TECHNICAL SPECIFICATIONS

AUTOMATED SOLUTIONS Tandem MIG Process Increased Production Tandem MIG is a dual wire, high productivity GMAW process designed for flexible robotic or fixed hard automation welding applications. The process utilizes high-speed inverter Waveform Control Technology to coordinate two separately generated GMAW welding arcs in unison for exceptional process flexibility. Independent control of both the lead and trail wire parameters of the tandem process allows procedure optimization for bead wetting, bead profile and penetration. Tandem MIG has proven to frequently double the production of single GMAW processes. Processes Description MIG Pulsed Output CV DC 3 Input PHASE 50 60 Hz Advantage Lincoln Exceptional travel speeds on thin gauge material. High deposition rates on thicker members, often exceeding 35 lbs/hr. Excellent weld bead toe wetting at high travel speeds. Handles poor fit-up common to large production runs of stamped or formed parts. Reduces number of required weld stations, reducing initial capital equipment investment costs. Digital control provides seamless integration. Tandem MIG Systems can be configured with either Tandem MIG Power Wave 455M Robotic power sources for a total of 900 amps of output, or Tandem MIG Power Wave 655 Robotic power sources for a total of 1300 amps of output. The unique output waveforms developed for Tandem MIG produces exceptional weld puddle control and controlled arc interaction. Recommended General Options Cool-Arc 40 Water Cooler, Magnum Wire Conduit, Accu-Trak Drum Payoff Kit, Tandem MIG 800 Amp Welding Torch, Tandem MIG 900 Amp Welding Torch, Tandem MIG Torch Reamer Order AD1201-1 Tandem MIG System 1 for robotic applications with two Tandem MIG Power Wave 455M Robotic power sources. AD1201-2 Tandem MIG System 1 for robotic applications with two Tandem MIG Power Wave 655 Robotic power sources. AD1202-1 Tandem MIG System 2 for advanced hard automation with a programmable PLC interface and two Tandem MIG Power Wave 455M Robotic power sources. AD1202-2 Tandem MIG System 2 for advanced hard automation with a programmable PLC interface and two Tandem MIG Power Wave 655 Robotic power sources. Call the Lincoln Electric Automation Division at 216.383.2667 for more information. For complete discription of, request Nextweld document NX-2.40. TECHNICAL SPECIFICATIONS Product Product Input Rated Output Input Current Output Dimensions Net Name Number Voltage Current/Voltage/Duty Cycle @Rated Output Range H x W x D Weight in (mm) lbs (kg) Tandem MIG Power Wave K2262-1-TM 230/460/575/3/50/60 60Hz: 60Hz: 5-570A 26.1 x 19.9 x 32.9 286 455M Robotic 450A/38V/100% 58/53/25/22A (663 x 505 x 835) (130) Tandem MIG Power Wave K1519-1-TM 460/575/3/60 60Hz: 60Hz: 20-880A 26.1 x 19.9 x 32.9 306 655 Robotic 650A/44V/100% 43/34A (663 x 505 x 835) (139) Publication E10.60 2/05

A CLOSER LOOK ADVANTAGE LINCOLN The has proven to be a valued means of reducing welding costs. As shown in figure 1, the process is capable of outperforming conventional single wire processes. This means that higher travel speeds or higher deposition rates can be used to retrofit existing welding stations to increase through-put. It is also an important consideration when designing new production lines. The reduced welding time afforded by the has allowed designers to achieve desired production capacities with fewer welding stations, substantially reducing initial capital equipment costs. Amperage 900 800 700 600 500 400 300 200 100 Single Wire GMAW Single Wire SAW Figure 1 Process comparison Single Wire FCAW Tandem MIG 0 5 10 15 20 25 30 35 40 45 Depostion rate (lbs/hr) High Travel Speed Welding The employs unique output waveforms engineered for exceptional weld puddle control and arc interaction. The process features controlled heat input and weld poolfollow characteristics which produce exceptional travel speeds on sheet metal components ranging in thickness from.040 to.250 inches. Travel speeds often doubling that of single wire processes have been achieved on a variety of fabricated assemblies ranging from small 2 roundabouts to long longitudinal seams. Typical applications Automotive components Wheels, large and small Cylinders Tanks Gussets and stiffeners Many thin gauge lap and fillet welds Applications over 180 ipm travel speed Excellent gap filling capabilities High Deposition Welding With Tandem MIG configurations having a total welding amperage capacity of 1300 amps, the process is capable of producing quality welds at deposition rates in excess of 35 lbs/hr. The high deposition rate has proven valuable to many companies producing large equipment components. Installations have spanned industries fabricating earth moving equipment, heavy haulers, railroad and off-shore platforms. The process is capable of producing high deposition rates at lower heat inputs than that of conventional single wire processes. The lower heat input means less post-weld work straightening and realigning parts due to distortion. Typical applications Heavy equipment ASME tanks Structural Railroad industry Pipe and tubular components [2]

AVAILABLE TANDEM CONFIGURATIONS SYSTEM 1 Robotic Applications The Tandem System 1 is configured for robotic use with a Fanuc R-J3 robot and controller with common ArcLink digital communication. The seamless digital communication architecture provides fast precise communication 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. Touch sensing to locate welding joint. Through The Arc Seam Tracking (TAST) Tandem MIG welding. Single electrode welding. Switching from Tandem 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. Tandem MIG Robotic Systems can be configured either with Tandem MIG Power Wave 455M Robotic high-speed inverters rated at 450 amps, 100% duty cycle each, or Tandem MIG Power Wave 655 Robotic highspeed inverters rated at 650 amps, 100% duty cycle each. The Lincoln Tandem MIG welding systems can be configured for most popular robot manufacturers. AD1038-3 S22683-XXX or G3494-XA K1780-2 K1795-25 or K1785-25 Robot Controller FANUC Robot Teach Pendant Welding Set-up Screen K2262-1-TM or K1519-1-TM SYSTEM 1 COMPONENTS (Tandem MIG is sold as a complete system) Components: AD1201-1 AD1201-2 Quantity TANDEM MIG POWER WAVE 455M ROBOTIC K2262-1-TM 2 TANDEM MIG POWER WAVE 655 ROBOTIC K1519-1-TM 2 Power Feed 10 Robotic Wire Feeder K1780-2 K1780-2 2 Drive Roll Kit K1505-XX K1505-XX 2 Wire Straightener K1733-1 K1733-1 2 ArcLink Communication cable, Power Source to Wire Feeder (25 ft.) K1785-25 K1795-25 2 Cable jumper, 22-pin to 14-pin (18 in.) NA K1804-2 2 Process Sense Lead K940-25 K940-25 2 Torch cooling package with flow detection AD1013-3 AD1013-3 1 or 3* 4/00 electrode cable (25 ft.) L-4/0-25-14-14 L-4/0-25-14-14 2 4/00 ground cable (25 ft.) L-4/0-25-14-14 L-4/0-25-14-14 2 OPTIONS: Fanuc R-J3 robot and controller 100 or 200 series 100 or 200 series 1 Arc Tool software (5.2.0 and above) R-J3 Controller R-J3 Controller 1 Fanuc Multi-equipment and Multi-process software 800 amp Tandem MIG torch (or below) S22693-XXX S22693-XXX 1 900 amp Tandem MIG torch G3494-XA G3494-XA 1 Tandem MIG Torch Reamer with external anti-spatter sprayer M18426-1 M18426-1 1 Pneumatic wire clipper M17815-2 M17815-2 1 9 ft. Boom for wire feeder mounting AD1038-3 AD1038-3 1 TOTAL: *Depending upon torch selection [3]

AVAILABLE TANDEM CONFIGURATIONS SYSTEM 2 Advanced Hard Automation The Tandem 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 sources provides 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 Tandem 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 Tandem MIG Power Wave 455M Robotic high speed inverters rated at 450 amps, 100% duty cycle each, or the Tandem MIG Power Wave 655 Robotic high speed inverter power sources rated at 650 amps, 100% duty cycle each. AD1038-3 K1780-2 S22683-XXX or G3494-XA K1795-25 or K1785-25 G3207-185 Tandem MIG Controller K2262-1-TM or K1519-1-TM SYSTEM 2 COMPONENTS (Tandem MIG is sold as a complete system) Components: AD1202-1 AD1202-2 Quantity TANDEM MIG POWER WAVE 455M ROBOTIC K2262-1-TM 2 TANDEM MIG POWER WAVE 655 ROBOTIC K1519-1-TM 2 Power Feed 10 Robotic Wire Feeder K1780-2 K1780-2 2 Drive Roll Kit KP1505-XX KP1505-XX 2 Wire Straightener K1733-1 K1733-1 2 ArcLink Communication cable. Power Source to Wire Feeders (25 ft.) K1785-25 K1795-25 2 Cable jumper, 22 pin to 14 pin (18 in.) NA K1804-2 2 Process Sense Leads K940-25 K940-25 2 Torch cooling package with flow detection AD1013-3 AD1013-3 1 or 3* Interface Controller G3207-185 G3207-185 1 DeviceNet Communications cable (19.5 ft.) S23383-2 S23383-2 2 4/00 electrode cable (25 ft.) L-4/0-25-14-14 L-4/0-25-14-14 2 4/00 ground cable (25 ft.) L-4/0-25-14-14 L-4/0-25-14-14 2 OPTIONS: 800 amp Tandem MIG torch (or below) S22693-XXX S22693-XXX 1 900 amp Tandem MIG torch G3494-XA G3494-XA 1 9 ft. Boom for wire feeder mounting AD1038-3 AD1038-3 1 *Depending upon torch selection TOTAL: [4]

A CLOSER LOOK TANDEM MIG POWER WAVE 455M ROBOTIC The Tandem MIG Power Wave 455M Robotic is a high performance digitally controlled power source, which is capable of executing the precise outputs required for Tandem MIG operation. The Power Wave is programmed with proprietary Tandem MIG software consisting of unique waveforms and power source response characteristics. Outputs are programmed for the range of the machine rating of 450 amps, 100% duty cycle. For additional information, request product literature number E10.90. TANDEM MIG POWER WAVE 655 ROBOTIC The Tandem 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 Tandem MIG process. The power source executes the proprietary Tandem MIG software up to the machine rated output of 650 amps. The higher welding capacity of 650 amperage rating per machine places the Lincoln Tandem 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 FEEDER The Power Feed 10 Robotic Wire Feeder is used in all Tandem MIG configurations. This high performance, 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 Tandem 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 lbs [5]

WELDING TORCH OPTIONS Tandem MIG 800 Amp Welding Torch The Lincoln Tandem MIG 800 Amp Welding Torch 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 a water-cooled nozzle for minimizing spatter build-up and extended tip life. To 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. Torch Specifications : Duty Cycle: 800 amps 60% duty, mixed gas 700 amps 100% duty, mixed gas Max. current per electrode: 450 amps Cooling 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 Torch Reamer with external sprayer: M18426-1 Ordering Information: Welding torch with torch mounting bracket and diffusers (less contact tips and liners) Torch with 4 ft. cables S22693-124 Torch with 6 ft. cables S22693-123 Torch with 8 ft. cables S22693-122 Torch with 10 ft. cables S22693-121 Torch with 12 ft. cables S22693-133 For additional information, request Tandem MIG 800 amp torch literature number E10.60.1 Tandem MIG 900 Amp Welding Torch The Lincoln Tandem MIG 900 Amp Welding Torch 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. Torch Specifications : Duty Cycle: 900 amps 100% duty, mixed gas 1200 amps 60% duty, mixed gas Max. current per electrode: 650 amps Cooling 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 Torch Reamer with external sprayer: M18426-1 Ordering 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) Torch with 4 ft. cables G3494-2A Torch with 6 ft. cables G3494-3A Torch with 8 ft. cables G3494-4A Torch with 10 ft. cables G3494-5A Torch with 12 ft. cables G3494-6A For additional information, request Tandem MIG 900 amp Torch literature number E10.60.2 [6]

TORCH MOUNTING OPTIONS Robots with arm collision detection software When Tandem 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 software and the rigid torch mounting insures repeatable wire placement and operator safety. Hard automated systems and robots without arm collision detection software The heavy duty M17809 Collision Sensor with 10 ft sensor cable assembly is recommended for hard automation or robotic systems where collision software is not an option. The heavy-duty sensor is capable of carrying the weight of the Tandem 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 occur due to improper robot programming, an open part clamp, or an improperly located part during hard automation indexing. Rapid acknowledgement of a collision not only saves torch repair costs; it allows rapid recovery after a collision. Tandem MIG Torch Reamer The Tandem MIG Torch Reamer is designed to provide fast efficient cleaning of both the 800 amp and 900 amp Lincoln Tandem 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 internal nozzle area. Total cleaning time with anti-spatter spray is approximately 6 seconds. M18426-1 Tandem MIG Torch Reamer Assembly with convenient slotted torch locator and pneumatic reaming tool. Cool-Arc 40 Water Cooler The Cool-Arc 40 Water Cooler is recommended for both the 800 amp and the 900 amp Tandem Torch 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 Tandem MIG welding torches. Narrow space saver design can be mounted vertically or horizontally for economy of space in congested 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. [7]

RECOMMENDED OPTIONS SuperArc L-50 and L-56 GMAW bulk welding wire packages : Accu-Trak bulk drum packaging Wire dia L-50 ( ER70S-3) L-56 ( ER70S-6).035 500, 1000 lbs. 250, 500, 1000 lbs..045 500, 1000 lbs. 250, 500, 1000 lbs..052 500, 1000 lbs. 250, 500, 1000 lbs..062 500, 1000 lbs. 500, 1000 lbs. Accu-Pak bulk box packaging Wire dia L-50 ( ER70S-3) L-56 ( ER70S-6).035 500 lbs. 500 lbs..045 500, 1000 lbs. 500,1000 lbs.052 500, 1000 lbs. 500,1000 lbs...062 500,1000 lbs. Speed Feed Reel packaging Wire dia L-50 ( ER70S-3) L-56 ( ER70S-6).035 1000 lbs. 1000 lbs..045 1000 lbs. 1000 lbs.052 1000 lbs. 1000 lbs...062 1000 lbs. For additional information, see publication C4.10 K515 Magnum wire conduit kits : Low friction wire conduit consists of specified feet of conduit and connection hardware. Available lengths : K515-15 (15 ft.) K515-25 (25 ft.) K515-50 (50 ft.) CUSTOMER ASSISTANCE POLICY The 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. THE LINCOLN ELECTRIC COMPANY 22801 St. Clair Ave., Cleveland, OH 44117-1199 216.481.8100