Lincoln Electric IM10024 manual

• 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 OPERA TOR’S MANUAL IM10024 July(R2), 2009 Safety Depends on You Lincoln arc [...]

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. ________________________________________________[...]

ii SAFETY ii ARC R A Y S can bur n. 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[...]

iii SAFETY iii FOR ELECTRIC ALL Y pow ered 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. N[...]

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: Sûr eté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v Thank Y ou 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 and keep it handy for quick reference. Pa[...]

Page Installation ..........................................................................................................Section A Product Description .....................................................................................................................A-1 Recommended Processes .....................................................[...]

A-1 PRODUCT DESCRIPTION MAXsa™ 22 & 29 WIRE DRIVES A-1 PRODUCT SUMMAR Y The MAXsa™ series of Automatic Wire Drives are designed for hard automation, submerged arc weld- ing. The heavy-duty gearbox and feed plate have many years of proven reliability while a new perma- nent magnet motor has been added. Th e MA Xs a™ 22 & 2 9 WI RE DR I[...]

A-2 GENERAL INFORMA TION MAXsa™ 22 & 29 WIRE DRIVES A-2 DESIGN FEA TURES - 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 mag[...]

A-3 INST ALLA TION MAXsa™ 22 & 29 WIRE DRIVES A-3 DESIGN FEA TURES - 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 - LOCATIO[...]

A-4 SPECIFICA TIONS MAXsa™ 22 & 29 WIRE DRIVES A-4 TECHNICAL SPECIFICA TIONS - MAXsa™ 22 & 29 WIRE DRIVES PHYSICAL DIMENSIONS TEMPERA TURE RANGES Wire Feeders - Input V oltage 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) 14.0in (355mm) 6.0in (152mm) DEPTH 10.0in [...]

A-5 INST ALLA TION MAXsa™ 22 & 29 WIRE DRIVES A-5 SAFETY PRECAUTIONS Read this entire installation section before you start 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 before working on this equipment. Turn off the i[...]

A-6 INST ALLA TION MAXsa™ 22 & 29 WIRE DRIVES A-6 POWER W A VE ® 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™ Wire Drive can be mounted by using the f[...]

A-7 INST ALLA TION MAXsa™ 22 & 29 WIRE DRIVES A-7 CHANGING THE WIRE DRIVE CONFIGURA TION The MAXsa™ 22 & 29 WIRE DRIVES can be recon- figured 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 requ[...]

A-8 INST ALLA TION 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 3/32 through 7/32(2.4mm - 6.0mm) wire. Other w[...]

A-9 INST ALLA TION 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 are required to switch between the dif- feren[...]

A-10 INST ALLA TION MAXsa™ 22 & 29 WIRE DRIVES A-10 K325 - TC-3 TRA VEL 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 ratio) 15” to 270”/min (381mm to 6.[...]

A-11 INST ALLA TION MAXsa™ 22 & 29 WIRE DRIVES A-11 INSTALLATION The TC-3 comes factory assembled to fit an 8” (203mm) beam. See print G1458 for instructions to use it on 10” (254mm) or 12” (305mm) beams. The Carriage Release Handle, the Wire Reel Support Bracket and the Wire Drive Support Bracket are not factory mounted. They should be[...]

A-12 INST ALLA TION 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 whenever the Carriage Release Handle is pulled down.[...]

A-13 INST ALLA TION MAXsa™ 22 & 29 WIRE DRIVES A-13 FIGURE A.8 - BEARING TRACKING INCORRECT P A TTERNS Bearing is not flat Against Drive Rail CORRECT P A TTERN Full Face Bearing Contact FIGURE A.7 - DRIVE GEAR TRACKING Beam Drive Rail Shims Full Face Contact Drive Gear Incorrect ADD Shims Incorrect REMOVE Shims .88” FIGURE A.9 BEARING SHIMS[...]

B-1 OPERA TION B-1 ROUTINE OPERA TION 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 reel(s) to finish the weld. b. The flux hopper is [...]

B-2 OPERA TION B-2 MAXSA™ 22 & 29 WIRE DRIVES FIGURE B.2 - HORIZONTAL ADJUSTMENT This Adjustment Can be Locked by Tightening T wo Socket Head Screws Rotating the K96 Allows for 2” Movement in any Direction in the Horizontal Plane T urn Handle to adjust Cross Seam Adjuster K96 Horizontal Adjuster MAXsa 29 MAXsa 22 2 1/2” 2 ” FIGURE B.1 -[...]

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 click on E9.181. All of the information for the P[...]

C-2 ACCESSORIES C-2 SUBMERGED ARC CONT ACT ASSEMBLIES 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 coverage with mini- mum flux consumption. Conta[...]

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 - Remove the two nozzle mounting clamps from the [...]

C-4 ACCESSORIES C-4 K148 CONTACT NOZZLE AND K149 Linc-Fill TM 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 - 4.8mm) wire. K148-C - For 1/16” to 5/64” (1.6 to 2.0mm) wire. Curr[...]

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 tip lock- ing nut will not clamp the tip securely[...]

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 of the contact tip. To do this, push the nozzle[...]

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. See Figure C.10 NOTE: The lower hose clamp mus[...]

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 nozzle to the faceplate and rotate the entire assembl[...]

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” (102mm) is possible with this attachment. Inst[...]

C-10 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-10 K96 HORIZONT AL 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 Lift Adjuster. Installation (See Figure C.14) 1[...]

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 & 29 WIRE DRI- VES as shipped is 142:1. T[...]

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 grease the O.D. of the new shorter drive rol[...]

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 wires must be the same size. The gear rat[...]

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. Insert one of the guide tubes (B) in the top of[...]

C-15 ACCESSORIES MAXsa™ 22 & 29 WIRE DRIVES C-15 K281 SOLID WIRE STRAIGHTENER FOR TINY TWINARC ® The K281 wire straightener can be used to straighten .045” through 3/32” (1.0-2.4mm) wiress. It is recom- mended for applications requiring long stickout and/or where accurate wire placement is essential. The fol- lowing table shows the recom[...]

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 disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE MAINTENANCE • Check weld cables, control[...]

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 Troubleshooting Guide is provided to help you l[...]

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 Observe all Safety Guidelines detailed throughout th[...]

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 Service Department for a replacement. Give the e[...]

F-2 DIMENSION PRINT F-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[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  Keep y our he ad out o f fumes .  Use ve ntil ation o r exha ust to remo ve [...]

• 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 •[...]