Tweco 2460 User Manual

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Page 1

Heavy Duty CC/CV Semiautomatic Solid-State Control

Wire Feeder Model 2460

For the Following Specs:

6877A-1 4-Roll Drive, 40-600 IPM

•

6877B-1 4-Roll Drive, 40-600 IPM

•

6877A-2 4-Roll Drive, 20-300 IPM

•

6877B-2 4-Roll Drive, 20-300 IPM

•

OWNER’S MANUAL Number 430429-249 (Rev - AC)

Revised April 14, 2005

IMPORTANT: Readtheseinstructionsbeforeinstalling,operating,orservicingthissystem.

THERMAL ARC INC., W. LEBANON, NH 03784, USA

Page 2

Page 3

430429-249

Table of Contents

INTRODUCTION 1

How To Use This Manual ..................................1-1

Equipment Identification ..................................1-1

Receipt Of Equipment ...................................1-1

SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3

General Description .....................................3-1

Current Capacity and Rating ................................3-1

Feedhead Assembly ....................................3-2

Tabulated Data .......................................3-2

Control Box Assembly ...................................3-2

Wire Reel Support Assembly ................................3-2

Baseplate ..........................................3-2

Options ...........................................3-2

OPERATION 4

Prewelding Checks .....................................4-1

Welding ...........................................4-1

PARTS LIST 5

Equipment Identification ..................................5-1

How To Use This Parts List .................................5-1

How To Select Recommended Spares ...........................5-1

CONTROL BOX ASSEMBLY NO. 376783A & 376783B TIP-218 FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4 TIP-219 PARTS LIST FOR ASSEMBLY NO. 376799A-1, -2, -3, -4 MPL-224 BASE ASSEMBLY PART NO. 375769-1 & -4 TIP-127 WIRE SPOOL SUPPORT I-169 DIAGRAMS

December 1, 1997 Revised

Page 4

INTRODUCTION

430429-249

INTRODUCTION

How To Use This Manual

This Owner’s Manual usually applies to just the underlined specification or part numbers listed on the cover. If none are underlined, they are all covered by this manual.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special headings are easily recognized as follows:

WARNING

A WARNING gives information regarding

possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers for future reference.

Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to:

Thermadyne, Inc. Thermal Arc Order Department 82 Benning Street West Lebanon, New Hampshire, USA 03784

For more information, call (603) 298-5711.

Include all equipment identification numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to uncrate the unit.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number given in the next section. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link:

http://www.thermadyne.com/tai

April14, 2005 Revised 1-1

Page 5

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

ARC WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERSKEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSETHESEINSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.

Safe practices are outlined in the American National Standard Z49.1 entitled: other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

SAFETY IN WELDING AND CUTTING. This publication and

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repairor replace damaged parts at once.

13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above floor level.

15. Keep all panels and covers securely in place.

ARC RAYS can burn eyes and skin; NOISE can damage hearing.

Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.

Welding or Cutting

Operation

Torch soldering Torch brazing Oxygen cutting

Light Medium Heavy

Gas welding

Light Medium

Heavy Shielded metal-arc welding (stick) electrodes

Electrode Size

Metal Thickness

or Welding Current

— —

Under 1 in., 25 mm

1 to 6 in., 25-150 mm

Over 6 in., 150 mm

Under 1/8 in., 3 mm

1/8 to 1/2 in., 3-12 mm

Over 1/2 in., 12 mm

Under 5/32 in., 4 mm

5/32 to 1/4 in., 4 to 6.4 mm

Over 1/4 in., 6.4 mm

Filter

Shade

No.

3or4

3or4 4or5 5or6

4or5 5or6 6or8

10 12 14

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

Welding or Cutting

Operation

Gas metal-arc welding (MIG)

Non-ferrous base metal

Ferrous base metal Gas tungsten arc welding (TIG) Atomic hydrogen welding Carbon arc welding Plasma arc welding Carbon arc air gouging

Light

Heavy Plasma arc cutting

Light

Medium

Heavy

Electrode Size

Metal Thickness

or Welding Current

All All All All All All

Under 300 Amp

300 to 400 Amp

Over 400 Amp

May 8, 1996 2-1

Filter

Shade

No.

11 12 12 12 12 12

12 14

9 12 14

Page 6

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases.Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

11. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

FLYING SPARKS ANDHOTMETAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to astationarysupportorequipmentcylinderracktoprevent falling or tipping.

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

ENGINES can be hazardous.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

2-2 May 8, 1996

Page 7

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, of Power Frequency Electric & Magnetic Fields — Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May

1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

2. Do not addfuel while smoking or if unit is near anysparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

3. Have only qualified people remove guards or covers for mainte-

nance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect nega-

tive (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving

parts.

6. Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

1. Do not remove radiator cap when engine is hot. Allow engine to

cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

Biological Effects

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away from body as practical.

About Pacemakers:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

May 8, 1996 2-3

Page 8

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001

This page intentionally left blank.

2-4 May 8, 1996

Page 9

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC

Instruction 830002

PRECAUTIONS DE SECURITE EN SOUDAGE A L′ARC

LE SOUDAGE A L′ARC EST DANGEREUX

PROTEGEZ-VOUS,AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTSS’APPROCHER,NI LES PORTEURS DE STIMULATEURCARDIAQUE(AMOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété,sil’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement

installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

3. Isolez-vous de la pièce à souder et de la mise à la terre au moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuitouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

LE RAYONNEMENT DE L′ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L′OUIE.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquéeci-après)

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez quedes porte-électrodesbienisolés.Nejamaisplonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Desécrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arcoudel’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

8-V-96 2-1

Page 10

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002

SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE

Opération

Coupage ou soudage

Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage

mince moyen épais

Soudage aux gaz

mince moyen

épais Soudage à l’arc avec electrode enrobées (SMAW)

Soudage à l’arc sous gaz avec fil plein (GMAW)

métaux non-ferreux

métaux ferreux Soudage à l’arc sous gaz avec électrode de tungstène (GTAW) Soudage à l’hydrogène atomique (AHW) Soudage à l’arc avec électrode de carbone (CAW) Soudage à l’arc Plasma (PAW) Gougeage Air-Arc avec électrode de carbone

mince

épais Coupage à l’arc Plasma (PAC)

mince

moyen

épais

( selon AWS A 8.2-73 )

Dimension d’électrode ou

Epaisseur de métal ou

Intensité de courant

toutes conditions toutes conditions

moins de 1 po. (25 mm)

de 1 à 6 po. (25 à 150 mm)

plus de 6 po. (150 mm)

moins de 1/8 po. (3 mm)

de 1/8 à 1/2 po. (3 à 12 mm)

plus de 1/2 po. (12 mm)

moins de 5/32 po. (4 mm)

de 5/32 à 1/4 po. (4 à 6.4 mm)

plus de 1/4 po. (6.4 mm)

toutes conditions toutes conditions

toutes conditions

toutes dimensions

moins de 300 ampères

de 300 à 400 ampères

plus de 400 ampères

Nuance de

de filtre

oculaire

3 ou 4

2 ou 3 4 ou 5 5 ou 6

4 ou 5 5 ou 6 6 ou 8

10 12 14

11 12

12 12

12 14

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé;sinécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager desfuméestoxiquesau moment du soudage.

2-2 8-V-96

Page 11

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC

Instruction 830002

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact

accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

LES BOUTEILLES EN DOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitezles avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portéede la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHA PPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau de carburant ou de faire le plein.

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

8-V-96 2-3

Page 12

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

DESETINCELLESPEUVENTFAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

1. Portez toujours un écran facial en travaillant sur un accumu-

lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des

câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un

accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger

un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas

refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le

bouchon.

PRINCIPALES NORMES DE SECURITE

Safety in Welding and Cutting,norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have HeldHazardous Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

2-4 8-V-96

Page 13

DESCRIPTION OF EQUIPMENT

430429-249

General Description

The Model 2460 Heavy Duty CC/CV Wire Feeder is designed to control the linear movement of 1/8 inch (3.2 mm) diameter (or less) tubular welding electrode or 3/32 inch diameter (or less) solid welding electrode. The basic feeder has been designed for self-shielding welding electrode and does not have a gas solenoid.

For use of non self-shielding electrode, optional gas solenoids are available and may be installed in this portable feeder.

Metal Inert Gas (MIG) welding process joins metal parts by electric arc which is established between a filler metal (consumable welding wire) and the work. The combination of the consumable wire with the parent metal forms the weld.

This wire feeder may be used with either a constant-voltage or constant-current type welding machine. A transformer-rectifier, motor-generator, or engine-driven welding machine may be used.

Current Capacity and Rating

The welding current on this equipment is passed through the feedhead assembly. Care must be taken to make sure that the connections between the feedhead and the power source connecting cable as well as between the feedhead and gun cable assembly connector are tight. Loose connections cause excessive heating and must be avoided.

This feeder uses arc voltage for its power. The cable connection between the feedhead and the power source also provide a power connection for the feeder control. The other power connection is made through the voltage sensing lead which must be connected to the work terminal. Care must be taken to make sure that the power cable connection is made between the power source and work. If this connection is not made, and an attempt is made to strike an arc, serious damage to the feeder will occur. By taking power from the welding arc, two modes of operation result. These are termed CC and CV mode. When a constant voltage power source is used, the input voltage to the feeder remains constant and a fixed wire feed speed will result for agiven dial selection on the feeder. If either the power source voltage setting or the feeder setting are changed, the output speed will change. This is called CV mode of operation. When a constant

current power source is used, the arc voltage will vary and as a result, the wire feed speed will vary for a fixed dial setting on the feeder. This is called CC mode of operation. When a constant current power source is used, an increase in arc voltage will cause an increase in wire feed speed, but an increase in wire feed speed causes a decrease in arc voltage. This results in a self-regulating system so that the feeder keeps the arc voltage constant by varying the wire feed speed as the arc attempts to fluctuate. A switch on the back of the feeder is provided to select between CV or CC. This switch selects proper control stability for the mode being

used. The switch does not select the mode of

operation. The mode of operation is determined by the type of power source being used.

The main application for this wire feeder is for CC application using tubular self-shielding wires. Most CC types of power sources do not have a remote contactor control available. This means that the electrode is always hot once the power source has been turned on. It also means that the gun switch on the wire feeder does not control the power source, but only controls the starting and stopping of the wire feeder itself. Since the power source remains turned on, when the gun switch is released, care must be taken when terminating the arc. When the gun switch is released, the operator must also pull the gun away from the arc to make sure that the arc is extinguished and does not burn back into the gun tip.

Internal limiting circuitry limits the maximum speed independent of input voltage. In addition, a slow run-in circuit is provided which automatically reduces the run in wire feed speed when open circuit voltage from a CC power source is present.

NOTE: Wire feeder input is protected by a 7 Amp slo-blow fuse. An 1/8 Amp fuse protects the P.C. Board circuitry should a short develop between the gun switch lead to electrode lead. A 5 Amp slo-blow in-line fuse

inside the case protects the wire feed

motor.

Feedhead Assembly

The feed roll drive motor is solid-state controlled on this unit. One of either of two different motors (see Parts List for numbers of each) are used,

May 22, 1997 Revised 3-1

Page 14

430429-249 DESCRIPTION OF EQUIPMENT

depending upon whichwire feed rate is desired. See Table 3-1 for correlation of numbers.

Speed Range of Wire

20.4:1 drive gear ratio — 40 to 600 IPM

(inches/minute)

SPEC. MODEL

6877A-1 2460 4 40-600 IPM 6877B-1 2460 4 40-600 IPM 6877A-2 2460 4 20-300 IPM 6877B-2 2460 4 20-300 IPM

The assemblies consist of Feed Rolls (which are made up of a Gear and Feed Roll) for various wire types and/or sizes, Wire Input Guide, Output Guide, Feedhead Mounting Plate, and Pressure Arm assembly. The drivemotor is 24 volts DC. See TIP-218 for details on the Feedhead Assembly. See Feed Roll Kit drawing 375980 for selecting part numbers for the Feed Rolls, Wire Guides, Contact Tubes, etc.

FEED

ROLLS

Table 3-1

WIRE FEED

RATE

Tabulated Data

Gearmotor Permanent magnet

24 V DC, 1/8.8 HP

5A ± .5 amps

Speed:

123 RPM ± 12 RPM

57 RPM ± 5.7 RPM

(optional @ no

load)

Voltages

43.9:1 drive gear ratio — 20 to 300 IPM

(inches/minute) (optional)

Wire Data

Spool weight 60 pounds

(27.2 kg) max.

Sizes 1/8 inch (3.17 mm)

and smaller

Control Box Assembly

The Control Box contains control and connection for the operation and component hook-up with the particular welding system it is being used with. See TIP-218 and MPL-224 included in this manual.

Wire Reel Support Assembly

The support bolts in place at the rear of the baseplate. See I-169 included in this manual for details on the installation and operation of the wire support assembly.

Baseplate

See TIP-127 for details on the baseplate used for this wire feeder when assembled to make the subject model configuration.

Motor 24 V DC

Gun Circuit 11 V DC or 24 V AC

(option)

3-2 May 22, 1997 Revised

Options

The options available with this unit are as follows:

Page 15

430429-249

DESCRIPTION OF EQUIPMENT

ITEM DESCRIPTION

KIT, CONTACTOR WITH GV

KIT, CONTACTOR LESS GV

KIT, CONTACTOR WITH GV AND MEGA-ARC REMOTE CONTROL

KIT, CONTACTOR LESS GV AND MEGA-ARC REMOTE CONTROL

KIT, CONTACTOR WITH GV AND MEGA-MIG REMOTE CONTROL

KIT, CONTACTOR LESS GV AND MEGA-MIG REMOTE CONTROL

KIT, VOLT AND IPM METERS

KIT, MEGA-MIG, R.C. 15 FT.

KIT, MEGA-MIG, R.C. 25 FT.

KIT, MEGA-MIG, R.C. 50 FT.

KIT, MEGA-MIG, R.C. 75 FT.

KIT, MEGA-MIG, R.C. 100 FT.

KIT, MEGA-ARC, R.C. 25 FT.

KIT, MEGA-ARC, R.C. 50 FT.

KIT, MEGA-ARC, R.C. 75 FT.

KIT, MEGA-ARC, R.C. 100 FT.

CABLE CONTROL 6 FT.

CABLE, “Y” MEGA-ARC 6 FT.

CABLE, EXT 6 PIN 50 FT.

CABLE, EXT 6 PIN 100 FT.

CABLE, EXT 6 PIN 25 FT.

CABLE, EXT 6 PIN 75 FT.

CABLE, 19 PIN–10 PIN 10 FT.

CABLE, 10 PIN–LEAD 10 FT.

CABLE, 19 PIN–6 PIN 15 FT.

CABLE, 19 PIN–6 PIN 25 FT.

CABLE, 19 PIN–6 PIN 50 FT.

CABLE, 19 PIN–6 PIN 75 FT.

CABLE, 19 PIN–6 PIN 100 FT.

FRAME, SKID

KIT, HANDLE

KIT, CASTOR

EYE, LIFTING

MOUNTING, SWIVEL

KIT, SPOOL

ADAPTER, SPOOL 10 LB.

ADAPTER, SPOOL 15 LB.

ADAPTER, COIL 14 LB.

COVER, SPOOL 30 LB.

ADAPTER, COIL 60 LB.

KIT, REEL, WIRE

COVER, COIL 60 LB./SUPPORT/LIFTING EYE

6877A-1 6877A-2

376809-1 376809-2 376809-3

376809-4 376809-5 376809-6

376847 376810-1 376810-2

376810-3 376810-4 376810-5

376810-6 376810-7 376810-8

376810-9 373059A 376510

376511-1 376511-2 376511-3

376511-4 376512-1 376513-1

376514-1 376514-2 376514-3

376514-4 376514-5 493263

375994 375605-2 375104

375606-2 374831A 375585

375584 375942 375582-2

407142 374819A 375733-1

6877B-1 6877B-2

376809A-1 376809A-2 376809A-3

376809A-4 376809A-5 376809A-6

376847 376810-1 376810-2

376810-3 376810-4 376810-5

376810-6 376810-7 376810-8

376810-9 373059A 376510

376511-1 376511-2 376511-3

376511-4 376512-1 376513-1

376514-1 376514-2 376514-3

376514-4 376514-5 493263-1

375994A 375605A-2 375104A

375606A-2 374831A 375585-1

375584-1 375942A 375582A-2

407142A 374819A 375733A-1

NOTE:Forinstallationand operation instructions for the above options, see thedrawingsand instructions furnished with each kit. The Welding Gun and Cable Assembly used with the Feedhead in the manual is covered by an Owner’s Manual. (See TIP publication included in this manual for particular Feedhead used.)

May 22, 1997 Revised 3-3

Page 16

430429-249 DESCRIPTION OF EQUIPMENT

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3-4 May 22, 1997 Revised

Page 17

OPERATION

430429-249

OPERATION

Prewelding Checks

Before attempting to operate the Model 2460 Heavy Duty CC/CV Wire Feeder, make certain that all installation instructions, including those for the welding machine (power source), and the welding gun and cable, have been carried out.

1. With the feeder properly connected to the power source and the work cables properly connected from power source to work and from feeder to work, turn on the power source.

WARNING: When the power source is turned on, the electrode (welding wire) is electrically “hot”. Do not permit it to touch any metal or a welding arc may be established which may be injurious to someone’seyes (flash) or skin (burn).

2. Select CC/CV characteristic on motor control circuit and set switch accordingly.

3. Determine desired operating voltage in case of a CV power source or desired operating current in case of a CC power source and set power source accordingly.

4. Set control on feeder to an approximate 3

position on the dial.

NOTE: When using a CV power source, increasing dial position will increase wire feed speed and as a result increase welding current.

Whenusinga CC power source, increasing dial position will increase wire feed speed and as a result will decrease arc voltage.

Welding

1. Position the gun above the workpiece but do not touch the electrode to the work as this will cause arc flash. With the gun in the proper position and eyes fully protected, pull the gun switch which will cause an arc to be initiated.

2. Releasing the gun switch trigger will cause the wire to stop feeding. At this time the gun must be pulled away from the work in order to extinguish the arc.

3. When the welding has been completed, or at the end of the work day, it is recommended that the power source and feeder be turned off.

May 22, 1997 Revised 4-1

Page 18

430429-249 OPERATION

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4-2 May 22, 1997 Revised

Page 19

430429-249

Troy, Ohio 45373 PARTS LIST

PARTS LIST

Equipment Identification

All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Specification or Assembly numbers.

How To Use This Parts List

The Parts List is a combination of an illustration (Figure Number) and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of theequipment are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded

to another part. The part descriptions may be indented to show part relationships.

To determine the part number, description, quantity, or application of an item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.

An “Application Code” is used to distinguish parts that are applicable only to certain Specifications and/or Assemblies. This code is found in the rightmost column ofthe Parts List. If anitem in the Parts List applies to all Specifications or Assemblies, the word “ALL” will be in the Application Code column. Refer to the following list to determine the appropriate Application Codes for the Specifications or Assemblies covered by this manual. If only the assembly or specification number is listed, the use of an Application Code does not apply to this manual.

SPECIFICATION NUMBER APPLICATION CODE

6877A-1 A 6877A-2 B 6877B-1 C 6877B-2 D

November 2, 1999 Revised 5-1

Page 20

430429-249 PARTS LIST Troy, Ohio 45373

Figure 5-1 Wire Feeder Assembly

5-2 June 18, 1999 Revised

Page 21

430429-249

Troy, Ohio 45373 PARTS LIST

Parts List for Figure 5-1

Item Part Description Qty Application

No Number per Code

Assy

S-6877A-1 Wire Feeder, CC/CV Operation

S-6877A-2 Wire Feeder, CC/CV Operation

S-6877B-1 Wire Feeder, CC/CV Operation

S-6877B-2 Wire Feeder, CC/CV Operation

1 376783B . Box - Control Assembly

376783B-1 . Box - Control Assembly

2 376799A-1 . Feedhead - Assembly 40-600 IPM

376799A-3 . Feedhead - Assembly 40-600 IPM

376799A-2 . Feedhead - Assembly 20-300 IPM

376799A-4 . Feedhead - Assembly 20-300 IPM

3 375769-1 . Base 1 AB

375769-4 . Base 1 CD

4 374818A-1 . Support - Wire Spool Assembly

374818A-9 . Support - Wire Spool Assembly

— 376827 List - Field Installable Options Ref. All 5 870087-1 Label - Thermal Arc 2 All 6 870194-1 Cable - Assy 1 All

4-Roll Drive, 40-600 IPM 1 A

4-Roll Drive, 20-300 IPM 1 B

4-Roll Drive, 40-600 IPM 1 C

4-Roll Drive, 20-300 IPM 1 D

(For Details See Figure 5-2) 1 AB

(For Details See Figure 5-2) 1 CD

(For Details See MPL-224) 1 A

(For Details See MPL-224) 1 C

(For Details See MPL-224) 1 B

(For Details See MPL-224) 1 D

(For Details See I-169) 1 AB

(For Details See I-169) 1 CD

— Not Illustrated

November 2, 1999 Revised 5-3

Page 22

430429-249 PARTS LIST Troy, Ohio 45373

Figure 5-2 Control Box Assembly

5-4 June 18, 1999 Revised

Page 23

430429-249

Troy, Ohio 45373 PARTS LIST

Parts List for Figure 5-2

Item Part Description Qty Application

No Number per Code

Assy

376826 Cover - Control Box Assembly 1 AB 376826-1 Cover - Control Box Assembly 1 CD

1 376782-1 . Cover - Control Box 1 AB

376782-2 . Cover - Control Box 1 CD 2 Deleted 3 204036 . Label - Precautionary 1 All

376783B Box - Control Assembly 1 AB

376783B-1 Box - Control Assembly 1 CD 4 405535-2 . Support - P.C. Board 4 All 5 376807C . Board - P.C., Motor Control 1 All 6 401937-2 . Block - Terminal, 20 Amp, 8 Station 1 All 7 407146 . Label - Terminal Block 1 All 8 403704-1 . Switch - Rocker, ON/OFF 1 All 9 Deleted 10 406926-3 . Potentiometer - 10K, 2 W 1 All 11 40209 . Strip - Weather, 1/16 x 1/2 68-1/4" All 12 40207 . Strip - Weather, 1/16 x 1/4 15-3/4" All 13 376718 . Plate - Cover 2 AB

376718-1 . Plate - Cover 2 CD 14 Deleted 15 406806 . Knob - Control 1 AB

406806-3 . Knob - Control 1 CD 16 408246-1 . Clip - Nylon 7 All 17 403091-4 . Plug - Hole, Plastic 1 All 18 402037-3 . Grommet 1 All 19 . Deleted 20 403091-2 . Plug - Hole, Plastic 2 All 21 405576-1 . Bushing - Terminal 1 All 22 376711B-1 . Wrapper - Control Box 1 AB

376711B-2 . Wrapper - Control Box 1 CD 23 W-10051-2 . Clamp - Wire Plastic 1 All 24 409838 . Grommet - Mtg. 4 All 25 409837 . Spacer - Nylon 4 All 26 371635 . Adapter - Gas R.H. 1 All 27 408242-1 . Fuseholder 2 All

2 28 401972-5 . Fuse - Slo-Blow, 7 Amp 1 All

— Not Illustrated

November 2, 1999 Revised 5-5

Page 24

430429-249 PARTS LIST Troy, Ohio 45373

Parts List for Figure 5-2

Item Part Description Qty Application

No Number per Code

Assy

29 407097-1 . Switch - Toggle 1 All — 403031 . Seal - Switch 1 All — 408243-1 . Boot - Switch 1 All 30 401972-2 . Fuse - 5 Amp, Slow Blow 1 All — 406008-13 . Receptacle, 6 Position 1 All — 406008-3 . Receptacle, 12 Position 1 All — 406008-10 . Receptacle, 4 Position 1 All — 406009-1 . Plug - Keying 3 All 31 404065-2 . Rectifier - Bridge 1 All 32 407961A-1 . Nameplate - Prod. Info. 1 All 33 170656 . Label - Fuse 1 AB 34 405535-5 . Support - P.C. Board 4 All 35 376507 . Board - P.C. Gas Valve 1 All 36 403091-11 . Plug - Hole, Plastic 1 All

— Not Illustrated

5-6 June 18, 1999 Revised

Page 25

TIP-218

CONTROL BOX ASSEMBLY NO. 376783A & 376783B

DESCRIPTION, INSTALLATION, OPERATION AND MAINTENANCE

Description

The Control Box assembly is the control medium for the operationof the Feedhead. Wire Feed Speed rate (IPM Inches-per-minute) is selected and regulated by the knob (potentiometer) on the front panel. The box is designed to function as a component of the 2000 Series Wire Feeder composite assembly, or as remote-mounted control medium, not situated close to the Feedhead. A side panel is available to replace the Feedhead Mounting Plate (see Figure

1) when used in a remote situation.

Controls and Connections

A. CV operation. When using a CV power source, this control is used to control wire feed speed. To increase wire feed speed, turn the control knob clockwise. To decrease wire feed speed, turn the knob counterclockwise.

B. CC operation. When using a CC power source, this control is used to control arc voltage by varying wire feed speed. To increase arc voltage (decrease wfs), turn knob counterclockwise. To decrease arc voltage (increase wfs), turn knob clockwise.

NOTE: Many CC power sources have a drooping V-I characteristic. On these types of power sources, the current is not exactly constant and changing the arc voltage will also change the output current. This again becomes a self-regulating stable system.

ON-OFF Rocker Switch — This switchcontrols the input circuit, applying or removing the input voltage of the unit.

Gun Switch Receptacle — The gun switch control cable connects to the gun switch receptacle (quickdisconnect type) to provide control from the gun switch to the wire feed mechanism.

Welding Gun Cable Connector — The gun cable is connected to the wire feeder at this receptacle. Connections must always be tight.

Fuse 7 A — The unit is equipped with a 7 A MDX slow blow fuse. This fuse is rated at 125 volt and

may never be replaced with a fuse of lower voltage

rating as this could cause serious damage to the equipment.

Fuse 1/8 A — Protects P.C. Board from welding electrode shorting to gun switch circuit.

Figure 1 Controls - Connections (Front End)

May 29, 1996 Revised Page 1

Page 26

TIP-218 CONTROL BOX ASSEMBLY NO. 376783A & 376783B

Figure 2 Connections (Rear End of Enclosure)

Fuse 5 A — Protects motor from excessive stall

current.

Label — Identifies 5 A fuse rating and location

(inside control box).

CC/CV Switch — This is a two-position switch that controls the droop characteristics of the motor control circuit. When in the CV position, the circuit uses IR compensation giving an almost flat speed torque curve. When in the CC position, the IR compensation is eliminated and the speed torque curve has a fairly high droop. The CV position is recommended for all CV types of power sources. The CC position is generally recommended when using a CC power source. For many types of wires however, the CV position is recommended even when a CC power source is used.

A 12-volt gas valve and P.C. Board control the shielding gas for solid wire welding. Welding gas will flow when the gun switch is closed.

The circuit board uses the output voltage of the bridge rectifier CR1 and converts this output into a 12-V DC voltage. The gas valve is a part of the total

DC to DC converter circuit and is always connected in the circuit.

The circuit board is installed next to the motor

control board.

Installation

Location

The model 2460 heavy duty CC/CV wire feeder is designed to withstand high moisture conditions encountered in outdoor welding applications. However, the wire feeder is not waterproof and therefore should not be stored outdoors for extended periods of time.

Connections

1. Make sure that the proper welding cable connections exist between the feeder feedhead (electrode) to power source and work connection to power source. Connect Feeder work lead (Figure 1) to work.

Page 2 May 29, 1996 Revised

Page 27

2. Attach the gun and cable to the wire feeder by following instructions found in the Owner’s Manual for the Gun and Cable assembly.

WARNING: The welding electrode is electrically “Hot”. Electrode contact to workpiece will causean arc withthewirefeeder connected to the workpiece and gun switch depressed — feed motor will run feeding “HOT” electrode.

TIP-218

CONTROL BOX ASSEMBLY NO. 376783A & 376783B

voltage and changes it to the proper DC voltage required to operate the motor. The motor is part of the operating circuit, and the circuit will not operate properly if the motor is removed.

The circuit is designed for continuous operation when the input voltage is 30 volts or below. Many CC power sources have an open circuit voltage of 60 to 100 volts. Under these input conditions, the circuit will operate and the motor will run. This condition may exist for a period long enough to feed wire through thegun when wire spools are changed, etc., but the motor must never be allowed to operate with open circuit voltage for prolonged periods of time.

Operation

Theory of Operation Refer to Connection Diagram 376784A

With the wire feeder connected to the welding electrode and the work terminal, turn the power source and wire feeder on. Power is supplied into Bridge rectifier CR1. Power on the output side of the CR1 is fed to the motor control board with the proper polarity independent of the welding polarity.

When the welding gun switch (S4) is closed, it energizes the proper components on the PC Board and causes the motor to run. When the gun switch is opened, it removes power from the motor and shorts the armature to provide dynamic braking of the motor.

When the CC/CV switch (S5) is open, IR compensation is used on the motor control circuit. When S5 is closed, the IR compensation circuit is not active.

Terminal strip TB1 is used to connect various options to the feeder.

Switch S1 is used to turn the power into the feeder on or off.

Resistor R1 isthe control potentiometer for the unit which varies the output speed.

The motor control circuit on this feeder is a DC to DC converter circuit.It uses the power supply output

Options

1. Remote Contactor Control Option — This option is externally located and connects to the feeder by means of a control cable which is added to the feeder. When this option is installed, a relay is added to the feeder and a 24-V AC gas valve option is available.

The remote box requires 115-V AC input and in turn provides 24 V AC to the feeder as well as a contactor control relay closure to the power source. The 24 V AC is also used to allow for inching of the wire feed motor.

2. A voltmeter kit as well as an inches per minute

kit are available for this unit.

3. A remote arc voltage/current control is also available which allows the user to adjust the power source at the feeder.

Maintenance

Cleaning of the Unit

Periodically remove a side panel of the cabinet, and blow out the interior with clean, dry, compressed air of not more than 25 psi (172 kPa) pressure. Do not strike any of the components with the air hose nozzle.

May 29, 1996 Revised Page 3

Page 28

TIP-218 CONTROL BOX ASSEMBLY NO. 376783A & 376783B

Troubleshooting

The following chart contains information which can be used to diagnose and correct unsatisfactory operation or failure of various components of the unit. Each symptom of trouble is followed by a list of probable causes and procedures to correct them.

Wire does not feed, open-circuit voltage is normal

Switch on Feeder not on or bad

Check and correct.

Fuse open on Feeder

Check and replace.

Work lead not connected

Check and connect.

Cables from Power Sources not properly connected

Check and connect.

Gun switch defective

Check for proper operation.

Feed rolls not properly tightened

Correct situation.

Bad PC board on feeder

Replace.

5 A internal fuse blown

Replace fuse.

Erratic weld output

Ground clamp loose at WORK connection

Check ground clamp for secure attachment.

Gun liner dirty

Check gun liner and replace if necessary.

Voltage/current and feeder settings are not correct

Readjust as necessary.

Improper wire for gas less welding

Change to proper wire.

Wire feed motor operates, but wire does not feed

Too little pressure on wire feed roll

Increase pressure adjustment.

Incorrect wire groove

Check wire size stamped on outside of feed roll. Match to wire size.

Page 4 May 29, 1996 Revised

Page 29

Wire spool tension too great

Loosen adjusting screw.

Restriction in gun or cable assembly

Examine cable, gun, and current contact tube (tip) for damage and correct size. Make sure correct contact tube and liner is being used.

Welding current or voltage not stable

Wire slipping in rolls

Readjust pressure on the drive roll pressure arm.

Restriction in gun cable or gun

See Welding Gun and Cable Description and Maintenance.

Wrong size liner or contact tube

Match liner and contact tube to electrode wire size.

Incorrect voltage adjustment for selected wire speed on the welding machine

Readjust. See Welding Guide in Operation section.

Loose connection on the welding leads or work table

TIP-218

CONTROL BOX ASSEMBLY NO. 376783A & 376783B

Check and tighten all connections.

Wire wraps around the drive roll

Too much feed roll pressure

Decrease the pressure adjustment on the drive roll pressure arm.

Incorrect liner or contact tube

Make sure that liner and/or contact tube is correct for the size of wire being fed.

No speed control

Broken or loose wires in wire feed control circuit

Correct by checking all connections.

Bad PC board

Replace.

Bad wire feed speed control potentiometer

Replace.

No gas flow

Gas valve not energizing

Broken lead to valve.

Bad PC board

Replace.

Open gas valve coil

Replace gas valve.

May 29, 1996 Revised Page 5

Page 30

TIP-218 CONTROL BOX ASSEMBLY NO. 376783A & 376783B

This page intentionally left blank.

Page 6 May 29, 1996 Revised

Page 31

TIP-219

FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4

DESCRIPTION, INSTALLATION, OPERATION AND MAINTENANCE

Description

The four-roll feedhead assembly consists of four idler gear/feed rolls (item 2, Figure 1) for various types and sizes of wire. See Feed Roll Kit (375980), wire input guide (item 1), center guide (item 7), output guide (item 5), feedhead plate (item 4) and pressure arm assembly (item 6). The drive motor is 115 volt DC, controlled by solid-state or variac speed control. See the data on the particular model which is found in the manual of which this TIP is a part.

Wire sizes from 0.030-inch (0.76 mm) diameter to 1/8 inch (3.18 mm) may be fed with selection of proper feed rolls. See Feed Roll Kit (Drawing 375980-X, included in this manual) for feed roll configuration and proper feed rolls for given sizes and types of wire.

The Solenoid (Gas Control) Valve (optional) is located on the back side of the Feedhead Plate. A fitting for gas supply extends through the back panel of the Control Box.

Installation

The feedhead assembly becomes a part of the modular assembly which includes a control box assembly, and a wire support assembly which may be mounted on a common baseplate, or remotely mounted, as on a boom unit.

Location — For best operating characteristics and longest unit life, take care in selecting an installation site. Avoid locations exposed to dust, high ambient temperature, or corrosive fumes.

Connections — The electrical connections for the wire feeder are made both at the feedhead and control box. The feedhead connection is made from the power supply terminal to the feedhead as with standard feeders. However, the feeder motor and controls use the feedhead potential to supply operating power for the feeder. Be sure the cable connection to the feedhead is tight. A loose cable will cause the feeder to malfunction.

Installation of Welding Wire Spool — See I-169 for details.

Adjustment of Spool Tension — Adjust the tension on the Wire Spool so that the wire will feed freely into the feedhead (feed rolls), but will not “coast” when wire feeding stops. Tighten or loosen the Hub Tension Screw accordingly.

Threading Wire Into Feedhead — Refer to Figure

CAUTION: Use care when handling the spooledwire asit tends to unravel when loosened from the spool. Grasp the end of the wire firmly; do not let it get away! Make sure the end of the wire is free of burrs, and that it is straight.

1. Loosen the Pressure Arm Knobs, and raise the

Pressure Arm UP as shown in Figure 2.

2. Place the end of the wire into the Input Guide, feeding it through the guide and over the feed roll grooves.

1. Input Guide

2. Idler Gear/Feed Roll

3. Drive Gear

4. Feedhead Plate

Figure 1

December 1, 1997 Revised Page 1

5. Output Guide

6. Pressure Arm Assembly

7. Center Guide

3. Pass the wire into the Output Guide and on into the Gun Cable. See Owner’s Manual for the Gun and Cable Assembly.

4. Make sure that the wire is directly over the grooves in the feed rolls and replace the Pressure Arm. Lock it in place with the Pressure Arm Knobs.

Page 32

TIP-219 FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4

Installing Gun and Cable Assembly — Refer to Figure 3. The Feedhead is designed for use with TWECO Guns and Cables. To install one of these guns, loosen the Gun Receptacle Knob and insert the gun Quick Connect Receptacle into the Feedhead until it bottoms out against the Output Guide. Tighten Gun Receptacle Knob. See “A” and “B” assemblies on Figure 3.

If a TWECO #5 Backend Gun and Cable is to be installed, the Gun Sleeve must be removed, the Gas Inlet must be removed and replaced with another one. See “B” on Figure 3. The Gas Inlet comes in a kit (375999). To install the Gun and Cable, proceed as follows:

1. Remove the Gun Receptacle Knob.

2. Remove the two retaining screws which secure the Gas Inlet into the Feedhead Plate. This allows the Gas Inlet to pull straight out.

3. Hold the Gas Tube (with hose attached) and turn the Gas Inlet counterclockwise to unscrew and remove it. Screw the Gas Tube into the Gas Inlet provided in kit 375999, but do not yet install the Gas Inlet into the Feedhead.

Figure 2

NOTE: If the Gun Sleeve does not come out easily, insert a screwdriver into the slot (see Figure 3) and gently, but firmly, pry the sleeve out.

5. Slide the new Gas Inlet (with Gas Tube installed) into place, making sure that the wide groove, toward feed rolls, goes in first.

6. Replace the Retaining Screws to secure the Gas Inlet into place.

NOTE: When the TWECO #5 Backend Gun and Cable is installed, it may be necessary to change the Output Guide, depending upon new wire size. See instructions for changing Output Guide in Installing Feed Rolls and Guides.

7. Raise the Gun Receptacle and reinstall the Gun Receptacle Knob. Do not tighten at this time.

8. Insert the quick-connect receptacle on the Gun Cable into the Feedhead, and tighten the Gun Receptacle Knob to a “snug” position. See Gun and Cable Manual for details on these parts.

4. Hold the Gun Receptacle and remove the Gun Sleeve (used only on the TWECO #4 Backend Guns). Lower the Gun Receptacle.

9. Attach electrode lead to the Gun Receptacle by use of a bolt in the threaded hole at the lower end of the receptacle.

Page 2 December 1, 1997 Revised

Page 33

TIP-219

FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4

Installing Feed Rolls and Guides — Feed Rolls, Input Guides, and Output Guides are supplied in Feed Roll Kit 375980-X, depending upon wire size, type, and Feed Roll style. Follow the procedure below for initial installation or changing Feed Rolls and/or guides for different wire size or type. See Figure 2 for reference to components below.

NOTE: When Feedhead assembly is shipped from factory, the Feed Roll Screws (quantity of 12) are placed separately in a cloth bag and furnished with the Feedhead assembly.

Feed Rolls

1. Locate and open the cloth bag with twelve feedhead screws (#8-32 x 1" allen socket-head screws).

2. Select proper Feed Rolls and Guides. See 375980 and determine the proper dash (–) number for wire type, Feed Roll style, Feed Roll part numbers, Input Guide, Center Guide, and Output Guide part numbers.

Figure 3

both bottom Feed Rolls. See Figure 2.

Gears. See Figure 4. Insert three Feed Roll screws in each roll and tighten.

4. Install Center Guide in place before installing

NOTE: The Center Guide may be installed if only one, but Feed Rolls are in place.

5. Install the two lower Feed Rolls onto the Idler

not both lower

3. Loosen the Pressure Arm Knobs and lift the Pressure Arm off.

December 1, 1997 Revised Page 3

Figure 4

Page 34

TIP-219 FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4

NOTE: An Allen wrench is supplied for tightening the Feed Roll Screws. It is “stored” in a nylon retainer, located on the rear end of the Feedhead Cover. See Figure 6.

6. To install the upper two Feed Rolls, follow the procedure below:

a. Remove shaft screws which secure the Idler Gear/Shaft in place in the pressure arm. See Figure 5.

b. Install the Feed Rolls onto the Idler Gears, and secure in place with the Feed Roll Screws. See Figure 4.

NOTE: When installing a Style 4 Feed Roll, which is made up of two pieces, be sure to place the narrow piece on the gear first. This makes the groove line up with the Guides.

2. Insert the steel or nylatron Input Guide into the

hex nylon Input Guide.

NOTE: The hex nylon Input Guide is a holding device for the Input Guide Spring and the Input Guide which is supplied in the Feed Roll and Guides Kit (375980-*).

*The dash number denotes which Feed Rolls and Guides are furnished.

3. Reinstall the Input Guide Spring, pushing it against the Input Guide, and tighten the Retaining Screw.

Output Guide — The Output Guide may be installed with the Gun Sleeve and the Gas Inlet (all models) in place.

1. Loosen the Output Guide Retaining Screw (see Figure 2), and turn it out far enough to allow the Guide to slide in or out.

c. Reinstall the Idler Gears/Feed Rolls into the Pressure Arm. Fasten in place with the Shaft Screws. See Figure 5.

d. Reassemble Pressure Arm onto the Feedhead Assembly by dropping it into place (see Figure 2) and adjusting the Pressure Arm Knobs for proper tension. Adjust Center Guide so that clearance between Guide and the first Feed Roll is approximately 1/32 inch (0.8 mm). Tighten Center Guide Retaining Screw.

Figure 5

Input Guides

1. Loosen the Input Guide Retaining Screw and pull the Input Guide Spring (Item 1, Figure 1) out of the hex nylon Input Guide.

2. Insert the Guide into the Feedhead with longnosed pliers or a piece of welding wire. Push the Guide up to the Feed Rolls until it “bottoms out” inside the Feedhead and tighten the Retaining Screw.

3. Proceed to install the Gun and Cable Assembly as detailed above under Installing Gun and Cable Assembly.

Operation

The operation of this feedhead is a function of the wire feeder assembly of which it becomes a part. See the Wire Feeder Manual for the 2000 Series for details which affect this operation.

Maintenance

Cleaning — Periodically blow off the feedhead assembly with clean, dry, compressed air of not more than 25 psi (172 kPa) pressure. Use care to not strike component parts of the feedhead with the air hose nozzle.

Cleaning Feed Rolls and Gears — Using a small wire brush, clean the grooves on the feed rolls and gear teeth frequently. To clean the wire groove, loosen the Pressure Arm Knob and raise the Pressure Arm. Remove the wire from the feed rolls. Clean the gear teeth and check the screws which hold the feed rolls on the gears.

Feedhead Maintenance — The only point of maintenance in the feedhead assembly is the motor brushes. To inspect and/or change the brushes, the feedhead assembly mustbe removed from the Con-

Page 4 December 1, 1997 Revised

Page 35

trol Box (in the 2000 Series composite assembly). See Figure 6 and instructions for removing feedhead and motor from Control Box.

NOTE: There are two possibilities for wire feed motors, depending upon which manufacturer’s stock was used for the particular assembly. The removal from the Control Box is the same for both motors, but the procedure for changing brushes is different.

1. Remove six screws from the top and side of the Control Box which holds the Control Box Cover in place. Loosen the screws (2) at the bottom of the Cover, to allow the Cover to slip up off from the screws in the slots provided.

2. Disconnect the power supply wire from the gun receptacle. Remove the four screws and lockwashers which secure the Feedhead Mounting Plate to the side of the Control Box. This will allow the Feedhead assembly (including the motor) to pull straight out of the Control Box, to a position (see Figure 6) wherethe motor brushes may be serviced.

3. The Bodine gear motors are equipped with a vent for the gearbox. The vent hole is plugged and does not have to be removed for operation.

TIP-219

FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4

Bodine Motor Brush Inspection and Installation — See Figure 7 — The brushes should be inspected every 300 hours of operation. When brushes are worn to about 3/8 inch (9.5 mm) in length, new brushes should be installed. (Refer to Parts List for brush part numbers.) See Figure 7 for following procedure.

CAUTION: Neglect in brush maintenance may cause damage to commutator in the motor if allowed to wear away completely.

1. See Step 1 on Figure 7. Lift and remove the Brush Cap by prying the Rivet out of the hole in the End Shield. This will reveal the brush assembly in place as in Step 2.

2. Using long-nosed pliers, grasp the Spring Retaining Bracket. Slightly push the Retaining Spring

down and toward the brush. When the Bracket

unhooks from theBrush Box, lift the Retainer/Spring out.

3. Using long-nosed pliers, grasp the connector on

one end of the brush pigtail and pull it straight up.

Disconnect it from the clip on the side of the Brush Box. The Brush may be removed at this time.

Figure 6

December 1, 1997 Revised Page 5

Page 36

TIP-219 FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4

Figure 7

NOTE: Blow dirt and foreign matter out of the Brush Box with compressed air of not more than 25 psi (172 kPa) pressure.

4. Install new brushes if necessary. Reassemble the unit in reverse order of the dismantling procedure.

Stature Motor Brush Inspection and Installation —

See Figure 8.

1. Remove Brush Cap from the End Cap using a screwdriver. As the cap is removed, the spring on the Brush Pigtail will pop up out of the hole.

NOTE: Observe the direction which the spring bends in order to reinstall the brush in the same position, for best fit to the motor commutator.

2. Lift the Brush/Spring out of the Brush Box.

3. Inspect Brush, check dimensions, blow out the

Brush Box with compressed air (see NOTE above).

4. Install new Brush/Spring, if necessary, and

screw the Brush Cap into the threaded hole.

5. Install the feedhead assembly into the Control Box in reverse order to that in Feedhead Maintenance, paragraph 1 and 2, above.

Figure 8

Page 6 December 1, 1997 Revised

Page 37

PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4

PARTS LIST FOR ASSEMBLY NUMBERS 376799A-1,-2, -3, -4

MPL-224

Equipment Identification

How To Use This Parts List

to another part. The part descriptions may be indented to show part relationships.

To determine the part number, description, quantity, or application of an item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.

An “Application Code” is used to distinguish parts that are applicable only to certain Specifications and/or Assemblies. This code is found in the rightmost column of the Parts List. If an item in the Parts List applies to all Specifications or Assemblies, the word “ALL” will be in the Application Code column. Refer to the following list to determine the appropriate Application Codes for the Specifications or Assemblies covered by this manual. If only the assembly or specification number is listed, the use of an Application Code does not apply to this manual.

ASSEMBLY NUMBER APPLICATION CODE

376799A-1 A

376799A-2 B

376799A-3 C

376799A-4 D

May 29, 1996 Revised Page 1

Page 38

MPL-224 PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4

Figure 1 Feedhead Assembly

Page 2 May 29, 1996 Revised

Page 39

MPL-224

PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4

Parts List for Figure 1

Item Part Description Qty Application

No Number per Code

Assy

376799A-1 Feedhead - 4 Roll, 600 IN./MIN.

376799A-2 Feedhead - 4 Roll, 300 IN./MIN.

376799A-3 Feedhead - 4 Roll, 600 IN./MIN.

376799A-4 Feedhead - 4 Roll, 300 IN./MIN.

Heavy Duty, CC/CV Assy 1 A

Heavy Duty, CC/CV Assy 1 B

Heavy Duty, CC/CV Assy 1 C

Heavy Duty, CC/CV Assy 1 D 1 406846 . Arm - Pressure 1 All 2 376001A . Knob - Pressure Arm 2 All 3 400562-38 . Spring - Compression 2 All

4 375784A . Washer - Pressure Arm 2 All 5 375789 . Rod - Pressure Arm 2 All 6 16DA-1202-13 . Pin - Spring 2 All 7 5CW-3884-2 . Screw - #10-24 x 1/2, HH, MH, ST. 1 All 8 406397 . Guide - Input 1 All 9 376037 . Spring - Input Guide Assy 1 All 10 16DA-1202-11 . Pin - Spring 1 All 11 375920 . Plate - Feedhead, 4 Roll 1 All 12 No Number . Screw - #10-32 x 1/2, Rd. Hd. MH. ST. 2 All 13 No Number . Screw - 1/4-20 x 3/4, Rd. Hd. MH. ST. 1 All 14 No Number . Washer - LK. Std., 1/4 10 All 15 No Number . Washer - FL. ST. 1/4 6 All 16 375793 . Washer - Insulating 2 All 17 406985 . Gear - Feed Roll, Assembly 1 All 18 375836 . Spacer - Feedhead 1 All 19 405836-3 . Ring - Snap, Retaining 1 All 20 407075-1 . Shim - .005 Thickness 3 All 21 407075-2 . Shim - .015 Thickness 3 All 22 406639-2 . Ring - Snap, External 1 All 23 407133-1 . Knob - Gun Receptacle 1 All 24 375787 . Spacer - Gun Receptacle 1 All 25 407044 . Screw - Retaining 2 All 26 375781-2 . Receptacle - Gun 1 All 27 No Number . Screw - 3/8-16 x 3/4 HHC, ST. 1 All 28 No Number . Washer - LK, ST. 3/8 1 All 29 No Number . Washer - FL, ST. 3/8 1 All 30 375962 . Sleeve - Gun 1 All

May 29, 1996 Revised Page 3

Page 40

MPL-224 PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4

Parts List for Figure 1

Item Part Description Qty Application

No Number per Code

31 375981 . Inlet - Gas 1 All 32 375298 . Tube - Gas 1 All 33 375840 . Spacer - Feedhead 3 All 34 375792 . Spacer - Feedhead 3 All 35 16DA-1202-3 . Pin - Spring 1 All 36 No Number . Screw - 1/4-20 x 1-1/4, HHC, ST. 1 All 37 402119-10 . Screw - 1/4-20 x 2, HHC, ST. 2 All 38 16DA-4249-5 . Ring - Snap, External 4 All 39 407108 . Washer - Flat 4 All 40 375921 . Gear - Feed Roll, Assembly 4 All 41 W-11144-3 . Screw - #8-32 x 1, Cap Socket Hd. 12 All 42 375790 . Shaft - Feed Roll 2 All 43 375825 . Spacer - Feedhead, Locating 1 All 44 403091-13 . Plug - Hole, Plastic 2 All 45 407567 . Label - Instruction 1 All 46 376804-1 . Strip - Weather 1 All 47 402037-25 . Grommet 1 All 48 No Number . Screw - #8-32 x 3/8 HWH, SF-Tap 1 All 49 No Number . Washer - #8, LK 1 All 50 404162-5 . Valve - Solenoid, 12 V 1 All 51 402927-1 . Connector - Male 1 All 52 No Number . Tie - Cable 1 All 53 16DA-3304-22 . Tubing - Gas, Water 1 All 54 370495A . Connector - Gas Hose 1 All 55 No Number . Clamp - Hose 1 All 56 373130-10 . Hose - Rubber 1 All

376130-11 . Cover - Mtg. Feedhead Assy 1 AB 373130-17 . Hose - Rubber 1 CD

57 375764-1 . . Cover - Feedhead Assembly 1 AB

375764-4 . . Cover - Feedhead Assembly 1 CD 58 407152-1 . . Rivet - Blind, Plastic 1 All 59 406334-4 . . Wrench - Allen 1 All 60 407175-1 . . Spring - Retaining, Door 1 All 61 376716-1 . . Plate - Mtg. Feedhead 1 AB

376716-2 . . Plate - Mtg. Feedhead 1 CD 62 407138 . . Label - Tension Indicator 2 All 63 407099 . . Label - Electric Shock 1 All

Assy

Page 4 May 29, 1996 Revised

Page 41

MPL-224

PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4

Parts List for Figure 1

Item Part Description Qty Application

No Number per Code

Assy

64 406636 . . Label 1 All 65 376721-1 . Motor - Gear, Feedhead Assy 1 A

376721-2 . Motor - Gear, Feedhead Assy 1 B

66 407192 Spring - Brush 2 67 407086 Cap - Brush 2 68 407193 Rivet 2 69 407089 Brush 2

May 29, 1996 Revised Page 5

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MPL-224 PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4

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Page 6 May 29, 1996 Revised

Page 43

BASE ASSEMBLY NO. 375769-1 & -4

DESCRIPTION AND INSTALLATION INSTRUCTIONS

TIP-127

Description

The base is designed for use in assembling a composite Series 2000 Wire Feeder. It is a component which makes it possible to bring together a Control Box and Feedhead Assembly (which have their own TIP Instruction Sheets), and a Wire Spool Support Assembly.

Installation

The illustration below shows the mounting of the Control Box, Feedhead Assembly, and the Wire Spool Support Assembly.

1. To mount the ControlBox Assembly, align holes

in the base with the grommets (in the Control Box

bottom panel), insert the self-tapping mounting screws through the holes in the base, into the nylon grommets.

2. Tighten the screws in place, which will expand the nylon grommets in the holes in the Control Box bottom.

NOTE: The Feedhead Assembly is secured to the Control Box, and does not bolt directly to the base.

3. Align four holes in the bottom flange on the Wire Spool Support with four holes in the base (as shown in illustration) and insert four capscrews through the holes in the base and stiffener (underneath the base) and secure in place with the four hex nuts.

May 17, 1996 Revised Page 1

Page 44

TIP-127 BASE ASSEMBLY NO. 375769-1 & -4

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Page 2 May 17, 1996 Revised

Page 45

INSTRUCTION SHEET - Installation of Wire “Reel” or “Spool” on the Support

The wire feeder will be shipped from the factory with a wire spool kit 870058 and a wire reel/spool support assembly 870060-X. An “optional” wire reel kit 870059 is also available.

WARNING: Mount spool with hub nut angled upward (see Figure1). Hub nutmay detachcausing personal injury from falling wire coil spool if improperly mounted.

c. Install the spool tension spacer, compression

spring, spacer, and the hub tension screw.

d. Place a wire spool on the hub (13). Align the positioning pin on the hub with the hole in the wire spool so that the wire feeds from the bottom of the coil. See Figure 3.

Figure 2

I-169

Figure 1

1. To install the Wire Reel/Spool Support Assem-

bly (870060-X) onto the Baseplate:

a. Use the four 1/4-20 x 7/8" screws, the four hex keps nuts, and the two flat washers to fasten the support (1) to the wire feeder base.

2. To install the Wire Spool Kit (870058):

a. Mount the shaft (6) in the lower hole (if using a 30-45 lb. spool) or in the upper hole (if using a 60 lb. spool) of the support (1). Make sure the 1/2-13 hex nut (2) is securely tightened on the shaft (6). See Figure 2.

b. Mount the Wire Spool Hub (13) on the Shaft (6).

December 1, 1997 Revised 1

e. Install the wire spool hub nut (17) and tighten until the spring ball plunger falls into the dimple on the wire spool hub.

f. Adjust the compression spring tension by use of the hub tension screw until the proper reel drag is achieved.

Figure 3

Page 46

I-169

Figure 4

3. To install the Wire Reel Kit (870059):

a. Mount the shaft (6) in the upper hole of the support (1) to assure proper clearance for the wire reel (7). See Figure 4.

b. Mount the wire reel (7) on the shaft (6).

c. Install the wire reel washer, the steel wire reel washer, compression spring, “T” wire reel washer, and the drag adjusting screw.

Figure 5

d. Loosen the wing nuts holding the movable arms. Rotate the arms inward towards the center of the reel (7). Place the coiled wire on the reel so the wire feeds from the bottom of the coil to the wire feeder. See Figure 5.

e. Reposition the movable arms outward and tighten the wing nuts.

f. Tighten the drag adjusting screw until the desired reel drag is achieved.

2 December 1, 1997 Revised

Page 47

I-169

December 1, 1997 Revised 3

Page 48

I-169

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4 December 1, 1997 Revised

Page 49

I-169

December 1, 1997 Revised 5

Page 50

I-169

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6 December 1, 1997 Revised

Page 51

I-169

December 1, 1997 Revised 7

Page 52

I-169

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8 December 1, 1997 Revised

Page 53

DIAGRAMS

• Note the model and specification number shown on the equipment nameplate.

• Locate these numbers in the model and specification number columns below.

• Use only those diagrams and instructions that are applicable.

MODEL

NUMBER

SPECIFICATION

NUMBER

SCHEMATIC/

CONNECTION

DIAGRAM OPTIONS

430429-249

DIAGRAMS

SYSTEM

OUTLINE

2460

Heavy Duty

CC/CV

6877A-1, -2 376784B

Sheet 1 & 2

6877B-1, -2 376784B

Sheet 1 & 2

376827 376823

June 17, 1997 Revised

Page 54

SCHEMATIC AND CONNECTION DIAGRAM 1 OF 2

78 6

363A

2 GN

5 WT-RD

4 BR

3 BL

10 BK611 RD

8 WT-YL

9 BL-BK

7 WT-BK

KEY76 WT-BR

1 WT

543

J2J1 J3

MOTOR CONTROL P.C. BOARD

1 WT

27 YL

28 OR

KEY

29 BL

GAS VALVE P.C. BOARD

6 5 4 3

KEY 27 YL 25 BR 28 OR 26 RD

1 11 1 11

CR1

17 YL

2 GN

12 BL-GN

8 WT-YL

9 BL-BK

BK(M)

10 BK

14 RD-WT

15 BL-RD

3A 4

FACING INSIDE REAR OF CASE

FACING INSIDE BOTTOM OF CASE

2 10/7/2002 Revised

Page 55

543 2 1

22 RD-BL

20 BK-OR

23 WT-GN 7 WT-BK 21 OR-WT

6 WT-BR

TB1

8765432 1

11 RD

26 RD

25 BR

FEEDHEAD

18 BK-BL

14 RD-WT 12 BL-GN 4 BK 17 YL

(M)

13 YL-BK

16 BR-BK

4 2 7 2

3 BL

4 BR

4 BK

5 WT-RD

TO WORK

15 BL-RD

23 WT-GN

21 OR-WT

16 BR-BK

FACING INSIDE FRONT OF CASE

150 8-91

TECH PUB

4 11

OUTSIDE DISTR.

ECN NO.REV

REVISION CHART

DATE

6-6-971472B 1, 2

PAGES AFFECTED

CHANGE RECORD

E.C. No. DATE

A) PP1192 8-14-96

CONFIDENTIAL: This drawing, including all information contained thereon, is the exclusive and confidential property of Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is not to be copied, reproduced, delivered or disclosed to others, in whole or in part, except with express written permission.

FILE NAME

376784B 10-7-02

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS TOLERANCES BELOW APPLY EXCEPT FOR VENDOR DESIGNED PARTS AND ITEMS. PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

FINISH CODE PER

PLOT DATE

MATERIAL SPEC.

ANGLES

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

TITLE

± 3˚

DESCRIPTIVE DATA

A THERMADYNE Company

TROY, OHIO 45373, U.S.A.

ACTIVITY

MATERIAL NO.

REPLACED BY REPLACES

QUANTITY-U.M.

DIAGRAM, CONNECTION & SCHEMATIC

2460 HEAVY DUTY WIRE FEEDER

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

TLT TLT 8-15-91

NONE

DWG. NO.SIZE

376784B

DISTRIBUTION TABLE

SHEET

12354

COMM. CLS.

1 OF 2

FULLTLT JLC 7-29-91

10/7/2002 Revised 3

Page 56

SCHEMATIC AND CONNECTION DIAGRAM 2 OF 2

78 56

TO FEEDHEAD

TB1-1

TB1-2

J2-5

J1-1

CR1

J1-2

J2-2

TO WORK

TB1-6

TB1-8

TB1-3

TB1-4

TB1-5

TB1-7

J1-3

J1-4

J1-5

J1-7

J1-8

4 10/7/2002 Revised

Page 57

4 3 2 1

LEGEND

GAS VALVE

P.C. BOARD

CR1

MOTOR, WIRE FEED

RECTIFIER, BRIDGE

FUSE, SLOW BLOW, 7A

FUSE, SLOW BLOW, 5A

MOTOR CONTROL

P.C. BOARD

J1-6

J3-1

J1-5

J3-2

J1-2

J3-3

J1-4

J3-4

J1-3

J1-1

J1-12

J1-11

J2-1

J2-3

J2 J3 J4

RECEPTACLE, MOTOR CONTROL BOARD, GAS VALVE BOARD RECEPTACLE, METER OPTION RECEPTACLE, MOTOR CONTROL BOARD RECEPTACLE, GUN SWITCH

L1 GAS VALVE, 12VDC

S1 S2

TB1

POTENTIOMETER, 10KOHMS, 2W

SWITCH, ON-OFF SWITCH, CC/CV

TERMINAL BLOCK

J1-9

J1-10

150 8-91

TECH PUB

OUTSIDE DISTR.

CHANGE RECORD

E.C. No. DATE

FILE NAME

376784B2 11-6-97

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS TOLERANCES BELOW APPLY EXCEPT FOR VENDOR DESIGNED PARTS AND ITEMS. PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

FINISH CODE PER

PLOT DATE

MATERIAL SPEC.

ANGLES

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

TITLE

± 3˚

DESCRIPTIVE DATA

A THERMADYNE Company

TROY, OHIO 45373, U.S.A.

ACTIVITY

MATERIAL NO.

REPLACED BY REPLACES

QUANTITY-U.M.

DIAGRAM, CONNECTION & SCHEMATIC

2460 HEAVY DUTY WIRE FEEDER

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

TLT TLT 8-15-91

NONE

DWG. NO.SIZE

376784B

DISTRIBUTION TABLE

SHEET

1234

COMM. CLS.

FULLTLT JLC 6-6-97

10/7/2002 Revised 5

Page 58

LIMITED W ARRANTY

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc pr oducts as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY , EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITA TION OF LIABILITY : THERMALARC SHALL NOT UNDER ANY CIRCUMST ANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS W ARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMALARC’S SOLE JUDGEMENT MA Y IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMALARC PRODUCT . PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NONAUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

POWER SUPPLIES ALL OTHER LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 3 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 3 YEAR CONTROL PC BOARD 3 YEARS 3 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT 1 YEAR 1 YEAR NOT LIMITED TO: CONTACTORS, RELAYS, SOLENOIDS, PUMPS,

POWER SWITCHING SEMI-CONDUCTORS ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE

ENGINE MANUFACTURER, SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS. CONSOLES, CONTROL EQUIPMENT, HEAT EXCHANGES, 1 YEAR 1 YEAR

AND ACCESSORY EQUIPMENT

TORCH AND LEADS 180 DAYS 180 DAYS REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS

NOTE: Dragster 85® excluded from this policy. Refer to Dragster 85 warranty in Dragster 85 Owner’s Manual.

POWER SUPPLIES

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind will be paid under this warranty . T ransportation char ges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.

September 27, 2004

April 14, 2005 Revised

Tweco 2460 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual