Lincoln Electric 900 User manual

Tandem MIG Dual Wire GMAW
Tandem MIG™ 800 Amp Welding Torch
AUTOMATED SOLUTIONS
The Lincoln Tandem MIG 800 Amp Welding Torch is designed for medium duty robotic and
hard automation applications. The streamline configuration with extended gooseneck profile
is ideal for robotic applications that require reaching welding joints with restricted access.
The lightweight high strength machined aluminum torch construction provides precise wire
placement that can be used on 5 kg load capacity and larger robot arms. The torch features
a heavy-duty brass water-cooled gas nozzle, designed to minimize spatter build-up and
provide extended contact tip life.
Publication E10.60.1 2/05
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Processes
Advantage Lincoln
Order
Recommended Expendable Parts
• 800 amp rating for mixed gases, 60% duty cycle designed to
meet most light gauge steel applications.
• Wide range of useable wire diameters (.035-.062 inches)
provides versatility to fill a variety of application requirements.
• Cool operation for extended component life. Water-cooled
nozzle extracts heat from the contact tips.
• Lightweight construction allows use with most common robot
arms.
• Extended length goosenecks provide access to tight weld joint
locations.
• 22 degree goosenecks provide positive wire contact at the
contact tip.
• Two process derived contact tip spacing and angularity options.
• Large contact tip to diffuser seating area for cooler contact tip
operation.
• Separate routing of air blast hose provides a nozzle cleaning
option without compromising shielding gas supply lines.
Wire liners, contact tips, diffusers, nozzles, nozzle retainers and nozzle
retainer insulators
Recommended Wire Feeders
Power Feed 10 Robotic Wire Feeders K1780-1* or K1780-2*
*Requires use of K1500-1 gun connector
Recommended Power Sources
Tandem MIG power sources:
K2262-1-TM Tandem MIG Power Wave 455M Robotic
K1519-1-TM Tandem MIG Power Wave 655 Robotic
S22693-XXX Tandem MIG 800 Amp Welding Torch
Current Per Electrode:
Total Current:
(both electrodes)
Rated Current with Mixed Gas (Argon-90%, C02-10%)
100% duty
60% duty
100% duty
60% duty
Amps 200 300 400 500 600 700 800 900 1000 1100
For additional Tandem MIG information, request Tandem MIG Process document E10.60.

Tandem MIG 800 Amp Welding Torch
[2]
SYSTEM RECOMMENDATIONS
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Recommended Wire Packaging:
The 22 degree bend in the gooseneck design provides positive wire
delivery to the contact tip for good electrical transfer of welding current.
Bulk wire packing in Accu-Trak™ drums, boxes or Speed-Feed reels is
recommended. It is also recommended to install a K1733-1 wire
straightener at the wire feeder. The addition of a wire straightener is to
adjust for irregular conditioning of the wire during long conduit runs
between bulk wire source and the wire feeder.
Automatic Torch Cleaning
Internal Air Blast: (robotic and fixed torch applications)
Each torch is supplied with an isolated gas hose and internal air routing
for performing an optional air blast function. As standard, the torch is
configured to receive a high pressure air purge that forces air between
the two diffusers to remove spatter from the internal portion of the
nozzle. Required equipment: high pressure air line capable of supplying
dry air and solenoid.
Torch Reamer: (robotic application)
Increased production efficiency is established when using the M18426-1
Torch Reamer. The reamer is designed to remove
unwanted spatter from the torch nozzle area, eliminating
costly downtime associated with nozzle
maintenance. The reamer is equipped with a
single stroke reaming tool that cleans one side
of the torch at a time. The torch is then
indexed to ream the second side. Reamer
comes complete with torch locating plate
and anti-spatter misting station.
Welding Torch Protection:
When mounted on a Fanuc Robot, the
S22693-172 Rigid Mounting Bracket is
used along with Fanuc Collision Guard
software. The rigid torch mounting and
software combination assures repeatable
torch placement and operator safety.
The M17809 Collision Sensor is recommended when using robotic arms
that are not supported with collision sensing software and for fixed torch
mounting associated with hard automation applications.
Water-cooling:
The torch is designed to operate with
one water cooler. The cooler is used
to supply cooling water to the torch’s
gas nozzle. Once cooling water is
applied, the brass nozzle is designed
to pull heat from the contact tips and
provide a cool nozzle surface that will
limit spatter build-up. Recommended
AD1013-3 cooling system includes:
Cool-Arc 40 water cooler, Magnum
Flow Sensor and 25 ft each of water
delivery and return hoses.

Tandem MIG 800 Amp Welding Torch
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[3]
A CLOSER LOOK
Torch Dimensions
Torch mounting bracket is included as part of
the torch assembly (dimensions in inches
[millimeters])
Torch mounting to Power Feed 10 Robotic wire feeders K1780-1 and K1780-2
The 800 amp Tandem MIG torch is supplied with Power Feed 10 Robotic Wire Feeder
compatible cable ends. The cable assemblies plug directly into the feeder power block,
(with K1506-1 gun connector installed.) Gas is delivered to each side of the torch through a
short hose extending from associated wire feeder gas outlet fitting.
ORDERING INFORMATION:
Welding torch with torch mounting bracket and diffusers (less contact tips and liners)
Description Part number Shipping weight
Torch with 4 ft. cables S22693-124 18.4 lbs.
Torch with 6 ft. cables S22693-123 21.8 lbs.
Torch with 8 ft. cables S22693-122 25.2 lbs.
Torch with 10 ft. cables S22693-121 28.6 lbs.
Torch with 12 ft. cables S22693-133 32.0 lbs.
Tandem MIG 800 Amp Welding Torch
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
EXPENDABLE REPLACEMENT PARTS
Water-Cooled Nozzle
Standard on all 800 amp torches.
Nozzle Retainers
Two different nozzle retainers are
available for different electrode spacing.
Nozzle Retainer Insulators
Two different Nozzle Retainer Insulators
are available to accommodate different
electrode spacing.
The S22693-118 water-cooled nozzle
assembly is designed to provide maximum
gas coverage for both high speed and
high deposit applications. Nozzle features
brass construction for maximum rigidity
and cooling.
Nozzle retainers are
available with two
different contact tip
spacings — standard
and wide. Each
retainer provides the
mounting surface for
the gas nozzle and
establishes contact tip
spacing. An air blast
hose is part of each
assembly.
S22693-152 (Std.)
S22693-135 (Wide)
Torch Nozzle Retainer Insulator mounts
between the torch retainer and gas
diffusers, protecting the retainer and
providing orifices for air blast cleaning.
There are two different sized insulators to
fit the two retainer sizes.
S22693-117 (Std.)
S22693-146 (Wide)
Torch alignment fixture L10430-1
Torch alignment should be performed after any severe torch collision or after any major
torch disassembly. The L10430-1 torch alignment fixture is configured to set the alignment
and spacing of the S22693-XXX torch contact tips. The bench fixture is engineered to
accept both standard and wide spaced torch configurations.
Torch alignment fixture L10430-1

Nozzle Assembly S22693-118
Retainer (Standard spacing for .045 and .052 dia electrodes) S22693-152
Retainer (Wide spacing for special applications) S22693-135
Retainer “0” ring S22693-136
Nozzle Retainer Insulator (Standard spacing) S22693-117
Nozzle Retainer Insulator (Wide spacing) S22693-146
Wire liners:
.035-.045 6 ft. S22693-9
.035-.045 15 ft. S22693-158
.052-.062 6 ft. S22693-10
.052-.062 15 ft. S22693-159
Diffuser (non-taper lock) S22693-120
Short diffuser (non-taper lock) S22693-206
Contact Tips:
.030” dia. Heavy Duty S22693-1
.035” dia. Heavy Duty S22693-2
.045” dia. Heavy Duty S22693-3
.052” dia. Heavy Duty S22693-4
.062” dia. Heavy Duty S22693-5
Taper Lock Diffuser S22693-207
Taper Lock Contact Tips:
.030” dia. Taper Lock S22693-191
.035” dia. Taper Lock S22693-129
.045” dia. Taper Lock S22693-181
.052” dia. Taper Lock S22693-194
.062” dia. Taper Lock S22693-195
TOTAL:
EXPENDABLE REPLACEMENT PARTS FOR TANDEM MIG 800 AMP WELDING TORCH
Parts Description Part Number Quantity Price
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
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 www.lincolnelectric.com for any updated information.
EXPENDABLE REPLACEMENT PARTS
Diffuser and contact tips:
High current capacity taper lock contact tips and diffuser
As standard, the Tandem MIG 800 Amp Welding Torch is supplied with Taper Lock
Diffusers (S22693-207) and Taper Lock Contact Tips. Diffusers are designed to provide a
larger seating surface for the contact tips. The enlarged seating surface provides better
current carrying capacity over conventional diffuser designs. Better current carrying
capacity means less heating of the contact tips, longer tip wear and fewer tip changes.
The diffuser design is complimented with a taper lock contact tip design providing a
generous contact mating surface, fewer screw threads and dual thread starting points to
speed tip replacement time.
Conventional heavy duty contact tips and diffuser
Industry standard contact tips and diffuser design are available for end users that have
established a plant standard. The diffuser design is unique to the Tandem MIG torch,
however the contact tip can be used on compatible semiautomatic welding torches.
Taper Lock Diffuser and Contact Tip
Conventional Diffuser
and Contact Tip