Lincoln Electric MAXsa 29 User manual

IM2070
04/2017
REV01
MAXsa™ 29 WIRE DRIVE
OPERATOR’S MANUAL
ENGLISH
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland Ohio 44117-1199 USA
www.lincolnelectric.eu

English English
I
THE LINCOLN ELECTRIC COMPANY
EC DECLARATION OF CONFORMITY
Manufacturer and technical documentation
holder:
The Lincoln Electric Company
Address:
22801 St. Clair Ave.
Cleveland Ohio 44117-1199 USA
EC Company: Lincoln Electric Europe S.L.
Address:
c/o Balmes, 89 - 802a
08008 Barcelona
SPAIN
Hereby declare that equipment: K2803, Power Wave AC/DC 1000 SD
K2444, CE Filter
K2814, MAXsa 10 Controller
K2626, MAXsa 19 Controller
K2370, MAXsa 22 Feed Head
K2312, MAXsa 29 Feed Head
(Sales codes may contain suffixes and prefixes.)
Is in conformity with Council Directives
and amendments: Electromagnetic Compatibility (EMC) Directive 2014/30/EU
Low Voltage Directive (LVD) 2014/35/EU
Standards: EN 60974-1: 2012, Arc Welding Equipment – Part 1: Welding Power
Sources;
EN 60974-5: 2013, Arc Welding Equipment-Part 5: Wire Feeders;
EN 60974-10: 2014, Arc Welding Equipment-Part 10: Electromagnetic
compatibility (EMC) requirements;
CE marking affixed in 09


SamirFarah,ManufacturerDarioGatti,EuropeanCommunityRepresentative
ComplianceEngineeringManagerEuropeanEngineeringManager
19January2017



MCD240f
20January2017


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II
12/05
THANKS! For having chosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code &
Serial Number can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Technical Specifications...................................................................................................................................................... 1
Safety .................................................................................................................................................................................. 3
Installation and Operator Instructions ................................................................................................................................. 4
WEEE ................................................................................................................................................................................ 14
Spare Parts ....................................................................................................................................................................... 14
Authorized Service Shops Location.................................................................................................................................. 14
Electrical Schematic.......................................................................................................................................................... 15
Suggested Accessories..................................................................................................................................................... 16

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Technical Specifications
MAXsa™ 29 WIRE DRIVE
MODEL TYPE 142:1 SPEED RATIO 95:1 SPEED RATIO 57:1 SPEED RATIO
WIRE SIZE WIRE SIZE WIRE SIZE
SPEED SOLID CORED SPEED SOLID CORED SPEED SOLID CORED
K2312-3 MAXsa™ 29 10-200 7/32 5/32 10-300 1/8 5/32 40-500 1/16 3/32
WIRE FEEDERS - INPUT VOLTAGE AND CURRENT
VOLTAGE INPUT AMPS
32VDC ()40V Pulse Width Modulated) 6.7 (max.)
PHYSICAL DIMENSIONS
HEIGHT (mm) WIDTH (mm) DEPTH (mm) WEIGHT (kg)
305
203 355 254 15.9
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE (ºC) STORAGE TEMPERATURE RANGE (ºC)
-20 to +40 -40 to +85
WELDING PROCESSES
PROCESS ELECTRODE DIAMETER
RANGE OUTPUT RANGE (A) WIRE FEED SPEED
RANGE
SAW 1.2-5.6 mm
200-2000+
(with paralleled machines) .25-11.43 m/minute

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Electromagnetic Compatibility (EMC)
01/11
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturbances
with, if necessary, assistance from Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
Personal medical devices like pacemakers and hearing aids.
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
WARNING
EMC classification of this product is class A in accordance with electromagnetic compatibility standard EN 60974-10 and
therefore the product is designed to be used in an industrial environment only.
WARNING
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radio-frequency disturbances.

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Safety
11/04
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this
equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible
for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician before operating this
equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.

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CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the
correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which
can cause serious injury. Keep your hands, body and clothing away from those parts during machine
starting, operating and servicing.
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
General Description
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™ 29 WIRE DRIVE consists 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
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-x Power Wave® AC/DC 1000 SD
K2814-x MAXsa™ 10 Controller/Feed Head
K2370-x MAXsa™ 22 Wire Drive
Basic Package with optional kits:
K2803-x Power Wave® AC/DC 1000 SD
K2311-x MAXsa™ Motor Retrofit Kit
K2312-x MAXsa™ 29 Wire Drive
K2626-x Wire Drive Controller (for fixture builders
that do not require the MAXsa™ 10 Controller).
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.
A. Connection box
B. Wire straighter
C. Gear box
D. Mounting
E. Drive motor
F. Drive rolls

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Figure 1 – Location of MAXsa™ Components Code
11616
Design Features - MAXsa™ 29
Closed-loop speed control.
Knurled drive rolls.
Heavy cast aluminum gearbox housing and feed
plate assembly.
Wire straightener.
Cross seam Adjuster.
Flux hooper (not shown)
Mounting hardware for accessories.
32Vdc permanent magnet, high torque motor.
Gears included to change speed range.
A. Connection box
B. Gear box
C. Cross seam adjuster
D. Mounting hardware
E. Drive rolls
Figure 1a – Location of MAXsa™ 29 Components
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.
A. Connection box
B. Wire straighterner
C. Gear box
D. Mounting
E. Drive motor
F. Drive rolls
Figure 1b – Location of MAXsa™ 29 Components Code

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11816
WARNING
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™29 Wire Drive. Wire drive installation should be
made in accordance with 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.
This equipment is for industrial use only and it is not
intended for use in residential locations where the
electrical power is provided by the public low-voltage
supply system. There can be potential difficulties in
residential locations due to conducted as well as radi-
ated radio-frequency disturbances. The EMC or RF
classification of this equipment is Class A
High Frequency Protection
Locate the MAXsa™ Wire Driveaway from radio con-
trolled machinery.
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 3).
Figure 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 4).
Figure 4 – Mounting Dimensions
Changing the Wire Drive Configuration
The MAXsa™ 29 WIRE DRIVE can be reconfigured to fit
in any hard automation application.
As shipped, the MAXsa™ 29 WIRE DRIVE Drive Rolls
rotate clockwise to feed the wire down. Reconfiguring
the Wire Drive per Figure 5 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 Electrical Scematic.
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 har-
ness by pulling the quick-connect terminals apart.
6. Reverse the motor leads and reconnect the quick-
connect terminals (see the Electrical Scematic).
Electrode Weld
Cable
Work weld
Cable
Work

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7
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 Channel that snaps into the
Connection Box. The Connection Box assembly
should be pushed all the way up to the Motor-to-
Gearbox 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
A. Loosen socket Head screw to rotate
motor/gearbox assembly
B. Remove connection box to change motor
polarity
C. Rotate
D. Loosen socket Head screw to rotate Feedplate
Figure 5
Wire Feed Mechanism
All MAXsa™ Wire Drive units are shipped with 142:1
ratio gears. Gears 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 2.4mm - 6.0mm wire. Other wire sizes will require
different drive rolls and guide tubes. See table 1.
The Idle Roll pressure will need to be adjusted for the
wire being used. The indicator shows two settings -
0.9 - 2.4mm
3.0 - 6.0mm
The tension adjustment is to be made after loading the
wire into the drive rolls.
NOTE: Lower tension may need to be needed to pre-
vent crushing of some cored wires or softer alloy solid
wires.
Gear Ratio Conversion
(See Figure 6)
1. Remove the 2 hex head screws and the 2 slot head
screws holding the Motor to the Wire Drive Gearbox
assembly.
2. Remove existing Adapter Plate and Motor
Assembly.
3. Take the two long screws removed in step 1 and
screw one into each of the tapped holes located on
the face of fiber input helical gear. Insert the screws
through the full thickness of the gear, and using a
screwdriver wedged between the screws to prevent
rotation, remove the hex nut that holds the gear to
the shaft. Remove plain washer.
4. Pull the gear from the shaft using the screws as a
pulling device.
5. Be certain woodruff key is properly located on the
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. Pull the pinion off. Remove the Ring
Magnet from the pinion gear and snap it onto the
new pinion gear. Before installing the new pin-ion
gear with the Ring Magnet onto the motor shaft,
ensure that the flat washer is located at the bottom
of the shaft. Install the new pinion and replace the
roll pin.
7. Cover the teeth of the motor pinion and the input
gear with a non-fluid molydisulfide type grease such
as Non-Fluid Oil Corporation’s A-29 Special/MS
Lubricant. This grease can be scooped from the
cavity of the gear case.
8. Reassemble the motor to the gearbox. Make sure
the gears mesh properly and the adapter plate
locating bead is in its cavity. Replace and tighten
the four screws removed in step 1.
Important: See the MAXsa™ 10, or power source
manual for instructions on configuring the system for the
new gear ratio.

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A. Drive motor brush
B. Hex head screw
C. Adapter plate and motor assembly
D. First chamber
E. Wire drive gearbox
F. Second chamber
G. Slot head screw
H. Pipe plug
I. Hex nut
L. Plain washer
M. Input helical gear (12)
N. Slot head screws (mounting screws)
O. Wire feed gearbox
P. Woodruff key (8)
Q. Wire drive motor
R. Shaft
S. Adaptor plate
T. Pinion
U. Roll pin
V. Mounting screw
Figure 6
Table 1 – Drive Roll Kit
KP1899 DRIVE ROLL KIT INCLUDED WITH KIT
Drive Roll Drive Roll Incoming Outgoing
Kit Number Wire sizes Types Part Number No. Required Guide Guide
KP1899-1 3/32-7/32” Wires KP1885-1 2 KP2116-2 KP1963-1
KP1899-2 1/16-3/32” Wires KP1886-1 2 KP2116-1 KP2097-2
KP1899-3 .035-.052” Solid Wire KP1887-1 1 KP1967-1 KP2097-1
KP1899-4 .045-.052” Cored Wire KP1892-1 2 KP1967-1 KP2097-1
NOTE: Twinarc drive rolls are included with the Twinarc kits.
Electrode Connections
Because the Power Wave®AC/DC 1000 SD can
produce 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
different polarities. All of this is controlled internally by
the Power Wave®AC/DC. The following directions apply
to all polarities:
Connect the electrode cable(s) to the "ELECTRODE"
stud(s) on the power source . Connect the other to the
contact assembly at the Wire Drive. Be sure the con-
nection makes tight metal-to-metal electrical contact.
The electrode cable should be sized according to the
specifications given in Table 2.
NOTE: On the Power Wave®1000 SD, the Electrode
studs are on the lower left rear corner of the machine.
On older units they are on the lower left front corner. On
those machines, the cables can be routed through the
oval hole in the cable tray before being connected to the
output terminals.

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Table 2 – Output Cable Guidelines
Total Cable
Length m
Electrode and
Work Combined
Duty
Cycle
Number of
Parallel
Cables
Cable Size
Copper
mm2
0 to 76.2 80% 2 120
0 to 76.2 100% 3 95
When using inverter type power sources like the Power
Wave®, use the largest welding (electrode and work)
cables that are practical. When using AC applications
the current can reach very high levels. Voltage drops
due to cable resistance can become excessive, leading
to poor welding characteristics if undersized welding
cables are used.
Remote Sense Lead Specifications
The MAXsa™ 29 Wire Drive has an Electrode 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 and connected to the electrode connection at
the nozzle. This connection should be made as close to
the welding arc as possible. Use at least a 12 AWG wire
with a proper sized ring terminal. Use a screw with a lock
washer and nut to make the connection, then insulate
the connection with electri-cal tape. Proper care should
be taken to protect the sense lead from becoming
disconnected or damaged. The loss of a sense lead
connection can adversely affect welding performance.
The system may have multiple sense lead configurations
available. Consult the power source manual on how to
configure the power source for the sense leads.
NOTE: The WORK sense lead (21) for the MAXsa™ 29
WIRE DRIVE system is typically connected at the back
of the Power Wave®AC/DC 1000 SD. If the MAXsa™
wire drive is to be used in an older system, (PF10A
and/or K2344-X) the WORK sense lead must be brought
out of the motor connection box and connected to the
workpiece
K325 - TC-3 Travel Carriage
The TC-3 travel carriage is available in two models. Both
are “High Capacity” and suitable for multiple arc welding.
K325- HC-S (Standard - 952:1 ratio)
127mm to 1.88M/mim.
K325-HC-F (High Speed - 254:1 ratio)
381mm to 6.86M/min.
NOTE: Although the carriages can be set for speeds
down to zero, speed variations increase dramatically
with uneven loading when operated below the
recommended minimum speeds.
The maximum amount of equipment that a K325
carriage can safely carry is shown in Table 3.
It is important when mounting wire reels,and other
equipment to the TC-3 Travel Carriage that there is a
minimum of overhung weight. The Wire Drive mountings
are to be such that the heads are within 483mm from the
front of the carriage as shown in Figure 7.
Figure 7
Table 3 – 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
Controls
Two Wire Reels
(60 # Coils)
Three Wire
Reels (60#
Coils)
Four Wire
Reels(60#
Coils) Centrally
Located
Two K29 Vertical
Adjusters
Three K29
Vertical
Adjusters
Two K29
Vertical
Adjusters
Two K96
Horizontal
Adjusters
Three K96
Horizontal
Adjusters
Two K96
Horizontal
Adjusters
Flux Hopper Flux Hopper Flux Hopper
150# of Auxiliary
Equipment
Centrally Located
over TC-3
No Auxiliary
Equipment
No Auxiliary
Equipment
Installation
The TC-3 comes factory assembled to fit an 203mm
beam. See print G1458 for instructions to use it on
254mm or 305mm beams.
The Carriage Release Handle, the Wire Reel Support
Bracket and the Wire Drive Support Bracket are not
factory mounted. They should be mounted to the
carriage before it is placed on the beam per the following
instructions:
1. Insert the clutch handle into the hole on the right
side of the carriage so that the end of the handle is
goes into the lift yoke.
2. Line up the hole in the handle and the hole in the lift
yoke and insert the roll pin that came taped to the
handle. Drive in the roll pin until it is flush with the
yoke.
3. There are 2 possibilities:
a) If the MAXsa™ 10 Control Box is not going
to be mounted on the carriage, mount the
Wire Reel Support Bracket to the left front
corner of the carriage using the hardware
provided.

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10
b) Do not mount the Wire Reel Support if the
K2462-1 Control Box Mounting Bracket for
the MAXsa™ 10 is to be mounted on the
carriage. Another means of mounting the
wire must be used such as a K390 or a
user supplied support for a K299 or K162-1
Spindle Kit (ordered separately).
NOTE: Do not mount the K2462-1 Bracket for the
MAXsa™ 10 Control Box until after the car-riage is
placed on the beam.
4. Install the Wire Drive Mounting Bracket that is sup-
plied with the MAXsa™, using the hardware and
insulators provided. See Figure 8.
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 the car-
riage on the beam. It should run freely along the beam.
With the release handle in the up position the drive gear
should engage the track and hold the car-riage securely
in position.
If the MAXsa™ 10 Control Box is to be mounted to the
TC-3:
1. Attach the K2462-1 bracket to the left side of the
carriage per the instructions included with the
bracket.
NOTE: Make certain that there is enough clearance to
the left of the beam to accommodate the K2462-1
bracket
2. Mount the MAXsa™ 10 Control Box to the brack-et
and connect the 4 pin connector from the Travel
Control to the mating receptacle on the bottom of
the MAXsa™ 10 Control Box.
Keep the load on the TC-3 as uniform as practical. Install
cables so that they move smoothly with the car-riage.
Clamp the weld cables to the carriage using the cable
clamp on the left rear corner.
After all of the equipment has been mounted to the
carriage, the tracking of the drive gear and the bear-ings
should be checked.
A. MaxSa™10 Mounting Bracket (K2462-1)
B. Wire reel mounting bracket
C. Clutch handle
D. Wire drive mounting bracket (M6769)
E. Head support (M8232)
Figure 8 – Wire Drive Mounting
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).
WARNING
When the carriage is used in an inclined application the
unit is free to move whenever the Carriage Release
Handle is pulled down. This may happen even if a
counter balance weight 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 Warning)
3. A tilt in excess of 5° will require a counter weight as
shown in Figure 9. The amount of counter-weight
will depend on the tilt angle and the amount of load
on the carriage. Beam angles should be limited to
10° or less.
A. Pulley
B. Beam
C. Carriage
D. Weight
Figure 9 – Inclined Operation
DRIVE GEAR TRACKING
The TC-3 is shimmed at the factory so that the drive
gear sits flat against a .88” (22mm) flange when the
release handle is in the up position. If the flange
dimension is other than .88” (22mm) the shims under the
TC-3 gear box mounting will have to be changed
accordingly. See Figure 10.
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.
A. Drive gear
B. Full face contact
C. Shims
D. Beam drive rail
E. Incorrect ADD shims
F. Incorrect REMOVE shims
Figure 10 – Drive Gear Tracking

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CARRIAGE BEARING TRACKING
Bearing tracking can be checked by placing a strip of
white paper over the area where the bearings ride. With
the drive gear disengaged (handle down), move the
carriage over the strips. If the tracking is correct the
bearings will leave a uniform trace on the paper. See
Figure 11. If traces are not correct add shims as
necessary. See Figure 12.
A. CORRECT PATTERN: full face bearing contact
B. INCORRECT PATTERNS: bearing is not flat
against drive rail
Figure 11 – Bearing Tracking
A. Shim here
Figure 12 – Bearing Shims
Routine Operation
Once the procedures and parameters are properly set at
the controller the operator should be able to make
production welds without changing those settings. A
typical weld sequence is as follows:
1. Before starting, make sure that:
a) There is enough wire on the reel(s) to finish the
weld.
b) The flux hopper is filled with new or properly
screened flux.
2. Energize the power source and wait for it to stabilize
(all Status LED’s Green).
3. Position the Wire Feed Head at the start of the weld.
Be sure the TC-3 Carriage or travel mecha-nism is
set to move in the proper direction
4. Set the travel switch for “Automatic Travel” if the
“Hand Travel” position was used to position the feed
head in Step 3.
STARTING TECHNIQUES
1. Hot Starting - refers to starting the weld with the
Wire Drive head stationary and the wire not
touching the workpiece.
a) Always cut the end of the wire to a sharp point.
b) Press Feed Forward until the wire touches the
work piece and the flux hopper acti-vates to put
flux around the starting point.
c) Press Feed Reverse to retract the wire 3.2 to
6.4mm).
d) Use the Set-Up menu of the MAXsa™ 10 or
remote controller to determine whether the
travel will begin with Start Button pressed or
with weld current (preferred).
e) Press the START button to initiate the weld.
f) Press the STOP button to begin the stop-ping
sequence.
g) If necessary, press the Feed Reverse to move
the electrode out of the way.
2. On-the-fly Starting - refers to starting the weld after
the travel begins to get a “scratch” start. Normally
this type of starting requires the use of a ‘run-on’ 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.
3. Cold Starting - refers to starting the weld with the
Wire Drive Head stationary and the electrode
touching the work.
a) This procedure is not recommended for the
Power Wave® AC/DC 1000 / MAXsa™ 29
WIRE DRIVE combinations but may work OK
with smaller diameter wires and proper setting
of the Start parameters.
b) Follow Hot Starting procedure but omit “step c”.
HEAD POSITION ADJUSTMENTS
The MAXsa™ 29 WIRE DRIVE can be easily adjusted to
any weld position. The most often used adjust-ments are
available on the MAXsa 29 Wire drive. See Figure 13.
Turn the Cross Seam Adjuster (MAXsa™ 29) to keep
the arc in the joint as necessary. With a MAXsa™, a K96
or some other means of horizontal adjustment is
recommended. See Figure 14
The entire Wire Drive can be moved into or out of the
Mounting Bracket (M6789). If using a K29 Vertical Lift
Adjuster it can be locked in either the horizontal or
vertical position once the vertical position is set. See
Figure 15.
If the Wire Drive is rotated to a position where the
faceplate is upside down, the contact nozzle and the
wire straighter and guide tubes will need to be reversed.
The polarity of the motor will also need to be changed so
the wire feeds in the proper direction. See the
Installation Section, Changing the Wire Drive
Configuration for instructions on changing the motor
polarity.

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A. The cross sea adjuster can be mounted to the top or
bottom of the gearbox.
B. Loosen this socket head screw to adjust faceplate
angle
C. 5/16’’ allen wrench
D. Face-plate rotates 360° around the drive roll shaft
E. Feed head rotates 360° around the motor axis.
Figure 13 – Feed Head Adjustment
A. MaxSA29
B. Cross seam adjuster
C. This adjustment can be locked by tightening two
socket head screws
D. Turn handle to adjust
E. Rotating the K96 allows for 2’’ movement in any
direction in the horizontal plane
F. K96 horizontal adjuster
Figure 14 – Horizontal Adjustment
A. Loosen to rotate entire head around mounting axis
B. With K29 loosen screw
C. Use this screw to lock vertical position
D. With standard mounting (M6767) or K29 vertical
adjuster
E. K29 clamps can be set to restrict in and out motion
to distances up to 3 ¾’’
F. Head may be rotated around the vertical axis
G. K96
H. Head mounting
I. With standard mounting (M6767) or K96 horizontal
adjuster.
Figure 15 – Vertical Adjustment
Maintenance
WARNING
For any maintenance or repair operations it is
recommended to contact the nearest technical service
center or Lincoln Electric. Maintenance or repairs
performed by unauthorized service centers or personnel
will null and void the manufacturers warranty.
WARNING
Do not open this machine and do not introduce anything
into its openings. Power supply must be disconnected
from the machine before each maintenance and service.
After each repair, perform proper tests to ensure safety.
Routine Maintenance
Check weld cables, control cables and gas hoses
for cuts
Clean and tighten all weld terminals.
Inspect and clean drive rolls and inner wire guide
and replace if worn.
Periodic Maintenance
Every six months check the motor brushes. Replace
them if they are less than 1/4" long.
Every year inspect the gearbox and coat the gear
teeth with a moly-disulfide filled grease. DO NOT
use graphite grease.
Calibration Specification
All calibration is factory set on the MAXsa™ Wire Drive.
To verify the wire feed speed:
Adjust the wire feed speed to 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 635mm +/-2%.
Sense Lead Fuse
There should never be any current flowing through
the sense leads! The sensing lead circuit is current
protected in the Power Wave® AC/DC 1000 SD.
If the MAXsa™ 29 WIRE DRIVE are used in an older
system, a fuse in series with the #21 sense lead in the
wire drive Connection Box protects the sense lead cir-
cuit from weld current due to incorrect configuration. If
this fuse ever opens, check the sense lead configura-
tion to ensure proper connections. The fuse must be
replaced with a comparable fuse with a rating of less
than 1 amp before welding. The fuse being open or
missing would have the same effect on the welding as
having a disconnected sense lead.
Customer Assistance Policy
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

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13
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
respon- sibility 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.

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14
WEEE
07/06
English
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment (WEEE)
and its implementation in accordance with national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an environmentally compatible recycling facility. As the
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment and human health!
Spare Parts
12/05
For Spare Parts references visit the Web page : https://www.lincolnelectric.com/LEExtranet/EPC/
Authorized Service Shops Location
09/16
The purchaser must contact a Lincoln Authorized Service Facility (LASF) about any defect claimed under Lincoln's
warranty period.
Contact your local Lincoln Sales Representative for assistance in locating a LASF or go to
www.lincolnelectric.com/en-gb/Support/Locator.

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Electrical Schematic

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Suggested Accessories
BASIC PACKAGE
Item number Description
K2803-x Power Wave
(R)
AC/DC 1000 SD CE
K2370-x MAXsa
TM
22 Wire Drive
K2814-x MAXsa
TM
10 Controller/Feed Head
BASIC PACKAGE with OPTIONAL KITS
K2803-x Power Wave® AC/DC 1000 SD
K2311-x MAXsa™ Motor Retrofit Kit
K2312-x MAXsa™ 29 Wire Drive
K2626-x Wire Drive Controller (for fixture builders that do not require the MAXsa™ 10 Controller)
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 “Enter” 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 PowerWave System
accessories can be found in this document.
K2311-1 Motor Conversion Kit (for 142:1 NA
Style Wire Drives)--This conversion kit converts
old NA style wire drives to MAXsa™ 29 WIRE
DRIVE.
1. Remove the 2 hex head screws and the 2 slot
head screws holding the Motor to the Wire Drive
Gearbox assembly.
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 the new Motor pinion gear with a
non-fluid molydisulfide type grease such as Non-
Fluid Oil Corporation’s A-29 Special/MS Lubricant.
This grease can be scooped from the cavity of the
gear case First Chamber.
5. Reassemble the new Adapter Plate and Motor
Assembly on the Wire Drive Gearbox; making sure
the gears mesh properly and the Adapter Plate
locat-ing bead is in its cavity. Replace and tighten
the 4 screws removed in step 1.
Submerged Arc Contact 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.
Contact tips for the electrode diameter specified on the
order are shipped with each nozzle. A dif-ferent contact
tip is required for each electrode diameter used.
Installation - Nozzles ordered for 2.4 mm electrode
include a liner and a contact tip adapter. Screw the
adapter into the end of the nozzle and the contact tip
into the adapter.
Insert the outgoing wire guide from the wire feed head
into the top of the K231 and install the assembly in
position on the bottom of the wire feed head. Lock it in
position using the two clamps provided with the head.
Connect one end of the rubber flux hose to the tube at
the bottom of the flux hopper. Fit the short copper tube
in the other end of the rubber hose then insert the
copper tube into the hole in the flux cone body. See
Figure 16.
WARNING
Pushing the copper tube too far into the flux cone body
will cause a short between the cone and nozzle if the
cone touches the work.
A. Socket head screw
B. Weld cable connection
C. Wing screw
D. Flux cone body
E. Flux cone
F. Flux hose
G. Copper tube
Figure 16 – K231
Connect the lug on the electrode cables from the power
source to the tab on the contact nozzle and tighten the
bolt and nut. See Figure 16

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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. Rusty and dirty wire or exces-sively high
currents increase tip wear. Always keep replacement
tips in stock.
To replace the contact tip, first loosen the retain-ing
wing nut and remove the flux cone body. Then unscrew
the tip and replace it.
A special socket head screw holds the nozzle body to
the insulator. If the nozzle body becomes loose, remove
the nozzle from the head, tighten the screw and
reassemble nozzle.
Extensions - The K231 nozzle can be extended if
necessary. Order part number S12003 for a 127mm
extension or make any length per drawing in Figure 17.
Figure 17 - Extension
Wire Size “A” dim.
2.0-2.4mm 3.2mm
3.2-4.0mm 4.8mm
4.8-5.6mm 6.4mm
K226 CONTACT ASSEMBLY
The K226 assemblies are used for welding at currents
from 600 to 1000 amps.
Model K226-T - (2 tapered jaws) 2.4 and 3.2mm
electrode
Model K226-R - (1 tapered and 1 rectangular jaw) 3.2 -
5.6mm electrode.
Installation - Remove the two nozzle mounting clamps
from the wire drive. Insert the outgoing wire guide from
the wire feed head into the top of the K226 and install
the assembly in position on the bottom of the wire feed
head. Use the two screws provided with the K226 to
attach it to the wire drive. See Figure 18.
NOTE: Removing the 4 screws that hold the noz-zle
body to the mounting block allows the nozzle to be
rotated to any of four posi-tions 90° apart. See Figure
18.
Connect two electrode cables to the contact jaws (one
under each 1/2-13 nut. Make sure that the cable lugs
are flat against the copper and tighten the nuts
securely. See Figure C.3.
Slip the rubber flux hose that comes with the K226 on
to the flux hopper valve. Fit the copper tube into the
other end and place it in the clip on the lower jaw
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 ‘dress’ 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 be kept in line with the wire
guide. Align the jaws as follows: (See Figure C.3)
1. Loosen the stationary contact jaw screws.
2. Release the tension on the moveable jaw by
loosening the screws holding the spring.
3. Place a straight 14” (or longer) piece of bare
4.0mm wire through the wire guide and into the
drive rolls of the feed head.
4. Adjust the stationary contact so the wire touches
the jaw at the center of the groove for the entire
length of the jaw.
5. Tighten the screws, remove the wire and re-tighten
the screws holding the spring to apply tension to
the moveable jaw. The moveable jaw should move
freely.
Material-hard drawn
Copper or heat
treatable copper
alloy