Issued June 2024 • Index No. DC/16.7 Deltaweld 500 Systems Heavy Industrial Manufacturing Quick Specs General manufacturing General fabrication Structural steel fabrication Transportation Sheet metal fabrication Light-gauge tube and sheet MIG (GMAW) Flux-cored (FCAW) Accu-Pulse® MIG (GMAW-P)* High-deposition MIG (GMAW)** RMD®** Air carbon arc (CAC-A) Rated: 3/8-inch carbons Auxiliary Power 115 V standard Input Power 208/230/460 V or 575 V, 3-phase, 60 Hz Rated Output 500 A at 100% duty cycle *With Intellx ™ Pro and Intellx ™ Elite feeders. **With Intellx ™ Elite feeders. The standard in manufacturing for welders of all skill levels, with Intellx™ wire feeder options that deliver application specific benefits. Dedicated wire feeder options • Intellx Basic feeder with arc control means welders can produce better welds with minimal parameter adjustments. • Intellx Pro feeder adds EZ-Set, Accu-Pulse®, memory buttons and steel and stainless weld programs. • Intellx Elite feeder adds additional weld programs, intuitive display with on-demand graphics and more control. Easy to use EZ-Set simplifies parameter setup based on material thickness, removing complexity. Pulse capable Accu-Pulse offers a more forgiving arc and compensates for variations in operator technique, providing a wider operating window. Ready to weld Reduce the time and hassle of setting up welding systems. Make your move to a weld-ready Deltaweld MIGRunner™. Deltaweld 500 MIGRunner ™ with Intellx™ Elite feeder shown. Optional Welding Intelligence™ weld monitoring system. Get more done, produce higher-quality welds and control costs. See page 6 for more information. Power source is warrantied for three years, parts and labor. Original main power rectifier parts are warrantied for five years. Gun warrantied for 90 days, parts and labor. Equipment Sales US and Canada An ITW Welding Company 1635 West Spencer Street P.O. Box 1079 Appleton, WI 54912-1079 USA Phone: 866-931-9730 FAX: 800-637-2315 International Phone: 920-735-4554 International FAX:

Dedicated constant-current gouge mode, rated for up to 3/8-inch carbons. Wind Tunnel Technology™. Internal air flow that protects electrical components and PC boards from dirt, dust, debris — greatly improving reliability. Fan-On-Demand™ operates only when needed reducing noise, power consumption, and the amount of airborne contaminants pulled through the machine. Quality-engineered cable management protects your connections to keep you productive. Deltaweld 500 with meters and Insight ArcConnect™ is a next generation communication that utilizes high speed signals to improve weld performance...

Intellx Feeder Features ™ Memory buttons for quick program recall Display and controls for volts/arc length, wire feed speed, and EZ-Set (if selected) Arc control to fine tune the welding arc LCD setup screen for easy selection of welding processes Balanced-pressure drive-roll design and tensioners feed wire in its truest and straightest form for consistent feedability, resulting in better welding performance. Accu-Mate™ connection aligns the gun perfectly in the drive-roll carrier — preventing the gun from being pulled loose and providing consistent wire feeding. Jog and purge button Trigger...

Intellx Feeders Comparison ™ Processes include: • MIG • EZ-Set MIG (Intellx Pro and Intellx Elite) • EZ-Set Accu-Pulse (Intellx Pro and Intellx Elite) • EZ-Set High-deposition MIG (Intellx Elite) • EZ-Set RMD® (Intellx Elite) Intellx™ Basic Feeder Digital meters Intellx™ Elite Feeder Full color LCD Remote voltage Intellx Pro and Intellx Elite feeder programs include: • Different wire sizes • Different gas types • Flux-cored • Metal-cored • Steel • Stainless steel Wire feed speed Arc control Trigger hold Wire jog and purge Wire feed speed feedback Four drive rolls Rotatable drive Up to 60 lb....

Deltaweld 500 System Processes MIG Standard Spray Short Circuit • Lower spatter than traditional MIG welders • Better arc performance with silicon bronze and coated materials Out-of-position welds • The most popular process for majority of industrial welding applications • Most adaptive arc on 16 gauge (1.6 mm) and thicker • Designed for all weld positions Thick metals Thin metals Increased travel speed • Higher deposition rates than standard spray transfer on thicker materials • Designed for welding applications in which spray transfer is preferred Ratings A, B, C, and D are relative values....

Insight Welding Intelligence With an Insight weld monitoring system you can get more done, produce higher-quality welds and control costs. Insight Core is an easy-to-use welding information solution that gives visibility into your operation so you can improve productivity. • Measure welding productivity. See each welder’s arc-on time to set baselines, plan improvements and measure goals. • View easy-to-understand reports. Dashboards show trends and develop reports. Compare welders, cells and plants. • Identify welding costs. Make improvements to reduce expenses. • Easily install and use. Just...

Deltaweld 500 MIGRunner Packages ™ Deltaweld 500 MIGRunner Packages with Intellx Basic Feeder ™ MIGRunner with single-wire Intellx Basic MIGRunner with dual-wire Intellx Basic Packages include: Deltaweld power source (907785) with factory-installed running gear with cable holder, gun holders and chains for gas cylinders Intellx Basic single- OR dual-wire feeder 15 ft. (4.6 m) Bernard® BTB Gun 400 A (two with dual-wire feeder) with AccuLock™ consumables Cart accessory kit for single- or dual-wire feeders consisting of flowmeter regulator with 5 ft. (1.5 m) gas hose (two with dual-wire feeder),...

Genuine Miller Accessories ® Deltaweld 350/500 Running Gear 301523 Features small footprint, dualcylinder rack, chains for gas cylinders, ergonomic handle design and lockable front casters with two torch holders, and storage area below. Spool Covers 295231 For single-wire feeders and left side of dual-wire feeders 090389 For right side of dual-wire feeders For 12-inch (305 mm) spool. Work Sense Leads (volt sense) 300461 25 ft. (7.6 m) 300462 50 ft. (15.2 m) When connected from the back of the wire feeder to the workpiece, the work sense lead provides accurate voltage feedback on the wire feeder...