Lincoln Electric APEX 3000 User manual

Operator’s Manual
APEX
®3000 CONTROL
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IM6118 | Issue Date 03/18
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
70310, 70313, 70316
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2
SAFETY
APEX ®3000
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser upon
receipt by the carrier. Consequently, Claims for material damaged in
shipment must be made by the purchaser against the transportation
company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built with
safety in mind. However, your overall safety can be increased by
proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you
act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to
avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use corrective lenses if necessary to
stay a reasonable distance away from
the arc.
READ and obey the Material Safety
Data Sheet (MSDS) 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.
1WARNING
CAUTION

3
SAFETY
APEX ®3000
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 repro-
ductive 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.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting and
maintenance work unless the maintenance
work requires it to be running.
1.b. Operate engines in open, well-ventilated areas
or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the
engine is running. Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing
on contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and
devices in position and in good repair. Keep
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS
MAY BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields
(EMF). Welding current creates EMF fields
around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY

4
SAFETY
APEX ®3000
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or
wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such
as floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage between
the two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect
your eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES CAN
BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the
fume. Use enough ventilation and/or exhaust at the arc to
keep fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) 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. In confined spaces or
in some circumstances, outdoors, a respirator
may be required. Additional precautions are also
required when welding on galvanized steel.
5.b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and your employer’s safety
practices. MSDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY

5
SAFETY
APEX ®3000
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 1235 Jefferson Davis
Highway, Arlington, VA 22202.
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 infor-
mation.
5
SAFETY
Welding Safety
Interactive Web Guide
for mobile devices

6
SAFETY
APEX ®3000
ELECTROMAGNETIC
COMPATIBILITY (EMC)
CONFORMANCE
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.
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.
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 electromagnetic screen enclosing the power source
and the work complete with associated input filters. In all cases electro-
magnetic disturbances must be reduced to the point where they are no longer
troublesome.
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
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:
a. other supply cables, control cables, signaling and telephone cables; above, below
and adjacent to the 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.
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 Supply
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.
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.
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.
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.
Screening and Shielding
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.
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic
Compatibility (EMC) product standard for arc welding equipment.”

TABLE OF CONTENTS
APEX ®3000
Technical Specications APEX® 3000 .....................................................................................................................A-1
Safety Precautions ..................................................................................................................................................A-1
Proper Handling ..................................................................................................................................................A-1
Operation.............................................................................................................................................................A-1
APEX® 3000 System..................................................................................................................................................B-1
Basic Information.................................................................................................................................................B-1
Front Panel...................................................................................................................................................B-1
Back Panel Connections..............................................................................................................................B-1
Wire Feeder Control Board ................................................................................................................................B-2
Wire Feeder Functions........................................................................................................................................B-2
Additional Info .............................................................................................................................................B-2
Maintenance..............................................................................................................................................................D-1
Maintenance Schedule........................................................................................................................................D-1
Every Shift....................................................................................................................................................D-1
Monthly.........................................................................................................................................................D-1
Using the Status LED to Troubleshoot System Problems...................................................................................F-1
List of Error Codes for Troubleshooting...............................................................................................................F-2
Cable Management ................................................................................................................... F-4
Diagrams ...................................................................................................................................................................G-1
APEX® 3000 PARTS MANUAL .................................................................................................................................P-1

A-1
INSTALLATIONAPEX ®3000
Technical Specications APEX® 3000
APEX®3000 Control Unit
Product Number
K52103-1
Input Power 40 VDC + 120 VAC
Rated Output 24V 9A
Input Current 5A AC / 9A DC
Dimensions L x W x H (in.) 7.35 X 13.85 X 24.4
Dimensions L x W x H (mm) 186.7 X 351.8 X 619.8
Net Weight lbs. (kg) 37.5 lbs. (17 kg)
Temperature Ranges
Operating Temperature Range
32F to 122F (0C - 60C)
Storage Temperature Range
-22F to 140F (-30C - 60C)
Safety Precautions
Read entire manual before installation or operation.
WARNING
Electric shock can kill
• Only qualied personnel
should perform this instal-
lation.
• 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 con-
nected to the welding system at the disconnect
switch or fuse box before working on the equip-
ment.
• Do not touch electrically hot parts.
• Always connect the power supply grounding lug
to a proper safety (Earth) ground.
Proper Handling
Do not attempt to pick up, move or manipulate the
control unit by the cables.
Always operate the control unit on stable, at and
level surfaces with the bottom or side rails facing the
ground. Unplug the control unit when not in use. Do
not place on wet ground or in puddles.
Operation
Read entire manual before operation.
Only operate while on rm level surface or attached to a
system cart.
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 begin-
ning to weld.
Refer to the individual system manuals for additional
instructions.

B-1
OPERATION
APEX ®3000
APEX® 3000 System
Basic Information
The APEX®3000 Control Unit (K52103-1) is part of
the APEX®3 Series family of controls. The control unit
enables the following welding process from the power
supply and optional advanced process modules which
include: GTAW, GMAW, Pulsed MIG, FCAW, and STT®.
All aspects of the welding process are synchronized
through the APEX®3000.
FIGURE 1 - APEX® 3000 Control Unit
The control unit works with ArcLink technology. This
technology allows all of the system components to
work together and communicate with the weld head
and other motion control components using the
CanOpen Protocol. Together these technologies allow
the system to be controlled digitally with less wires.
The status of the system can be monitored on the front
panel, see FIGURE 1 - APEX® 3000 Control Unit and
FIGURE 2 - APEX® 3000 Front Panel. Additionally,
the front of the control has a Reset button, pendant
and weld head connectors, and a USB port.
FIGURE 2 - APEX® 3000 Front Panel
Front Panel
For all front panel connections, see FIGURE 2 -
APEX® 3000 Front Panel.
1. USB - Welding programs and data can be saved
and loaded via the USB port.
2. Power Off - Allows operator to remove power from
the weld head and halt welding operation. The
weld head will remain off until switch is rotated
clockwise. This switch does not remove power from
the pendant or the welding power source.
3. Wire Feed Status - The wire feed status will show
green if the wire feed control board is operational.
4. Motion System Status - The Motion System
Status light (CANOpen Status) will be green if all
motion systems are operational.
5. Weld Head CONNECTOR - Connection from the
APEX®3000 to the weld head.
6. ArcLink CONNECTOR - One ArcLink Cable con-
nection for the pendant or other ArcLink devices.
FIGURE 3 - APEX® 3000 Back Panel
Back Panel Connections
For all back panel connections, see FIGURE 3 -
APEX® 3000 Back Panel.
1. Breaker, 5A - Will trip in overcurrent situations;
push to reset.
2. ArcLink In - The ArcLink connection from the
Power Wave or other ArcLink enabled device.
3. System Label - Contains part number,
serial number and code number of the machine.
4. 14 Pin CONNECTOR - Provides motor power,
tach feedback, solenoid drive and electrode sense
(wire # 67) between the APEX®3000 control unit
and the wire feeder.
5. External I/O CONNECTOR - Terminal Strip is for
making simple input signal connections for
the wire feeder for use external of the APEX®
Pendants; for example to have gas purge and
wire forward jog switches near the wire feed head,
See FIGURE 5 - External I/O CONNECTOR on
page B-2. The terminal strip is divided into three
groups: Shutdown, Trigger and Feed groups.

B-2
OPERATION
APEX ®3000
Wire Feeder Control Board
The APEX®3000 incorporates a wire feeder control
board to communicate with the wire feed drive head.
Wire Feeder Functions
Refer to FIGURE 4 - Wire Feeder Functions for the
different parts of the AutoDrive®.
1. Status LED - The status light is a two color LED.
Normal operation is steady green. Flashing green
or red/green indicates a system error. See the
troubleshooting section. Note: At power up of
the Power Wave system, the status light will flash
green for up to 60 seconds. This is normal and
indicates that the system is performing a self test
and mapping each component in the local ArcLink
system. The status lights will also flash green as
a result of a system reset or configuration change
during operation. When the status lights become
steady green, the system is ready for operation.
FIGURE 4 - Wire Feeder Functions
2. ArcLink Input CONNECTOR (5 Pin) - Receives
power and communication from the power source.
3. Wire Feeder CONNECTOR (14 Pin) - The wire
feed head receives power and motor speed volt-
ages through this connector and provides encoder
feedback to the wire feeder control board.
4. ArcLink Output CONNECTOR (5 Pin) - Provides
power and communication to a robotic controller.
5. External I/O CONNECTOR - Terminal Strip is for
making simple input signal connections for
the wire feeder for use external of the APEX®
Pendants; for example to have gas purge and
wire forward jog switches near the wire feed head,
See FIGURE 5 - External I/O CONNECTOR on
page B-2. The terminal strip is divided into three
groups: Shutdown, Trigger and Feed groups.
Additional Info
See 4R220 Wire Feeder Manual for specics on the
wire feeder.
All inputs for the terminal strip below use “normally
open” logic except the shut-down group. The shutdown
inputs use “normally closed” logic, and are always
enabled. Unused shut-downs must be tied to the +15V
supply for the shut-down group, e.g., Terminal 10 and
11, must be jumpered to Terminal 9 to operator normal-
ly. The APEX®3000 controllers are shipped from the
factory with jumpers installed on both shutdown inputs,
Terminal 9, 10, and 11 are jumpered.
FIGURE 5 - External I/O CONNECTOR

D-1
MAINTENANCE
APEX ®3000
Maintenance
The APEX®3000 Control System is designed for
trouble free operation and normally requires minimal
preventive care and cleaning. This section provides
instructions for maintaining user serviceable items.
The suggested repair procedure for all such items is
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 main-
tenance requirements may be required depending on
the work being performed and the requirements of the
customer for whom the work is performed. All main-
tenance 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 hoses for loose connections
and worn areas.

F-1
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
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.
CAUTION
APEX ®3000
Using the Status LED to Troubleshoot System Problems
The APEX®30M and Power Wave®is equipped with a Status Light. 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 Wave® power source and APEX®30M Status LEDs and a
basic troubleshooting chart for both the machine and the weld performance. The APEX®30M and Power Wave®
Status Lights are dual-color LEDs that indicate system errors. Normal operation for each is steady green. Error
conditions are indicated in FIGURE 6 - Status LED Light Conditions.
FIGURE 6 - Status LED Light Conditions
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
mapped (identifying) each component in the system. This is normal for the rst 1 to
60 seconds after the power is turned on, or if the system conguration is changed
during operation.
Fast Blinking Green Under normal conditions indicates Auto-mapping has failed. Also used by the Weld
Manager Utilities (included on the Service Navigator CDs or at www.powerwavesoft-
ware.com to identify the selected machine when connecting to a specic IP address).
Alternating Red and Green Non-recoverable system fault. If the Status lights are ashing any combination of red
and green, errors are present. Read and note the error code(s) before turning off the
machine.
Error code interpretation through the Status light is detailed in the Service Manual.
Individual code digits are ashed 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
Service Navigator CDs or 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 the power source off and back on to reset the sys-
tem.
Steady Red Not applicable.
Blinking Red Not applicable.

F-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
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.
CAUTION
APEX ®3000
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 110VAC 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 Check weld head cable and cycle power.
5-3-7 Calbrated 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.
5-3-6 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 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 pro-
grammed limit
Recalibrate the system/cycle power. Make sure Weld Head
arm moves all the way in and you have full range of move-
ment.
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 har-
nesses and connectors are secure.
5-4-9 Oscillation fault unknown Check all of the above items. Cycle Power. Contact a
Service Representation at the number on the cover of this
manual.
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.

F-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
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.
CAUTION
APEX ®3000
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 move-
ment. 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 har-
nesses and connectors are secure.
5-5-9 Height fault unknown Check all of the above items. Cycle Power. Contact a
Service Representation at the number on the cover of this
manual.
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 har-
nesses and connectors are secure.
5-6-9 Travel fault unknown Check all of the above items. Cycle Power. Contact a
Service Representation at the number on the cover of this
manual.
5-7-1 Wire motor following error Check for resistance when pulling wire through the liner.
Wire speeds too high.
5-7-2 Wire motor overcurrent Check power supplies, cycle power. Check for wire bird-
nest. Check for resistance when pulling wire through the
liner.
5-7-3 Wire motor overheat Check welding conditions. Turn off power for 5 minutes.
Check for resistance when pulling wire through the liner.
5-7-4 Wire communications fault Check Weld Head cable and make sure no extra power /
noise is being discharged into the Weld Head.
5-7-5 Wire communications off Check Weld Head cable and make sure no extra power /
noise is being discharged into the Weld Head.
5-7-6 Wire motor / encoder issue Cycle power to the system and allow the sysatem to recali-
brate. Make sure you can jog wire in Jog mode.
5-7-7 Wire motor overvoltage Check power supplies, cycle power. Check for wire bird-
nest. Check for resistance when pulling wire through the
liner.
5-7-8 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.

F-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
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.
CAUTION
APEX ®3000
5-7-9 Wire fault unknown Check all of the above items. Cycle Power. Contact a
Service Representation at the number on the cover of this
manual.
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 a Service Representation at the number on the
cover of this manual.
8-4 Shutdown #2 is open Contact a Service Representation at the number on the
cover of this manual.
Cable Management
Always use the shortest cable lengths possible. Do not coil excess cable. It is recommended that the total length
of control cable does not exceed 100ʼ (30.5M). The use of non-standard cables in excess of 25ʼ (7.5M) can lead
to communication problems (system shutdowns), poor motor acceleration (poor arc starting), and low wire driving
force (wire feeding problems).
Best results will be obtained when the control cables are routed separate from the weld cables. This minimizes
the possibility of interference between the high currents owing through the weld cables and the low level signals
in the control cables.

G-1
DIAGRAMS
APEX ®3000
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.
Diagrams

P-1
PARTS
P-787
GENERAL ASSEMBLY
APEX ®3000
This parts list is provided as an informative guide only.
APEX® 3000 PARTS MANUAL
Code: 70317

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.
P-787
GENERAL ASSEMBLY
APEX ®3000 PARTS
P-787
ILLUSTRATION OF PARTS

P-3
PARTS
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the
Lincoln Electric Parts List.
P-787
GENERAL ASSEMBLY
APEX ®3000
APEX®3000 CONTROL
For Code: 70310, 70313, 70316
P-787-A.1
GENERAL ASSEMBLY
Sub Assembly Item
No.
123
APEX®3000 Control APEX®System Cables APEX®3 series Pendant
SUB ASSEMBLY
PAGE NAME
PAGE NO. P-787-B P-787-C P-787-D
CODE NO.
70310 1 1
70316 2
70313 1

P-4
PARTS
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the
Lincoln Electric Parts List.
P-787
GENERAL ASSEMBLY
APEX ®3000
P-787-B
APEX 3000 Control