APEX / HELIX WeldingMultiple Process Solutions

www.lincolnelectric.com/automated-solutions

Choose Your Process

Choose your process, between GTAW and GTAW.

Contact us and we can guide you through the process of choosing which system is right for you. We can evaluate what you do currently and what you will be doing in the future. This includes finding out if we can integrate your new equipment with some of your existing Lincoln Electric equipment.

Plan for the Future of your Business

Is this the last welding purchase you’ll ever make? Odds are it isn’t, and so we can help you plan ahead. Maybe the Apex 3000 with a TIG head is all you need, but if the needs of your business are always in flux we can assist with getting you the right equipment for right now, and help you come up with a plan for future upgrades. Our equipment can grow with your business.

K52101-1 Helix M85MIG & TIG Setup

K52160-1 APEX 30MK52102-1 APEX 3000

K4107-1 Vantage 520SDK2904-1 Power Wave S500

For best welding results with Lincoln Electric equipment, always use Lincoln Electric consumables. Visit www.lincolnelectric.com for more details.

C U S T O M E R A S S I S T A N C E P O L I C Y 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 information or advice about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is specifically disclaimed.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

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APEX / HELIX Welding Multiple Process Solutions

www.lincolnelectric.com/automated-solutions

Interchangeable Components

All components for both GTAW and GMAW are standard between the two processes. The HELIX M85 Weld head is a precision weld head which can be configured based on your needs. There are multiple off board wire feeding solutions for the GMAW process, as well as a on and off board feeders for GTAW processes. Only the welding components such welding torches would need to be changed. The main components: Controller, Weld Head Power Supply and Control Pendant all remain the same.

SYSTEM OPTIONS GMAW GTAW Combination GMAW/GTAW Hot Wire GTAW

BENEFITS Base equipment does not change

between processes ‘Upgrading’ to another process

doesn’t require a new capitol expense purchase

Precision system that is perfect for TIG welding with the speeds needed for MIG welding

Can be set up as: Orbital, Flat Track, or as a 1G welding solution

OPTIONS Multiple feed arms for feeling in

either direction Magnetic Arc Oscillation add on to

magnetically stir the puddle Featurekey software to secure weld

programs

TRAINING One system control with multiple

welding options Operators trained for one process

are already familiar with the controls Designed to be as similar as

possible between processes for intuitive input and control

Icon based controls for international deployment

One Platform, Multiple Solutions

The Apex 3000 Platform has always offered extremely precise welding controls for GMAW welding applications, but now Lincoln Electric has expanded the capabilities of the platform to allow for GTAW welding in both fixed and out of position applications. This process expansion is accomplished using the same standard equipment and controls.

Easily Switched

Customize the weld head as needed, to include a solution for welding both GTAW and GMAW. With this system setup the user can switch quickly back and forth by simply changing out one torch for the next.

K52101-1 TIG Setup Dual Wire Feed

K52101-1 MIG Setup 15’ Torch

Configurations

The system can be configured in a number of ways. The most common are the cart and mobile setup.

Cart Setup

The cart setup was the first release through Lincoln Electric. It consists of all of the components needed for welding together on a mobile cart. This type of setup is perfect for indoor welding in pipe and fab shops. The heavy duty cart was designed to withstand heavy abuse and to be lifted with a crane as needed.

Mobile Setup

The mobile setup is more designed for field welding, while still fitting the needs of indoor welding. Instead of a Controller and Wire Feeder as separate units they were combined together into the APEX 30M. The 30M has all the same functionality of the standard APEX 3000, with the addition of being more portable and offering an integrated wire delivery solution.

Additional Setups

There are many different ways that the APEX HELIX solution can be deployed. Many setups have employed a combination of the two example setups as well as completely stationary systems or partially stationary. Whatever your needs the equipment can be catered specifically to your particular situation.

GMAW SYSTEMThe GMAW welding system is digital welding solution for MIG, Flux Cored, and Innershield. All aspects of the weld are controlled by the weld head and saved into different programs and passes. While welding, the operator has the ability to make ‘on the fly’ corrections. These corrections can be set to a specific window by the welding engineer or supervisor.

Ease of use meets precision

The weld head is a quick release head that was designed around the user. It allows for tool-less installation and removal from the custom engineered track ring, as well was tool-less adjustment of the welding angles. The track ring works with a spring loaded gear driven motor system that propels the tractor while it smoothly moves along the edges of the ring. This promotes smooth travel without sacrificing the power of a geared solution. Specially engineered track rings and digital motors means that the operator is not required to do time consuming calibrations in between welding.

Options

Welding with all the options or limit them as required. The standard pendant allows for full control of the weld, to include locking out operator’s access, or use an even more rugged Operator Pendant that only allows access to the crucial weld settings as defined by the welding engineer.

BENEFITS Rugged design Multiple options Lightweight components Intuitive interface Save weld programs Repeatable welds High Quality

OPTIONAL WELDING COMPONENTS Operator Pendant (left) Advance Process Module STT Process Module 15’ or 25’ welding torch Multiple Pendant Cable Lengths Multiple Power Supply Options Custom Track Rings

K52147-1 Operator Pendant

Track Rings

Both the MIG an TIG options of the APEX/HELIX System use the same specifically engineered track rings.

These track rings come in sizes form 10” to 64” as standard sizes, with the option of a custom made track of any size larger than that. Since these track rings are engineered to exacting standards the system knows exactly how big the ring is, that is how it is able to allow for welding without calibration. Before welding you enter the track ring size and the size of the weld and you will get precise travel speeds at the arc. This is especially necessary in Nuclear and other such applications where weld procedures are very heavily monitored.

All standard track rings are hinged and open from the center. Two metal latches keep the track closed and can be pulled out when it is time to move the track.

Tracks are sized from 10 to 24 inches in two inch increments and then four inch increments from 28 to 64 inches. Each of these tracks have the option of adding in shoe extensions of 0.5, 1, 2, & 3 inches. This allows you to purchase a track sized for your primary weld diameter, and still be flexible to weld smaller sizes if necessary. Extension shoes can be stacked for sizes beyond 3 inches.

Additional Track Options

48“ Flat Track- these tracks can be bolted together to whatever length is required Inside Diameter Track Rings- For ID Welding on sizes greater than 30”Partial Tracks- After a certain size pipe using a track ring is neither cost effective or easy, partial tracks that go part way around the pipe can be used in the place of a full ringMagnetic Shoes- For both flat tracks and partial track rings, these magnetic shoes hold the ring on ferrous materials.

Sync Mode

The TIG process setup allows the customer the ability to sync the current to the Oscillation, Pulse, or to have a constant current. During setup it is possible to also set up Voltage, Wire Feed and Travel to the current. This is shown in the screen above.

TIG SCREENS

Modular Systems

Every application is different which is why is our systems were designed around a modular platform.

Benefits of a Modular Platform

Modularity means you can design the system around what you need. If the S500 PowerWave does not offer the duty cycle you require then you can move up to the S700. The APEX/HELIX platform can work off of any Arclink Enable Power Wave system, as well as any of the Arclink enabled tier 4 final Vantage engine drives. This modularity also means that we can help to eliminate redundancies in equipment. If you have an existing power wave S system then odds are that with a software update it will work with the Apex Helix system components.

TIG and MIG Controls

All inputs for the APEX / HELIX platform can be done through the main pendant (left). The pendant has a large, well-lit screen for use in low and direct light. In order to limit operator confusion very few buttons were used, relying on the program to only show options for the operator as needed. Primary inputs while welding are the dedicated steering knob in the center and the two paddles on either side.

Comparisons

Between the two processes, care was taken to keep the screen similar. The images to the right show how closely two of the screens mirror each other. The MIG screens are on the left, and the TIG screens are on the right. The welding Screen is nearly identical. The major change between the two was the need to for TIG welding to have different settings for peak and background.

Vantage Offers portability and is frequently

used in areas where power is not provided

Power Wave Offers the owner the ability to use

such tools as checkpoint and production monitoring.

Unlocks advanced processes

MIG SCREENSAPEX 30MControl and wire feed components have been combined together into the Apex 30M. Where there is welding there will always be a need for portability. Welding does not always happen in a convenient location so Lincoln Electric combined their existing, high quality weld system with wire feeding capabilities to allow for the same superior welds in remote locations. The Apex 30M, has the same functionality as the APEX 3000. They can be swapped out with one another - with the addition of an Autodrive 4R220. The biggest benefit of the Apex 30M is that it is less than 50 lbs with a convenient handle at the top, making it incredibly mobile.

The wire feed and connections are the same as those found in the Autodrive, but this all in one unit includes a wire spool and with the door closed keeps the wire spool clean and free from falling debris.

The front of the unit contains an extra Arclink connection. This allows the operator to use the operator pendant without needing a splitter.

WIRE FEED Best in class torque for reliable wire delivery High res tachometer for precise wire feed speed control Maxtrac heavy-duty aluminum drive system Replaceable brushes extend service life 4 Geared drive roll system Tool-less drive roll, wire guide and pressure arm adjustment

K52160-1 APEX 30M(Front and Side View)

Flux Cored Cap &Solid STT Root

APPLICATIONS Structural Maritime Power Generation Pipeline Process Construction

K52160-1 APEX 30M(Front and Side View)

APPLICATIONS Structural

BENEFITS High precision Common, easy to source consumables Stacks onto existing APEX / HELIX MIG

Equipment Common controls Unified interface

GTAW SYSTEMTIG capability has been added to the Apex 3000 Platform. Using the same base equipment used for MIG welding you can now achieve higher quality welds without the expense of purchasing a completely different system.

Why it’s Better

Part of the cost of ownership of any system is the training. This can be especially true with orbital equipment. The Apex 3000 platform was designed to be easy to learn and intuitive while operating. This idea has been taken to an entirely new level by adding the TIG process to the existing MIG operator screens. Anyone familiar with operating this system for either TIG or MIG can easily navigate through the screens thanks to an almost identical setup.

Precision

The Helix M85 has always been a precision weld head, which makes it the ideal platform for TIG welding. The weld head has a travel speed range of .1 to 100 IPM while the TIG Wire Feeder has a speed range of 1 to 500 ipm. This package provides high speeds while maintaining precision at lower speeds.

Options

The Apex / Helix platform offers multiple options between the MIG and TIG compo-nents, but this can really be seen with the TIG setup. There are multiple wire feed options, as well as the ability to choose between mechanical oscillation or magnetic oscillation.

Wire Feed

Wire feed can be set up in a variety of options depending on what is right for your particular setup. The Helix M85 as a standard head, comes with two handles on the sides for easy carrying. Each handle can be easily detached with four screws and be replaced with a wire feed arm that plugs directly into the back of the unit. As shown above depending on the needs of the user either wire feed or the other can be installed, or both can be used which adds the ability to weld both up and down a pipe with the same weld head.

Directarc

Lincoln Electric uses Directarc technology to magnetically stir the puddle with an optional probe add on. This probe induces an electrical current which will manipulate the welding arc to create a stirring motion that can be completely controlled by the welder to be as fast or slow as required. All controls are set through the existing pendant and do not require using an additional pendant or operator interface.

Hot Wire

TIG precision at near MIG speeds? By adding hot wire to the system you are able to achieve the speeds you need to dramatically increase productivity.

BENEFITS High precision Common, easy to s

St k t i ti

K52101-1 TIG Dual Torch Setup

K52101-1 Wire Feed 2

DirectArc Probe

Orbital TIG Weld on Titanium

K52101-1 Wire Feed 1

COMMON COMPONENTS Helix M85 Weld Head APEX 3000 Power Wave S500 CoolArc 55 Water Cooler TIG Torch Wire Feeder (Onboard or Offboard)

APPLICATIONS Nuclear Energy Thermal Energy Processing Pressure Vessels Contractors Pharmaceutical Power Generation

Feature Key

Customer Security: Ability to lock weld sets / wave formsAbility to lock welding programsUnlock equipment software features and capabilities

1G Welding

The APEX/ HELIX platform is not limited to Orbital welding, thanks to the precision offered by the control unit the system is ideal for flat track welding and can easily be adapted for welding in a 1G position. By keeping the weld head in a fixed position and rotating the pipe, the weld head can be used to precisely place and control the arc for high quality welds. This can be especially useful in pipe shops where orbital welds are only occasionally required and keeping both orbital equipment, and a dedicated orbital welder on hand are not cost effective. By using the APEX / HELIX platform in the 1G position, it be used every day by experienced welders, and when an orbital weld is required, instead of resorting to hand welding or renting an orbital unit, the weld head can be quickly removed from the 1G position and clamped around an orbital track.

1G welding is especially useful when welding with Hot Wire.

HOT WIRE WELDINGHot Wire Welding, especially with the addition of Magnetic Arc Oscillation might be the solution for bringing your company into a higher level of automation.

Equipment Required

Hot wire welding requires the addition of a few different items such as a power supply, advanced process module, weld power cables, , and Lincoln Electric’s feature key to unlock the correct weld modes. These and the other items do not need to be purchased with the original equipment, they can be added on later as required.

Why it’s better

Hot wire is able to dramatically increase the amount of material delivered to the weld joint, but in the past an operator would still be limited by the inability to get proper sidewall penetration. Magnetic Arc Oscillation helps to correct that by directing the arc into the sides of the joint.

Shown: Welding with the M85 TIG Head in a 1G SEtup