Lincoln Electric HELIX M45, 12885 Operator's Manual

Operator’s Manual

HELIX ® M45 WELD HEAD

For use with machines having Code Numbers:

12885

ORIGINAL INSTRUCTIONS

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Date Purchased

Code: (ex: 12735)

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IM6129 | Issue D ate 02/19

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SPAIN

a

HELIX® M45 WELD HEAD

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

WARNING

This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.

SAFETY

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.

READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.

USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away
from your face.

If you de velop 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.

2

HELIX® M45 WELD HEAD

SAFETY

SAFETY

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State
of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a
well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to
www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.

)

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.

WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov

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

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 pos­sible to the area being welded.

2.d.5. Do not work next to welding power source.

3

HELIX® M45 WELD HEAD

SAFETY

SAFETY

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

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 It ems 6.c. and 8.

between the

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

hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.

5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.

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

injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

4

HELIX® M45 WELD HEAD

SAFETY

SAFETY

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF
DAMAGED.

7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected
to physical damage.

• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.

FOR ELECTRICALLY
POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

5

5

HELIX® M45 WELD HEAD

SAFETY

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 (2014/30/UE). 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 electro­magnetic 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 and

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 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 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.”

6

HELIX® M45 WELD HEAD

SAFETY

7

HELIX® M45 WELD HEAD

TABLE OF CONTENTS

Safety .............................................................................................................................................................. 3

Disposal Guide .......................................................................................................................................... 7

Dimensions ................................................................................................................................................A-1

Technical Specications ........................................................................................................................... A-2

Safety Precautions ...................................................................................................................................A-3

Proper handling ..................................................................................................................................... A-3

Operation .............................................................................................................................................. A-3

HELIX M45 WELD HEAD ........................................................................................................................... A-4

Basic Information .................................................................................................................................. A-4

Basic Components ................................................................................................................................ A-4

Body Assembly ..................................................................................................................................... A-4

Main Body Assembly ............................................................................................................................ A-4

Torch Height Assembly ......................................................................................................................... A-4

Work Angle Adjustment .........................................................................................................................A-5

Track Engagement ................................................................................................................................ A-5

Handle Adjustment ................................................................................................................................ A-5

Operational Safety Precautions ...............................................................................................................B-1

Operation Information ........................................................................................................................... B-1

External inputs ..................................................................................................................................... B-1

Control ...................................................................................................................................................B-1

Welding Power ......................................................................................................................................B-1

Manual Adjustments ............................................................................................................................. B-1

Accessories .........................................................................................................................................B-1

Maintenance ........................................................................................................................................D-1

Maintenance Schedule ..........................................................................................................................D-1

Every Shift ............................................................................................................................................. D-1

Monthly .................................................................................................................................................D-1

Semi Annually ........................................................................................................................................D-1

Tools ...................................................................................................................................................... D-1

Belt Change Adjustment .......................................................................................................................D-2

Trouble Shooting ....................................................................................................................................... F-1

Wiring Diagram ..........................................................................................................................................G-1

Helix M45 Parts Manual ............................................................................................................................H-1

HELIX M45 Weld Head Dimensions

16.63 in

42.24 cm

14.96 in

38.99 cm

5.08 in

12.90 cm

INSTALLATIONHELIX® M45 WELD HEAD

15.22 in

38.65 cm

View Front

19.70 in±2.5 in

50.08 cm± 6.35 cm

10.35±2.5 in

26.28±6.35 cm

9.3 in

23.62 cm

View Side

A-1

Technical Specications HELIX M45 Weld Head

HELIX M45 Weld head
Product Number
K52224-1

Input Power 24 VDC

Radial Clearance (on 8" Track Ring) 4.5" (114.3 mm)

Travel Speed 0.1 - 120 ipm

Max Oscillation Speed 150 ipm (381 cm/min)

Oscillation stroke 5" (49.78 mm)

Work Angle +45 degrees in / -45 degrees out

Pipe Sizes 8" OD to Flat Track

Weld Head Physical Dimensions

Depth (minus the torch): 19.70” (500.38 mm) Weight: 28 lbs (12.7 kg)

Environmental

Operating Temperature Range

32F to 140F (0C - 60C)

Ingress Protection - IP00

Storage Temperature Range

-22F to 140F (0C - 60C)

INSTALLATIONHELIX® M45 WELD HEAD

A-weighted emission sound pressure level: less than 70 db (A)

Explanation of Symbols

Electric Shock Warning Hot Surface Warning

A-2

INSTALLATIONHELIX® M45 WELD HEAD

Safety Precautions

Read entire manual before installation or operation.

WARNING

ELECTRIC SHOCK CAN KILL

• Only qualied personnel
should perform this instal­lation.

• Turn the input power OFF
at the disconnect switch
or fuse box before work­ing on this equipment turn
off the input power to any
other equipment connect­ed to the welding system
at the disconnect switch
or fuse box before working
on the equipment.

• Do not touch electrically
hot parts.

• Always connect the power
supply grounding lug to
a proper safety (Earth)
ground.

Operation

Read entire manual before operation.

Only operate the HELIX M45 weld head while it is
rmly attached to the track ring with the clutch
engaged. Always verify that the track is properly
attached to the work surface before operating.

Keep hands away from weld head while in operation.

Verify that the system cable assembly is free from
obstruction before operating. While welding, the weld
head will rotate around the pipe. Be certain that there
is plenty of play in weld cable. If the cable binds up
during welding, parts of the weld cable or the weld
head assembly may become damaged.

Never unplug or plug in control cables to the weld
head while the system is powered on.

Verify that the system is properly grounded before
beginning to weld.

Proper Handling

The HELIX M45 weld head is only meant to be picked
up and supported by the handles. Only attempt to
attach the weld head to the track ring while the clamp
mechanism and clutch are disengaged.

Do not hang persons or objects from the handles of
the weld head while operating.

Keep machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.

Always place the weld head on a steady, at level sur­face when not in use or not clamped onto a track ring.
Always be sure to engage the clutch when the weld
head is left on the track.

Do not force the torch motion assembly in or out man­ually. Manually adjusting the torch in this manner can
cause undue wear and tear on the gear and motors.

After welding allow adequate time for the weld head
to cool before moving, making adjustments or putting
into storage.

A-3

INSTALLATIONHELIX® M45 WELD HEAD

HELIX M45 Weld Head

Basic Information

The HELIX M45 weld head is the second weld head in
the APEX 3 world of digitally controlled, precision

welding. Designed with a low prole, this device also
oers a pivoting torch height assembly, providing

perpendicular height control to the puddle face.

The handles on the HELIX M45 weld head rotate,
allowing for optimized clearance. Designed to work with
the APEX® 3 Series Orbital Controllers, the HELIX M45
weld head uses cross-roller bearings for rigid clamping
and is able to change weld parameters based on its
orientation in space.

The HELIX M45 weld head has automatic height
control, oscillation capabilities, and multiple toolless
torch adjustment options. These give the operator
greater control of the weld puddle for complex welds
in limited space.

Basic Components

The three basic components of the weld head are:

• Body Assembly

• Torch Clamp

• Torch Height Assembly

See FIGURE 1 - Weld Head Components –
for the dierent weld head parts. Each piece of
the machinery is discussed separately.

CLUTCH
HANDLE

Adjustments and controls located on the
body include:

• Clutch Handle

This handle is engaged with a pushing motion

and disengaged by a pulling motion. Pushing the
weld head back and forth along the track makes
the engagement of the clutch easier.

• Clamp Latch

Using a compression spring to add force to

the clamp, this latch engages or disengages
the clamp which secures the weld head onto
the track.This compensates for variance in
track width dimension and maintains weld
head position.

CONTROL
CABLE
INPUT

CLAMP
LATCH

FIGURE 2 - Rear Weld Head Components

ACCESSORY
CABLE

BODY

FIGURE 1 - Weld Head Components

Body Assembly

The body assembly is the main component for the
HELIX M45 weld head. It contains the gears, mo­tors and belts that provide travel and oscillation for
the weld head – see FIGURES 1 and 2 - Weld Head

Components and Rear Weld Head Components.

TORCH
CLAMP

• Control Cable Input

A connecting point for the control cable which

delivers all signals to the weld head.

• Accessory Cable

TORCH

This cable connects the onboard wire feeder and

HEIGHT

the torch height assembly.

Torch Height Assembly

The torch height assembly holds the torch and pro­vides vertical motion to the torch. It also allows for
toolless work angle adjustment.

A-4