow the inst ructi ons on compre ss ed g as
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 co des and the manuf acturer’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.

Jan ‘09

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:

Sûr

eté Pour Soudage A L’Arc

Protegez-vous contre la secousse électrique:

1.

Les circuits à lʼélectrode et à la piéce sont sous tension

a.

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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte 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 lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la mas se. Un co urt-circuit a ccident al peut p rovoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼo pérations de dégraissage, nettoyage ou pistola ge. La
chaleur ou les rayons de lʼarc 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 dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼa ut re pe rsonnel travaill an t à pr oximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des go uttes de laitier en fusion sont é mises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ʻ93

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

“Product Registration”. 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 “Quick Links” and then

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

________________________________________________________________________________

®

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.

A-1

PROCESS LIMITATIONS

• MIG welding

• Robotic applications

EQUIPMENT LIMITATIONS

The MAXsa™ series of wire drives cannot be used
with t h e N A 3 , N A-4, or NA-5 serie s o f L i n c oln
Automatics.

COMMON EQUIPMENT PACKAGES

Basic Package

• K2803-1 Power Wave® AC/DC 1000 SD

• K2814-1 MAXsa™ 10 Controller/Feed Head

• K2370-1 MAXsa™ 22 Wire Drive

Basic Package with optional kits:

• K2803-1 Power Wave® AC/DC 1000 SD

• K2311-1 MAXsa™ Motor Retrofit Kit

• K2312-2 MAXsa™ 29 Wire Drive

• K2626-2 Wire D r ive Contro l ler (for fi x t ure

builde r s t hat do not re q u i re the
MAXsa™ 10 Controller).

MAXsa™ 22 & 29 WIRE DRIVES

A-2

Connection

Box

Gear Box

Drive Rolls

Cross Seam

Adjuster

Mounting

Hardware

Drive Motor

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.

• Conversion kits included to change speed range.

FIGURE A.1 - LOCATION OF MAXsa™ 22 COMPONENTS

A-2

MAXsa™ 22 & 29 WIRE DRIVES

A-3

Connection

Box

Wire Straightener

Gear Box

Drive Rolls

Mounting

Drive Motor

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.

• Conversion kits included to change speed range.

FIGURE A.2 - LOCATION OF MAXsa™ 29 COMPONENTS

A-3

MAXsa™ 22 & 29 WIRE DRIVES

A-4

SPECIFICATIONS

TECHNICAL SPECIFICATIONS - MAXsa™ 22 & 29 WIRE DRIVES

Spec. Type 142:1 Speed Ratio 95:1 Speed Ratio 57:1 Speed Ratio

A-4

K2370-2
K2312-2

MODEL

K2312-2
K2370-2
K2311-1

Process

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

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

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)

-40°F to 185°F (-40°C to 85°C)

Wire Feed Speed Range

WEIGHT

35.0lbs (15.9kg)

80.0lbs (36.3kg)

10.0lbs (4.5kg)

SAW

.045” – 7/32" (1.2 – 5.6 mm)

200 - 2000+

(with paralleled machines)

10 - 500 ipm (.25 – 11.43 m/minute)

MAXsa™ 22 & 29 WIRE DRIVES

A-5

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-5

CAUTION

The PF-10S series of wire drives may be at weld­ing voltage potential when the output of the power
source is active.

------------------------------------------------------------------------

INPUT AND GROUND CONNECTIONS

Onl y a quali fied e l ectri c ian sh o uld con nect th e
MAXsa™ 22 & 29 WIRE DRIV E S . Wire Dr i v e
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 Drivewill operate in harsh environ­ments.

HIGH FREQUENCY PROTECTION

Locate the MAXsa™ Wire Driveaway from radio con­trolled machinery.

MAXsa™ 22 & 29 WIRE DRIVES

A-6

K2683-XX

Arclink Cable

67 Lead

K1795-XX
14-Pin Cable

Work

K231-XX
Contact Nozzle

K

2803-1

Power Wave

® AC/DC 1000

K2814-1
MAXsa™ 10

K2370-2
MAXsa™ 22

K1811-XX
Sense Lead

Electrode
Weld Cable

Work
Weld Cable

K1543-XX or

7.70

4.70

4.24

.62 2.50

.41

2.69

.96

.50

2.50

.50

.562 (2 HOLES)

3/8-16 TAPPED HOLE

(4 PLACES)

ø

INSTALLATION

A-6

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).

See Figure A.3)

FIGURE A.3 - CONNECTION DIAGRAM

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.4 - MOUNTING DIMENSIONS

MAXsa™ 22 & 29 WIRE DRIVES

A-7

Rotate

Rotate

Loosen Socket

Head Screw to

Rotate Feedplate

Loosen Socket

Head Screw to Rotate

Motor/Gearbox Assembly

Remove ConnectionBox

to Change Motor Polarity

INSTALLATION

A-7

CHANGING THE WIRE DRIVE
CONFIGURATION

The MAXsa™ 22 & 29 WIRE DRIVES can be recon­figured to fit in any hard automation application.

As shipped, the MAXsa™ 22 & 29 WIRE DRIVES
Drive Rolls rotate clockwise to feed the wire down.
Reconfiguring the Wire Drive per Figure A.3 may
require reversing the direction of the motor. This is
accomplished by reversing the motor polarity so that
the wire will feed correctly. Follow these instructions to

reverse the motor polarity. See the Wiring Diagram in

Section F of this manual

1. Remove all power from the MAXsa™ Wire Drives.

2. Disconnect the Control Cable from the MAXsa™
Wire Drive Connection Box.

3. Loosen the fastener from the Band Strap to the
Connection Box, which secures the assembly to the
Motor housing, and expose the leads inside of the
Connection Box.

4. Locate the Motor leads that go from the Motor to
the Control Cable connector on the inside of the
Connection Box.

5. Carefully disconnect the Motor leads from the har­ness 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
cov ered by t he Chan nel tha t snaps i nto the
Connection Box. The Connection Box assembly
should be pushed all the way up to the Motor-to­Gearbox Adapter Plate.

8. Before securing the Connection Box to the Motor
housing with the Band Strap, ensure that none of
the harness leads are being pinched underneath
the edges of the Connection Box and Channel.

9. Place the Band Strap into the "T" slot on the side
of the Connection Box and wrap it around the
Motor housing.

10. Replace the fastener between the Band Strap and

the Connection Box. Tighten so that the Connection
Box cannot move on the Motor housing.

FIGURE A.3

MAXsa™ 22 & 29 WIRE DRIVES