RETURN TO MAIN MENU IM666-A Tandem MIG Torch February, 2005 G3494-2, 3, 4, 5, 6 G3494-2A, 3A, 4A, 5A, 6A 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii 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.
iii iii SAFETY WELDING 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.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 General Description..............................................................................................................A-2 Design Summary ............................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Tandem MIG Torch Tandem MIG Torch Cable Length Availability Product Number Gun Cable Length G3494-2, 2A 4 ft (1.2 m) G3494-3, 3A 6 ft (1.8 m) G3494-4, 4A 8 ft (2.4 m) G3494-5, 5A 10 ft (3.0 m) G3494-6, 6A 12 ft (3.6m) Shielding Gas Flow Rate 65 scfh (31 liters/min) minimum Water Cooling Flow Rate for each Power Cable .45 gal/min at 40 psi (1700 ml/min at 2.7 bar) Water cooling flow rate for nozzle/gas cable .
A-2 A-2 INSTALLATION GENERAL DESCRIPTION DESIGN SUMMARY The Tandem MIG torch delivers two wire electrodes to the weld pool. The wires are insulated from each other for the purpose of independent arc regulation. When welding, the wires or arcs are oriented one behind the other. The torch provides a small but rugged housing for delivering the two wires and it provides secure delivery of the shielding gas. Each side of the torch is rated for 450 Amps, 100% duty cycle with argon mix shielding gases.
A-3 INSTALLATION A-3 CABLE ASSEMBLY MOUNTING BRACKETS Three cable assemblies deliver the necessary power and cooling fluids to the torch. A bracket for mounting the torch to a robot is available (see ACCESSORIES section). The bracket features an insulating plate to electrically isolate the torch from other equipment. The insulating plate also serves as a breakaway piece in the event of a severe collision.
A-4 INSTALLATION FIGURE 2 CONNECTION DIAGRAM For G3494-2 thru -6 and G3494-2A thru -6A G3494-2 thru -6 To Lead Water cooler To Lead Wire Feeder To Trail Wire Feeder To Trail Water cooler To Shielding Gas LINER INSTALLATION AND TRIMMING INSTRUCTIONS a) Lay the torch and cable on a flat surface and straighten the cables. b) With a 12 mm open-end wrench, unscrew the nut on the cable connector that restrains the liner. Remove the nozzle, and then remove both diffusers.
A-5 INSTALLATION b) Push the end connector from torch into K489-7 Fast-Mate adapter on the wire feeder, and then tighten the locking nut. Do this for both of the torch power cables. c) Attach the water lines from the torch power cables to a supply of cooling water. d) Connect the water lines from the nozzle bundle to the Tandem MIG interface. If a Tandem MIG interface is not used, connect the water lines directly to the water cooler or other type of controller.
A-6 INSTALLATION MOUNTING THE TORCH Always insulate the torch from any equipment or fixturing. Use M19190 Bracket Arm to Torch Body Insulator if necessary. (See Figure 4, Torch mounting dimensions) Check to make sure the cables are free to flex and do not get tangled or caught on other equipment. Do not let the cables drag on moving or hot parts. A-6 Use a collision sensor if there is a risk that the torch may impact an object when the torch or work piece moves.
A-7 INSTALLATION A-7 WORK LEAD WIRE STRAIGHTENERS Minimize the length of the electrode and work lead cables. Do not exceed 50 ft (15m) of combined electrode and work lead length. Use a wire straightener with each wire drive. Failure to use a wire straightener may result in inconsistent welds and weld bead placement. To make the work lead connection, run a properly sized lead from the work connection on the power source directly to the fixture.
B-1 OPERATION ELECTRODES AND EQUIPMENT TheTandem MIG torch has been designed for use with 0.035" through 5/64" (0.9 mm to 1.9 mm) Lincoln solid steel MIG wires and metal core wires. Refer to the appropriate Lincoln Process and Procedure Guidelines for further information on welding settings. B-1 e) Use only clean, rust-free electrodes. Electrodes manufactured by Lincoln Electric have proper surface lubrication.
C-1 C-1 ACCESSORIES Gas Nozzles GENERAL OPTIONS / ACCESSORIES S24198-1 The following options/accessories are available for your Tandem MIG Torch from your local Lincoln Distributor.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS TORCH SHIELD REPLACEMENT WARNING Have qualified personnel do the maintenance work. If a problem cannot be corrected by following the instructions, take the equipment to the nearest Lincoln Field Service Shop for repair. ----------------------------------------------------------------------ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
D-2 MAINTENANCE CONTACT TIP REPLACEMENT Each application will dictate the frequency of contact tip replacement. Higher amperage higher duty cycle operations will require more frequent contact tip replacement. The condition of the contact tip greatly effects the welding performance. A routine tip replacement schedule should be established and adhered to. For general operations contact tips should be changed at the beginning of every shift.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION The drive rolls turn, but wire will not feed a. Gun cable is kinked and/or twisted. or wire feeding is rough. b. Wire jammed in gun or cable. a. Keep as straight as possible. Inspect cable and replace if necessary. b. Remove wire from gun and cable, then feed in new wire. Check for any obstructions. Replace the liner if necessary. c.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) PPOSSIBLE CAUSE Porosity in the weld. (Continued) g. Wrong shielding gas composition. The arc length is inconsistent. a. The contact tip is worn. g. Make sure the shielding gas is appropriate for the weld procedure. h. Lead arc length too short. h. The lead arc should be in the spray or pulse mode and not in globular or short arc transfer. i. Water is leaking into the arc. i.
NOTES TANDEM MIG TORCH
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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