HyperFill Dual Feeder Ready-Pak

HyperFill® Dual Feeder Ready-Pak®


Power Wave S500 advanced process welders have multi-process capability for welding on thicker materials.


Output Output Output Output


USD $19,150.00/EA


Revolutionize your welding productivity with HyperFill - an innovative twin-wire MIG solution that takes your high deposition welding to the next level. With the HyperFill Dual-Feeder Ready-Pak, you will have everything you need to run the HyperFill process and an additional single wire process all on one machine and all in one convenient part number.


  • Pre-assembled plug and play package designed to get you up and running within minutes
  • Dual Process ready - Run HyperFill and a single wire process on the same system
  • CheckPoint ® production monitoring technology easily tracks essential welding and system data
  • Solution Requirements » HyperFill® is a patented and licensed twin-wire MIG solution that is designed to perform specifically with select Lincoln Electric welding wire. The solution requires a licensed waveform which may require an additional purchase. For more details, reference document MC20-106.


Warning -

Cancer and Reproductive Harm -


What's Included

  • Power Wave® S500 (K2904-1) • Power Feed® 84 Dual Wire Feeder (K3330-3) • Cool Arc® 55S Water Cooler (K3086-2)(1) • Magnum® PRO Water Cooled 500A Gun (K4522-2-10-564) • 7 ft. Water Hose Kit (K4544-7) • HyperFill Dual Reel Cart Kit (K4630-1) • 4-Ball Inlet Guide (K1551-2) • HyperFill .035-.040 (0.9-1.0 mm) Drive Roll Kit (KP4388-1) • HyperFill Diffuser (KP4481-1) • HyperFill .035 Contact Tip (KP4482-035) • 1/8 in. Recess Nozzle (KP4523-1-75R) • 15 ft.
  • 5/64 in. Liner (KP44-564-15) • Standard Duty Wire Reel Stand (K3342-1) • Magnum® PRO Curve™ 300A Gun (K2951-2-10-45) • Standard .040-045 (1.0-1.1 mm) Drive Roll Kit (KP1505-045S) • Work Lead Package (K2149-1) • Electrode Cable (K1842-10) • ArcLink® Cable (K1543-8) • Inverter and Wire Feeder Cart (K3059-4) • Gas Y Fitting (KP4773-1) • Harris Flowmeter Kit (3100211)


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Machine Inputs & Outputs

Phase 3: Input Voltage #1 (Voltage/Phase/Hertz) 200/208/220/230/380/400/415/460/575 3 50/60
Phase 3: Rated Output #1A (Current/Voltage/Duty Cycle) GMAW: 550A/41.5V/40% GMAW: 450A/36.5V/100%
Phase 3: Rated Output #1B (Current/Voltage/Duty Cycle) SMAW: 550A/42V/40% SMAW: 450A/38V/100%
Phase 3: Rated Output #1C (Current/Voltage/Duty Cycle) GTAW-DC: 550A/32V/40% GTAW-DC: 450A/28V/100%
Phase 3: Input Current at Max Rated Ouput #1 (Current) 3 Ph / 40% Duty Cycle: 80/73/41/37/29 3 Ph / 100% Duty Cycle: 60/54/30/27/21

Product Weights & Dimensions

Dimensions (H x W x D) 22.5 in x 14 in x 24.8 in (571 mm x 355 mm x 630 mm)
Net Weight 450 lbs (204.12 kg)


Machines Processes Stick (SMAW)
Gouging (CAC-A)
Flux-Cored (FCAW)
Pulsed MIG (GMAW-P)
Flux-Cored Self-Shielded (FCAW-SS)
Flux-Cored Gas-Shielded (FCAW-G)
Orbital TIG
Orbital MIG
Metal-cored Wire (GMAW-C)
Max Rating 550
Maximum Electrode Size x
Minimum Electrode Size x
Number of Operators per Machine 1
Data Technologies Ethernet
Machines Communication Technology ArcLink
Wire Feeder Supply Voltage 40VDC
Amphenol Pins (type of connector) 5
Work Lead Connector Type Lug
Welding Gun Cable Assembly Length 15 FT
Spool Gun Compatible (Duty) Heavy

Wire and TIG Feeders

Number of driven rolls 4 rolls
Feeder type Bench
Configuration Dual
Max spool diameter 60lb
Communication Technology ArcLink
UI type Meters
Max Rated Output Capable 500A
Max WFS 1200IPM
Feedhead Configuration Dual
Wire Configuration Hyperfill
Power Source to Feeder Communication Connector Type 5-pin
Accesories Communication Connector Type 12-pin
Gun Bushing Tweco #2-#4
Wire Feed Speed Range (IPM) 500-1100
Max Spool Size (lbs) 60
Max Spool Size (kg) 30
MIG-WireFeeders Yes
MIGPulse-WireFeeders Yes
Contact Tips Included Yes

Basic Specification

Input Voltage 200/208,220/230/240,380/400/415,460,575
Input Current 3PH/40% - 80/73/41/37/29A,3PH/100% - 60/54/30/27/21A
Input Hertz 50,50/60,60
Input Power 208/230/380/415/460/575/3/50/60
Input Phase 3
Mode Icon CC/CV
Output Range 5-550A DC
Polarity DC
Rated Output 550A/41.5/40%


Typical Application Construction
Typical Application Mining
Typical Application Railroad Maintenance
Typical Application Armor Plate (military)
Typical Application Automotive
Typical Application Construction and field erection
Typical Application Elevated Temperature Piping
Typical Application Gasification Plants
Typical Application General fabrication
Typical Application Heat Exchangers
Typical Application Heavy equipment
Typical Application Heavy fabrication
Typical Application High Pressure Piping
Typical Application High Temperature
Typical Application High-strength pipe
Typical Application LPG & LNG storage vessels
Typical Application Marine applications
Typical Application Marine fabrication and repair
Typical Application NACE applications
Typical Application Offshore
Typical Application Oil and Gas
Typical Application Petrochemical
Typical Application Petrochemical Industry
Typical Application Petroleum Processing
Typical Application Pharmaceutical equipment
Typical Application Pipeline & Offshore
Typical Application Piping
Typical Application Power Generation
Typical Application Power Plants
Typical Application Pressure vessels
Typical Application Process piping
Typical Application Railcar fabrication
Typical Application Railing industry
Typical Application Robotics/ Hard automation
Typical Application Shipbuilding
Typical Application Structural fabrication
Typical Application Structural welding


Warranty 5 Years