Lincoln Electric HELIX T55 User manual

HELIX™ T55 WELD HEAD
For use with machines having code Numbers: 70301 & 70300
Copyright © Lincoln Global Inc.
World’s Leader in Welding and Cutting Products
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX:[phone] WEB Site: www.lincolnelectric.com
OPERATOR’S MANUAL
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 READ-
ING THIS MANUAL,
AND
THE
SAETY PRECAUTIONS CON-
TAINED THROUGHOUT.
And,
most importantly, think before
you act and be careful.
IM6112
October, 2012

•••
•
•

TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS ................................. i
TABLE OF FIGURES.....................................ii
BASIC INFORMATION................................. 1
Toolbox........................................................ 1
Technical Specifications.............................. 2
Track Ring ................................................... 3
Shoe Placement........................................ 4
Shoe Extension ........................................ 4
Track Ring Installation ............................ 5
Weld Head................................................... 8
Weld Head Installation ............................ 8
Torch Setup.................................................. 9
Fillet Weld Angle .................................... 9
Lead Lag Angle ....................................... 9
Torch Stick Out........................................ 9
Tungsten Stick Out................................ 10
Torch Height.......................................... 10
Wire Feeder Angle................................. 11
Verify Drive Rolls ..................................... 12
Change Upper Drive Roll...................... 12
Change Lower Drive Roll...................... 13
Wire Feed Setup ........................................ 14
Wire Spool Installation.......................... 14
Feeding the Wire.................................... 14
Adjustments for Radial Clearance......... 15
OPERATION................................................. 16
MAINTENANCE.......................................... 17
Preventative Maintenance Schedule.......... 17
Track Ring ................................................. 17
Monthly Maintenance............................ 17
Quarterly Maintenance .......................... 17
Annual Maintenance.............................. 17
T55 Weld Head..........................................17
Daily Maintenance.................................17
Weekly Maintenance .............................17
Monthly Maintenance............................17
Quarterly Maintenance...........................17
PARTS LIST..................................................20
Index ..............................................................37

TABLE OF CONTENTS
TABLE OF FIGURES
Figure 1 –TRACK RING................................ 3
Figure 2 –SHOE PLACEMENT .................... 4
Figure 3 –SHOE EXTENSION...................... 5
Figure 4 –ASSEMBLY STEP 1..................... 5
Figure 5 –ASSEMBLY STEP 2..................... 6
Figure 6 –ASSEMBLY STEP 3..................... 6
Figure 7 –TRACK DISTANCE...................... 6
Figure 8 –TRACK PLACEMENT ................. 7
Figure 9 –WELD HEAD ................................ 8
Figure 10 –LATCH AND KNOB................... 8
Figure 11 –FILLET WELD ANGLE ............. 9
Figure 12 –FILLET WELD ANGLE 2 .......... 9
Figure 13 –TORCH LEAD/LAG ................... 9
Figure 14 –LEAD/LAG ADJUSTMENT....... 9
Figure 15 –TORCH STICK-OUT ................ 10
Figure 16 –BACK CAP................................ 10
Figure 17 –SLIDE CLAMP BOLTS............ 10
Figure 18 –TORCH HEAD REMOVAL ..... 10
Figure 19 –AVC PLATE.............................. 11
Figure 20 –WIRE GUIDE HEIGHT ............ 11
Figure 21 –WIRE GUIDE ADJUST ............ 11
Figure 22 –LOWER DRIVE ROLL............. 12
Figure 23 –TENSION KNOB ...................... 12
Figure 24 –SET SCREW.............................. 12
Figure 25 –DRIVE ROLL SHAFT............... 12
Figure 26 –ROLLER SET SCREW 2 .......... 13
Figure 27 –MOTOR KEY ............................ 13
Figure 28 –HUB NUT .................................. 14
Figure 29 –THUMB NUT ............................ 14
Figure 30 –WIRE 1 INSTALLATION......... 14
Figure 31 –WIRE 2 INSTALLATION......... 14
Figure 32 –INLET GUIDE........................... 15
Figure 33 –THUMB SCREW....................... 15
Figure 34 –WIRE ARMS ADJUSTED........ 15

Helix™T55

1BASIC INFORMATION 1
BASIC INFORMATION
The T55 Helix™ is a precision, gear driven weld
head designed for GTAW (TIG) welding. Paired
with the specifically designed steel and chromoly
track ring, the Helix™ provides strong, reliable
welds for a rugged and stable welding solution.
The T55 Helix™ tractor is controlled by a handheld
controller and AVC. It features an easy release
clutch which disengages the drive roll allowing free
movement along the track, without removing the
unit from the track ring. A heavy duty Nylon cover-
ing protects power, control, water and gas cables
from wear and tear; and a high temperature Teflon
coated sleeve protects the area closest to the weld
head.
The standard T55 weighs in at 35 lbs., without the
wire arms, and has two handles for easy carrying.
Two wire arms come standard with the option to
remove one of the arms for added versatility. The
Weld Head has 1”of oscillation stroke allowing the
operator flexibility when installing the Weld Head
and Track Ring. 3. 5” of AVC stroke allows the op-
erator to weld in deep groove applications. Torch
and Arc orientation can be adjusted 140° to adjust
for numerous weld parameters. Precision motors
allow for travel speeds from 0.5 IPM to 20 IPM.
The track ring is a low profile heavy duty track ring
stabilized at even intervals with cross braces.
Mounting shoes, containing spring cushions rated
to 800lb, attach to the cross braces and allow for
the work surface’s heat expansion which stops
binding and ring distortion. The geared system of
the track eliminates slippage and the angled section
interface prevents tractor jump.
The T55 Helix™ comes fully assembled in a rugged
waterproof case along with a gas line, water in and
water out, power cable, control cable, and a Helix™
tool box.
Toolbox
Included with the Helix™ is a toolbox of common
tools and consumables. These tools are for general
operation and maintenance; more in-depth mainte-
nance may require additional tools.
Tools
60” Flexible cloth Measuring tape
7/64” Hex Key (wire guide clamp)
1/8” Hex Key (wire guide angle adjust)
3/16” Hex Key (Oscillation plate, Lead/Lag Angle)
1/4” Hex Key (track shoes)
5/16” Hex Key (Weld Angle)
5/32” Hex Key (track clamp bolts, barrel clamp,
torch slide)
Wire Cutters
Consumables
Pyrex Cup (2)
1/8 Tungsten adapter (2)
Collet Body
1/8 Collet (2)
1/8 Tungsten (3)
Back Cap Long
Back Cap Medium
Optional Consumables not included
5/32 Tungsten Adapter
5/32 Collet
5/32 Tungsten

2INSTALLATION 2
Technical Specifications
Product
Helix™ T55 Tractor
Product Number
K52002-1
Input Power
25V DC
Travel Speed
0.5 –20 ipm
Wire Feed Speed
0.1 to 130 ipm
Wire Size Range
0.030 - .052
Radial Clearance
5.5 in (139.7 mm)
Axial Clearance
11.5 in (292.1 mm)
Oscillation Stroke
1 in (25.4 mm)
Arc Voltage Control
(AVC) Stroke*
3.5 in (88.9 mm) AVC can be manually offset 3”
Net Weight
57 lb with cables (25.86 kg)
Track to Rear
3.41 in (86.6 mm)
Track to Electrode
(Min –Max)
Minimum: 5.03 in (128 mm) - Maximum: 10.64 in (270.4 mm) with standard 6 in (152.4 mm) OSC plate
Optional 12” and 24” plates are available.
Electrode to Front
1.93 in (49 mm)
Lead/Lag*
360°
Torch tilt in*
30° maximum
Torch tilt out*
110° maximum
Manual Torch
Height Adjustment*
±0.9 in (23 mm)
*See Pages 9-10 for adjustment instructions
Product
Helix™ Track Ring
Product Number
K52000-XX (Where XX is equal to the track size)
Track to Work Surface
Minimum
Inside of Track .67”
Outside of Track 1.42”
Nominal
Inside of Track .80”
Outside of Track 1.55”
Maximum
Inside of Track 1.19”
Outside of Track 1.94”
Track Width
3.90 in (99.1)

3INSTALLATION 3
Track Ring
Standard track rings come in two varieties. Two
segment tracks and four segment tracks. Two
segment tracks start at an 8 inch diameter and in-
crease in size by 2 inch increments up to 28 inches.
Four segment tracks start at 30 inches and increase
in size by 4 inch increments up to 64 inches. Spe-
cial sizes are available upon request.
Each segment will have 2 end caps; one threaded
one with bolts.
Track rings will have cross braces evenly distribut-
ed between the end caps. The number of cross
braces per segment is determined by the size of the
track ring:
x8” track rings have 3 cross braces
6 per track ring
x10”-32” track rings have 5 cross braces
10 per track ring
x32” and above sizes will vary
Not all cross braces require shoes.
Track shoes come already installed on the track
ring (see Figure 2 –Shoe Placement). Figure 2 is
an example of a 2 segment track ring.
Pipe dimensions vary by size, type and application.
A 12” track rings is designed for a 12” outside di-
ameter pipe.
Do not use different serial number track rings of the
same size.
Track rings are serialized by size and engi-
neered to fit together, Tracks of the same
serial number only join the correct way.
FIGURE 1 –TRACK RING

4INSTALLATION 4
Shoe Placement
The number of track shoes is determined by the
size of the track ring:
x8”-22” track rings have 6 track shoes
x24-32” track rings have 8 track shoes
Track shoes screw into the cross braces using a 1/4
inch Hex Key. Turn counterclockwise to attach
track shoe to track ring.
8” track rings require a track shoe on every cross
brace. 10”-28” track rings will have a shoe starting
on the cross brace nearest the end caps and con-
tinuing on every other cross brace per segment
(see Figure 2 –Shoe Placement).
Thread track shoes onto cross braces using 2 to 3
turns per bolt then switch to the next bolt on the
same shoe. Ensure that the track shoe stays even,
tighten until a minimum of 5 threads are engaged
for each bolt. Repeat process with every track
shoe.
Shoe Extension
In order to accommodate different size pipes, ex-
tensions are available. These extensions attach
onto the track shoes and are stackable to adjust for
various size pipes.
Extension sizes are in ½”, 1”, 2”, and 3 “ incre-
ments. Screws are provided for the extension siz-
es. Stacking extensions creates a unique size and
will require the user to purchase their own .25x20
Socket Head Cap Screw for the particular stacked
length.
Part numbers for the Extensions are as follows:
x.5” K52060-05
x1” K52060-10
x2” K52060-20
x3” K52060-30
Adding extensions decreases the ac-
tual travel speed at the Weld. Cali-
bration may be required.
FIGURE 2 –SHOE PLACEMENT

5INSTALLATION 5
Shoe extension bolts pass through the shoe exten-
sion and thread into the track shoe to keep the ex-
tension firmly in place (see Figure 3 –Shoe Exten-
sion).
FIGURE 3 –SHOE EXTENSION
Track Ring Installation
If the track rings are assembled, separate the 2
halves of the track ring by unscrewing the 2 clamp-
ing screws at each end cap with a 5/32” hex key.
For 4 segment tracks, separate into 2 halves leav-
ing 2 segments joined for each half.
Four segment track rings can be bro-
ken down into four individual seg-
ments for easy shipping and storage.
FIGURE 4 –ASSEMBLY STEP 1
1. After separating into two segments, retract
each shoe completely by turning both ad-
justment screws (see Figure 4 –Assembly
Step 1) evenly with a 1/4” hex key until the
shoe is flush with the cross brace. Do not
over tighten.
2. Place one half of the track ring over the
work surface with the threaded end nearer
the top. Slide the track over the pipe angled
with more of the track over the top of the
pipe, so that the weight of the track is sup-
ported (see Figure 5 –Assembly Step 2).
Verify that the track ring is supported
and will not fall before moving on to
Step 3.

6INSTALLATION 6
FIGURE 5 –ASSEMBLY STEP 2
3. Bring the second half of the track ring up to
the pipe and secure the topmost joint by in-
serting and tightening the clamping screws
through the tapped end cap into the
threaded end cap (see Figure 6 - Assembly
Step 3).
FIGURE 6 –ASSEMBLY STEP 3
4. Rotate the track ring around the pipe until
you have access to the second joint. Se-
cure this joint by tightening both clamping
screws. It is normal to have a small gap at
the joints between the tubular track sec-
tions.
5. Ensure that track moves freely around the
work surface. If the track does not move
freely verify that all track shoes are backed
against the cross brace. If the track shoes
are all backed against the cross brace and
there is not free movement it may be nec-
essary to use the next larger size track ring.
See Technical Specification on page 2
for nominal distance from track to work
surface.
6. Position the track ring the desired distance
from the weld joint (see Figure 7 –Track
Distance). This distance will typically be be-
tween 5 and 9 inches (130 –230 mm).
FIGURE 7 –TRACK DISTANCE
7. Rotate the track ring so that the middle of
any segment is at the topmost point of the
work surface which will position one track
shoe at the top most point and one track
shoe for the second segment at the bottom
most point (see Figure 8 –Track Place-
ment).

7INSTALLATION 7
FIGURE 8 –TRACK PLACEMENT
8. Adjust shoes to center the track around the
pipe by turning both adjustment screws on
each shoe evenly. Start by adjusting only
the top most and bottom most shoes to
center the track. Once those shoes are
firmly onto the work surface move on to op-
posing track shoes. Be sure to only tighten
opposing shoes in order to keep the track
centered. Repeat until all shoes are se-
cured firmly to the work surface.
Figure 8 shows the order to tighten the track shoes.
Start with the top and bottom shoes labeled “1”.
Next move on to the opposing shoes labeled “2”.
Lastly tighten the remaining shoes labeled “3”.
The shoes only need to be adjusted
tight enough so that the track ring is
not loose. Over-tightening the ad-
justment screws will cause the shoes
to lose their ability to accommodate
pipe expansion.

8INSTALLATION 8
Weld Head
This section covers weld head installation and set-
up. For operational instructions and calibration re-
fer to control system manual.
Weld Head Installation
1. Turn the clamping knob counter clockwise
until the track rollers are fully separated.
Ensure that the clutch latch is in the disen-
gaged (up) position.
FIGURE 10 –LATCH AND KNOB
2. Lift up the tractor by the handles (not the
wire feed motors), place the tractor on top
of the track with the torch perpendicular to
the track.
3. Turn the clamping knob clockwise to close
the tractor onto the rails, ensure the weld
head is secure but still loose enough to
move fluidly. Over-tightening the clamping
knob can result in a small jerk during the
transition over the track joint, as well as ex-
cess motor stress.
4. Roll the tractor to the desired starting posi-
tion on the track and engage the clutch
latch.
5. Verify that there is no side to side or for-
ward/backward motion before beginning the
weld. Side to Side motion can be adjusted
out by tightening the Clamping knob. For-
ward and back motion can be adjusted out
by turning the clutch latch clockwise. Do
not over-tighten.
FIGURE 9 –WELD HEAD

9INSTALLATION 9
Torch Setup
Before welding ensure the torch is set up for opti-
mal weld parameters There are six adjustments that
can be set:
xFillet Weld Angle
xLead/Lag Angle
xTorch Stick Out
xTungsten Stick Out
xTorch Height
xWire Guides
Fillet Weld Angle
Before adjusting the Fillet Weld Angle hold firmly
onto the weld head to prevent damage. To set the
fillet weld angle of the torch loosen the fillet adjust-
ment bolt with a 5/16” hex key and set the angle as
desired. Swing up and tighten the bolt to clamp the
torch in place. Torch can be moved 110 degrees
out and 30 degrees in.
FIGURE 11 –FILLET WELD ANGLE
FIGURE 12 –FILLET WELD ANGLE 2
Lead Lag Angle
To set the lead/lag angle (see Figure 13 –Torch
Lead/Lag) of the torch loosen the barrel clamp bolts
with a 5/32” hex key on one side of the torch so that
the torch is free to rotate (see Figure 14 –Lead/Lag
Adjustment). Set the torch at the desired angle and
tighten the barrel clamp bolts to lock it in place.
There are markings in 5 degree increments to
achieve the desired angle. The lead lag angle can
be adjusted 360 degrees.
FIGURE 13 –TORCH LEAD/LAG
FIGURE 14 –LEAD/LAG ADJUSTMENT
Torch Stick Out
Adjust the torch stick-out after the controller has
been turned on and the oscillation has moved to
center position. Loosen the oscillation plate bolts on
top of the tractor with a 3/16” hex key and slide the

10 INSTALLATION 10
entire torch assembly to align the torch with the
seam (see Figure - 15 Torch Stick Out). Leave at
least two bolts overlapping the Main Body Assem-
bly. Once in place, tighten the oscillation plate bolts
starting with the bolts furthest out from the torch
head and moving in. If the torch cannot reach the
seam, the track may need to be repositioned.
Standard oscillation plates are 6”, and are included
with the T55 Helix™. 12” and 24” oscillation plates
are available for special applications.
FIGURE 15 –TORCH STICK-OUT
Tungsten Stick Out
Adjust the tungsten stick-out by loosening the back
cap on top of the torch (see Figure 16 –Back Cap).
Move the tungsten by hand to the desired position
and tighten the back cap.
FIGURE 16 –BACK CAP
Torch Height
You can adjust the torch height by jogging the AVC.
If the AVC travel range will not allow the torch to
reach the desired height you will need to manually
change the torch height offset by adjusting the torch
mount slide or the AVC plate mounting.
Set AVC travel range back to zero before manually
adjusting.
To adjust the torch mount slide loosen the slide
clamp bolts with a 5/32” hex key (see Figure 17
Side Clamp Bolts).
Slide the torch up or down as needed, then retight-
en the bolts.
FIGURE 17 –SLIDE CLAMP BOLTS
To adjust the AVC plate mounting location, remove
the torch head from the AVC assembly. Remove
the barrel clamp bolts on one side of the torch with
a 5/32” hex key and remove the barrel clamp (see
Figure 18 –Torch Head Removal). The torch can
now be removed.
FIGURE 18 –TORCH HEAD REMOVAL
Unscrew the AVC plate bolts with a 3/16” hex key
and move the AVC plate up or down (see Figure 19

11 INSTALLATION 11
–AVC Plate). The AVC plate can move to any posi-
tion so long as all four bolts are re-attached.
Replace the torch and re-attach the barrel clamp.
Removing the torch head may require the operator
to re-adjust the lead/lag angle.
FIGURE 19 –AVC PLATE
Wire Feeder Angle
The angle of the fed wire can be adjusted for specif-
ic applications. Adjust the position of the wire
guides to aim the wire.
Height adjustment is accomplished by turning the
height adjustment knob on the wire manipulator unit
(see Figure 20 –Wire Guide Height). The side to
side angle of the wire guide can be adjusted by
turning the angle adjustment knob on the wire ma-
nipulator unit.
The up-down angle of the wire guides can be
changed by pressing out the wire angle pin and
loosening the wire angle bolt with a 1/8” hex key
(see Figure 21 –Wire Guide Adjust). Move the wire
guide to the desired position and retighten the bolt.
In-out adjustment is accomplished by loosening the
wire holder bolt with a 7/64” hex key. Slide the wire
guide in or out and then tighten the wire holder bolt
to lock it in place.
FIGURE 20 –WIRE GUIDE HEIGHT
FIGURE 21 –WIRE GUIDE ADJUST