APEX® 30M - Lincoln Electric

Operator’s Manual
APEX 30M
®
For use with machines having Code Numbers:
12675
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
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Date Purchased
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Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
Code: (ex: 10859)
For Service outside the USA:
Email: globalservice@lincolnelectric.com
Serial: (ex: U1060512345)
IM6120 |
Issue D­ate 09/16
© Lincoln Global, Inc. All Rights Reserved.
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.
WARNING
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
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.
Safety 01 of 04 - 06/15/2016
SAFETY
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
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.
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.
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.
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 possible to the area being welded.
2.d.5. Do not work next to welding power source.
Safety 02 of 04 - 06/15/2016
SAFETY
ELECTRIC SHOCK
CAN KILL.
ARC RAYS CAN BURN.
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.
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.
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.
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.
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.
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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
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.
3.j. Also see Items 6.c. and 8.
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 03 of 04 - 06/15/2016
SAFETY
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 04 of 04 - 06/15/2016
SAFETY
APEX ® 30M
The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
ELECTROMAGNETIC
COMPATIBILITY (EMC)
METHODS OF REDUCING EMISSIONS
Mains Supply
CONFORMANCE
Welding equipment should be connected to the mains supply according
to the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains supply.
Consideration should be given to shielding the supply cable of permanently
installed welding equipment, in metallic conduit or equivalent. Shielding
should be electrically continuous throughout its length. The shielding should
be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Products displaying the CE mark are in conformity with European Community
Council Directive of 3 May 1989 on the approximation of the laws of the
Member States relating to electromagnetic compatibility (89/336/EEC). It
was manufactured in conformity with a national standard that implements a
harmonized standard: EN 60974-10
Electromagnetic Compatibility (EMC) Product Standard for Arc Welding
Equipment. It is for use with other Lincoln Electric equipment. It is designed
for industrial and professional use.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers
should be closed and properly fastened when the welding equipment is in
operation. The welding equipment should not be modified in any way except
for those changes and adjustments covered in the manufacturers instructions.
In particular, the spark gaps of arc striking and stabilizing devices should be
adjusted and maintained according to the manufacturer’s recommendations.
INTRODUCTION
All electrical equipment generates small amounts of electromagnetic
emission. Electrical emission may be transmitted through power lines or
radiated through space, similar to a radio transmitter. When emissions are
received by other equipment, electrical interference may result. Electrical
emissions may affect many kinds of electrical equipment; other nearby
welding equipment, radio and TV reception, numerical controlled machines,
telephone systems, computers, etc. Be aware that interference may result
and extra precautions may be required when a welding power source is used
in a domestic establishment.
Welding Cables
The welding cables should be kept as short as possible and should be
positioned close together, running at or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent
to it should be considered. However, metallic components bonded to the
work piece will increase the risk that the operator could receive a shock by
touching these metallic components and the electrode at the same time. The
operator should be insulated from all such bonded metallic components.
INSTALLATION AND USE
The user is responsible for installing and using the welding equipment
according to the manufacturer’s instructions. If electromagnetic disturbances
are detected then it shall be the responsibility of the user of the welding
equipment to resolve the situation with the technical assistance of the
manufacturer. In some cases this remedial action may be as simple as
earthing (grounding) the welding circuit, see Note. In other cases it could
involve construction of an electro- magnetic screen enclosing the power
source and the work complete with associated input filters. In all cases
electromagnetic disturbances must be reduced to the point where they are no
longer troublesome.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not
connected to earth because of its size and position, e.g., ships hull or
building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the
earthing of the work piece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct connection
to the work piece, but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is competent to
access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current
return paths which may damage the earth circuits of other equipment.
ASSESSMENT OF AREA
Screening and Shielding
Before installing welding equipment the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The following
shall be taken into account:
Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the
entire welding installation may be considered for special applications.
a. other supply cables, control cables, signaling and telephone cables;
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic
above, below and adjacent to the welding equipment;
Compatibility (EMC) product standard for arc welding equipment.”
b. radio and television transmitters and receivers;
c. computer and other control equipment;
d. safety critical equipment, e.g., guarding of industrial equipment;
e. the health of the people around, e.g., the use of pacemakers and hearing aids;
f. equipment used for calibration or measurement
g. the immunity of other equipment in the environment. The user shall ensure that other
equipment being used in the environment is compatible. This may require additional
protection measures;
h. the time of day that welding or other activities are to be carried out.
6
APEX ® 30M
TABLE OF CONTENTS
Technical Specifications APEX® 30M.......................................................................................................................A-1
Symbols & Icons ......................................................................................................................................................A-2
Safety Precautions ...................................................................................................................................................A-3
Proper Handling...................................................................................................................................................A-3
Operation.............................................................................................................................................................A-3
Explanation of Welding Terms..............................................................................................................................A-3
APEX® 30M System....................................................................................................................................................A-4
Basic Information.................................................................................................................................................A-4
Control Unit..........................................................................................................................................................A-4
System Components............................................................................................................................................A-4
Power Supply................................................................................................................................................A-4
Weld Head....................................................................................................................................................A-4
System Cart..................................................................................................................................................A-4
Installation ...........................................................................................................................................................A-5
System Cart..................................................................................................................................................A-5
Optional Modules..........................................................................................................................................A-5
Power Supply................................................................................................................................................A-5
Cart Top.........................................................................................................................................................A-5
APEX 30M....................................................................................................................................................A-5
Additional Items............................................................................................................................................A-5
Cart Accessories...........................................................................................................................................A-5
Cable Installation .........................................................................................................................................A-7
Front Panel...................................................................................................................................................A-9
Wire Compartment........................................................................................................................................A-9
Back Panel Connections...............................................................................................................................A-10
Shielding Gas Connection............................................................................................................................A-11
Procedure to Install Wire Guides and Drive Rolls.........................................................................................A-11
Pressure Arm Adjustment.............................................................................................................................A-12
Loading Wire.................................................................................................................................................A-12
Conduit Installation.......................................................................................................................................A-13
Operational Safety Precautions...............................................................................................................................B-1
Operation Information..........................................................................................................................................B-1
External inputs ....................................................................................................................................................B-1
Control..................................................................................................................................................................B-1
Welding Power.....................................................................................................................................................B-1
Manual Adjustments.............................................................................................................................................B-1
System Start Up...................................................................................................................................................B-2
Emergency Off..............................................................................................................................................B-2
Reset.............................................................................................................................................................B-2
Startup Screen..............................................................................................................................................B-2
Pendant Operation...............................................................................................................................................B-3
Button Actions...............................................................................................................................................B-3
Selection buttons..........................................................................................................................................B-3
Navigation Controls.......................................................................................................................................B-3
Menu buttons................................................................................................................................................B-3
Control buttons..............................................................................................................................................B-3
Color Coding.................................................................................................................................................B-4
Fast Movement.............................................................................................................................................B-4
Fast Movement Screens...............................................................................................................................B-4
System Log In......................................................................................................................................................B-5
Fast Movement.............................................................................................................................................B-5
Login.............................................................................................................................................................B-5
Log In Screen................................................................................................................................................B-6
Idle Screen...........................................................................................................................................................B-7
Menu Option Variables..................................................................................................................................B-7
Idle Screen Buttons.......................................................................................................................................B-8
Idle Screen Test/Weld Modes...............................................................................................................................B-9
Weld Screen..................................................................................................................................................B-10
Weld Screen Buttons....................................................................................................................................B-10
Test Screen...................................................................................................................................................B-10
Test Screen Buttons......................................................................................................................................B-10
Jog Screen...........................................................................................................................................................B-11
Jog Buttons...................................................................................................................................................B-12
Oscillation Screen................................................................................................................................................B-13
Oscillation Buttons........................................................................................................................................B-14
APEX ® 30M
TABLE OF CONTENTS
Setup Screen.......................................................................................................................................................B-15
Setup Screen Options...................................................................................................................................B-15
Track Setup...................................................................................................................................................B-17
Heavy Wall Pipes..........................................................................................................................................B-17
Positioner Setup............................................................................................................................................B-17
Travel Setup Screen.....................................................................................................................................B-18
Travel Pattern ...............................................................................................................................................B-18
Process Setup Screen.........................................................................................................................................B-19
Standard Process Options............................................................................................................................B-19
Weave Process Options................................................................................................................................B-19
Mode Select.........................................................................................................................................................B-20
Guided Mode Select.....................................................................................................................................B-20
Manual Mode Select.....................................................................................................................................B-21
Advanced Process Setup ....................................................................................................................................B-21
Advanced Options.........................................................................................................................................B-21
Wave Controls...............................................................................................................................................B-21
Sensitivity Recommendations.......................................................................................................................B-22
Start Settings........................................................................................................................................................B-23
End Settings.........................................................................................................................................................B-23
Service ................................................................................................................................................................B-24
Version..........................................................................................................................................................B-24
Motion...........................................................................................................................................................B-24
Users....................................................................................................................................................................B-25
Fast Movement.............................................................................................................................................B-25
Adding Users................................................................................................................................................B-25
Deleting Users..............................................................................................................................................B-26
Changing User Access..................................................................................................................................B-26
Log Out.........................................................................................................................................................B-27
Operator Log In.............................................................................................................................................B-27
Increments Settings.............................................................................................................................................B-27
Increment Options.........................................................................................................................................B-27
Programs .............................................................................................................................................................B-29
Fast Movement.............................................................................................................................................B-29
Saving an Independent Pass........................................................................................................................B-29
Saving a Program Base................................................................................................................................B-30
Saving a Program Pass................................................................................................................................B-30
Hide Program Passes...................................................................................................................................B-31
Saving to a USB............................................................................................................................................B-31
Copy to/from USB.........................................................................................................................................B-32
Deleting a Program.......................................................................................................................................B-32
Deleting a Program Base..............................................................................................................................B-32
Loading a Program.......................................................................................................................................B-33
Overwriting a Program..................................................................................................................................B-33
Operator Views.............................................................................................................................................B-34
Operator Pendant.........................................................................................................................................B-35
Weld Mode....................................................................................................................................................B-35
Idle Mode......................................................................................................................................................B-36
Test Mode.....................................................................................................................................................B-36
Operator Pendant Cable...............................................................................................................................B-36
Arclink T Connector.......................................................................................................................................B-36
Pendant Light................................................................................................................................................B-36
Accessories...............................................................................................................................................................C-1
Maintenance...............................................................................................................................................................D-1
Maintenance Schedule.........................................................................................................................................D-1
Every Shift.....................................................................................................................................................D-1
Monthly.........................................................................................................................................................D-1
Semi Annually...............................................................................................................................................D-1
List of Error Codes for Troubleshooting...............................................................................................................D-3
Diagrams....................................................................................................................................................................G-2
APEX ® 30M
INSTALLATION
Technical Specifications APEX® 30M
APEX® 30M Control Unit
Product Number
K52160-1
Input Power
40 VDC
Rated Output
24V 9A
Input Current
10A Max
Dimensions L x W x H (in.)
25.33 x 11 x 14.33
Dimensions L x W x H (mm)
644.4 x 279.4 x 363.2
Net Weight lbs. (kg)
48.5 (22.0)
Duty Cycle
@ 500 Amps
60%
@ 450 Amps
100%
GEARING
GMAW
FCAW
WFS Range
Wire Sizes
WFS Range
Wire Sizes
50 - 1200 ipm
(0.8 - 30.5 m/m)
0.023 - 1/16”
(0.6 - 1.6 mm)
50 - 1200 ipm
(1.3 -30.5 m/min)
0.035 - 5/64”
(0.9 - 2.0 mm)
Temperature Ranges
Operating Temperature Range
32oF to 122oF (0oC - 50oC)
Storage Temperature Range
-22oF to 140oF (-30oC - 60oC)
APEX® 30M Pendant
Product Number
K52113-1
Input Power
40 VDC
Input Current
250 mA
Dimensions (in.)
11.33 x 7.8 x 2.71
Dimensions (mm)
287.8 x 198.1 x 68.8
Net Weight lbs. (kg)
2.65 (1.2)
A-1
APEX ® 30M
INSTALLATION
Symbols & Icons
This list is a quick reference for all icons from the pendant and on the control unit.
Users
Settings
Wire
Reboot
Insert
Weld
Weld Time
Upslope /
Start Settings
Process
Track Ring
Test Mode
Reset
Settings
Downslope /
End Settings
Version
Track Ring
Diameter
Segment
Enter
Time
Motion
Pipe
Trash
Voltage
Program
Return Home
Pipe
Diameter
Gas Purge
Pre/Post Flow
Amperage
Trim Volts
Trim
Log Out
Save
Travel /
Travel Setup
Osc Speed
Left Dwell
Settings /
Service Page
Swap
Shift Case
Osc Width
Right Dwell
Increment
Unit Settings
Gas
Advanced
Settings
Next /
Index
Travel
Direction
Positioner
Kilowatts
Wire Feed
Travel
Direction
Wire / Wire
Feed Speed
OD Track
Steering /
Oscillator
Wire
Retract
Travel
Direction
Previous /
Index
Flat Track
Wire Diameter
Pass
Travel
Direction
Add User
Direction
Delay
Amps
Details
Weave
Type
Manual
Height
Torch/Auto
Height
Oscillation
Speed
Copy To
Constant
Travel
Exit
Oscillation
Mode
Select
Cancel
Step
Travel
Oscillation
Width
Weld Mode
Load
Okay
No Weave
Travel
ID Track
K
Snapshot
A-2
APEX ® 30M
INSTALLATION
Safety Precautions
Explanation of Welding Terms
Read entire manual before installation or operation.
GMAW
• Gas Metal Arc Welding
WARNING
FCAW
• Flux Cored Arc Welding
Electric shock can kill
• Only qualified personnel
should perform this installation.
• Turn the input power
OFF at the disconnect switch
or fuse box before working
on this equipment turn off
the input power to any other
equipment connected to the
welding system at the disconnect switch or fuse
box before working on the equipment.
• Do not touch electrically hot parts.
• Always connect the power supply grounding lug
to a proper safety (Earth) ground.
STT
• Surface Tension Transfer
WFS
• Wire Feed Speed
OSC
• Oscillation
ACC
• Automatic Current Control
ID
• Inside Diameter
OD
• Outside Diameter
Proper Handling
Do not attempt to pick up, move or manipulate the
control unit by the cables.
WFS
• Wire Feed Speed
Always operate the control unit on stable, flat and
level surfaces with the bottom or side rails facing the
ground. Be sure to leave adequate room to open the
door to the wire feed assembly. Unplug the control
unit when not in use. Do not place on wet ground or in
puddles.
IPM
• Inches per minute
The system cart is designed for flat even surfaces. Do
no overload cart.
CM/MIN
• Centimeters per minute
Volts
• Voltage
Amps
• Amperage
Operation
Read entire manual before operation.
Only operate while on firm level surface or attached
to a system cart. Always verify that the system cart is
secured in place before operation.
Keep hands away from weld head while in operation.
CAUTION
Never unplug or plug in control cables to the tractor
while the system is powered on.
Verify that the system is properly grounded before
beginning to weld.
Refer to the individual system manuals for additional
instructions.
A-3
APEX ® 30M
INSTALLATION
APEX® 30M System
Basic Information
APEX systems are digital Lincoln Electric systems
designed for mechanized automation. These systems
consist of three main components, an APEX control
unit, a HELIX weld head, and a welding power supply.
In addition to the main components there are various
cables, pendants and other items that make up the
complete offering.
These digital control systems operate a variety of weld
heads for multiple applications. Despite system differences there are several commonalities both software
and operational.
Control Unit
The APEX® 30M Control Unit (K52160-1) is part of the
APEX 3 Series family of controls. The control unit enables welding process from the power supply and optional advanced process modules which include: MIG,
Pulsed MIG, Flux-Cored, & GMAW-STT®. All aspects
of the weld are synchronized through the 30M.
System Cart
The 30M was designed for use with a system cart
(K52164-1). This cart is based on a standard inverter
cart with a reinforced top and handles to stand up to
demanding shop environments. It includes hooks and
trays for organizing consumable parts and cables as
well as a hook to hold the weld head. The system cart
can be configured to fit the power supply as well as an
add on component such as the Advance Process Module, Water Cooler and others.
The system cart makes moving the complete system
around a shop environment easy, see FIGURE 2 - System With Cart. The system shown is the APEX 30M/
HELIX M85 system with a PowerWave and an Advance
Process Module (K52165-2)
The system cart is not required for operation. The
APEX 30M control unit can also be hooked up to a
stationary power supply and carried to the welding station. The length this can be moved will depend on the
type of weld. Many processes support remote welding
as far as 100 feet from the power supply.
The APEX 30M is a digital control and wire feeder designed for portability and ease of use. The wire feeder
is capable of supporting up to a 44lb spool.
FIGURE 1 - Apex 30M
System Components
FIGURE 2 - System With Cart
Power Supply
The system is designed to work with a PowerWave S
series or an Arclink enabled Vantage Engine Drive.
Weld Head
All HELIX M and MP weld heads work with the APEX
30M control unit.
A-4
APEX ® 30M
INSTALLATION
Installation
Slide the system back until the rear of the 30M is
secured under the catch, and the latch has locked into
place. Refer to FIGURE 3 - System Assembly
The complete system cart is meant to be installed in a
very specific order. Refer to FIGURE 3 - System Assembly for reference.
1.Catch - Holds the rear of the control in place
System Cart
2. Latch - Latches onto the front of the control to hold
it in place. Pull on the latch to disengage.
The system cart (K52166-1) comes fully assembled
when ordered as a part of a complete system. If ordered individually it may require additional assembly.
Please refer to system cart assembly instructions for
complete step by step instructions.
Optional Modules
The optional modules are installed in the cart before the
power supply. Set the module into the mounting holes
provided and push backwards to seat the module.
1
Install bracket to lock the unit in place.
Optional modules have brackets in the top to supporting PowerWaves.
2
Power Supply
The PowerWave will be installed either onto the base
or on top of the optional modules (if installed). Set the
module into the mounting holes provided and push
backwards to seat the module.
Once this unit is in place remove the front and back
handles. The top of the system cart will be screwed
into the handles holes left by removing the front handle.
Cart Top
To affix the PowerWave in place attach the top of the
cart. Adjust the sliding back brace of the cart so that it
is in line with the cart top. Verify that the cart top lines
up with both the screw holes on the sliding back brace
and the holes from the power supply handle. Secure
the top in place.
With the top secured in place, attach the handle from
the front of the power supply to the front of the cart top
into the holes provided. This will prevent the handle
from being lost and is a convenient holder for the system pendant.
FIGURE 3 - System Assembly
APEX 30M
Once all other components are secured in place the
30M can be installed onto the top of the system cart.
There are channels provided to help guide the 30M into
place.
Additional Items
There are other items that can be secured or included
on the system cart. These items can include cables,
weld head, track ring or gas canisters. Verify that any
additional items are properly secured.
Cart Accessories
The system cart includes configurable accessories.
A-5
APEX ® 30M
INSTALLATION
These accessories are screwed into the side of the cart Once the entire system is fully assembled it should
as required by the customer.
look similar to FIGURE 6 - System Complete. System
shown includes optional module.
See FIGURE 4 - Cart Accessories, for all the accessories. These items include:
1. Tractor Hook - Holds the tractor in place, includes
pads and a backing to prevent the weld head from
swinging during transportation. 1 ea.
2. Hook - Holds cables or track rings. 3 ea.
3. Trays - Holds lightweight system consumables like
tips and gas cups. 2 ea.
3
2
1
FIGURE 4 - Cart Accessories
FIGURE 6 - System Complete
FIGURE 5 - Accessories Installation, shows how the
accessories screw into the provided holes. Utilization
and location of accessories is up to the user.
Note: To prevent PowerWave from overheating do
not block vents while in operation
FIGURE 5 - Accessories Installation
A-6
APEX ® 30M
INSTALLATION
Cable Installation
Basic System
The system is shipped out with cables connected, how- 1. Pendant Cable - Connects from the pendant to the
ever the components can be ordered separately and
control unit
installed by the operator, or the cables and components
2. Control Cable - Connects from the weld head to
may be removed during routine maintenance. For the
the control unit
complete system cable map see FIGURE 7 - System
3.Mechanized Torch - Runs from the Control unit
Assembly.
out to the weld head
Note:
4. Electrode Cable - Connects from the positive stud
• Always use the shortest cable lengths possible. DO
on the PowerWave (or Advanced Process Module if
NOT coil excess cable. It is recommended that the total
installed) to the rear of the Control Unit
length of control cable does not exceed 100ʼ (30.5M).
The use of non-standard cables in excess of 25ʼ (7.5M) 5. Work Cable* - Connects from the negative stud
of the PowerWave (or Advanced Process Module if
can lead to communication problems (system shutinstalled) to the work piece
downs), poor motor acceleration (poor arc starting),
and low wire driving force(wire feeding problems).
6. Sense Lead* - Optional sense lead, can extend
from the PowerWave to the work piece
• Best results will be obtained when the control cables
7. ArcLink Cable - Connects from the power supply
are routed separate from the weld cables. This minito the control unit
mizes the possibility of interference between the high
8. 3 Phase Power Cable* - Connects power supply
currents flowing through the weld cables and the low
to facility power (refer to power supply manual for
level signals in the control cables.
installation)
Arclink Cables can be used to extend the pendant
9. Gas Hose* - Supplies gas to the system from
cable length.
external source
Standard Lincoln Cables
Location #
10.Ethernet Cable* - Optional cable to connect the
power supply to a local area network for added system functionality
Torch & Cables
Part Number
Pendant Cable 25’
K52130-25
1
Pendant Cable 15’
K52130-15
1
Advanced System
Control Cable 15 ft. (4.6 m)
K52107-15
2
Control Cable 25 ft. (7.6 m)
K52107-25
2
Mechanized Torch 25 ft. (7.6 m)
K52106-1
3
11.Sense Lead Pigtail - Comes as part of the
Advanced Process Module, allows sensing from the
new module
Mechanized Torch 15 ft. (4.6 m)
K52106-2
3
Weld Power Cable 10’
K1824-10
4/5
Weld Power Cable 35’
K1824-35
4/5
Weld Power Cable 60’
K1824-60
4/5
Weld Power Cable 110’
K1824-110
4/5
Sense Lead
M20023-1
6
Arclink Cable 8’
K1543-8
7
Arclink Cable 25’
K1543-25
7
Arclink Cable 50’
K1543-50
7
Arclink Cable 100’
K1543-100
7
12.Arclink Pigtail - Comes as part of the Advanced
Process Module, connects to the power supply
* Indicates items not included with the system
A-7
APEX ® 30M
INSTALLATION
9
GAS
1
2
3
10
ETHERNET
4
WORKPIECE
5
7
FRONT
6
8
4
FRONT
TO BACK
FACILITY POWER
BASIC SYSTEM
WORKPIECE
9
GAS
1
3
2
10
4
ETHERNET
7
WORKPIECE
11
FRONT
6
12
FACILITY POWER
4
5
WORKPIECE
8
TO BACK
ADVANCED SYSTEM
FIGURE 7 - System Assembly
A-8
APEX ® 30M
INSTALLATION
7. ArcLink Status - The ArcLink Status light will be
green if all ArcLink systems are operational.
8. Weld Head Control Cable - Connection from the
Apex 30M to the weld head.
1
2
9. ArcLink Cables - Two ArcLink Cable connections
for one pendant, and the optional operator pendant
or other ArcLink device.
3
10.Mechanized Torch - Welding Torch passes
through the front panel (connected and secured
through side panel).
4
5
10
6
7
Wire Compartment
For all wire Compartment connections, see FIGURE 9 Wire Compartment.
9
8
FIGURE 8 - Front Panel
1. Electrode Sense Selector - Electrode sense can
be set to sense from control unit bus bar (Down) or
from a remote connection (Up). Sensing from the
Control unit bus bar (Down) is the default mode.
For all front panel connections, see FIGURE 8 - Front
Panel.
2. Cold Feed / Gas Purge Switch - Allows the operator to cold wire feed (Up) or purge the gas (Down)
from the control unit.
Front Panel
1.Work Sense - Optional connection for Work Sense.
3. Outer Wire Guide - Removable outer wire guide
(Sense lead can be direct from Power Wave).
for easy access to change drive rolls. No tools
2. USB - Welding programs and data can be saved
required.
and loaded via USB.
4. Drive Rolls - Standard drive rolls available in
3. Power Off - Allows operator to remove power from
many sizes for different weld requirements.
the weld head and halt welding operation. The system will remain off until switch is rotated clockwise. 5. Pressure Arms - Allows pressure of the drive rolls
on the wire to be adjusted by hand.
4. Electrode Sense - Optional connection for
6. 44lb Wire Hub - Wire hub designed for 10 - 44 lb
Electrode sense to welding torch.
spools.
5. Trigger Input - Optional trigger input for manual
welding.
6. Motion Network Connection - The network connection light will show green if all motion systems
are operational.
1
2
3
4
5
6
FIGURE 9 - Wire Compartment
A-9
APEX ® 30M
INSTALLATION
1
2
3
4
5
6
FIGURE 10 - Back Panel
Back Panel Connections
For all back panel connections, see FIGURE 10 - Back
Panel.
1.
Work Sense Lead - Used when the work
sense lead signal is passing through the Apex 30M.
(Optional)
2. Breaker 10A - Will trip in overpower situations,
push to reengage.
3. ArcLink In - The ArcLink connection from the
Power Wave or other ArcLink enabled devise.
4. Gas Input - Gas supplied to the system ties into
the back of the 30M.
5. System Label - Contains part number, serial number and code number of the machine
6. Weld Cable Connection - Connection supplies
power to the mechanized torch for welding.
A-10
APEX ® 30M
INSTALLATION
Shielding Gas Connection
Procedure to Install Wire Guides and Drive
Rolls
WARNING
WARNING
CYLINDER may explode if damaged.
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the welding power
source before installation or changing drive rolls
and/or guides.
•Keep cylinder upright and chained to
support.
• Do not touch electrically live parts.
• Keep cylinder away from areas where it may be damaged.
• When inching with the gun trigger, electrode and drive
mechanism are “hot” to work and ground and could remain
energized several seconds after the gun trigger is released.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Do not operate with covers, panels or guards removed or
open.
• Keep cylinder away from welding or other live electrical
circuits.
• Only qualified personnel should perform maintenance work.
• BUILD UP OF SHIELDING GAS MAY HARM HEALTH OR KILL.
• Shut off shielding gas supply when not in use.
• See American National Standard Z-49.1, “Safety in
Welding and Cutting ” Published by the American
Welding Society.
-------------------------------------------------------------------To remove drive rolls and wire guides:
1. Turn power off at the welding power source.
2. Remove the outer wire guide.
Maximum inlet pressure is 100 psi. (6.9 bar.)
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
2. Remove the cylinder cap. Inspect the cylinder valves
and regulator for damaged threads, dirt, dust, oil or grease.
Remove dust and dirt with a clean cloth. DO NOT ATTACH
THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas supplier of this condition. Oil or grease
in the presence of high pressure oxygen is explosive.
3. Stand to one side away from the outlet and open the
cylinder valve for an instant. This blows away any dust or dirt
which may have accumulated in the valve outlet.
4. Attach the flow regulator to the cylinder valve and tighten
the union nut(s) securely with a wrench. Note: if connecting to 100% CO2 cylinder, insert regulator adapter between
regulator and cylinder valve. If adapter is equipped with a
plastic washer, be sure it is seated for connection to the CO2
cylinder.
3. Rotate all of the triangular rings to the unlocked
position.
5. Attach one end of the inlet hose to the outlet fitting of the
flow regulator. Attach the other end to the welding system
shielding gas inlet. Tighten the union nuts with a wrench.
6. Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting spring pressure
is released.
7. Standing to one side, open the cylinder valve slowly a fraction of a turn. When the cylinder pressure gage stops moving,
open the valve fully.
8. The flow regulator is adjustable. Adjust it to the flow rate
recommended for the procedure and process being used
before making a weld.
4. Open the idle arms.
5. Remove the drive rolls and inner wire guide.
A-11
APEX ® 30M
INSTALLATION
Pressure Arm Adjustment
To install drive rolls and wire guides:
WARNING
1. Turn off power at the welding power source.
ELECTRIC SHOCK can kill.
2. Open the idle arms.
• Turn the input power OFF at the welding power
source before installation or changing drive rolls
and/or guides.
3. Assemble the inner wire guide.
• Do not touch electrically live parts.
IDLER ARM OPENED
INNER WIRE GUIDE
• When inching with the gun trigger, electrode
and drive mechanism are “hot” to work and
ground and could remain energized several seconds after the
gun trigger is released.
• Do not operate with covers, panels or guards removed or
open.
• Only qualified personnel should perform maintenance work.
-------------------------------------------------------------------The pressure arm controls the amount of force the
drive rolls exert on the wire. Proper adjustment of the
pressure arm gives the best welding performance.
=
DRIVE ROLLS
OUTER WIRE GUIDE
4. Slide the drive rolls onto the drive hubs.
Set the Pressure arm as follows:
(See Figure A.3)
Aluminum wires
between 1 and 3
Cored Wires
between 2 and 4
Steel, Stainless wires between 4 and 6
5. Close the idle arms.
FIGURE A.3
6. Rotate all of the triangular rings to the locked position.
7. Assemble the outer wire guide.
8. Adjust the pressure arms to the recommended setting.
Loading Wire
WARNING
• Keep hands, hair, clothing and tools away from
rotating equipment
• Do not wear gloves when threading wire or
changing wire spool.
• Only qualified personnel should perform
maintenance work.
A-12
APEX ® 30M
INSTALLATION
Conduit Installation
The K1546-xx series of conduits are compatible with K515-xx, K565-xx, Wire Wizard
and Electron Beam Technologies conduits.
To install conduit to the wire drive:
1. Slide the conduit bushing into the feed
plate and secure with the set screw.
2. Slide the conduit into the bushing and
lock in place with the thumb screw.
SET
SCREW
THUMB
SCREW
CONDUIT
BUSHING
CONDUIT
A-13
APEX ® 30M
NOTES
A-14
APEX ® 30M
OPERATION
Operational Safety Precautions
Read and understand this entire section before operating the machine.
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel should
perform the installation.
• Turn the input power OFF at the
disconnect switch or fuse box.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
• Always dry insulating gloves.
• Read and follow “Electric Shock
Warnings” in the Safety section if
welding must be performed under
electrically hazardous conditions
such as welding in wet areas or on
or in the work pieces.
FUMES AND GASES
can be dangerous.
* Keep your head out of fumes.
* Use ventilation or exhaust to
remove fumes from breathing zone.
WELDING SPARKS
can cause fire and explosion
* Keep flammable material away.
* Do not weld on containers that
have held combustibles.
ARC RAYS
can burn.
* Wear eye, ear and body
protection.
Operation Information
The APEX® 30M Control System is a precision digital
control system designed for multi process welding and
is designed to work with the HELIX® M and MP type
weld heads. Refer to the specific weld head manual for
installation and safety instructions.
External inputs
The external inputs for the APEX 30M are welding
power supplied by the power source, gas, ArcLink.
Control
Control of the weld head and wire feeder is provided by
the APEX 30M controller. Through the use of a handheld pendant the operator is able to control and monitor
all aspects of the weld and change parameters while
welding.
Welding Power
Welding power is provided through a standard Lincoln
Electric Power Wave or Vantage power supply. See the
correct IM for the power supply chosen for complete
installation and operation instructions.
Manual Adjustments
Manual adjustments for this system are limited to physical wire adjustments, such as torch placement, lead/
lag, work angle etc...
Before operation check all cable connections for fraying or loose connections or damage. All consumables
should be changed out per shift, or as needed during
each shift. Operating welding equipment with incorrect
or broken consumables can cause bodily harm or damage to the machine.
Observe additional Safety Guidelines detailed in the
beginning of this manual.
B-1
APEX ® 30M
OPERATION
System Start Up
Ensure all components are connected, refer to individual component manuals for full connection instructions.
When the complete system is ready to weld turn on the
power to the power supply. The system is designed to
be turned on and off through the power supply.
NOTE
With power applied to the system ensure that the
reset button is not engaged. If the reset button is
engaged the system will not initialize. To disengage the reset button rote the knob clockwise.
This reset button can be used to restart the system for
troubleshooting purposes and to halt system movement.
FIGURE 11 - Startup Screen
Once initialization has been completed the user is
presented with a log in screen, see FIGURE 12 - Log
In Screen.
Emergency Off
To remove all welding power use the emergency off
button located on the specific power supply being
used.
FIGURE 12 - Log In Screen
Reset
Note:
During the start up cycle the weld head goes
through a self calibration cycle. The system will
not allow the user to log in until the calibration
cycle has been completed.
Startup Screen
At this point the user can begin using the system. See
the next sections for pendant operation and log in
information.
During welding the control unit has a reset button that
will remove the 24volts to the weld head. This function
stops all welding but does not function as an emergency stop button.
For some software versions when the system is reset
at the power wave the screen will display multicolored
bars, see FIGURE 11 - Startup Screen. This is a normal part of the initialization process.
B-2
APEX ® 30M
OPERATION
Pendant Operation
Navigation Controls
Items 6 through 8 control navigation, their functions are
primarily navigating through the menus and changing
values while setting up the system.
Note: While welding the steering knob #7 functions
only for oscillation steering.
The Apex 3000 Pendant, frequently called the teach
pendant or standard pendant is designed around full
functionality and an easy operator experience. As
such the pendant’s different buttons can serve multiple
purposes depending on the screen, see FIGURE 13 Pendant Items for all buttons, knobs and switches.
6. Left Toggle (White Border) • Short Press - Changes selected value (in this example it will change the value in the left dwell box)
• Hold - Increases value / change speed
Button Actions
Each of the buttons and toggles can perform differently
on the different screens depending on how the buttons
are pressed. There are three types of button press:
7. Steering Knob • Rotate - Steers the oscillation in and out, or
changes the selected variable
• Short Press - Centers the oscillation, or moves to
the next variable
• Long Press - Starts/stops oscillation test (in idle
mode only)
• Hold & Rotate - Fast navigation between selected variables
Short Press - A short press is a standard press that
engages the button and is not held in place, most operations are performed as a short press.
Example: Quickly pressing down on #7 the steering
knob, will center the oscillator
Long Press - For some screens, by holding a button
down for a length of time exceeding 2 seconds the
system performs an alternate function
Example: A long press of more than 2 seconds of #7
will start the oscillation test mode
Hold - By pressing and holding down a button or toggle
the effects exhibited will continue or will speed up
Example: When pressing the selection button #1 in the
jog screen gas will purge for 3 seconds, by holding
down the button gas will continuously purge
Hold & Rotate - The steering knob also acts as a button. It can be pressed, as well as rotated for different
actions and in some screen can be held down and
rotated for fast navigation.
Selection buttons
Buttons 1 through 5 are selection buttons, their functions change depending on the screen. In each screen
there will be an icon to indicate their functions. If there
is no icon above the variable button then pressing that
button will have no effect.
1. Selection Button 1 • Short Press - Enables/Disables shown variable
2. Selection Button 2 • Short Press - Enables/Disables shown variable
3. Selection Button 3 • Short Press - Enables/Disables shown variable
4. Selection Button 4 • Short Press - Enables/Disables shown variable
5. Selection Button 5 • Short Press - Enables/Disables shown variable
8. Right Toggle (Gray Border) • Short Press - Navigates or changes the selected
value (in this example it will change the value in
the right dwell box)
• Hold - Increases value / change speed
Menu buttons
Buttons 9 through 12 are the menu buttons, pressing these buttons bring up the specified menu screen
while in the idle, test or welding screens. (if the user is
already in that menu, the button will have no effect)
9. Wire Feed/Amps • Short Press - Wire Feed/Amps options
• Long Press - Navigates to the Jog Screen from
the Idle Weld screen
10. Dwell • Short Press - Dwell options
• Long Press - Navigates to the Oscillation Screen
from the Idle Weld screen
11. Oscillation • Short Press - Oscillation options
• Long Press - Navigates to the Oscillation Screen
from the Idle Weld screen
•
12. Travel/Volts • Short Press - Travel/Voltage options
• Long Press - Navigates to the Jog Screen from
the Idle Weld Screen
Control buttons
Buttons 13 through 15 are the control buttons. These
buttons have a specific purpose that does not change.
Note: Buttons may be disabled in menu screens
13. Start/Stop • Short Press - Start if idle, stop if welding, stop/
start test weld when in test mode
B-3
APEX ® 30M
OPERATION
15
1
2
3
6
4
5
7
9
10
13
8
11
12
14
FIGURE 13 - Pendant Items
14. Sector • Short Press - Switches between sectors (if available)
15. Reset • Short Press - Initiates a system reset
*Important* this is not an emergency stop
button, power is still applied to the system
Color Coding
The menu buttons and Toggles are color coded. For
button #9 the icons above are Wire Feed (White Icon)
and Amps (Gray Icon). This means when the operator
presses that menu button (#9) the value for Wire Feed
(White Icon) will be presented and can be changed by
the Left Toggle (White Border) and the value for Amps
(Gray Icon) will be presented and can be changed by
the Right Toggle (Gray Border).
Fast Movement
Certain screens allow for fast movement using the
steering knob. Movement and selection can still be
accomplished with the left and right toggle. In addition the Steering Knob will allow the user to change the
selections by turning the knob and moving to the next
section by pressing the knob.
For fast movement between selections hold the steering knob down while turning to rapidly move from one
selection to the other.
Fast Movement Screens
The screens where fast movement is enabled are:
• Log In Screen
• Users Screen
• Programs Screen
B-4
APEX ® 30M
OPERATION
System Log In
change the selected variable.
Every time the system is powered on it will go through
a self calibration routine. Ensure that the torch is free
to move before starting the system.
After the system finishes powering up and calibrating
the user will be presented with a Log In Screen see
FIGURE 14 - Log In Screen.
Fast Movement
Fast movement using the steering knob is enabled
on this screen. Use the steering knob or left and right
toggles for navigation and selection.
Login
The system requires a four digit log code in to log in.
Press the Enter selection button when user code has
been entered. Once a four digit code is accepted
the system automatically moves into the default Idle
screen, see FIGURE 15 - Idle Screen Default. This
screen is shown when a supervisor logs into the system.
FIGURE 14 - Log In Screen
Use the left toggle or the press the steering knob to
change from one variable to the next.
FIGURE 15 - Idle Screen Default
From the Idle screen is possible to move into the Setup
screen, Jog and Oscillation screens as well as switch
between test and weld modes.
Note: The values shown on each screen are representative only.
Use the right toggle or the turn the steering knob to
B-5
APEX ® 30M
OPERATION
Log In Screen
The following buttons and options are available from
the log in screen:
1. N/A
• No Effect
15
2. N/A
• No Effect
3. N/A
• No Effect
1
4. Reset • Short Press - Will change password entry back
to “0000”
5. Enter • Short Press - Attempts to log in to the system
with the currently entered user code
10. Dwell • No Effect
4
5
7
9
7. Steering Knob • Short Press - Moves cursor to the next space
• Rotation - Quickly cycles through available character options
• Hold & Rotate - Quickly moves the cursor from
one selection to the next
9. Wire Feed/Amps • No Effect
3
6
6. Left Toggle (White Border) • Short Press - Pressing up or down moves cursor
between spaces
8. Right Toggle (Gray Border) • Short Press - Pressing up or down changes
value of the selection
2
10
13
8
11
12
14
FIGURE 16 - Log in Buttons
13. Start/Stop • No Effect
14. Sector • No Effect
15. Reset • Short Press - Initiates a system reset
11. Oscillation • No Effect
12. Travel/Volts • No Effect
B-6
APEX ® 30M
Idle Screen
The Idle Screen is the first screen presented to the
supervisor when logging in, see FIGURE 15 - Idle
Screen Default. This screen functions as a jumping
off point to either weld, or set up all the parameters for
welding as well as testing those parameters.
OPERATION
Press the Menu button to open the Oscillation Menu
options
Menu Option Variables
The Idle Screen will show the user four separate
variables depending on which Menu button has been
pressed. Pressing the different Menu buttons will
change the shown values.
The different variables shown correspond to the icons
on the Menu buttons.
Press the Menu button to open the Wire Feed/Amps
Menu options.
Press the Menu button to open the Travel/Voltage
Menu options
Press the Menu button to open the Dwell Menu Button
options
Similar variables are paired together. The variables
shown on the screen can be changed using the left and
right toggles. It is possible to change between these
menu options while idle or welding.
B-7
APEX ® 30M
OPERATION
Idle Screen Buttons
The Idle Screen will change depending on which menu
button has been selected. Some items in the Selection button windows will change depending on system
configurations.
15
1. Auto Height • Short Press - Turns Auto Height on and off
2. Setup • Short Press - Navigates to the Setup Screen
3. Pass • Short Press - Switches to the next pass in the
weld program (if available)
1
4. N/A • No Effect -
2
3
6
4
5
7
8
5. Test/Weld • Short Press - Switches between weld and test
modes (Image shows system in Weld Mode)
9
6. Left Toggle (White Border) • Short Press - Changes the value displayed in
the top left box (in this example it will change the
value in the left dwell box)
• Hold - Increases adjustment speed
7. Steering Knob • Rotate - Moves the oscillation in and out
• Short Press - Centers the oscillation
• Long Press - Starts/stops oscillation test
8. Right Toggle (Gray Border) • Short Press - Changes the value displayed in the
top right box (in this example it will change the
value in the right dwell box)
• Hold - Increases adjustment speed
10
11
13
12
14
FIGURE 17 - Idle Screen
13. Start/Stop • Short Press - Starts welding
14. Sector • Short Press - Switches to the next sector*
9. Wire Feed/Amps • Short Press - Wire Feed/Amps options
• Long Press - Navigates to the Jog Screen
15. Reset • Short Press - Initiates a system reset
Important: this is not an emergency stop button,
power is still applied to the system
10. Dwell • Short Press - Dwell options
• Long Press - Navigates to the Jog Screen Dwell
Current sector is displayed at the center of the screen
near the sector Icon.
11. Oscillation • Short Press - Oscillation
options
15
• Long Press - Navigates to the Jog Screen Oscillation
12. Travel/Volts • Short Press - Travel/Voltage options
• Long Press - Navigates to the Jog Screen
B-8
APEX ® 30M
OPERATION
Idle Screen Test/Weld Modes
Static Screen Items
After preparing a program it is recommended that the
user test the parameters before striking an arc. The
system allows for a test mode, which will allow for testing of all non weld functions such as travel, gas purge/
flow, oscillation and others.
1. Arc Time • Tells the amount of time spent welding
There are many items common through the Idle, Weld
and Test screens. These items give helpful information
to the user throughout the setup and welding process.
2. Heat Input • Displays the amount of heat input for current weld
Press the Weld / Test Selection button.
3. Sector • Displays the current sector in the weld set, if applicable
4. Program Name • Displays the currently loaded weld program and program pass
Note: P
rogram Name changes to Italics when program parameters have changed
5. Oscillation Location • Displays where the torch is in relation to the oscillation
width.
6. Torch Height • Torch location in relation to maximum travel distance.
FIGURE 18 - Static Items illustrates the different items
that appear on the weld screen. These items are for
information only and are not selectable variables.
1
2
3
4
5
This changes the system from Test, to Weld mode. The
icon showing in the Selection Button window denotes
the mode that the system is in.
Auto Height is no longer an option while in Test mode.
From either of these modes, pressing the Start/Stop
Control button will enter the Weld Screen or the Test
Screen depending on which mode the user is in.
FIGURE 18 - Static Items
B-9
6
APEX ® 30M
OPERATION
Weld Screen
Test Screen
The Setup Selection disappears and is replaced with
the Adv Selection, Autoheight can also be disengaged,
see FIGURE 19 - Weld Screen Options 1.
Auto Height is disable while testing.
While welding the screen will show voltage and amperage feedback on the Weld Screen, see FIGURE 19
- Weld Screen Options 1. Pressing the menu buttons
will move the user through the Menu Option Variables
similar to FIGURE 21 - All Test Screens.
As with the Weld screen the test screen will show voltage and amperage feedback on the Weld Screen, see
FIGURE 20 - Weld Screen Options 1. Pressing the
menu buttons will move the user through the Menu
Option Variables as shown in the Idle Screen section.
FIGURE 20 - Weld Screen Options 1
FIGURE 19 - Weld Screen Options 1
Test Screen Buttons
The Test Screen buttons work similar to the Idle screen
buttons, see FIGURE 17 - Idle Screen with changes
being made to the parameter settings.
Pressing the Start/Stop button during the weld halts the
test and moves into the Jog Menu.
Weld Screen Buttons
The Weld Screen buttons work similar to the Idle
screen buttons, see FIGURE 17 - Idle Screen.
Pressing the Start/Stop button during the weld halts the
weld and moves into the Jog Menu.
B-10
FIGURE 21 - All Test Screens
APEX ® 30M
OPERATION
Jog Screen
Press the “Exit” selection button to return Idle screen
The Jog Screen is used to test movement of the system
before welding. The Jog Screen can be entered from
the Idle or Oscillation screens.
FIGURE 22 - Idle Screen
From the Idle Screen see FIGURE 22 - Idle Screen,
press and hold the Wire Feed/Amps or the Travel/Voltage menu buttons to enter the Jog Menu.
This screens allows for moving the tractor along the
track, adjusting torch height, purging gas as well as
wire feed and retract.
B-11
APEX ® 30M
OPERATION
Jog Buttons
The following buttons and options are available from
the from the Jog Menu:
1. Gas Purge • Short Press - Purge welding gas for 3 seconds
• Hold - Continually purges welding gas while held
15
2. Cold Feed Forward • Short Press - Feeds wire slightly
• Hold - Feeds wire continuously & accelerates the
WFS
1
3. Cold Feed Reverse • Short Press - Retracts wire slightly
• Hold - Retracts wire continuously & accelerates
the WFS
Note: Be sure to keep the spool tight as wire
is retracted
5
10
8
11
13
6. Left Toggle (White Border) • Short Press - Travels forward or backward
slightly
• Hold - Ramps travel speed
9. Wire Feed/Amps • No Effect
4
7
9
5. Exit • Short Press - Returns to Idle Screen
8. Right Toggle (Gray Border) • Short Press - Adjusts the torch up and down
• Hold - Ramps adjustment speed
3
6
4. Home • Short Press - Returns the weld head to starting
position on the track. Starting position is determined by power up or previous weld start.
7. Steering Knob • Rotate - Moves the oscillation in and out
• Short Press - Centers the oscillation
• Long Press - Starts/stops oscillation test
2
12
14
FIGURE 23 - Jog Screen
13. Start/Stop • No Effect
14. Sector • No Effect
15. Reset • Short Press - Initiates a system reset *Important* this is not an emergency stop button,
power is still applied to the system
10. Dwell • Short Press - Navigates to Oscillation screen
Dwell option
11. Oscillation • Short Press - Navigates to Oscillation screen
12. Travel/Volts • No Effect
B-12
APEX ® 30M
Oscillation Screen
The Oscillation Screen is used to test and adjust system oscillation before welding. To enter press and hold
the Dwell or Oscillation menu buttons while in the Jog
or Idle screens.
OPERATION
Press the Swap selection button to be taken to the
travel setup screen.
Pressing and holding the Oscillator menu button will
present the user with the option to change the oscillation width and the oscillation speeds.
The travel setup page is discussed in the in the travel
screen section on page B-18. This screen allows
the user to quickly change weld head orientation or
change the weave pattern.
Holding down the Dwell menu button will present the
user with the option to change the left and right dwells.
Press the “Exit” selection button to return to the Jog
Screens. Once all parameters have been input and
verified exit out of the Jog Screen to return to the idle
screen.
Once in the Oscillation screen, use a short press to
switch between Oscillation and Dwell. The items highlighted in red are the variables that can be changed.
B-13
APEX ® 30M
OPERATION
Oscillation Buttons
The following buttons and options are available from
the from the Oscillation Menu:
1. Purge • Short Press - Purge welding gas for 3 seconds
• Hold - Continually purges welding gas while held
15
2. L/R Swap• Short Press - Navigates to the Travel Direction
Setup Screen
3. N/A
• No Effect
1
2
3
4
5
4. Test/Weld • Short Press - Starts/Stops oscillation test
6
7
8
5. Exit • Short Press - Returns to idle screen
6. Left Toggle (White Border) • Short Press - Increases or decreases Left Dwell
time or Oscillation Width
• Hold - Increases increment speed
9
10
13
7. Steering Knob • Rotate - Moves the oscillation in and out
• Short Press - Centers the oscillation
• Long Press - Starts/stops oscillation test
10. Dwell • Short Press - Switches to Dwell option (when in
Oscillation option, otherwise no effect)
12
14
FIGURE 24 - Oscillation Screen
8. Right Toggle (Gray Border) • Short Press - Increases or decreases Right Dwell
time or Oscillation Speed
• Hold - Increases or decreases value continuously
9. Wire Feed/Amps • Short Press - Navigates to Jog Menu
11
13. Start/Stop • No Effect
14. Sector • No Effect
15. Reset • Short Press - Initiates a system reset *Important* this is not an emergency stop button,
power is still applied to the system
11. Oscillation • Short Press - Switches to Oscillation option
(when in Dwell option, otherwise no effect)
12. Travel/Volts • Short Press - Navigates to Jog Menu
B-14
APEX ® 30M
OPERATION
Setup Screen
The setup screen allows the appropriate user to set all
parameters for welding. Please note that this screen
can only be accessed by authorized supervisors set up
in the “Users” menu. This is explained further in the
Users Setup Screen section.
The Setup Screen, see FIGURE 25 - Setup Screen
can be accessed from the weld menu. This menu is
accessible in either test or weld mode, but it is not
accessible while welding. Press the Setup Selection
button to enter into the setup screen.
Setup Screen Options
Track Setup - The track setup screen allows the user
to choose the type and size of the track as well as the
size of the pipe (where applicable)
Travel Setup - The travel setup screen allows the operator to change the steering controls based on where
the operator is standing in relation to the track, as well
as setting up the travel pattern.
Once in the setup screen the user has access to
change multiple system parameters.
Process Setup - The process setup screen will allow
the user to set up the weld processes.
Start Settings - The start settings screen allows the
user to adjust the run in settings specific to the program, which affect how the system will react when the
weld starts.
End Settings - The end setting screen allows the user
to adjust the end settings specific to the program, which
affect how the system will react when the weld ends.
Service - The service screen allows the user to access currently loaded software information and change
certain motion settings.
Users - The users screen allows the Supervisors to assign operator and supervisor codes for the system.
FIGURE 25 - Setup Screen
To select the individual screens the user moves the
red cursor to the desired field using the Left Toggle
(White Border), and presses the Enter Selection button. Pressing Exit will return the user back to the Idle
Screen.
Increments - In this menu the supervisor can set which
variables the operator can adjust and to what degree
for each program. This screen also allows the user to
choose between imperial and metric units.
Programs - The programs screen is where all programs are saved, loaded or deleted.
B-15
APEX ® 30M
OPERATION
Track Setup
The Track setup screen presents the user with several
options. From this screen the operator can change the
type of track, the size of the track and the size of the
pipe.
Track Type
The first selectable option is track type. With the track
type field highlighted in red the user is able to switch
between the different types of tracks. These tracks
consist of:
•
•
•
Pipe Size
The third field that can be changed is the pipe size.
This can range from 4 in. to 300 in. The value can be
changed in increments of 0.1 in. Holding the switch for
longer than 2 seconds will increase the speed at which
the increments increase.
Heavy Wall Pipes
Heavy wall pipes may require the user to change the
pipe size in later passes.
Example: A 20” schd 120 pipe would have the first
pass pipe size entered at: 17” (true pipe ID) As
the joint is filled in the diameter being welded will
increase until the last pass where a true 20” (true
pipe OD) diameter is being welded.
Outside Diameter Track
Inside Diameter Track
Flat Track
Positioner Setup
This system can be used as a part of a 1G system with
certain positioners When the system detects positioners as part of the setup the Travel Setup screen will
change, see FIGURE 26 - Positioners Setup Screen.
FIGURE 26 - Positioners Setup Screen
Track Ring Size
Track sizes can range from 4 in. to 300 in. the value
can be changed in increments of 0.1 in. Holding the
switch for longer than 2 seconds will increase the
speed at which the increments increase. Use the nominal sizes for the track rings. These nominal sizes are
stamped into the track.
With both the Outside and Inside Diameter options the
user is required to enter in the track ring size, and the
pipe size. These numbers need to be input correctly
in order to calibrate to the correct travel speed. This
ensures that the torch travel is consistent.
When the system is set to control multiple positioners
the right toggle will switch between positioner A and B.
Use the Index Selection buttons to index the weld head
on its mount.
When the system is used to control positioners the
weld and idle screens will show the current positioner
as a selection. Pressing the Positioner Selection button
will switch from positioner A to positioner B.
B-17
APEX ® 30M
OPERATION
Travel Setup Screen
Travel Pattern
The travel setup allows the operator to set how the
controls will work while welding and change the weave
pattern.
The second field the operator can choose is the weave
pattern.
Travel
The operator has the option of choosing how the tractor
is oriented on the track. This is a benefit when welding
because the operator is able to choose which direction
is forward and which direction is reverse. The travel direction being oriented correctly with the user allows the
steering to be intuitive. With some tractors that don’t allow the user to set orientation, forward and reverse can
be confused; pressing up will make the tractor move
forward, but when the tractor is oriented 180 degrees
pressing up will move the tractor backward. This can
lead to confusion and weld errors.
There are three options to choose from.
No Weave
When no weave is selected the oscillator does not
move during the welding process. The user can still
manually steer the oscillator.
Step Travel
During step travel the travel speed stops during the
dwells. This allows the heat to be directed to the side
walls.
With the travel field highlighted the tractor orientation
can be selected, as well as the travel direction. There
are four different options available. All directions refer
to the tractor and are in relation to the users view facing
the tractor.
1.
2.
3.
4.
Continuous Travel
Continuous travel will continue travelling throughout
the weld process, as well as during oscillation, excursion and dwells.
Facing Right, Traveling Down
Facing Left, Traveling Down
Facing Right, Traveling Up
Facing Left, Traveling Up
B-18
APEX ® 30M
OPERATION
Process Setup Screen
The Process Setup Screen, see FIGURE 27 - Process
Setup, allows the user to select from various options
to determine the variables in the weld.
and travel options. Without multiple sectors enabled
the system will only register 1 sector for the entire
weld. With only one sector selected the Idle, Weld and
Test screens will not show the sector icon.
Weave Process Options
Weave is an optional process option that is set up depending on the user’s and application’s requirements.
•
•
•
•
•
Weave - Refer to the Travel Pattern section on
page B-18 for the different weave options.
Oscillation Width - Determines the width of the
oscillation weave (up to 2 in.)
Oscillation Speed - The speed at which the torch
moves during oscillation
Left Dwell - How long the torch remains on the left
side of oscillation
Right Dwell - How long the torch remains on the
right side of oscillation
With no weave selected, oscillation settings do not appear on the screen.
FIGURE 27 - Process Setup
Standard Process Options
Certain process options should be set up for every
weld and every sector. These options are:
•
•
•
•
•
Sector - Determines which sector options are being set for. There are 8 possible sectors.
Wire Speed - Sets wire feed speed
Trim/Voltage - The voltage option which controls
the amount of voltage applied to the wire
Torch Height (Amperage) - The Amperage value
which determines how close the torch is to the work
surface
Travel Speed - Sets the electrode travel speed
Change sector “1” to “2”
Many settings on the Process Setup Screen can be
adjusted during the weld. The purpose of this screen is
to set base settings before the weld begins.
Weld Mode and Weave Pattern cannot be adjusted during the weld.
Enabling a sector presents the Wire, Trim, Torch height
B-19
APEX ® 30M
OPERATION
Mode Select
Selecting wire diameters moves to wire type
The weld mode is determined by the wire size, type,
process and type of gas being used. It is important to
have the correct weld mode set because that allows the
power supply to drive the different aspects of the weld.
These aspects determine how the power supply will
behave throughout the weld.
Mode select provides a range for weld controls such as
WFS, Amps, Volts and others.
Guided Mode Select
The system allows for a guided mode select, see FIGURE 28 - Guided Mode Select for when the user is
not sure which mode is appropriate for their application.
Press the Mode selection button
Wire type leads to specific process and then to gas
selection
Much like other screens only pertinent information appears on the screen. The user is prompted to select
the wire size, type, process, and then gas type.
Mode Select guides the user through the settings.
Each selection filters the list of available weld modes to
match your application. A cored wire would not allow
the user to select an STT process. This prevents errors
before the weld even begins.
The currently selected mode is displayed on the left
side of the screen, see FIGURE 27 - Process Setup.
These processes are accessed from the Power Wave,
and are updated with the standard Power Wave updates.
FIGURE 28 - Guided Mode Select
B-20
APEX ® 30M
OPERATION
Advanced Process Setup
Manual Mode Select
Lincoln power supplies come with pre set welding
modes for particular welding applications and wire
types. Press the Mode selection button to see a list of
weld modes loaded into the power supply.
Certain weld modes have advanced settings specific to
that mode or process. Pressing the ADV Selection button on the Process Setup screen will present the user
with the advanced options associated with the selected
weld mode, see FIGURE 30 - Advanced Process
Setup.
Press the Modes selection button
Press the ADV Selection button.
The available weld modes are displayed in sequential
order. These available modes depend on the available
equipment. STT modes will not be selectable without
an STT or Advance Process Module connected to the
welding equipment.
Advanced Options
Options available depend on the selected weld mode.
See the PowerWave settings for a full breakdown and
explanation of advanced options.
Wave Controls
Some typical wave controls are:
• Pinch
• Hot Start
• UltimArc
FIGURE 29 - Automatic Mode Screen
FIGURE 30 - Advanced Process Setup
Height Sensitivity
Height sensitivity is a global setting available regardless of the weld mode selected.
B-21
APEX ® 30M
OPERATION
The operator is able to chose how quickly the auto
height will react to changes. Higher sensitivity will
result in faster adjustment which might cause hesitation
in torch height motion and abrupt changes in the weld.
Sensitivity Recommendations
• 0 • 20 • 50
• 80 No movement
STT/FCAW or pipe out of roundness
CV (Also factor default setting
Pulse or Joint Profile tracking
B-22
APEX ® 30M
OPERATION
Start Settings
End Settings
Start setting should be set up after the process setup
has been completed. The start settings screen, see
FIGURE 31 - Start Settings Screen, allows the user to
adjust the run in settings specific to the program which
affect how the system acts when the weld starts. The
start settings take effect as soon as the Start / Stop button is pressed to initiate the weld. Refer to page G-7
to see a full timing diagram.
The end setting screen, see FIGURE 32 - End Settings Screen, allows the user to adjust the end settings
specific to the program, which affect how the system
will behave at the end of the weld. End settings take
effect as soon as the Start / Stop button is pressed to
stop the weld. Refer to page G-7 to see a full timing
diagram.
The settings that can be changed in this screen are:
Crater WFS
The wire feed speed during crater
Crater Volts
The amount of voltage after downslope
Crater Time
The voltage setting that downslope will ramp to
Burnback
The time the arc is maintained after the wire stops.
Downslope
How quickly the system ramps from welding parameters to crater parameters
FIGURE 31 - Start Settings Screen
The setting that can be changed in this screen are:
Preflow
The amount of time (sec) that gas flows before welding
begins to ensure adequate gas coverage for the weld.
This prevents porosity.
Postflow
How long the gas continues to flow after the weld to
provide shielding
Upslope
This is the amount of time (sec) it takes for the system
to ramp from start settings to welding parameters.
RunIn WFS
Determines the speed at which the wire will travel at the
beginning of upslope. Will ramp up to welding WFS.
RunIn Volts
The voltage setting at which the system begins to weld.
Will then ramp to welding voltage.
Motion Delay
This determines how long the system will wait before
beginning to travel and oscillate.
FIGURE 32 - End Settings Screen
B-23
APEX ® 30M
Service
The Service Screen allows for advanced welding options. There are two menus available in the Service
Screen: Version and Motion.
OPERATION
Motion
Allows the user to select certain motions and behaviors
of the weld system, see FIGURE 35 - Service Screen
Motion for available options.
FIGURE 35 - Service Screen Motion
FIGURE 33 - Service Options Page
If a USB is installed the system allows for a system
snapshot to be taken from this screen.
Service Motion items are:
• Steering Increment - Allows the supervisor to set
the distance the oscillation will move for each click of
The version option of the service menu shows the user
the steering knob.
information about the installed software and hardware.
Page through the screen using the Next Selection but- • Head Orientation - To change the torch orientation
ton.
relative to the weld head the supervisor must also
change the system settings in addition to physically
inverting the weld head.
Version
• Torch Retract Distance - Change how far the
torch retracts at the end of the weld. This allows for
greater retract distance when clearance is desired,
and less distance when restarting the weld needs to
be rapid.
• WFS Test - The APEX system does all calibrations
internally, however in order to comply with welding
standards our system allows for verification. WFS
Test will produce a desired amount of wire for a desired length of time for verification.
FIGURE 34 - Service Screen Versions
• Travel Test - The APEX system does all calibrations
internally, however in order to comply with welding
standards our system allows for verification. Travel
Test will travel for the specified distance for verification. The speed the weld head will travel is determined by the program parameters.
B-24
APEX ® 30M
OPERATION
Users
The Users Screen, see FIGURE 36 - Users Screen
allows the user to set up operator and administrator
log in codes. Each user can be assigned an individual
code which determines the level of access.
Fast Movement
Fast movement using the steering knob is enabled
on this screen. Use the steering knob or left and right
toggles for navigation and selection.
Adding Users
Only those with supervisor access are able to view the
users screen.
FIGURE 37 - Add User
Operator
Limited access to settings, will only be able to operate
within the increment settings placed by the supervisor
per program.
Supervisor
Full rights and access to all weld parameters and setup
screens.
Change selected value.
FIGURE 36 - Users Screen
Press the Add User Selection button.
Pressing the Add Selection button will bring up the Add
User screen, see FIGURE 37 - Add User.
After the code has been selected the user can determine the level of access:
B-25
APEX ® 30M
OPERATION
The warning screen allows the user the chance to review what is being deleted. The warning screen shows
the level of access and the user code. In this instance
it is USER: 1000. If this User Code had Supervisory
access the screen would read, SUPERVISOR: 1000.
Once you have chosen the appropriate User code and
level of access then select OK.
Reset will change characters back to “0000”.
Deleting Users
Press the Delete Selection Button after selecting a user
from the list.
FIGURE 38 - Multiple Users
If there are too many users to fit on the screen the last
box will contain ellipses, see FIGURE 38 - Multiple
Users. This indicates that there are additional system
users. At the bottom of the fields it will tell how many
user codes are currently listed in the system.
Changing User Access
Deleting a user account will bring up a warning screen.
Press the Detail Selection button to see more information about the shown screen.
To change the level of access that a user has been
granted press the ADD selection button. Instead of entering a unique user code add in the existing user code
that needs to be changed.
With “Level” highlighted choose the new access level.
B-26
APEX ® 30M
OPERATION
Increments Settings
Log Out
To change users press the Logout Selection button.
This logs out the current user so that a new user can
log in.
The increments screen, see FIGURE 40 - Increments
Screen is used to set how much a single button press
will change each value and limit the operator’s access
to certain parameters.
The minimum and maximum values provided to the
user are based on welding power source, weld mode,
wire diameter and other items.
The increments that can be set are:
Increment Options
•
•
•
•
•
•
•
Wire Feed Speed
Amperage
Voltage
Travel Speed
Oscillation Width
Oscillation Speed
Dwell Time
Note: If the new user code is set as an operator
they may not have full access to the system settings. Be sure to always have at least one operator
code at all times for full system access.
Each of these values can have a minimum and maximum value set that the operator will not be able to exceed. These increments can be changed per program
and per pass.
Operator Log In
To reset all increments back to their widest tolerance
press the Reset Selection button.
When an operator logs into the pendant they are presented with program screen, see FIGURE 39 - Operator Log In.
In addition to limits the operator has the ability to set
the system units between Imperial to Metric.
FIGURE 39 - Operator Log In
FIGURE 40 - Increments Screen
Since operators cannot save or create programs, they
are presented with the program options available to
them. They can select only these programs.
See FIGURE 41 - Increments Reference for a list of
the different values for imperial and metric.
When entering setup mode operators are automatically
brought to the Programs Screen.
B-27
APEX ® 30M
OPERATION
Increments quick reference document
Refer to FIGURE 41 - Increments Reference for a
complete list of increment values for both imperial and
metric measurements.
Setup Name
Screen
Value
Imperial
Increments
Value Name
Metric Increments
Increments & Limits Menu
Wire Speed
ipm
cm/min
Amperage
Amps
Amps
Voltage*
Volts
Volts
ipm
cm/min
Oscillation Width
Inches
Centimeters
Oscillation Speed
ipm
cm/min
Oscillation Dwell
Seconds
Seconds
Travel Speed
Start Settings Menu
Preflow
Seconds
Seconds
Upslope
Seconds
Seconds
Runin Wire Feed Speed
ipm
cm/min
Runin Voltage
Volts
Volts
Motion Delay
Seconds
Seconds
End Settings Menu
Crater Wire Feed Speed
ipm
cm/min
Volts
Volts
Crater Time
Seconds
Seconds
Burnback
Seconds
Seconds
Downslope
Seconds
Seconds
Postflow
Seconds
Seconds
Crater Voltage
Process Setup Menu
Wire Feed Speed
ipm
cm/min
Voltage*
Volts
Volts
Amperage
Amps
Amps
ipm
cm/min
Travel Speed
Process Setup Menu (Continued)
Oscillation Width
Oscillation Speed
Inches
Centimeters
ipm
cm/min
Left Dwell
Seconds
Seconds
Right Dwell
Seconds
Seconds
FIGURE 41 - Increments Reference
B-28
APEX ® 30M
OPERATION
Programs
From the program screen, see FIGURE 42 - Program
Screen, programs can be saved into the system or
onto a usb memory stick.
Fast Movement
Fast movement using the steering knob is enabled
on this screen. Use the steering knob or left and right
toggles for navigation and selection.
FIGURE 42 - Program Screen
Once the location and level are set choose a unique name
for the program. This name should be distinct to prevent
confusion.
Saving an Independent Pass
By going to the different system settings pages the supervisor can change the parameters of the loaded program.
Once these parameters have changed they can be saved
as a new program.
Saving to a USB limits the program to 8 characters.
The “name” field always auto populates with the name for
the currently loaded program. Change this independent
pass to “New Program 01” and press the OK Selection
button.
Pressing the save selection button will take the user to a
sub menu. This menu will allow the user to set
Location: Selects where the program is saved
• Local: This saves directly to the Pendant
• USB: This saves to the installed USB. This option only
appears when a USB is plugged in.
Level: Selects what type of Program is being saved
• Independent Pass: stand alone weld procedures, not
tied to any other program
• Program Base: The first step in creating a multiple
passes which tie together to form a full welding procedure; this is explained in the next section.
• Program Pass; These are tied to the Program Base and
can be created as needed by the user. For example a
pipe could require four passes, so each pass could be
saved under a Program Base for easy retrieval
Pass Name: Allows the user to select a unique pass
name to identify the pass or program.
FIGURE 43 - New Independent Pass
A new independent pass is created with the selected
name.
B-29
APEX ® 30M
OPERATION
Saving a Program Base
Saving a Program Pass
In the save program sub menu change the level from
Independent Pass to Program Base
A new options is now available, “Program Pass”. With
Program Pass selected it will allow the user to choose
which “Base” to save to. Choose the appropriate base.
Independent passes work for single pass welds. For
instance if the system is only going to be performing
the root pass then an independent pass is ideal. If
there are multiple passes on the same material then it
is better to set up a Program Base.
Change the name of the base to something easily remembered for the operator. Descriptions of the material and size may be helpful.
With a program base saved it is necessary to create individual passes within the Program Base for the
settings to be saved. Press the Save Selection button
again.
For this example the pass has been named “Root”
FIGURE 45 - New Base Pass: Root
FIGURE 44 - New Program Base
Continue to save programs to this base until the required passes are all saved.
B-30
APEX ® 30M
OPERATION
For this example we will save three passes, a Root, Fill
and Cap Pass.
After saving the required passes they are all displayed
under the base, see FIGURE 46 - Full Program Base.
FIGURE 47 - USB Folder Notification
Pressing “Ok” will create the folder in the USB. To access files already saved on the USB move them to the
specified directory.
FIGURE 46 - Full Program Base
Hide Program Passes
The passes in a program base can be hidden by highlighting the program base and pressing the steering
knob once, this collapses the group. Press again to
expand.
Note: USB File save is restricted to 8 characters.
Local files can be up to 16 characters.
Note: The only program named not allowed is
“Lincoln”
Saving to a USB
All of the examples shown have been saved locally to
the pendant, they can also be saved to a USB.
The USB is required to have a specific folder to save
or read files. If this folder is missing then a prompt will
appear on the screen, see FIGURE 47 - USB Folder
Notification. If this is a new flash drive the system will
create the required folder.
B-31
APEX ® 30M
OPERATION
Copy to/from USB
Deleting a Program
With the USB inserted a Copy Icon appears in bottom
left of the screen see, FIGURE 48 - Copy Icon.
Saved programs can be deleted by highlighting the program and pressing the Delete Selection button. This
will bring up a new window, see FIGURE 50 - Program
Delete.
Press the Copy Selection Button
Press the Delete Selection Button.
FIGURE 48 - Copy Icon
FIGURE 50 - Program Delete
A copy of the selected program is made, see FIGURE
49 - Copy to USB.
Deleting a Program Base
If a Program Base is deleted then all associated passes
are also deleted.
FIGURE 49 - Copy to USB
If the file is currently saved on the USB it will save to
the Pendant, if it is a Local file (saved to the pendant)
then it will save to USB as shown in FIGURE 49 - Copy
to USB.
Note: If a locally saved program has more than 8 characters then copying to the USB will truncate the name
to the first 8 characters. To save with a unique name
load the program and then manually save to the USB
with the desired 8 character name.
B-32
APEX ® 30M
OPERATION
Loading a Program
Once a program is saved, or when starting the system
you can go into the Programs menu and load the desired program. Simply highlight the desired program or
base and press the Load Selection button.
Press the Load Selection button.
Overwriting a Program
If you attempt to save a file with the same name you
will overwrite the existing program. The system will
give you a warning asking if you are sure you want to
overwrite the existing program. Overwriting will delete
the original program.
FIGURE 52 - Program Select
This will load the desired program, see FIGURE 51 Loaded Program.
FIGURE 51 - Loaded Program
B-33
APEX ® 30M
OPERATION
Operator Views
Supervisors will have access to all levels of the system,
however the system is designed to lock out operators
from higher level functions at the supervisors discretion.
Log In Screen
Operators have access to a limited number of
screens. The following flow chart provides a
reference of all the screens available, how to
get to them and navigate back.
Setup Screen
1
ENTER
1. After logging in the operator can choose any
existing program to load.
2. The loaded program will move into the idle
screen in test mode.
3. Return to the setup screen by pressing the
Setup Selection button.
4. Move into Active Test to verify all weld
settings, or Active Weld to begin welding.
LOAD
2
Idle Screen
4
Active Weld Screen
START/
STOP
BUTTON
ADV
5
3
Advanced Process
SETUP
LONG PRESS MENU BUTTONS
Oscillation
Jog Screen
6
EXIT
MENU
BUTTONS
5. While actively welding or testing the
operator can access process specific
items.
SWAP
7
EXIT
Travel Setup
6. From the idle screen long pressing the
menu buttons will take the operator to
the corresponding Jog or Oscillation
menu. Use the menu buttons to
switch between the two menus.
7. It may be necessary to change the tractor orientation. This allows the user
to set how the tractor steers and operates in relation to their position.
Pressing exit from any screen will return the operator to the previous menu.
Refer to the operators manual for more detailed operating instructions.
EXIT
FIGURE 53 - Operator Navigation Chart
B-34
APEX ® 30M
OPERATION
Operator Pendant
The Apex systems allow for the addition of an Operator Pendant. This pendant is a more rugged and
simple version of the standard pendant. Not every user
needs access to the wide range of welding and system
parameters that can be accessed by a supervisor, to
accommodate this an operator pendant was created
with limited functionality.
1
2
3
Like the standard pendant the operator pendant uses
colors for quick reference. White Icons are Weld/Test
Icons, while Gray icons are Idle Icons.
4
The operator pendant operates in three modes.
• Weld Mode
• Jog Mode
• Test Mode
5
The various buttons and knobs on the pendant will
change based on which mode the system is in. Weld
and Jog modes are both accessible from the Operator
Pendant. To get into and out of test mode will require
the use of the standard pendant.
Weld Mode
6
8
These settings are available when the system is welding.
7
9
1. Reset - Pressing will reset the system
10
2. Sector/Pass - Will move to the next sector when a
multi-sector program is loaded
3. Display - Displays current sector
4. Steering Knob - Manually steer torch
5. Oscillation/Gas - Adjusts the oscillation width
FIGURE 54 - Operator Pendant Buttons
6. Status - Status LED should show solid green
7. Travel - Adjusts travel speed
8. Amps/Torch Height - Adjusts amperage, or if the
auto height is turned off it will manually adjust
the torch height
9. Trim Volts/Wire Feed - Adjusts trim or voltage
depending on the selected process
10. Start/Stop - Stops the weld.
B-35
APEX ® 30M
OPERATION
Idle Mode
Operator Pendant Cable
These settings are available when the system is idle.
Operator pendants can be used with various size
arclink cables. These Arclink cables can be linked together to form longer or different sizes other than those
shown.
1. Reset - Pressing will reset the system
2. Sector/Pass - Will move to the next pass when a
multi-pass program is loaded
• K1543-8
• K1543-25
• K1543-50
• K1543-100
3. Display - Displays current pass
4. Steering Knob - Manually steer torch
• Short Press - Centers torch
• Long Press - Begins oscillation test
Arclink T Connector
8. Amps/Torch Height - Adjusts height up or down
and will ramp speed*
An Arclink T Connector (K2429-1) can be used to
aid in cable management. It is useful when only one
arclink cable needs to be extended from the control unit
instead of two. In this instance a 50’ Arclink cable could
be used to extend away from control unit. An Arclink
T connector and two 8’ Arclink cables could then be
connected to the end of the longer cable. This would
eliminate the need for two 50’ Arclink Cables. There
are many different configurations to save weight or
prevent inconvenience.
9. Trim Volts/Wire Feed - Feeds Wire and will ramps
speed*
Pendant Light
5. Oscillation/Gas - Purges gas
6. Status - S
ystem status LED
7. Travel - Adjusts travel speed
The operator pendant comes with a built in LED light
for inspecting welds.
10. Start/Stop - Starts the weld.
1. Light Switch - Pressing and hold to turn on light
Test Mode
These settings are available when the system is testing
in Test mode.
2. LED Light - Light used for inspecting welds
1. Reset - Pressing will reset the system
2. Sector/Pass - Will move to the next sector
3. Display - Displays current sector
4. Steering Knob - Manually steer torch
1
5. Oscillation/Gas - Adjusts the oscillation width
6. Status - S
ystem status LED
7. Travel - Adjusts travel speed
2
8. Amps/Torch Height - Adjusts height up or down.
Will ramp speeds*
9. Trim Volts/Wire Feed - No effect
10. Start/Stop - Starts or stops weld head movement
*Ramping speeds means that the system will start
off adjusting speeds slowly, and gradually move to
max speed
FIGURE 55 - Operator Pendant Back
B-36
APEX ® 30M
ACCESSORIES
Accessories
Common Contact Tips
Drive Roll & Wire Guide Kits
Description in (mm)
Description in (mm)
Part Number
Part Number
Standard Magnum Pro 550 Tip
Steel Wire Sizes (includes stainless steel):
0.035 (0.9)
KP1696-035S
0.035 (0.9) 550A Contact Tips
KP2745-035R
0.045 (1.2)
KP1696-045S
0.040 (1.0) 550A Contact Tips
KP2745-040R
0.052 (1.4)
KP1696-052S
0.045 (1.2) 550A Contact Tips
KP2745-045R
0.035, 0.045 (0.9, 1.2)
KP1696-1
0.052 (1.3) 550A Contact Tips
KP2745-052R
KP1696-2
1/16 (1.6) 550A Contact Tips
KP2745-116R
0.040 (1.0)
1/16 (1.6)
Tapered Tips*
KP1696-1/16S
0.035 (0.9) Contact Tips
Cored Wire Sizes:
0.035 (0.9)
KP1697-035C
0.040 (1.0) Contact Tips
0.040 - 0.045 (1.0 - 1.2)
KP1697-045C
0.045 (1.2) Contact Tips
0.052 (1.4)
KP1697-052C
0.052 (1.3) Contact Tips
1/16 (1.6)
KP1697-1/16C
1/16 (1.6) Contact Tips
Extended Length Tapered Tips
Mechanized Torches & Liners
Length ft. (m)
Description
Part Number
0.035 (0.9) Contact Tips
KP52108-035R
15 (4.6)
Mechanized Torch 15’
K52106-15
0.040 (1.0) Contact Tips
KP52108-040R
KP52108-045R
25 (7.6)
Mechanized Torch 25”
K52106-25
0.045 (1.2) Contact Tips
15 (4.6)
Wire Liner 0.035- 0.045 in
(0.9 - 1.14 mm)
KP45-3545-15
0.052 (1.3) Contact Tips
KP52108-052R
1/16 (1.6) Contact Tips
KP52108-116R
25 (7.6)
Wire Liner 0.035- 0.045 in
(0.9 - 1.14 mm)
KP45-3545-25
15 (4.6)
Wire Liner 0.052- 1/16 in
(1.3 - 1.6 mm)
KP45-116-15
25 (7.6)
Wire Liner 0.052- 1/16 in
(1.3 - 1.6 mm)
KP45-116-25
* Contact customer service
ArcLink Control Cables/Extensions
Length ft. (m)
Description
Part Number
8 (2.5)
ArcLink Cable 8’
K1543-8
25 (7.6)
ArcLink Cable 25’
K1543-25
50 (15.2)
ArcLink Cable 50’
K1543-50
100 (30.4)
ArcLink Cable 100’
K1543-100
25 (7.6)
Heavy Duty ArcLink 25’
K2683-25
50 (15.2)
Heavy Duty ArcLink 50’
K2683-50
100 (30.4)
Heavy Duty ArcLink 100’
K2683-100
Extended Length
Tapered
Contact Tip
Teflon Spacer
Standard Slip-on
Torch Components
Description in (mm)
Part Number
Gas Diffuser, Thread-on
KP2747-1
Teflon Spacer, Std Slip-on
KP52144-1
Teflon Spacer, Self Shielding
KP52162-1
Gas Nozzle, Thread-on 1/8 (3.2) Recessed
KP2743-1-62R
Gas Nozzle, Thread-on Flush
KP2743-1-62F
Gas Nozzle, Thread-on 1/8 (3.2) Stick Out
KP2743-1-62S
Bottleneck Gas Nozzle, Recessed
KP3161-1-62R
Bottleneck Gas Nozzle, Flush
KP3161-1-62F
Bottleneck Gas Nozzle, Stick Out
KP3161-1-62S
Magnum Pro 550A
Contact Tip
Gas Nozzle
for 550A
Thread-on
1/8 in. (3.2 mm)
Recessed
C-1
Tapered
Contact Tip
Teflon Spacer
for Self Shielded
Threaded
Bottleneck Gas
Nozzle for 550A
Thread-on
1/8 in. (3.2 mm)
Recessed
Gas Diffuser
for 550A
Thread-on
APEX ® 30M
MAINTENANCE
Maintenance
Semi Annually
The APEX® 30M Control System is designed for
• Based on a 40 hour work week it is recommended
trouble free operation and normally requires minimal
that the belts be replaced every six months.
preventive care and cleaning. This section provides
• Verify that all motors are working correctly without
instructions for maintaining user serviceable items.
strain. Listen to the motor to verify that there is no
The suggested repair procedure for all such items is
excess noise or grinding.
to remove and replace defective assemblies or parts.
When users and/or service personnel are not familiar
with electrical and electronic equipment, the product
should be returned to the factory or serviced by factory
authorized representatives.
Maintenance Schedule
The maintenance schedule is suggested as a guideline
for proper system maintenance. More stringent maintenance requirements may be required depending on
the work being performed and the requirements of the
customer for whom the work is performed. All maintenance schedules are based on a 40 hour work week.
Any excess play in parts or equipment should be
noted and reported to an authorized repair facility. Any
anomalous activity, such as motor hesitation, clicking
or other noises, or anything out of the ordinary should
be noted and reported to an authorized repair facility.
Every Shift
• Check lines, cables, and drive belts for loose connections and worn areas.
• Change out consumables as needed.
• Check torch height, oscillation and travel for slop or
wearing parts.
NOTE: Do not force the Oscillator in or out while
checking for worn parts.
• Inspect torch cable for wear or damage.
Monthly
• With the clutch latch and clamp latch engaged grab
the weld head by the handles and gently move back
and forth to check for excess play in the weld head
along the track.
• Release the clutch latch and verify that the weld
head moves smoothly along the track without rubbing or binding.
• Examine all cable connections to verify that there are
no gas leaks, and that all cables are seated correctly
and that there is no visible wear and tear to any connector or associated cables.
• Check over the all weld head components for any
signs of damage or wearing.
• Ensure track ring gears and weld head gears are
clean and clear of debris.
• Check for wear of drive wheels on wire feeder.
D-1
APEX ® 30M
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
USING THE STATUS LED TO TROUBLESHOOT
SYSTEM PROBLEMS
The APEX System is equipped with Status Lights. If a problem
occurs it is important to note the condition of the status lights.
Therefore, prior to cycling power to the system, check the power
source status light for error sequences as noted below.
Included in this section is information about the power source and
Wire Drive Module Status LED’s, and some basic troubleshooting
charts for both machine and weld performance.
The STATUS LIGHTS are dual-color LED’s that indicate system
errors. Normal operation for each is steady green. Error conditions are
indicated in the following table E.1.
TABLE E.1
Meaning
Light
Condition
Steady Green
System OK. Power source is operational, and is communicating normally with all healthy
peripheral equipment connected to its ArcLink network.
Blinking Green
Occurs during power up or a system reset, and indicates the POWER
WAVE® is mapping (identifying) each component in the system. Normal for
first 1-60 seconds after power is turned on, or if the system configuration is
changed during operation.
Fast Blinking Green
Under normal conditions indicates Auto-mapping has failed.
Also used by the Weld Manager Utility (included on the POWER WAVE®
Submerged Arc Utilities and Service Navigator CDs or available at www.powerwavesoftware.com to identify the selected machine when connecting to a
specific IP address.
Alternating Green and Red
Non-recoverable system fault. If the Status lights are flashing any combination
of red and green, errors are present.
Read the error code(s) before the
machine is turned off.
Error Code interpretation through the Status light is detailed in the Service
Manual. Individual code digits are flashed in red with a long pause between
digits. If more than one code is present, the codes will be separated by a
green light. Only active error conditions are accessible through the Status
Light.
Error codes can also be retrieved with the Weld Manager Utility (included on
the POWER WAVE® Submerged Arc Utilities and Service Navigator CDs or
available at www.powerwavesoftware.com. This is the preferred method,
since it can access historical information contained in the error log.
To clear the active error(s), turn power source off, and back on to reset.
Steady Red
Not applicable.
Blinking Red
Not applicable.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-2
APEX ® 30M
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
List of Error Codes for Troubleshooting
Error ID
Description
Potential Solution
5-3-1
Weld Head network not recognized by
controller. Weld Head has no power.
Check to make sure the Weld Head cable is plugged in and
that the APEX 3000 controller has power via 110v aux connector (if applicable). Cycle power to Power Wave.
5-3-3
Communication with oscillation motor
has halted.
Check Weld Head cable for potential bad connections.
Cycle power.
5-3-4
Communication with height motor has
halted.
Check Weld Head cable for potential bad connections.
Cycle power.
5-3-5
Communication with travel motor has
halted.
Check Weld Head cable for potential bad connections.
Cycle power.
5-3-6
Calibrated fault with oscillation
5-3-7
5-3-9
Calibration fault with height
Wire drive timeout
“Other”
Check weld head cable and cycle power.
Check weld head cable and cycle power.
Check weld head cable and cycle power.
Cycle power.
5-4-1
Oscillation motor following error
Check for resistance on the torch arm. Oscillation speeds
too high.
5-4-2
Oscillation motor overcurrent
Check power supplies, cycle power. Clear any resistance/
debris from track and the weld head arm.
5-4-3
Oscillation motor overheat
Check welding conditions. Turn off power for 5 minutes.
5-4-4
Oscillation communications fault
Check Weld Head cable and make sure no extra power/
noise is being discharged into the Weld Head.
5-4-5
Oscillation communications off
Check Weld Head cable and make sure no extra power/
noise is being discharged into the Weld Head.
5-4-6
Oscillation was moved passed programmed limit
Recalibrate the system/cycle power. Make sure Weld Head
arm moves all the way in and you have full range of movement.
5-4-7
Oscillation motor overvoltage
Check power supplies, cycle power. Clear any resistance/
debris from track and the weld head arm.
5-4-8
Oscillation motor position sensor error
Cycle power. Make sure internal motor controller wire harnesses and connectors are secure.
5-4-9
Oscillation fault unknown
Check all of the above items. Cycle Power. Contact Arc
Products.
5-5-1
Height motor following error
Check for resistance on the torch arm. Height movement
speeds too high.
5-5-2
Height motor overcurrent
Check power supplies, cycle power. Clear any resistance/
debris from track and the weld head arm.
5-5-3
Height motor overheat
Check welding conditions. Turn off power for 5 minutes.
5-5-4
Height communications fault
Check Weld Head cable and make sure no extra power/
noise is being discharged into the Weld Head.
5-5-5
Height communications off
Check Weld Head cable and make sure no extra power/
noise is being discharged into the Weld Head.
5-5-6
Height was moved passed programmed
limit
Recalibrate the system/cycle power. Make sure Weld Head
arm moves all the way in and you have full range of movement. Check Setup
5-5-7
Height motor overvoltage
Check power supplies, cycle power. Clear any resistance/
debris from track and the weld head arm.
5-5-8
Height motor position sensor error
Cycle power. Make sure internal motor controller wire harnesses and connectors are secure.
5-3-8
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-3
APEX ® 30M
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
5-5-9
Height fault unknown
Check all of the above items. Cycle Power. Contact Arc
Products.
5-6-1
Travel motor following error
Check for resistance on the torch arm. Travel speeds too
high.
5-6-2
Travel motor overcurrent
Check power supplies, cycle power. Clear any resistance/
debris from track and the weld head arm.
5-6-3
Travel motor overheat
Check welding conditions. Turn off power for 5 minutes.
5-6-4
Travel communications fault
Check Weld Head cable and make sure no extra power/
noise is being discharged into the Weld Head.
5-6-5
Travel communications off
Check Weld Head cable and make sure no extra power/
noise is being discharged into the Weld Head.
5-6-6
Travel was moved passed programmed
limit
Recalibrate the system/cycle power. Make sure you can jog
travel along your track.
5-6-7
Travel motor overvoltage
Check power supplies, cycle power. Clear any resistance/
debris from track and the weld head arm.
5-6-8
Travel motor position sensor error
Cycle power. Make sure internal motor controller wire harnesses and connectors are secure.
5-6-9
Travel fault unknown
Check all of the above items. Cycle Power. Contact Arc
Products.
6-3-3-1
Unstable or “noisy” WFS feedback signal
Check the cables and connections. Cycle power.
8-1
Motor Overload (Long Term)
Check the electrode feeds easily through feed system.
Verify the wire reel bracket is not too tight. Verify quality of
electrode.
8-2
Motor Overload (Short Term)
Check that motor can turn freely when idle arm is open.
Check gears for dirt and debris. Check all items for error
8.1.
8-3
Shutdown #1 is open
Contact Arc Products.
8-4
Shutdown #2 is open
Contact Arc Products
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-4
APEX ® 30M
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
Auto height does not operate / operates incorrectly.
1. Check WFS/Amps
2. Check ACC is on.
3. Check wire.
Travel hesitates or does not work.
1. Check clutch latch to ensure it is
engaged (locked).
2. Check all cable connections.
Travel is inconsistent.
1. Check gear contact and lever.
2. Check travel settings.
No oscillation / inconsistent oscillation.
1. Check all cable connections.
2. Check oscillator settings on jog
screen.
3. Check bellows for free movement.
3. Check oscillator belt.
Wire does not feed properly.
1. Check drive rolls
2. Check wire feed for blockage.
3. Check contact tip.
4. Check for kinks or obstructions in
the torch or wire liner.
Gas issues
1. Verify gas is turned on.
2. Verify there is gas present in the
tank.
3. Check the gas line for kinks or
obstructions.
Tractor drags on work surface
1. Check that the shoes are all
equally spaced around the track.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misjudgment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Services Facility
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
F-1
A
B
C
D
E
F
G
H
J
K
L
M
E
D
C
B
A
E
D
C
B
A
E
D
C
B
C3
C2
3024J
3024K
3024L
3024M
AL Status
CASE
CASE
4700pf
3000V
1
2
1
2
8516
BLK
WHT
8515
3032
BLK
WHT
3031
Motion Controls Status
Receptacle Plug
4700pf
3000V
3025A
3025B
3024C
3024D
813B
814B
67B
812B
811B
813B
814B
67B
812B
811B
8512
8501
21
67Y
3055
3056
3057
3058
3058
811B
812B
813B
814B
811B
812B
813B
814B
1
2
3
4
1
2
3
4
1
2
3
4
5
CON1
CON3
CON2
S31042-1B0
CON4
541E
542E
500E
540E
1
2
3
4
1
2
3
4
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
F-Faston
CON1
3024F
X
CON12
CON11
CON14
541E
542E
500E
540E
541E
542E
500E
540E
CON13
CON4
S31010-1B0
CON3
CON6
4
3
2
1
CON7
4
3
2
1
CON8
3032 BLK
3031
WHT
M24377-1A0
CON5
CON3
CON4
CON1
CON2
1
2
3
4
1
2
3
4
4
3
2
1
2
1
Bus Bar
67Z
541E
542E
500E
540E
541E
542E
500E
540E
3025B
3025A
3042
3041
+
-
541E
542E
500E
540E
541E
542E
500E
540E
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
4
1
2
3
4
J83
J84
J82
J81
X
X
F-Bullet M-Bullet
X
X
M-Bullet F-Bullet
X
Plug
1
2
3
4
24V PSU
J85
J88
3024Z
3024Y
3024X
*3RD wire may not exist
G6752-1B0
Output
Output
+
Input
Input
-
M-Bullet F-Bullet
X
8301
8302
8303
8304
8401
8402
8403
8404
8405
8406
+
Receptacle
3024Z
1
3024Y
2
3
4
3024
3024F
+
M-Faston F-Faston
-
+
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
2
1
X
X
J1
X
F-Faston
J2
X
M-Faston
M19540-3
M-Bullet F-Bullet
67B
67
67A
8514
8513
541E
542E
500E
540E
4700pf
3000V
541E
542E
500E
540E
8304
8303
Ring
Rec
8505
1
8506
2
8508
3
CHS
4
X
X
Motor
Plug
WHT
1
2
Plug
3
Receptacle
4
1
2
3
4
5
6
7
8
Ring
Ring
J800
TACH INTERFACE BOARD
J801
Tach Leads
F-Faston
BLU
X
Plug
F-Faston
8505 RED
1
X
8506 F-Faston
2
GRY
8508
3
X
CHS F-Faston
4
*Toroid Not Shown
8401
8402
8403
8404
8405
8406
1
2
3
4
Work Sense Output
E
D
C
B
A
Gas Solenoid
F-Faston
21
500E
540E
67
542E
Arclink Input
Circuit Breaker
541E
F-Faston
+
+
F-Faston
Wire Drive Sub-Assembly
Rec Plug
67Z
6
6
X
67A F-Faston
5
5
67Y
4
4
X
F-Faston
3
3
2
2
X
CHS F-Faston
CHS
1
1
C1
1
2
3
4
Receptacle
CASE
Rec
BLK 8301
1
8302
2
WHT
3
4
Ring
CASE
1
2
3
4
Plug
3024F
3024
CASE FAN
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
Tractor Control Output
Arclink Output
Arclink Output
Trigger
Work Sense Input
A
1
2
3
4
1
2
3
4
5
3041
3042
3043
3044
1
2
3
4
1
2
1
2
Electrode Sense Input
USB A Female
Pole 2
Pole 1
J2
X
CON5
1
2
3
4
J1
3024Z
STOP SW NC
J3
G7417-1C0
3024Y
+
8516
8515
8514
8513
8512
F-Faston M-Faston
8508
F-Faston M-Faston
8506
8505
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
8501
3044
500E
500E
500E
3044
3043
540E
540E
WHT
BLK
1
2
3
4
5
6
7
8
537
CON2
F-Faston
534
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
RED
3055
3056
3057
3058
3024C
3024K
3024J
3024D
3024L
3024M
BLK
BLU
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
G-2
535
531
Diagrams
1
2
3
4
5
6
7
8
1
2
3
4
5
APEX ® 30M
DIAGRAMS
APEX ® 30M
DIAGRAMS
CO N3
301
303
1
3
7
8
9
10
E ST OP
3011
3012
CO N2
1
2
3005
3003
814B
5
4
2
6
PE NDA NT UI
M24325
INSIDE VIEW OF TOP PANEL
307
308
309
3010
Panel Mini A rc L ink
CO N7
811B
812B
814B
813B
1
2
3
4
CO N5
A
B
C
E
D
F
3011
3012
1
2
3
4
Micro Fit Cable Plug Micro Fit Cable Receptacle
1
2
3
4
Bl ue T op
Red Center
Bl ack Bottom
T op Bl ue
Center Red
Bottom Bl ack
PE NDA NT I/O
M24328
User
Ri ght Switch
1
2
3
4
User
L eft Switch
1
2
3
4
Micro Fit Cable Plug
Micro Fit Cable Receptacle
1
2
3
4
3091
1
3092
2
3093
3
3096
6
3095
5
3094
4
CO N3
3005
3003
814B
1
2
3
4
301
303
1
2
307
308
309
3010
3
4
5
6
CO N2
CO N4
Standard Pendant Wiring Diagram
HA L T SWIT CH
3066
3062
1 (NC)
2 (NC)
3 (NO)
4 (NO)
0
0
3072
3080
PRO GRA M SWIT CH
CO N2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3061
3062
3063
3064
3065
3066
CO N1
L IG HT SWIT CH
3063
T OGGL E SWIT CH
T RA V E L
3083
CE NT E R
3082
BO T T OM CON
0
3065
T OP CON
L E D LA MP
+
-
CE NT E R
BO T T OM CON
FL AT SIDE OF L ED ON SIDE OF BL AC K WIRE
541E
542E
500E
540E
0
T OGGL E SWIT CH
V OL T A GE
T OP CON
3085
3084
CE NT E R
BO T T OM CON
3086
T OGGL E SWIT CH
T ORCH HE IG HT
3079
RE CE PT A CL E
1
2
3
4
PL UG
1
2
3
4
541E
542E
500E
540E
T OP CON
CE NT E R
BO T T OM CON
4700pf
3000V
3071
541E
542E
500E
540E
GND
ST A RT /ST OP
E
3078
0
C
3076
MA L E
0
A RCL IN K STA T US LE D
3061
3077
3081
T OP CON
FE MA L E
T OGGL E SWIT CH
OSCIL L A T IO N
B
3074
0
CO N3
1
2
3
4
5
6
7
8
D
3075
0
3063SW
3064
3073
541E
542E
500E
540E
1
2
3
4
A
3071
3072
3073
3074
3075
3076
3077
3078
3079
3080
3081
3082
3083
3084
3085
3086
A RCL IN K INPU T
0
0
Operator Pendant Wiring Diagram
Pendant Wiring Diagrams
G-3
APEX ® 30M
DIAGRAMS
16.57 Circle
14.33
8.13
11.00
14.33
25.34
K52160-1 Dimensions
G-4
APEX ® 30M
41.39
29.97
45.61
DIAGRAMS
K52165-1 Dimensions
G-5
APEX ® 30M
DIAGRAMS
16.57 Circle
14.33
8.13
11.00
14.33
25.34
K52160-1 Dimensions
G-6
GMAW Timing Diagram
G-7
OSCILLATION
SPEED
TORCH
HEIGHT
SPEED
TORCH
HEIGHT
POSITION
ON
RUNIN
WFS
RUNIN
VOLTS
OFF
OSCILLATION
POSITION
TRAVEL
SPEED
WIRE
FEED
SPEED
VOLTS
AMPS
GAS
PREFLOW
AR
ST
C
AR
ED
SS
RE
P
T
MOTION
DELAY
D
HE
LIS
B
TA
ES
OSC
WIDTH
UPSLOPE
STEP TRAVEL
DWELL
DOWNSLOPE
CRATER
TIME
BURNBACK
ED
SS
RE
P
OP
ST
POSTFLOW
CRATER
WFS
CRATER
VOLTS
TORCH
RETRACT
APEX ® 30M
DIAGRAMS
WARNING
AVISO DE
PRECAuCION
Spanish
l Do not touch electrically live parts or
l No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
l Aislese del trabajo y de la tierra.
French
l Ne laissez ni la peau ni des vête-
German
l Berühren Sie keine stromführenden
ATTENTION
WARNuNG
Portuguese
ATENÇÃO
Japanese
l Keep flammable materials away.
l Wear eye, ear and body protection.
l Mantenga el material combustible
l Protéjase los ojos, los oídos y el
electrode with skin or wet clothing.
l Insulate yourself from work and
ground.
ments mouillés entrer en contact
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
fuera del área de trabajo.
l Gardez à l’écart de tout matériel
inflammable.
l Entfernen Sie brennbarres Material!
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
l Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
l Isole-se da peça e terra.
cuerpo.
l Protégez vos yeux, vos oreilles et
votre corps.
l Tragen Sie Augen-, Ohren- und Kör-
perschutz!
l Mantenha inflamáveis bem guarda-
dos.
l Use proteção para a vista, ouvido e
corpo.
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
l Keep your head out of fumes.
l Use ventilation or exhaust to
l Turn power off before servicing.
l Do not operate with panel open or
guards off.
remove fumes from breathing zone.
l Los humos fuera de la zona de res-
piración.
l Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-
l Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
l Débranchez le courant avant l’entre-
tien.
teur pour ôter les fumées des zones
de travail.
l Vermeiden Sie das Einatmen von
Schweibrauch!
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para
remover fumo da zona respiratória.
l Strom vor Wartungsarbeiten
l No operar con panel abierto o
guardas quitadas.
l N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
l Anlage nie ohne Schutzgehäuse
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer
l Mantenha-se afastado das partes
serviço.
l Não toque as partes elétricas nuas.
moventes.
l Não opere com os paineis abertos
ou guardas removidas.
WARNING
AVISO DE
PRECAuCION
Spanish
French
ATTENTION
German
WARNuNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers
and to exceed their expectations. On occasion, purchasers may
ask Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position
to warrant or guarantee such advice, and assumes no liability,
with respect to such information or advice. We expressly disclaim
any warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also cannot assume
any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information or
advice create, expand or alter any warranty with respect to the sale of
our products.
Lincoln Electric is a responsive manufacturer, but the selection and
use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service
requirements.
Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.