Lincoln Electric MAXsa 29 WIRE DRIVE User manual

Operator’s Manual
MAXsaTM 29 WIRE DRIVE
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IM10265 | Issue Date June-15
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12424
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.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.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
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 must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to 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.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

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 the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
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.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. 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. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

Page
Installation ..........................................................................................................Section A
Product Description .....................................................................................................................A-1
Recommended Processes ..........................................................................................................A-1
Process Limitations .....................................................................................................................A-1
Equipment Limitations .................................................................................................................A-1
Common Equipment....................................................................................................................A-1
Specifications ..............................................................................................................................A-2
Safety Precautions. .....................................................................................................................A-3
Non-Safety Standard Equipment..........................................................................................A-3
Input and Ground Connections ............................................................................................A-3
Location and Mounting .........................................................................................................A-3
High Frequency Protection...................................................................................................A-3
Power Wave®AC/DC1000 SD Systems Connections ...............................................................A-4
Mounting Dimensions...........................................................................................................A-4
Connection Diagram.............................................................................................................A-4
Changing Wire Drive Configuration .............................................................................................A-5
Wire Feed Mechanism.................................................................................................................A-6
Gear Ratio Conversion Kits .........................................................................................................A-6
Electrode Connectios ..................................................................................................................A-7
Remote Sense Lead Specifications.............................................................................................A-7
TC-3 Travel Carriage...................................................................................................................A-8
Installation ............................................................................................................A-9 thru A-11
________________________________________________________________________________
Operation ...........................................................................................................................Section B
Routine operation ........................................................................................................................B-1
Starting Techniques .............................................................................................................B-1
Head Positioning ..................................................................................................................B-2
________________________________________________________________________________
Accessory ...........................................................................................................Section C
Options and Accessories Website ..............................................................................C-1
Motor Conversion Kit For (142:1 NA Style Wire Drives) .......................................C-1
Sub-Arc Contact Assemblies....................................................................C2 thru C-8
Vertical Head Adjuster...........................................................................................C-9
Horizontal Head Adjuster ....................................................................................C-10
K129 Tiny TwinArc Kit .........................................................................................C-11
K225 Sub-Arc TwinArc Kit...................................................................................C-13
K281 Solid Wire Straightener for TwinArc...........................................................C-15
________________________________________________________________________________
Maintenance........................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Engine Maintenance ...........................................................D-1
Calibration Specification........................................................................................D-1
________________________________________________________________________________
Troubleshooting .................................................................................................Section E
Safety Precautions ................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
________________________________________________________________________________
Wiring Diagrams and Dimension Print .............................................................Section F
________________________________________________________________________________
Parts List.............................................................................................P-623, P-697, P-101
________________________________________________________________________________
vi
vi TABLE OF CONTENTS

A-1
PRODUCT DESCRIPTION
MAXsa™ 29 WIRE DRIVE
A-1
PRODUCT SUMMARY
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.
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).

A-2
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-2
DESIGN FEATURES - MAXsa™ 29
•Closed-loop speed control.
• Knurled drive rolls.
• Heavy cast aluminum gearbox housing and feed plate assembly.
• Wire straightener.
• 32Vdc permanent magnet, high torque motor.
• Gears included to change speed range.
FIGURE A.2 - LOCATION OF MAXsa™ 29 COMPONENTS CODE 11616
Connection
Box
Wire Straightener
Gear Box Drive Rolls
Mounting
Drive Motor

A-3
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-3
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 Hopper (not shown)
• Mounting Hardware for accessories
• 32Vdc permanent magnet, high torque motor.
• Gears included to change speed range.
Connection
Box
Gear Box Drive Rolls
Cross Seam
Adjuster
Mounting
Hardware
Drive Motor
FIGURE A.1a - LOCATION OF MAXsa™ 29 COMPONENTS

A-4
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-4
DESIGN FEATURES - MAXsa™ 29
•Closed-loop speed control.
• Knurled drive rolls.
• Heavy cast aluminum gearbox housing and feed plate assembly.
• Wire straightener.
• 32Vdc permanent magnet, high torque motor.
• Gears included to change speed range.
FIGURE A.2a - LOCATION OF MAXsa™ 29 COMPONENTS CODE 11816
Connection
Box
Wire Straightener
Gear Box Drive Rolls
Mounting
Drive Motor

A-5
SPECIFICATIONS
MAXsa™ 29 WIRE DRIVE
A-5
TECHNICAL SPECIFICATIONS - MAXsa™ 29 WIRE DRIVE
PHYSICAL DIMENSIONS
TEMPERATURE RANGES
Wire Feeders - Input Voltage and Current
Voltage
32V DC (40V Pulse Width Modulated)
HEIGHT
12.0 in. (305 mm)
8.0 in. (203 mm)
MODEL
K2312-3
WIDTH
14.0in (355mm)
DEPTH
10.0in (254mm)
WEIGHT
35.0lbs (15.9kg)
Input Amperes
6.7 Amps (max.)
OPERATING TEMPERATURE RANGE
-4°F to 104°F (-20°C to 40°C)
STORAGE TEMPERATURE RANGE
-40°F to 185°F (-40°C to 85°C)
WELDING PROCESSES
Spec. Type 142:1 Speed Ratio 95:1 Speed Ratio 57:1 Speed Ratio
Process
SAW
Electrode Diameter Range
.045” – 7/32" (1.2 – 5.6 mm)
Output Range (Amperes)
200 - 2000+
(with paralleled machines)
Wire Feed Speed Range
10 - 500 ipm (.25 – 11.43 m/minute)
K2312-3 MAXsa™ 29
Wire Size
Speed Solid Cored
10-200 7/32 5/32
Wire Size
Speed Solid Cored
10-300 1/8 5/32
Wire Size
Speed Solid Cored
40-500 1/16 3/32

HIGH FREQUENCY PROTECTION
Locate the MAXsa™ Wire Driveaway from radio con-
trolled machinery.
A-6
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-6
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 input power to any other equip-
ment connected to the welding sys-
tem at the disconnect switch or fuse
box before working on the equipment.
• Do not touch electrically hot parts.
------------------------------------------------------------------------
NON-STANDARD SAFETY INFORMATION
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 the appropriate National Electrical
Code, all local codes and the information in this manual.
LOCATION AND MOUNTING
The MAXsa™ Wire Drive will operate in harsh indoor
environments. It has an IP2X rating.
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.
WARNING
CAUTION

A-7
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-7
POWER WAVE®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 four 3/8-16 tapped holes or the two 0.562 through
holes. See mounting hole locations (See Figure A.4).
FIGURE A.3 - CONNECTION DIAGRAM
FIGURE A.4 - MOUNTING DIMENSIONS
K2683-XX
Arclink Cable
67 Lead
K1785-XX
14-Pin Cable
Work
K231-XX
Contact Nozzle
Power Wave®AC/DC 1000
K2814-X
MAXsa™ 10
MAXsa™ 29
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

A-8
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-8
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 A.4a 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 har-
ness by pulling the quick-connect terminals apart.
6. Reverse the motor leads and reconnect the quick-
connect terminals (see the Wiring Diagram).
7. Carefully replace the wire harness back into the
Connection Box and place back onto the Motor
housing locating over the Motor lead grommet.
Ensure that the tachometer leads are completely
covered by the 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.
Rotate Rotate
Loosen Socket
Head Screw to
Rotate Feedplate
Loosen Socket
Head Screw to Rotate
Motor/Gearbox Assembly
Remove ConnectionBox
to Change Motor Polarity
FIGURE A.4a

A-9
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-9
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 3/32 through 7/32(2.4mm - 6.0mm) wire. Other
wire sizes will require different drive rolls and guide
tubes. See table A.1.
The Idle Roll pressure will need to be adjusted for the
wire being used. The indicator shows two settings -
.035 - 3/32” (0.9 - 2.4mm)
.120.- 7/32” (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 A.4b)
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.
WIRE
DRIVE
MOTOR
SHAFT
ADAPTOR
PLATE
PINION
ROLL PIN
MOUNTING
SCREW
- DRIVE MOTOR PINION
GEAR REMOVAL
- CHANGING THE WIRE FEED GEAR RATIO
HEX NUT (11)
PLAIN WASHER (9)
WOODRUFF
KEY (8)
WIRE FEED
GEARBOX
INPUT
HE LI C AL
GEAR (12 )
SLOT HEAD
SCREWS
(MOUNTING
SCREWS)
- WIRE DRIVE MOTOR
GEAR BOX
HEX HEAD
SCREW
ADAPTER
PLATE AND
MOTOR
ASSEMBLY
FIRST
CHAMBER
WIRE DRIVE
GEARBOX
SECOND
CHAMBER
SLOT HEAD
SCREW
PIPE
PLUG
DRIVE MOTOR
BRUSH ACCESS
FIGURE A.4b

A-10
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-10
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-
ferent 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 A.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.
TABLE A.2 - Output Cable Guidelines
When using inverter type power sources like the
Power Wave®, use the largest welding (electrode and
work) cables that are practical. When using AC appli-
cations 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.
Total Cable Length
ft (m)
Electrode and Work
Combined
0 (0) to 250 (76.2)
0 (0) to 250 (76.2)
Duty Cycle
80%
100%
Number of
Parallel Cables
2
3
Cable Size
Copper
4/0 (120 mm2)
3/0 (95 mm2)
TABLE A.1 - DRIVE ROLL KITS
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
KP1899 DRIVE ROLL KIT INCLUDED WITH KIT
NOTE: Twinarc drive rolls are included with the Twinarc kits.

A-11
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-11
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.
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 6.86M/min)
NOTE: Although the carriages can be set for speeds
down to zero, speed variations increase dra-
matically with uneven loading when operated
below the recommended minimum speeds.
The maximum amount of equipment that a K325 car-
riage can safely carry is shown in Table A.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 mount-
ings are to be such that the heads are within 19”
(483mm) from the front of the carriage as shown in
Figure A.5.
TABLE A.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
FIGURE A.5
19”
(483mm)

A-12
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-12
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 mounted to the car-
riage 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. 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.
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 sepa-
rately).
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 A.6.
NOTE: To install a MAXsa™ 29 Wire Drive order a
Mounting Bracket (M6769) and the appropri-
ate Head Support (K29 or M8232).
5. Use an ohmmeter to be sure that the Wire Reel
shaft and the Wire Drive Mounting Bracket are
electrically isolated from the TC-3 frame.
With the release handle all the way down, set 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.
FIGURE A.6 - WIRE DRIVE MOUNTING
Wire Reel
Mounting Bracket
Clutch
Handle Wire Drive Mounting
Bracket (M6769)
Head Support
(M8232)
MAXsa™ 10
Mounting Bracket
(K2462-1)

A-13
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-13
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. 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 CAUTION).
3. A tilt in excess of 5° will require a counter weight
as shown in Figure A.10. 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.
CAUTION
FIGURE A.10 - INCLINED OPERATION
Beam
Carriage
Weight
Pulley

A-14
INSTALLATION
MAXsa™ 29 WIRE DRIVE
A-14
FIGURE A.8 - BEARING TRACKING
INCORRECT PATTERNS
Bearing is not flat
Against Drive Rail
CORRECT PATTERN
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
Shim Here
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 A.7.
NOTE: TC-3 units are shipped with a helical tooth
drive wheel that is suitable for use on a
smooth drive rail. A straight tooth gear
(T13586) is available for use on a drive rail
with a straight cut knurl.
CARRIAGE BEARING TRACKING
Bearing tracking can be checked by 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 A.8. If traces are not correct add shims as
necessary. See Figure A.9.