A-2
INSTALLATION
TANDEM MIG TORCH
A-2
GENERAL DESCRIPTION
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.
The 900 amp Tandem MIG torches are supplied in
two different configurations, the G3494-2 thru -6, (sin-
gle gas delivery configuration) and the G3494-2A thru
-6A (dual gas delivery configuration). The G3494-2
thru -6 is configured to be used with .035"-.052" diam-
eter electrodes. Shielding gas delivery is by a single
gas hose that delivers gas to the torch body. Internal
to the torch body the gas is split and delivered to the
two gas diffusers.
The G3494-2A thru -6A model is configured for .035"-
5/64" diameter wires. The G3494-2A thru -6A design
provides larger volumes of gas for gas shielding of the
welding arcs and weld pool. Gas is delivered through
the two welding power cable assemblies of the
G3494-2A thru -6A; each assembly receives separate
shielding gas from the two separate wire feeder sole-
noids. The dual source of gas provides additional gas
volume needed for proper gas shielding of larger weld
pools.
The torch can be operated bi-directionally, or even as
a single wire torch as the need arises.
The Tandem MIG torch is not factory equipped with a
feeder end connector. Use a K489-7 Fast-Mate
adapter kit (see ACCESSORIES section) to attach the
torch to the feeders. A K1500-1 gun connector must
be installed in addition to the K489-7 Fast-Mate
adapter, when using a Power Feed 10R Wire Feeder.
Liners are not included with the torch and must be
ordered separately (see ACCESSORIES section).
The torch is suitable for welding with Lincoln solid wire
steel MIG wires and metal core electrodes, from .035"
to 5/64" (0.9 mm to 1.9 mm) diameter.
Argon based shielding gases are recommended.
100% CO
2
is not recommend because of the higher
spatter levels associated with the gas.
DESIGN SUMMARY
The case, internal components and cables are the
main sub-assemblies of the torch.
TORCH CASE
The case is made from several pieces fabricated from
aluminum. The aluminum parts offer rigidity, strength
and resistance to heat and spatter. The main housing
is drilled and tapped for easy mounting to fixturing
equipment. For automation and robotic applications,
the barrel of the torch is removable and replaceable
without having an effect upon the existing tool center
point.
INTERNAL ASSEMBLY
Figure 1 Internal Assembly
All of the internal components are over molded with a
high temperature epoxy material. The over molding
rigidly holds all the parts in place while simultaneously
insulating the sub-assemblies. Each "subgun" in the
torch is electrically isolated from all other components
and individually water cooled. Separate water cooling
circuits minimize corrosion from electrical or galvanic
action.
Each face on the subguns where the diffuser engages
the torch is milled at a precise angle. The angle helps
to keep the ends of the wires close together while
allowing the use of standard contact tips. The slight
bend also creates good electrical contact between the
wire electrode and the tip.
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