WELDING AUTOMATION

PRODUCT BROCHURE
TABLE OF CONTENTS
History ........................................................................................................................................................... 3
Car Shredder ................................................................................................................................................. 4
Car Shredder Options................................................................................................................................ 6
Carbide Dispensing ....................................................................................................................................... 8
Cement Pulverizer Rolls & Tables ............................................................................................................... 10
Coal Pulverizer Rolls .................................................................................................................................... 12
Coal Pulverizer Tables ................................................................................................................................. 14
Cone Type Rock Crushers (Gyr-O-Matic) .................................................................................................... 16
Custom Equipment ..................................................................................................................................... 18
Dredge Pump Shells .................................................................................................................................... 20
Hand Guns ................................................................................................................................................... 22
Metal Spray ................................................................................................................................................. 24
Multiple Axis Welding System - Vers-O-Weld 25........................................................................................ 25
Multiple Axis Welding System - Vers-O-Weld 45........................................................................................ 28
Pipe Welding ............................................................................................................................................... 29
Plate Overlay Systems ................................................................................................................................. 32
Rock Impact Crusher (Impact-O-Weld) ....................................................................................................... 34
Roll Style Rock Crushing (Roll-O-Matic) ...................................................................................................... 36
Single Axis Welding Systems ....................................................................................................................... 38
Sub Arc Welding .......................................................................................................................................... 40
Sugar Cane Roll Arcing ................................................................................................................................ 41
Torches ........................................................................................................................................................ 44
Welding Lathes............................................................................................................................................ 46
Wire Feeders ............................................................................................................................................... 47
MAVRIX CORPORATION LEGAL NOTICE ...................................................................................................... 48

2
HISTORY
MAVRIX Welding Automation originated from the Teledyne McKay Company who created the
foundations of the products back in the 1950’s. The early history of the company involved the
design and manufacture of special machines for weld buildup and hardfacing of such things as
earth moving, undercarriage equipment and steel mill rolls.

MAVRIX began its existence in 1986 when Dick Haak purchased the assets of the Automatic
Welding Division of Teledyne McKay. Dick would focus on products that were portable, reliable
and easy to use and operated the company under the name Mavrix Automatic Welding.

MAVRIX has custom developed machines for special purpose weld fabrication tasks including
sub-arc welding of rail tank car internal girths with precision level control and have also
supplied a number of integrated systems including some metal spraying systems. The product
design is modular in nature and is grouped into typical product families that can be mixed and
matched in many cases. Our focus is hard facing and metal build up and we participate in the
following industries and applications

 Pulverizers – Coal, Cement

 Crushing – Rock, Aggregate, Roll/Impact/Cone type systems
 Recycling – Hammer Shredders
 Steel Mill – Slab caster rolls and chocks
 Oil & Gas – ID & OD pipe and hardbanding
 Sugar Mill – Roll Arcing
 Dredge Pumps – Shells and Covers
 Construction – Wear Surface Protection
 Wear Plate

In May of 2009 Dick sold the company to Glen Senger after nearly 23 years of service and
invention. Since the sale of Mavrix the company has expanded its products to enter new
markets in hard facing. With an expanded large lathe product offering and ID pipe welding
equipment capable of 3” ID in 11 foot long pipe Mavrix believes in making a substantial
investment in new products and configuring our current systems into unique welding
automation system specific to the customer’s requirements.

Now in our 25th year Mavrix continues to service products manufactured by McKay and we are
proud to support those products manufactured through the past 25 years. All products shown
in this brochure are manufactured by our experience staff in our facility located in Muskego
Wisconsin-USA.

3
CAR SHREDDER

 Automatically rebuilds shredder discs in place.

 Cuts welding costs 50% or more, and designed for easy mounting.
 Deposits up to 25 to 30 pounds of weld metal per hour minimizing downtime.
 Easy, frequent rebuilding maintains roll size and proper shredder performance.
 Remote pendant operation allows the operator to be clear of welding arc, assuring maximum
comfort, safety, and production.
 Reduces your cost per ton by extending the life of your discs.

4
 CAR SHREDDER REBUILD
SYSTEM COMPONENTS
SERIES 130
1. Motorized Carriage Assembly: The unit includes a rack-and-pinion gear system for accurate and
repeatable weld positioning. A clutch is provided for easy disengagement of the drive motor, which
allows quick positioning of the weld nozzle. A dual carriage weld system is also available.
2. Travel Beam: The standard travel beam is a 2" x 3" rectangular steel section 135 inches long. Two
support legs are provided. The leg size (height) is determined by the rotor disc diameter.
3. Wire Feeder: Our PA-10 Wire Feeder is mounted atop the motorized carriage assembly. We
recommend using 60 lb. coils of weld wire as shown to minimize wire feed problems.
4. Rotor Rotation Gearmotor: This gearmotor is used to turn the rotor at welding speeds 20 to 40 ipm.
Sprockets and chain are also provided.
5. Control with Operator's Pendant: The main control box contains the DC motor control boards and
associated 24V circuitry. The operator control is a convenient 3 1/2" x 3 1/2" x 10 1/2" fiberglass
box. Our new Series 130 contains a digital weld voltmeter.
6. Trip Weld Index Switch: A trip switch is provided to index the carriage after each revolution.
7. Rotary Weld Ground: A 500 amp rotary ground is included.
8. Weld Nozzle Assembly: The copper weld nozzle with internal spring liner mounts off the motorized
carriage and weld arm. The weld arm is easily adjustable in and out. The nozzle adjustor allows  4
inches of wire stick-out control.

5
Car Shredder Options
Car Shredder System Options

The second carriage option is a non motorized carriage that acts as a trailer and is pushed or
pulled by the main carriage. The contents include;
 Standard closed carriage with adjustable link to primary carriage
 Weld arm assembly
 Mavrix constant speed PA-10 four roll wire feeder with dynamic braking and a 60# wire reel
 Mavrix 48-130 adjustable torch assembly
 1500 amp rotary ground with credit given for the 800 amp from the base system
 Pendant upgrade to add second wire feed control and volt meter control of second power
supply

6
 Mavrix Open Carriage Option

The open carriage option allows the main beam to be fully installed and then the carriage is
added to the fixed beam. In Shredders with limited safe footing it is sometimes difficult to load
the carriage onto the beam and install the beam at the same time. This option simplifies the
installation process.
 Open carriage box assembly with DeStaco clamping system

7
 CARBIDE DISPENSING
Drop Carbide Dispenser
The MAVRIX drop carbide dispenser can be ordered with any MAVRIX automatic welding system
or as a standalone system to be added to your current welding equipment. The difference in our
system is in our custom engineered control which provides greater precision of deposits over a
wider range of voltage control. Additionally, our control is less sensitive to input voltage changes
that can normally occur in any plant causing variation in deposit rate. The system highlight in this
brochure is the standalone system and includes these main components.

 Vibrator control with current

sensing to auto start upon weld
arc start up
 Hopper and vibratory track
assembly with insulated
mounting block
 Hose and torch nozzle
attachment.

CARBIDE FEED RATE

12-35 WC GRIT

10
9
Typical deposit rates that can be 8
achieved are represented by the 7
OZ/MIN

6
chart to the right. Our unit may also 5
be calibrated for other variations of 4
3
carbide. 2
1
0
0
0
10
20
30
40
50
60
70
80
90
10

DIAL SETTING

8
The photo to the right shows the carbide dispensing
unit paired with our adjustable torch assembly and
gas nozzle. This heavy duty gas shielded nozzle with
the ceramic tipped carbide drop tube has a 25
degree bend in the copper nozzle above the gas
nozzle. This relationship between the carbide drop
tube and the gas shielded nozzle does an effective
job of adding carbide particles to the back of the
weld puddle. The travel direction is to the right on
the photo. Note that this is a typical mounting using
the MAVRIX torch assembly. Ceramic tipped drop
tube comes with brackets for your custom
installation.

When the system is ordered as a standalone system it

will include this control facia layout. With easy to
understand control function this can be mounted in
close relation to the operator. When ordered as part
of our welding automation this control is integrated
into the primary machine control.

 Power ON/Off – This is the main power switch for

master on/off
 Rate – The rate is the voltage potentiometer for quick
adjustment to the dispensing rate. Our superior
control design provides control throughout the range
 Mode – The mode switch provides three functions
o On-Turns the unit on “manual mode” for
testing deposit rates
o Off – No function
o Auto – Works with the current sensing switch
to turn on automatically with the power supply

9
CEMENT PULVERIZER ROLLS & TABLES

The post style system provides a single post with a vertical adjustment. This system is
specifically designed for metal build up on rolls that have been removed from the pulverizer
and placed in a stand manufactured by the customer that has turning capability. The MAVRIX
control system can run the motor for turning the roll, and a step switch must be mounted to
trip once per revolution.

Features
1. Single post automatic welding system. The system will provide 2 axis of motion including
the automated Y-axis for welding and a power actuated vertical step axis for dynamic
adjustment of torch standoff.
2. PA-10 4 roll wire feeder with dynamic braking and forward and reverse inching. Includes
pull linear and feed cable.
3. Auto Pak 1000 lb capacity wire feeding system.
4. Series 125 Roll-O-Matic provides control of the roll rotation speed, weld arm extension,
wire feeder, step timer and dynamic vertical height adjustment. Control is integrated with a
step over switch to provide a signal to the torch arm to step via control of carriage speed
and step timer for circumferential welding. System is also capable of longitudinal welding
to stripe the roll if required.
5. Contactor cable to connect to a Lincoln Brand Power Wave AC/DC 1000 or Idealarc DC1000.
Power supply must be specified at time of order.
6. Weld Arm Carriage fabricated from 3 x 5 x 12 inch steel tubing and integrated cam roller
guide bearings.
7. Weld Arm Assembly fabricated from .25 x 2 x 3 heavy wall structural tubing. Arm is 84
inches long and allows for 60 inches of travel with the wire feeder mounted on the back of
the arm.
8. Torch assembly with rotation, tilt and height adjustment capability.
9. ½ hp motor and 1000:1 gearbox for roll rotation. Onsite installation required by customer
during machine installation and training. NOT INCLUDED IN TABLE APPLICATIONS

10
Post system may be made with a shorter post to be mounted outside of the crusher table, and
a pivot is added to the carriage interface. This allows the weld arm to reach into the machine
for welding the pulverizer table. A drive motor can be added to power a gearbox on the end of
the torch arm to pivot the torch for tables with concaved bowls. Photos below include
adjustable and rotary torch options. This system is provided with a pendant control as shown.
Table drive provide by the customer.

 Easily adjustable travel limits

 Weld in circumferential mode or strip
mode
 Use to fill in break out sections
 Comes complete with 10 inch travel
adjustable nozzle
 Includes our standard PA-10 4 roll
constant speed wire feeder with
forward and reverse inching and
dynamic braking to eliminate wire
coasting
 Includes either motor/gearbox drive
shaft or control of remoter mounted
motor/gearbox
 Includes rotary ground on the stand or
mounted on the roll
 Mavrix Roll-O-Matic 125 controller
 Autopak wire dispensing option

11
COAL PULVERIZER ROLLS

Our coal pulverizer system for resurfacing rolls comes in many variations. These variations are
altered to fit each customer and in most cases are modified to fit how they fixture the rolls. We
can build a system that will turn the roll or we can integrate with your motor/gear box into the
Mavrix control.

 Easily adjustable travel limits

 Weld in circumferential mode or strip mode
 Use to fill in break out sections
 Comes complete with 10 inch travel adjustable nozzle
 Includes our standard PA-10 4 roll constant speed wire feeder with forward and reverse inching and
dynamic braking to eliminate wire coasting
 Includes either motor/gearbox drive shaft or control
of remote mounted motor/gearbox
 Includes rotary ground on the stand or mounted on
the roll
 Mavrix Roll-O-Matic 125 controller
 Autopak wire dispensing option

12
Most of the roll rebuild systems utilize the Roll-O-Matic 125
control. This is a robust circuit board based system that is
easy to learn and provides the base functionality.
Included with this control is a contactor cord that will
provide remote control of your welding supply. An option
is available to provide a weld voltage control and a meter.

Designs shown have been sold!

Design #1
This was a vertical post system that we designed to directly mount to the customer’s current roll turning fixture.
Our control ran the customer’s motor/gearbox and also integrated their current trip switch. This system provided
them a long reach and on the fly vertical adjustment.
Design #2
This was a spin off version of the system shown above. In this case the custom fixture didn’t present the welding
surface horizontal so we built them the flexibility they needed to adapt the torch angle to the roll surface. A
complete self contained cart allowed them to bring the roll under a hood using a fork lift. Our cart attaches to the
roll cart and clamps together. Drive motor, ground, step switch are all contained and operated by a single control
box. The box is mounted on a stand with 20 ft. of cable to keep the operator safely out of the welding zone.
Design #1 Design #2

Mavrix recommends the use of Stoody wire consumables such as 100HD or CP2000 for
overlaying rolls and tables. For additional information on these wires and their application,
please visit www.stoody.com.

13
 COAL PULVERIZER TABLES

CE MODEL 1003 SHOWN ABOVE

 Automatically rebuilds pulverizer table in place

 Decreased down time. Dual torch system shown will deposit up
to 50 lbs. of weld metal per hour
 Operators are remote from welding arc assuring safety and
production
 Designed for quick and easy setup
 System can be sold as a double torch (as shown) or a single
 Unit can be configured to weld curved bowl table typical of MPS
design

4x4x10 inch

Operator’s Pendant

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 PULVERIZER TABLE REBUILD SYSTEM COMPONENTS
1. TWO WELD ARM MANIPULATORS – (single arm available)
The weld arms will be 1 ½”  tubular steel sections with rack and pinion drive. A telescoping tube will be fitted
inside the working end of the 1 ½”  tube to increase the working length.
2. SUPPORT SYSTEM –
A lightweight aluminum beam, 3” x 6” x the width of the opened pulverizer door, will be provided to support the
weld arm manipulators described above. The beam is easily mounted to the face of the opened pulverizer and has
two (2) adjustable saddles which accept the tubular mounting posts on the manipulator carriage.
3. GROUNDING DEVICE –
A 1500 AMP rotary ground device will be included and installed by the customer to the table center.
4. WIRE FEED ASSEMBLIES (TWO) –
Our heavy duty PA-10 Wire Feeder will be included along with Auto-Pak weld wire payoff turntables.
5. OPERATING CONTROL – Two identical operating controls will be supplied, one for each manipulator. A picture
of the operator control pendant is included on the opposite side. A source of 120 VAC, 60 HZ with 10 AMP will be
required to power the system.
6. STEP-OVER SWITCH – This switch is used to signal the weld arm carriage motors to step after each revolution of
the table.
7. TABLE TURNING DEVICE – A gearmotor with sprockets and chain will be included.
8. WELD POWER SUPPLIES AND CABLING – Can be supplied
9. TORCH ADJUSTORS – A torch adjustor will provide + 5 inches up and down motion.

OPTIONAL The units can be modified with an extra motor and gearbox to weld rebuild curved bowls like the
typical MPS designs shown below.

Mavrix recommends the use of Stoody wire consumables such as 100HD or CP2000 for
overlaying rolls and tables. For additional information on these wires and their application,
please visit www.stoody.com.

15
CONE TYPE ROCK CRUSHERS (GYR-O-MATIC)

CRUSHER CONE & BOWL REBUILDING SYSTEM

 Improved particle size control to better meet DOT standards
 Extend the life of new components as much as two to three times
 Longer life of wear parts means less time wasted in change overs
 Built to handle cones and liners weighing up to 30,000 lbs. and 6 foot in diameter

STANDARD CONTENT
 Motorized Turntable
 Motorized Carriage with Travel Beam
 Support Column with Torch Angle
Adjustor
 PA-10, 4 Roll Wire Feeder
 Trip Switch
 Sliding Ground Shoe
 Adjustable Weld Nozzle Assembly
 AutoPak 1000 lbs Capacity Turntable
 Control System Roll-O-Matic 125

The Gyr-O-Matic system comes in 3 sizes.

GYR-O-MATIC SERIES 8
8,000 lb capacity, 48” table

GYR-O-MATIC SERIES 10
10,000 lb capacity, 72” table

GYR-O-MATIC SERIES 30
30,000 lb capacity, 72” table

16
 ALTERNATE SETUP FOR BOWL LINERS
Crusher bowl liners may also be rebuilt by moving the support column to the alternate support
location at the table center. When anchored at the center of the turntable, the unit can
resurface the inside of a bowl liner as it rotates.

GYR-O-MATIC REBUILD SYSTEM COMPONENTS

 MOTORIZED TURNTABLE ASSEMBLY - The unit includes a gear driven table that rotates the cone
or bowl liner at suitable weld speeds.
 TRAVEL BEAM - This beam guides the travel of the carriage and weld nozzle.
 SUPPORT COLUMN - This support column can be mounted off to the side or to the fixed center of
the rotating table. An adjustable pivot bracket allows easy positioning of the weld arm in
conjunction with the cable winch.
 MOTORIZED CARRIAGE ASSEMBLY - The unit includes a rack and pinion gear system with clutch
for accurate and repeatable weld positioning.
 WIRE FEEDER - Our PA-10 4-Drive roll wire feeder is included as part of the package. An Auto Pak
turntable is also included to dispense wire tubs up to 1000 pounds.
 CONTROL BOX - The main control box contains the DC motor controls and associated 24V circuitry.
A stand is also included.
 TRIP WELD INDEX SWITCH - A trip switch with adjustable trip dog is provided to index the
carriage and weld nozzle after each revolution of the turntable.
 SLIDING SHOE GROUND - A sliding shoe ground of 500 AMP capacity is built into the frame of the
Gyr-O-Matic.
 WELD NOZZLE ASSEMBLY - The copper weld nozzle, with internal spring liner, mounts on top of
the motorized carriage. The weld nozzle adjuster allows for movement of plus or minus four inches
of travel for the stick out control.

17
CUSTOM EQUIPMENT
While we sell standard configuration systems most of what we sell has some customization to it. The
following photos provide a brief look at systems manufactured by Mavrix.

The system to the right was made at the

request of the customer to allow them to
permanently mount the welding system
next to the machine and retract it out of the
work zone when not in use.

The system to the left was built for the steel mill
slab caster roll resurfacing. The customer had the
turning lathe and mounted the single beam. This
machine also has a PLC for position control and
powered torch adjustment.

The system to the right was built complete

by Mavrix. It included the headstock,
tailstock, pre-heat burners, and angular axis
adjustment and in the final configuration
included a water cooled torch.

The system to the left was a special welder that

would perform skip welding on sample plates for
metallurgical evaluations. The customer shipped
the fixture and base to our factory and we
mounted the side beam version Vers-O-Weld.

18
The machine to the right is a custom welding cart
for welding the inside of railroad tank cars. With
automatic level adjustment, the cart is lowered
into the tank and aligned to the seam. Integrated
with the customer supplied turning rolls the cart
used the level sensing circuit to control the speed
of rotation. The design included a hopper for sub
arc welding process.

We often get asked to build custom controls for

people who are making their own equipment. The
control to the left is used to run 6 wire feeders in a
plate overlay application.

Other controls can include drives for table and roll

movements. If you want to design the equipment
and need help with the welding controls give us a
call, we would be happy to discuss your project
with you.

The photos below were from a custom machine for welding cultivator sweeps. A simple table
top machine with two fixture locations, the torch welded using a weave motion and laid a hard
surface material to extend the life of the sweeps. Due to the curvature of the sweeps a PLC was
added to our control to follow the curve.

19
DREDGE PUMP SHELLS

DREDGE-O-MATIC (DOM)

The Dredge-O-Matic (DOM) is a highly flexible system for use in pumps with output diameters
from 14”(35cm) to 30”(76cm). This document will help explain the basic function of the
equipment, setup and operation.

1. The DOM is placed into the shell and

centered on the ring diameter.
2. Use the 3 leg leveling jacks to level the
table of the DOM. Assumes that the
pump shell is also level to the DOM.
3. Manually position the main beam and
lock the cam follower into the
template profile.
4. Using the control you can jog the torch
beam to extend or retract.
5. Using the control you can jog the vertical carriage to raise or lower the torch beam.
6. Using the control you will want to sweep the torch to determine that you have it is located
in the center of the radius of the shell surface to be welded.
7. Set limit switches to limit the travel and not sweep entire shell surface diameter if wear is
greater in a single area.
8. After DOM is aligned you set the limits. Keep in mind the automatic welding motion is;
a. Arc will begin.
b. Rotation motor begins moving the main beam and following the template which
extends or retracts the beam length to keep the torch relative to the surface. Speed of
the rotation is based on speed setting on the control, this is the “Run” axis.
c. Rotation will reach end of travel when it reaches the trips switch.
d. Rotation will stop and the torch will sweep up based upon the timer and speed of the
motor. This is the “Step” axis.
e. Rotation will begin to travel in the opposite direction and will repeat the process of
reaching the trip switch and indexing the torch until the operator stops the machine.

NOTE: The vertical and torch beam axis can be jogged at any time.

20
9. Given that the shell ID is not circular, a pattern
must be made based upon the final profile
desired. This can be made from a cad file or
hard copy drawing of the shell and by plotting
points from the centerline.
10. A cam bearing will follow this template to
sweep the elliptical shape and keep the torch
relative to the desired shape of the ID. As torch
distance variation occurs the weld will build
higher or flatter and after several passes will
begin to level out.
11. One half of the shell can be welded and then
must be flipped and the alignment must be
done again.

21
HAND GUNS

We manufacture a complete line of hand guns for our legacy wire feeding systems
and our current PA-10 heavy duty 4 roll wire feeder.
Cable
Model # Description Wire Feeder Length Part Number
G700 Open Arc, Scratch Start PA-1 10 ft. 3-7673-8-1
G701 Open Arc, Scratch Start PA-1 15 ft. 3-7673-8-2
G728 Open Arc, Trigger Start PA-1A, PA-6 & PA-10 10 ft. 3-7673-36-1
G728-15 Open Arc, Trigger Start PA-1A, PA-6 & PA-10 15 ft. 3-7673-36-2
G730 Open Arc, Trigger Start PA-1A, PA-6 & PA-10 10 ft. 3-7673-37-10
G740 Open Arc, Trigger Start PA-1A, PA-6 & PA-10 15 ft. 3-7673-37-15
Open Arc, Push Button 10 ft. 3-7678-9-10
G800 Trigger Start PA-10 15 ft 3-7678-9-15

G730 & G740

The Mavrix G730 & G740 are

designed for direct plug into the
Mavrix 4 roll wire feeder.
Provided in a 10 ft or 15 ft
length, this heavy duty
semiautomatic welding gun is
ruggedly constructed with 500
amp capacity. With a brazed tip
adapter and slightly curved
nozzle the design insures good
visibility for the operator.

22
 G800

The G800 is available in a 10 ft. or 15 ft. version and has been designed to minimize operator
exposure. The G800 has nearly 18” of exposed torch and a heat shield for an added layer of
shelter from the heat.

This gun assembly uses an electric push button trigger which requires little pressure to actuate.
An alternate trigger circuit is available on the PA-10 that when used with this gun allows the
operator a single touch of the trigger to start welding and a single touch to stop. Assembled
ready to plug into the Mavrix PA-10 wire feeder and supplied with a lug for quick termination.

23
METAL SPRAY

We have built over a dozen special machines for metal arc spraying. In some cases we transport
the item to be coated past fixed torches in other cases we manipulate the spray guns. A
number of machines have been built to arc spray flat plates. This can be performed either
vertically or horizontally. We have also designed some special machines to arc spray tubular
items.

We can build a system for:

 Plasmaspray
 Flame Spray
 Arcspray
 HVOF

This shows the metal arc spray being applied from top to bottom. Once the spray is past the
end of the cylinder, the torch is tilted to better apply the coating to the bottom.

Using our standard modules we can configure a torch manipulator to meet your needs.

24
 MULTIPLE AXIS WELDING SYSTEM - VERS-O-WELD 25
VERS-O-WELD 25
Automatic Welding Surfacing System

This is our fully automatic surfacing/welding system. This system is highly configurable to accomplish
nearly any flat or cylindrical welding need. Capable of open arc, gas shielded, sub-arc, carbide
dispensing, interrupted welds, oscillation weld weave and circumferential ID/OD. Purchase the system
and install yourself or let Mavrix design a turnkey solution for you.

VERS-O-WELD Series 25 Specifications

 72” long Main X-axis beam with 48” of travel  10” adjustable welding nozzle for on the fly
 54” long Y-axis weld arm with 39” of travel adjustment
 90 VDC Gear motor driven X & Y axis with easily  Contactor cable provided for connection to
adjustable travel limits customer provided power supply for automatic
 4 roll wire feed system with reel for 60lb coils control
 Control console with stand  Net weight 375 lbs.
 No programming required  Weld power control integrated in the control

25
 VERS-O-WELD Series 25 Options
 Increased travel lengths up to 10 ft. on the main  Gas shielded nozzle with solenoid valve for
beam and 6 ft. on the weld arm (for longer automatic gas control
travels refer to the VOW45)  Auto Pak 300 lb or 1000 lb wire delivery turn
 Automatic step over switch for performing table in place of 60 lb. coil reel
circumferential welding  Encoder based motion control for
 Arc interruption kit to create intermittent welds programmable travel lengths
in a straight line motion  Power Z torch axis for remote torch height
 Sub-arc kit includes a 15 lb. capacity hopper, adjustment or automatic motion
flux nozzle and manual gate valve  Rotary torch motion parallel or perpendicular to
 Tungsten carbide dispensing system with the torch beam
automatic start/stop control  Torch oscillation motion parallel to the torch
beam while maintaining complete range in X-Y

VOW25 with Carbide Dispenser Option. VOW25 with powered rotary torch option.

VERS-O-WELD Series 25 Control Console

(Control shown is fully populated for 5 axis control)

1. Main power
2. Run/Standby: Run mode starts automatic welding
cycle
3. Step Timer: Controls duration of step between
configurable axis
4. Optional: Use for control of optional torch motions
5. Weld Power: Regulates the power supply voltage
6. Main Carriage: Mode and speed control
7. Weld Arm: Mode and speed control
8. Rotary Axis Option: Controls an auxiliary motor
9. Wire Feeder: Mode and speed to vary the
amperage of the welding process

26
VERS-O-WELD Sample Applications

27
MULTIPLE AXIS WELDING SYSTEM - VERS-O-WELD 45
VERS-O-WELD 45
Automatic Welding Surfacing System

This is the largest version of our Vers-O-

Weld family. This particular machine is
shown with a dual carriages dual controls
and manual sub-arc. It utilizes a larger
travel beam and open face carriage that will
clear backside support posts. This machine
was 25 ft long and made in 3 beam section
for easy of shipping. We also build a closed
carriage version for travels up to 14 feet
that can be supported on the ends without
risk of beam sag.

This VOW45 was built with a set of fixtures and a chuck drive system for turn rolls and welding
using a manual sub arc process. The open carriages were used to keep the system back for the
work zone to minimize heat induced in the drive motors.

28
PIPE WELDING

Mavrix manufactures a variety of ID and OD pipe welding systems. Given the nature of the
applications all systems are custom engineered to meet customer specifications. Mavrix will
design all or a part of the welding system and will work with you to integrate with your
equipment as required. Our systems will generally fall into one of the follow categories.
 Traveling vertical post and a fixed length lance torch beam ID/OD.
 Stationary lance with traveling and rotating pipe ID/OD.
 Fixed vertical post with a traveling extend/retract torch beam ID/OD.
 Fixed side beam with moving carriage and torch and fixed beam OD applications only.

While our focus is on the welding equipment we can also build integrated turning rolls and
water cooling, collection and recycling systems. The following will give you some idea of a
system we have built, engineered and quoted.

Sample 1:
Customer supplied positioner. This was a flexible system for ID and OD welding using a light
weight aluminum beam and easily adjustable carriage components.

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Sample 2:
This was a custom long travel beam made
to the customer specification. Turning rolls
were supplied by the customer and a
special dual carriage system was
engineered to minimize beam sag.

Sample 3:
This design is a recent fixed vertical post custom job quoted for a turnkey welding system.
Turning rolls are fixed and can accommodate the specified load range of 1,200 to 12,000 lbs.
The torch was specified as water cooled MIG and had a powered vertical axis, carriage drive,
wire feeder and roll drive motor. System also includes a 1000 lb capacity auto pak wire
dispenser.

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Sample 4:
This is a traveling vertical post and traveling lance machine developed for pipe 10 feet in length
and ID ranges from 12” to 60”. This was a turnkey design and quotation that included an
oscillating torch while performing circumferential welds. With water cooling, collection and
recycling, this system was quoted without power supplies.

Sample 5
This is a stationary lance and rotating and traveling pine machine capable of 3” ID to 12” OD pipe.

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PLATE OVERLAY SYSTEMS

Mavrix has custom manufactured a variety of controls for plate overlay work. We can build
only the wire feeder controls or one that will run the entire system.

Power
This is the master power on/off. Typical voltage is 115-120 VAC.

Plate Travel
Plate travel controls a motor and gearbox that moves the plate cart under the torches.

Step Timer
Step timer controls how long the torch actuator will run to change the torch positions.

Step Arm
The step arm controls a drive that moves all of the torches at the same time to create a step over for the
next longitudinal weld. The combination of step arm speed and time will control the distance that the
torches move.

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Weld Weave
Weld weave or oscillation controls the speed of oscillation. This control used a 90 VDC motor and an
eccentric to move all of the torches from side to side while the plate traveled below. This oscillation
creates a wide bead up to 38-40 mm but also put a high concentration of heat into the plate.

Run/Standby
Standby is manual mode and Run starts the automatic welding process.

Weld Station Control

Each weld station controls an individual power supply per torch

Voltage
The voltage adjust provide remote adjustment of power supply voltage and a meter read out to ensure
all torches are operating the same.

Wire Feeder
Wire feed controls the speed of the wire feed and the resultant amperage. The wire feeder has three
modes of operations.
Off- Feeder will not run and power supply will not turn on.
Continuous-In this mode the wire feeder will run all the time the machine is in automatic including the
step over movement
Interrupt-The wire feeder stops feeding wire during the step over movement.

Torch lift
Torch lift provides an ability to change the torch height at any time. In most cases this height
adjustment is done using a small gear motor.

The control shown below was custom built to control only the 6 wire feeders. All or our controls use
solid state controls and are proven to perform in the harsh welding environments.

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ROCK IMPACT CRUSHER (IMPACT-O-WELD)

IMPACT-O-WELD
IMPELLER BAR REBUILDING SYSTEM
The IMPACT-O-WELD 125 & 130 Series has many model variations for a variety of impactors.
The series 130 includes a hand held pendant to allow the operator to stay close to the action.
The carriage and motors are different than the standard Vers-O-Weld to allow weld coverage of
the impeller bars near the sidewalls. The primary variation differences result from an interior
mounting method or an exterior cantilever method. Primary information required to design
the system for you is to evaluate your impactor and determine if the welding can be done
through the current door(s) openings.

STANDARD CONTENT
 X-Y Axis dual motorized carriage assembly
 Custom fit X-Axis travel beam
 Weld arm assembly
 PA-10, 4 Roll Wire Feeder
 Adjustable Weld Nozzle
 IOW Control system with Pendant

Photo right is a custom version with horizontal

travel and an 84” arm to reach inside.

This is a 2 torch system to reduce the welding time.

It also has a powered Z axis for remote torch height
adjustment.

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This system was a small 1-1/2” square steel beam to keep it light for ease of installation. A hole
was required to route the wire feed cable using a 6 role wire feeder. Keeping the feeder out of
the harsh environment improves the life of the feeder and reduced the time to set up. Simple
drop legs were welded to the impactor and left for future resurfacing.

This system is built as a cantilever system and reaches into the impactor. The torch was
mounted on a horizontal powered axis to allow for adjustment of the torch remotely and to
perform step over welding for impactor impellers. The photo on the right is the operator
pendant included in the series 130 control for the operator to get close enough to view the
action while maintaining a safe distance.

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ROLL STYLE ROCK CRUSHING (ROLL-O-MATIC)

ROLL-O-MATIC
CRUSHER ROLL REBUILDING SYSTEM

The Roll-O-Matic machine is based off of the single arm Vers-O-Weld system but adds a control
specifically designed for roll rebuilding applications. Capable of circumferential or variations of
longitudinal welding the Roll-O-Matic is a very portable, easy to use surfacing system that will
let you: Get in. Get out. And get running again. While typically mounted as a cantilever
configuration the main beam can also be supported on each end and allow the carriage to
move with the torch mounted off of the side of the carriage.

STANDARD CONTENT

 Single axis welding system with motorized

carriage and travel limits
 Circumferential or strip welding modes
 Custom fit X-Axis travel Beam
 PA-10, 4 Roll Wire Feeder
 Crusher rotation gear motor system (installed
by customer)
 Welding Nozzle Assembly
 Rotary ground – mounted by customer
 ROM Control system with Pendant Option

Drive motor and gear box controlled by MAVRIX mounted by customer. MAVRIX carriage
mounted by customer.

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Optional Configurations
 Loss of motion detection for auto shut down in the event of drive motor failure
 Digital volt meter & wire speed meter to monitor while making changes to volts or current
These are standard in the series 130 control
 Auto pak wire dispensing in 300 lb. or 1000 lb. capacity
 Operator Pendant to allow the operator to view the welding activity and make adjustment
 Dual arm welding machine is available with the ROM Series 40 dual shell pendant

Rotary ground installed by customer Remote Pendant Option

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SINGLE AXIS WELDING SYSTEMS

SINGLE ARM VERS-O-WELD

This is the lowest cost version of the Vers-O-Weld family and a great place to start if you only
need to perform straight line or circumferential welding. Purchase this system and add your
own equipment to turn your hand gun into an automatic welding system.

 The unit can be used to overlay cylindrical parts which

are rotated under a customer supplied torch. Optional
step over switch will be required.
 The system can also be used for straight line welds.
With the addition of the optional adjustable limit stops
and trigger control you are able to control travel
distance and stop welding automatically.
 Can be mounted as shown in the cantilever style or
support the beam on each end and let the carriage
travel from end to end.
 Durable Rack and Pinion Drive on 48” long 1-1/2 square
tube. Longer lengths are available.
 Variable travel speeds up to 45 IPM. Higher travel
speeds are possible.
 Adjustable timer for step operations to control the rate
and distance of the step.
 Optional torch oscillation available, consult factory.

Base price includes the control box shown above that is pre-wired for direct plug in of options.
The picture on the right includes the optional step trip switch, optional contactor cord for
automatic control of your power supply and the optional travel limit proximity switches.

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 SIDE BEAM VERSION
The side beam version replaces the 1-1/2 square travel beam with a stronger 2” x 3” zinc plated
structural steel beam. Standard beam length is 6’ with the option to increase the length to 12’.
The side beam is strong enough to bolt on many of the optional equipment offered by Mavrix
to make the custom system required for your needs. Light weight and easy to operate it is
perfect for temporary welding setups to allow you to: Get in. Get out. And get running again.

SIDE BEAM VERSION

 2” X 3” Steel beam 72” long and 48” of travel.
 10” rack and pinion 90 VDC gear motor driven
carriage.(10’ beam shown in photo)
 2” x 3” fixed adjustable torch beam, 3’ long
standard.
 Adjustable carriage speed and direction
provided with control.
 Optional travel limit proximity switch and step
over switch is available to control travel
distance and for performing circumferential
welds.

Photo Details:
 Standard 6’ side beam VOW.
 Optional powered Z torch motion for remote
adjustment of torch height.
 Optional Sub Arch hopper with manual gate valve.

Additional Options
 Parallel or perpendicular torch oscillation
 Carbide dispensing
 Longer fix beam lengths
 Adjustable torch assembly
 Gas nozzle
 Wire Feeder
 Auto Pak wire dispenser

When options are added the control must be upgraded to provide additional logic and drives for the
additional motor drives.

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SUB ARC WELDING

The Sub Arc hopper assembly includes the hopper

with various mounting arrangements, flexible
tubing, manual gate valve and angular torch
extension. Sold separately or with a Mavrix
Automatic Welding System.

The nozzles are available in two designs one for flat

surfaces and one for radius applications.

Vacuum flux recovery pans are also available.

If you desire sub-arc with recovery and automatic functions, we can integrate Weld Engineering
CO. Inc. products into our welding systems.

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SUGAR CANE ROLL ARCING
Automated System for Arcing of Sugar Mill Crusher Rolls
The Mavrix RA-4000 for automatic arcing of sugar mill rolls has been developed after extensive
consultation with many mills to assess their requirements. Use of this system will result in
greatly increased efficiency of arcing with the additional benefits of longer roll life and
improved crushing efficiency.

The RA-4000 can be used for straight line welding and roll rebuilding in workshop as well as
arcing during crushing. The system can be quickly broken down into individual components
with the largest component fitting through a 600 x 600 mm (24" x 24") opening. The system
can be easily relocated from one location to another by one person in 10-15 minutes.
Lightweight and portable the total weight is approximately 155 lbs (70 kg) with the heaviest
individual component weighing 44 lbs (20 kg).

Benefits
 Lower consumable consumption by as much as 75%.
 Reduced time (Properly arc a roll on three faces in as little as 2 hours).
 One operator can operate two (2) Systems with time to spare.
 Repeatability - weld each roll the same way each time. No manual variations.
 Greater health and safety - remove operator out of hazard area of fumes etc.
 Automate welding tasks in workshop during slack period.

System Components
Main Control
The main control contains the controls necessary to operate the ROLL-ARC system in one
compact (400 x 350 x 175 mm) light weight (10kg) box. Manufactured from high strength, light
weight thermoplastic and is well sealed against moisture. A new indexing controller will allow
programming flexibility resulting in the system being capable of arcing in 1, 3, 5, 7 (or more)
locations on each tooth of the roll. This capability will allow the complete face of each tooth to
be arced in one traverse of the beam if required.

WIRE FEEDER
The wire feeder is a PA-11 extra heavy duty, constant potential type with 4 drive rolls to allow
continuous, positive feeding of arcing wire. Drive rolls are covered for protection from moisture
and crushing residue during operation. The feeder can be fitted on the top of the main carriage
assembly to overcome the need to drive wire long distances. (Maximum length to torch tip 900
mm (3'))

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WELDING TORCH
The welding torch is a heavy duty, open arc type requiring no shielding gas and no water
cooling. These features overcome the problems associated with auxiliary water cooling. Torch is
rated for continuous welding at 600 amps, thus, ensuring long and reliable service life. The
torch can be adjusted in the forward plane from vertical down to 10° below horizontal and
rotated to + 45° to allow for welding on the sides of the roll teeth. Torch feeds forward and
reverses automatically for ease of contact tip change. Torch is fitted with quick disconnect
power cable for ease of set up and removal.

WELD ARM
The weld arm is fully automatic with in-out axis of 800 mm plus pivot axis through 45°, all
controlled electronically from the pendant.

PENDANT CONTROL
Provided is a compact and light (2kg), sealed box to allow the operator remote and close-up
adjustment of the weld centering, inching, weld direction, carriage speed, wire speed (current)
and weld voltage on electronically controlled power supplies. All functions may be adjusted
during operation and are integrated with the welding power supply contactor. This ensures that
weld voltage is off when the shutdown switch is activated.

MAIN BEAM
High strength, blue zinc plated main beam with precision engineered drive rack is supplied for corrosion
protection. Beam mounting is by U-Shaped brackets to customer supplied mounting points.

MAIN TRAVERSING CARRIAGE

The main carriage is fitted with variable speed DC gear motor driving through a positive rack
and pinion. Motor has an encoder to give infinitely adjustable pitch settings with precision and
repeatability. Motor and encoder are fitted with an additional cover giving extra mechanical
protection and water proofing.

ADDITIONAL FEATURES

WATER PROOFING: Improved waterproofing including the use of waterproof connectors and switches.
SYSTEM SHUTDOWN ON MILL STOPPAGE: This function is to ensure that the ROLLARC System
will shut down if there are any unexpected mill stoppages. This switch is located in the main
control box and an adjustable potentiometer is provided to allow settings for shutdown point
to be changed.
SHUTDOWN ON LOSS OF WELD CURRENT: To ensure the wire feeder does not continue to feed
if there is a loss of welding current, a current sensing circuit has been added to the system
which will stop the system operation completely upon weld current failure.
OPERATION AND SHUTDOWN INDICATION: Flashing indicator light has been fitted to indicate remotely
to others in the area the status of the machine.

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Photo Gallery

43
TORCHES

Torch assemblies are manufactured by Mavrix and we often manufacture custom designs to fit
our customer’s needs. All assemblies come complete with spring liner and power block. Tips
(.045 to 5/32), tip adapters and various length extensions are always in stock.

Adjustable Torch Assemblies

Our adjustable torch assembly provides 10” inches of total travel and provides an inexpensive
way to make quick changes to the torch standoff. Includes spring liner to increase the life and
can be built with extensions of various lengths. Also available in a 5” inch travel version.

10 inch travel 5 inch travel

Gas Nozzle
The Mavrix gas nozzle shown
with the carbide dispensing
brackets mounted, provides a
straight forward gas shielding
capability. When coupled with a
Mavrix wire feed and gas
solenoid valve you can achieve
safe and integrated gas delivery.

44
The photo show to the right is the gas torch nozzle
with the carbide drop system attached.

The drawing below shows a typical torch

assembly. The radius of the bend and resulting
angle can all be customized to fit your welding
application. This design includes a 6” extension to
reduce cost when replacement parts are required.

Water Cooled Torch

The Mavrix water cooled torch is an
inexpensive approach to provide cooling to the
torch tip and avoid the occasional thread strip
during tip change over. Coupled with your
choice of heat exchanger this design provides
cooling to extend the life of your torch
assembly.

We also manufacture water cooled gas

shielded and water cooled ID pipe welding
torches.

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 WELDING LATHES

We manufacture a wide variety of welding lathes and most are custom engineered to the
customer’s specific requirements.

16 ft. Slab caster journal welder with adjustable rolling 32 ft. Dual slab caster journal welder with adjustable
tailstock and 4000 lb roll capacity. rolling headstock & tailstock, 4000 lb capacity per side.

Custom lathe with pre-heat burner system and 10 ft. Lathe with oscillating torch and programmable
adjustable beam angle and precision control indexing chuck rotation distance control.

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WIRE FEEDERS
PA-10 WIRE FEEDER
A dependable heavy duty all purpose constant speed (90VDC) wire feeder. Use this to create
your own automation or add a MAVRIX hand held gun and contactor cable for a complete hand
held welding system.

 Constant speed 110 VAC 4 roll wire feeder

 1/8 HP Motor with high efficiency gear box
 Adjustable feed rate from 70 to 500 IPM (Higher speeds available)
 Dynamic braking eliminates wire coasting
 Wire sizes from 5/64” to 1/8” (1.98 mm to 3.17 mm)
 Forward and reverse inching
 Contactor cable available for control of the power supply
 Optional 6 roll feeder for soft or hard to feed wire
 Optional gas solenoid for gas shielded welding

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 MAVRIX CORPORATION LEGAL NOTICE

This notice applies to all pages, images, text, and other material available throughout this document.

Intellectual Property:
Unless otherwise noted, product names, designs, logos, titles, text, ("Intellectual Property") within this
document are the trademarks, service marks, trade names, copyrights or other property of Mavrix, Inc.
Nothing contained in this document should be construed as granting any license or right to any of Mavrix
Incorporated Property. Mavrix conducts business under the names Mavrix Automatic Welding as well as
Mavrix Welding Automation.

Use of this Document:

Mavrix maintains this Document to provide information to its distributor and end-user customers. You may
view this document and /or download material displayed in it for evaluation of Mavrix product or to
represent the product as a distributor. You may copy, reproduce, duplicate or distribute information
contained within for the sole purpose of transacting business with Mavrix, Inc.. You may not modify in any
way the information contained within this document for any purpose. You may request permission to use
the information contained for representation of Mavrix products on your company website by contacting
us at Mavrixweld@ameritech.net.

Limitation of Liability:
This Document is provided "AS IS" without warranties of any kind, either express, implied, or statutory
including but not limited to the implied warranties of merchantability, fitness for a particular purpose, or
non-infringement. Mavrix, Inc. assumes no responsibility, and shall not be liable for operator exposure to
welding related fumes during the use of our equipment. Mavrix highly recommends that the end user of
this equipment review OSHA 29 CFR 1910.1026 and ensure that they are in compliance with this standard
when operating the equipment.

Governing Law:
This Site shall be governed by the laws of the State of Wisconsin.

Availability of Products:
This document may contain references to products of services not available in all countries and availability
of product may change at any time.

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 TMAVRIX TERMS, WARRANTY AND SERVICE RATES
Terms (Effective 3-1-2011)
1. All prices F.O.B Muskego, WI., freight prepaid but not allowed, in domestic package. These prices do not include
taxes and are subject to the addition of any and all taxes which MAVRIX, Inc. might be required to pay or collect by
reason of sale, purchase, or use of the material listed.
2. $50.00 minimum on all billing.
3. All machines over $12,000 total sale price require a down payment of 30%. Orders for all special machines are
strictly non-cancelable once confirming purchase order has been received. Orders in excess of $50,000 are subject
to 40% down payment and may require progress payments thereafter.
4. International orders require 50% down with order and the final 50% payment prior to shipping regardless of
purchase price.
Warranty
MAVRIX, INC. STANDARD EQUIPMENT WARRANTY TO APPLY:
The seller warrants to the first purchaser for a period of six (6) months after the date of shipment all products or
equipment manufactured by the seller under normal use and service to be free from defects in material and
workmanship. The Sellers obligation under this warranty shall be limited to replacing or repairing any parts found
on Seller’s inspection to be defective and furnishing any parts necessary to correct engineering defects, as
determined by Seller, without charge to the Buyer, FOB Seller’s plant, provided the use of the products or
equipment is discontinued immediately. The allegedly defective products or equipment shall be returned by the
Buyer for inspection by the Seller, Transportation charges prepaid. This warranty or repair and replacement applies
solely to such products or equipment manufactured by the Seller. Seller is not responsible for unauthorized
alterations to any products or equipment.

THIS WARRANTY, AND THE SELLER’S OBLIGATION HEREUNDER IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTIES MERCHANTABILITY AND OF FITNESS
FOR A PARTICULAR PURPOSE, AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING INCIDENTAL AND
CONSEQUENTIAL DAMAGES RESULTING FROM ANY DEFECTIVE GOODS.

STANDARD POLICY ON SERVICE CALLS

Labor --------- $120 per hour
$130 per hour all over 8-hour day and Saturday
$140 per hour all over 8-hour Saturday, all day Sundays and holidays
Portal to portal, travel time paid during normal working hours.

Expenses------ Transportation, Meals, Lodging, and Normal Incidentals.

Terms---------- A purchase order will be required prior to service.

Requirements for installation and training: All services required must be in place and adequate help and
handling available. Operators to be experienced welders and will be trained in the use and operation of the Mavrix
welding system. Welding materials to be on hand and work to be on hand and ready for welding. Delays caused by
above conditions not being met will be treated as a service call and billed accordingly.

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WARNING

The equipment quoted herein has been designed for hardfacing or metal build up of your products.
Mavrix highly recommends that the end user of this equipment review OSHA 29 CFR 1910.1026 and
ensure that they are in compliance with this standard when operating this equipment. The end user
must specifically implement available engineering controls to comply with the permissible exposure
limits set forth by this standard. A brief summary of the standard follows.

OSHA STANDARD FOR HEXAVALENT CHROMIUM

On February 28, 2006, OSHA promulgated a revised hexavalent chromium standard for general industry
("the Standard") that includes a permissible exposure limit ("PEL") for hexavalent chromium of 5
micrograms per cubic meter ("µg/m3") measured as an 8-hour time-weighted average ("TWA"), and a
deadline of May 31, 2010, for employers to come into compliance with this PEL through the
implementation of engineering controls. The deadline for compliance with the remaining provisions of
the Standard, including those requiring the use of respiratory protection to comply with the PEL, is
November 27, 2006, for employers with twenty (20) or more employees, and May 30, 2007, for
employers with nineteen (19) or fewer employees. 29 CFR 1910.1026, 71 FR 10100 (Feb. 28, 2006);

“Get out of the smoke and into compliance”

Automate Today

FOR MORE INFORMATION, PLEASE CALL, WRITE or EMAIL

MAVRIX AUTOMATIC WELDING
info@mavrixweld.com www.mavrixweld.com
3020 S. Calhoun Road * New Berlin, WI. 53151 * (262) 439-8477 * FAX (262) 4399-8877

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