Tandem MIG

Publication E10.60 2/05 High Deposition WeldingWith T andem MIG configurations having a total welding amperagecapacity of 1300 amps, the process is capable of producing quality weldsat deposition rates in excess of 35 lbs/hr. The high deposition rate hasproven valuable to many companies producing large equipmentcomponents. Installations have spanned industries fabricating earthmoving equipment, heavy haulers, railroad and off-shore platforms. Theprocess is capable of producing high deposition rates at lower heatinputs than that of conventional single wire processes. The lower heatinput means less post-weld work straightening and realigning parts dueto distortion.Typical applications• Automotive components• Wheels, large and small• Cylinders• T anks• Gussets and stiffeners• Many thin gauge lap and fillet weldsTypical applications• Heavy equipment• ASME tanks• Structural• Railroad industry• Pipe and tubular componentsTandem MIG Process[2]ADVANTAGE LINCOLNApplications over 180 ipm travel speed Excellent gap filling capabilitiesFANUC Robot Teach PendantWelding Set-up ScreenSYSTEM 1 Robotic ApplicationsThe T andem System 1 is configured for robotic use with a Fanuc R-J3robot and controller with common ArcLink® digital communication. The seamless digital communication architecture provides fast precisecommunication of critical motion and welding commands for positive arc striking, through the arc seam tracking and touch sensing functions. The system is configured to perform common welding tasks as both a tandem and a single wire process.• T ouch sensing to locate welding joint.• Through The Arc Seam Tracking (TAST) T andem MIG welding. • Single electrode welding.• Switching from T andem MIG to single wire and back on the fly without breaking the arc.• Bi-directional welding when using like diameter electrodes (Switches welding mode and parameters from lead wire to trail wire, and vice versa).• On the fly output mode switching (Pulse modes and CV).Welding parameters and welding commands are conveniently displayed on the Fanuc I-pendant. Easy to learn menu-driven display screens provide operators the comfort of programming ease.T andem MIG Robotic Systems can be configured either with T andem MIG Power Wave 455M Robotic high-speed inverters rated at 450 amps,100% duty cycle each, or T andem MIG Power Wave 655 Robotic high-speed inverters rated at 650 amps, 100% duty cycle each.The Lincoln T andem MIG welding systems can be configured for most popular robot manufacturers.K1795-25 or K1785-25ControllerS22683-XXX orT andem MIG Process[4]SYSTEM 2 Advanced Hard AutomationThe T andem MIG Hard Automation System is configured for use in automated weld stations that require precise and managed procedure control. The system features a user-friendly interface with touch screen advanced programming control. The seamless integration using DeviceNet communication between controller and power sourcesprovides fast accurate execution of parameter commands. The controller features an Allen Bradley PLC and touch screen for reliable service in the most demanding environments.The T andem MIG weld controller is configured with isolated I/O to be compatible with other control devices for common commands such as:weld start/stop, system fault and emergency stopping.The system can be configured with either T andem MIG Power Wave 455M Robotic high speed inverters rated at 450 amps, 100% duty cycle each, or the T andem MIG Power Wave 655 Robotic high speed inverter power sources rated at 650 amps, 100% duty cycle each.*Depending upon torch selectionTandem MIG ControllerS22683-XXX or G3494-XAAD1038-3K1780-2K1795-25 or K1785-25K2262-1-TM or K1519-1-TMT andem MIG Process[5]TANDEM MIG POWER WAVE 455M ROBOTICThe T andem MIG Power Wave 455M Robotic is a high performance digitally controlled power source,which is capable of executing the precise outputs required for T andem MIG operation. The Power Wave is programmed with proprietary T andem MIG software consisting of unique waveforms and power source response characteristics. Outputs are programmed for the range of the machine rating of 450amps, 100% duty cycle.For additional information, request product literature number E10.90.TANDEM MIG POWER WAVE 655 ROBOTICThe T andem MIG Power Wave 655 Robotic is a high output capacity, high performance, digitally controlled inverter power source capable of complex, high-speed waveform control. The higher amperage of the Power Wave 655 Robotic provides the opportunity for higher amperage procedures with the T andem MIG process. The power source executes the proprietary T andem MIG software up to the machine rated output of 650 amps. The higher welding capacity of 650 amperage rating per machine places the Lincoln T andem MIG process deposition capabilities well above conventional dual wire GMAW processes.For additional information, request product literature number E10.95.POWER FEED 10 ROBOTIC WIRE FEEDERThe Power Feed 10 Robotic Wire Feeder is used in all T andem MIG configurations. This highperformance, digitally controlled wire feeder is specifically designed to mount on a robot arm or be mounted in a hard automation cell. The unique four drive roll design provides reliable positive feeding for common T andem MIG wire diameters .035-5/64 inches. Wire feed ranges are 50-800 ipm with standard gearing and 75-1200 ipm with the high speed option.For additional information, request product literature number E9.160.Feeder weight 22.4 lbsT andem MIG Process[6]T andem MIG 800 Amp Welding T orchThe Lincoln T andem MIG 800 Amp Welding T orch is designed for medium duty robotic and hard automation applications. The streamline configuration and extended gooseneck profile is ideal for robotic applications that require reaching into tight locations. The torch features awater-cooled nozzle for minimizing spatter build-up and extended tip life. T o ensure maximum up time, the torch is constructed with an air blast cleaning feature with a separate air line and internal air orifices in the nozzle retainer to remove spatter.T orch Specifications :Duty Cycle: 800 amps 60% duty, mixed gas700 amps 100% duty, mixed gasMax. current per electrode: 450 ampsCooling requirements: one water circulating source providing a min. of .45 gpm, at 40 psi Weight: 7.5 lbs. (with cables elevated 1 ft., 4 ft. from torch mounting bracket)Available Lengths: 4 ft., 6 ft., 8 ft., 10 ft., 12 ft.Compatible T orch Reamer with external sprayer: M18426-1Ordering Information:Welding torch with torch mounting bracket and diffusers (less contact tips and liners)T orch with 4 ft. cables S22693-124T orch with 6 ft. cables S22693-123T orch with 8 ft. cables S22693-122T orch with 10 ft. cables S22693-121T orch with 12 ft. cables S22693-133For additional information, request Tandem MIG 800 amp torch literature number E10.60.1T andem MIG 900 Amp Welding T orchThe Lincoln T andem MIG 900 Amp Welding T orch is designed for high amperage welding applications. The water-cooled torch provides continuous duty welding at 900 amps with mixed gases. Three water coolers are used to maintain cool operation under extreme welding conditions. Each electrode power cable is water cooled to provide extended life of current carrying cables. A third cooler is used to provide coolant directly to the nozzle, further extending contact tip life and minimizing nozzle maintenance. Rigid machined aluminum case and molded internal body components provide consistent contact tip alignment and dimensional stability.T orch Specifications :Duty Cycle: 900 amps 100% duty, mixed gas1200 amps 60% duty, mixed gasMax. current per electrode: 650 ampsCooling requirements: Three separate water circulating sources each providing a min. of .45 gpm, at 40 psi each Weight: 9.8 lbs. (with cables elevated 1 ft., 4 ft. from torch mounting bracket)Available Lengths: 4 ft., 6 ft., 8 ft., 10 ft., 12 ft.Compatible T orch Reamer with external sprayer: M18426-1Ordering Information:Welding torch with diffusers (less contact tips, liners, mounting bracket and Fast-Mate™ adapters)Requires (2) K489-7 Fast Mate adapters (For Power Feed 10 Robotic Wire Feeders)T orch with 4 ft. cables G3494-2A T orch with 6 ft. cables G3494-3A T orch with 8 ft. cables G3494-4A T orch with 10 ft. cables G3494-5A T orch with 12 ft. cables G3494-6AFor additional information, request Tandem MIG 900 amp Torch literature number E10.60.2T andem MIG T orch ReamerThe T andem MIG T orch Reamer is designed to provide fast efficient cleaning of both the 800 amp and 900 amp Lincoln T andem MIG torches. The self-contained system runs on filtered 80-100 psi shop air and 24-vdc power supplied by the robot controller. Operation consists of a single stroke reaming tool that cleans one side of the nozzle at a time. The torch is then indexed, and the reaming tool cleans the second side.After cleaning, the torch nozzle area is sprayed with an anti-spatter compound to lower spatter accumulation and promote easy removal of any spatter that does adhere to the internalnozzle area. T otal cleaning time with anti-spatterspray is approximately 6 seconds.M18426-1 T andem MIG T orch Reamer Assembly withconvenient slotted torch locator andpneumatic reaming tool.Cool-Arc® 40 Water CoolerThe Cool-Arc 40 Water Cooler is recommended for both the 800 amp and the 900 amp T andem T orch assemblies.The efficient positive displacement pump design of the water circulating system provides .45-.60 gpm of water coolant to cool the critical areas of the T andem MIG welding torches. Narrow space saver design can be mounted vertically or horizontally for economy of space incongested work cells. The AD1013-3 torch-cooling package comes complete with Cool-Arc 40 water cooler, Magnum flow sensor and 25 ft. of supply and return water hoses.For additional information, request Cool-Arc 40 literature number E12.170. Hard automated systems and robots without arm collision detection softwareThe heavy duty M17809 Collision Sensor with 10 ft sensor cable assembly is recommended for hard automation or robotic systemswhere collision software is not an option. The heavy-duty sensor is capable of carrying the weight of the T andem MIG torches as well as having the required recovery accuracy to return the torch back to the same location after a collision. The sensor is designed to communicate acknowledgement of a torch collision to motion controlling devices to limit damage to equipment in the event of a collision. Collisions occurdue to improper robot programming, an open part clamp, or an improperly located part during hard automation indexing.Rapid acknowledgement of a collision not only savestorch repair costs; it allows rapid recovery after acollision.Robots with arm collision detection softwareWhen T andem MIG torches are mounted on a Fanuc Robot or other robots that provide robot arm collision protection software, it is recommended to use the S22693-172 Rigid Mounting Bracket. The combination of Fanuc Collision Guard softwareand the rigid torch mounting insures repeatablewire placement and operator safety.C U S T O M E R A S S I S T A N C E P O L I C YThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.Subject to Change — This information is accurate to the best of our knowledge at the time of printing. Please refer to for any updated information.SuperArc® L-50 and L-56 GMAW bulk welding wire packages :K515 — Magnum wire conduit kits :Low friction wire conduit consists of specified feet ofconduit and connection hardware. Available lengths :K515-15 (15 ft.)K515-25 (25 ft.)K515-50 (50 ft.)。