Lincoln Electric 12835 Operator'S Manual Download Page 1

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Operator’s Manual

APEX

30S CONTROL

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IM6125

| Issue D ate 02/19

For use with machines having Code Numbers:

12835

Need Help? In the USA and Canada, call
1.800.770.0063 to talk to a Service Representative.

Hours of Operation:
7:00 AM to 5:00 PM (PT) Mon. thru Fri.

After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.

For Service outside the USA and Canada, please call
1.619.628.1022 or e-mail us at:
[email protected]

Save for future reference

Date Purchased

Code: (ex: 12675)

Serial: (ex: U1060512345)

c/o Balmes, 89 - 8

08008 Barcelona

SPAIN

ORIGINAL INSTRUCTIONS

Summary of Contents for 12835

Page 1: ...all 1 800 770 0063 to talk to a Service Representative Hours of Operation 7 00 AM to 5 00 PM PT Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA and Canada please call 1 619 628 1022 or e mail us at orbitalsupport lincolnelectric com Save for future reference Da...

Page 2: ...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 ...

Page 3: ...om vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing eq...

Page 4: ... and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES CAN BE DANGEROUS 5 ...

Page 5: ...ossibility 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...

Page 6: ...onment is compatible This may require additional protection measures including h the time of day that welding or other activities are to be carried out 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 METHODS OF REDUCING EMISSIONS Mains Supp...

Page 7: ... System Cart B 2 Optional Modules B 2 Power Source B 3 Inverter Cart Top Bracket B 3 Lift Cart Top Bracket B 3 Cable Installation B 4 Cable List B 4 Inverter and Lift Cart Cable Installation B 5 Shielding Gas Connection B 6 Maintenance D 1 Maintenance Schedule D 1 Every Shift D 1 Monthly D 1 Using the Status LED to Troubleshoot System Problems F 1 Weld Head Status LED Error Codes F 2 Diagrams G 1 ...

Page 8: ... 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 36 1 16 4 Temperature Ranges Operating Temperature Range 32oF to 122oF 0oC 50oC Storage Temperature Range 22oF to 140oF 30oC 60oC A weighted emission sound pressure level less than 70 db A ...

Page 9: ...t by the cables 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 The system cart is designed for flat even surfaces Do no overload cart Operation Read entire manual before operatio...

Page 10: ...Front Panel Additionally the front of the control has a halt button two connections for pendants a weld head connector and a USB port Front Panel For all front panel connections see FIGURE 2 Front Panel 1 Halt Switch Removes power from the weld head pendant and any ArcLink device connected to the front of the 30S controller The system will remain off until the switch is rotated clockwise This swit...

Page 11: ...a standard APEX 30S Control the components are designed to be installed on the system cart in a specific order System Cart The system cart comes fully assembled when ordered as a part of a complete system If ordered separately it may require additional assembly Please refer to system cart assembly instructions for complete step by step instructions Optional Modules The optional modules are install...

Page 12: ...ack 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 handles removed earlier Secure the top bracket in place See FIGURE 4 on page B 2 Inverter Cart System Assembly Cart Top Bracket Lift Cart To affix the Power Wave power source in place attach the support bracket to the Power Wave ...

Page 13: ...routed separate from the weld cables This mini mizes the possibility of interference between the high currents flowing through the weld cables and the low level signals in the control cables ArcLink cables can be used to extend the pendant cable length Cable List 1 Pendant Cable Connects from the pendant to the control unit 2 Control Cable Connects from the weld head to the control unit 3 Torch As...

Page 14: ...B 5 INSTALLATION APEX 30S FIGURE 8 Inverter Cart System FIGURE 9 Lift Cart System 1 2 3 4 GAS 5 FACILITY POWER 5 7 1 2 3 4 GAS 6 FACILITY POWER 7 5 ...

Page 15: ...nform your gas supplier of this condition 3 Stand to one side away from the outlet and open the cyl inder 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 percent CO2 cylinder insert regulator adapter between regulator an...

Page 16: ...ine 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 hesitati...

Page 17: ...eral equipment connected to its ArcLink device network Blinking Green Occurs during power up or a system reset and indicates the Power Wave unit is mapped identifying each component in the system This is normal for the first 1 to 60 seconds after the power is turned on or if the system configuration is changed during operation Fast Blinking Green Under normal conditions it indicates that Auto mapp...

Page 18: ... 3 9 Other Cycle power 5 3 6 Calibrated fault with oscillation Check weld head cable and cycle power 5 3 7 Calibration fault with height Check weld head cable and cycle power 5 3 8 Wire drive timeout Check weld head cable and cycle power 5 3 9 Other 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 overcurr...

Page 19: ...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...

Page 20: ...Wire motor encoder issue Cycle power to the system and allow the system to recali brate Make sure you can jog wire in Jog mode 5 7 9 Wire fault unknown Check all of the above items Cycle Power Contact a Service Representative at 800 770 0063 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 throu...

Page 21: ... 3123D 3125D 3123D 3125D S32575 FAN 3123E 3125E S32585 3092A 3091B 3095A 3092A 3091B 3094B 3094B 3095A S32576 E D C B A BLK BLK WHT WHT 541E 542E 500E 540E M23389 541E 542E 500E 540E M23389 541E 542E 500E 540E M23682 500F 540F 500F 540F 500G 540G 24V 40V DIST PCB S31010 1 4700pf 3000V C3 541E 540E 500E 542E 1 2 Pole 1 1 2 Pole 2 STOP SW NC S32573 52C 3140 RED BLK 3140 A B C D E M23501 ARCLINK OUT ...

Page 22: ...G 2 DIAGRAMS APEX 30S APEX 30S Controller Dimensions ...

Page 23: ...G 3 SAFETY APEX 30S ...

Page 24: ...P 1 PARTS APEX 30S This parts list is provided as an informative guide only APEX 30S CONTROL PARTS MANUAL ...

Page 25: ...P 2 PARTS NOTE This Parts Manual is provided as an informative guide only When ordering parts always refer to the Lincoln Electric Parts List APEX 30S PARTS CODE 12835 FINAL ASSEMBLY 2 1 3 4 5 ...

Page 26: ...for any code numbers not listed Use the illustration of Sub Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine Sub Assembly Item Number 1 2 3 4 5 Case Top Assembly Front Panel Assembly Rear Panel Assembly Subpanel Assembly Base Assembly SUB ASSEMBLY PAGE NAME PAGE NO P 4 P 6 P 8 P 10 P 12 CODE NO 12835...

Page 27: ...This Parts Manual is provided as an informative guide only When ordering parts always refer to the Lincoln Electric Parts List APEX 30S CASE TOP ASSEMBLY 1 2 3 4 4 4 5 5 5 6 7 8 8 14 9 10 11 12 13 7 14 15 14 16 17 18 ...

Page 28: ...9 1 X 2 Front Mounting Bracket Assembly 9SS28458 2 X 3 Locking Bracket 9SS28375 2 X 4 Lock Washer 9SE106A 27 10 X 5 Hex Head Screw 9SCF000013 10 X 6 Roof 9SL12763 3 1 X 7 Case Side 9SM23613 2 X 8 Bracket 9SL15091 1 2 X 9 USB PC Board Assembly 9SS31189 1 X 10 Self Tapping Screw 9SS8025 80 4 X 11 Corner Cap 9SL13138 4 X 12 Plain Washer 9SS9262 182 12 X 13 Self Tapping Screw 9SS9225 100 12 X 14 Self ...

Page 29: ...PARTS NOTE This Parts Manual is provided as an informative guide only When ordering parts always refer to the Lincoln Electric Parts List APEX 30S FRONT PANEL ASSEMBLY 1 2 3 4 5 6 8 7 9 9 10 10 10 11 13 12 ...

Page 30: ... print FRONT PANEL ASSEMBLY ITEM DESCRIPTION PART NO QTY 1 1 Case Front 9SM23596 1 X 2 Front Decal 9SM23598 1 X 3 Led Lens 9SS23093 1 2 X 4 Led Retaining O Ring 9SS23094 1 2 X 5 USB Cable Cover 9SS31791 1 X 6 Connector 9ST14557 3 2 X 7 1 2 13HN 9SCF000027 2 X 8 Self Tapping Screw 9SS9225 99 8 X 9 Output Harness 9SM23501 2 X 10 4 40 Locknut Nylon Insert 9SS31350 17 12 X 11 USB Input Harness 9SS3046...

Page 31: ...8 PARTS NOTE This Parts Manual is provided as an informative guide only When ordering parts always refer to the Lincoln Electric Parts List APEX 30S REAR PANEL ASSEMBLY 1 2 3 4 5 6 7 8 12 9 10 11 13 14 14 ...

Page 32: ...SCRIPTION PART NO QTY 1 1 Case Rear 9SM23599 1 X 2 Rating Plate 9SM23615 1 X 3 Circuit Breaker 10A 9ST12287 20 1 X 4 Output Harness 9SM23684 1 X 5 4 40 Locknut Nylon Insert 9SS31350 17 4 X 6 Solenoid Valve 9SM17294 8 2 X 7 Plain Washer 9SS9262 149 2 X 8 Conduit Locknut 9ST14370 1 2 X 9 Arc Link Cable Asbly 9SM22438 1 X 10 Grommet 9ST9274 8 1 X 11 Sealing Boot 9SS22061 3 1 X 12 Rear Decal 9SM23601 ...

Page 33: ...P 10 PARTS NOTE This Parts Manual is provided as an informative guide only When ordering parts always refer to the Lincoln Electric Parts List APEX 30S SUBPANEL ASSEMBLY 1 2 3 4 5 6 4 4 6 7 8 3 ...

Page 34: ...ber called for in the model index Indicates a change in this print ITEM DESCRIPTION PART NO QTY 1 1 Subpanel 9SM23608 1 X 2 Self Tapping Screw 9SS9225 99 6 X 3 ArcLink Distribution Board 9SS31042 1 2 X 4 Self Tapping Screw 9SS8025 80 12 X 5 Can Open Bridge PCB Assembly 9SS31338 1 X 6 40V 24V Distribution Board 9SS31010 1 1 X 7 Power Supply 9SS31750 1 X 8 1 4 20 Locknut Nylon Insert 9ST9187 16 4 X ...

Page 35: ...TE This Parts Manual is provided as an informative guide only When ordering parts always refer to the Lincoln Electric Parts List APEX 30S BASE ASSEMBLY 1 2 3 4 5 6 7 8B 8A 8B 9 8C 3 3 3 2 10A 10B 11 12 13 14 15 16 ...

Page 36: ... 9SS9225 99 18 X 4 Lock Washer 9SE106A 27 4 X 5 Hex Head Screw 9SCF000013 4 X 6 Hose Clamp 9ST13777 8 8 X 7 Gas Hose 33 in 9ST10642 265 1 X 8 Gas Flow Sensor Includes K3338 1 2 X 8A Flow Sensor NSS 2 X 8B Hose Nipple Male 9ST14557 8 4 X 8C Pan Head Screw NSS 4 X 9 Flow Sensor Bracket 9SM23611 1 X 10 Fan Kit Includes 9SS32586 1 X 11 Fan NSS 1 X 12 Pan Head Screw NSS 4 X 13 Fan Bracket 9SM23609 1 X ...

Page 37: ...stomer 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 manufactur...

Page 38: ...stomer 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 manufactur...

Page 39: ...stomer 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 manufactur...

Page 40: ...stomer 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 manufactur...

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