Tweco 2460 User Manual
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
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
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
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.
2
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
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
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
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
This page intentionally left blank.
2-4 May 8, 1996
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
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
de
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 conditions
toutes conditions
toutes dimensions
moins de 300 ampères
de 300 à 400 ampères
plus de 400 ampères
Nuance de
de filtre
oculaire
2
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
12
12
14
12
14
9
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
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
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
DESCRIPTION OF EQUIPMENT
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
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:
430429-249
DESCRIPTION OF EQUIPMENT
ITEM DESCRIPTION
KIT, CONTACTOR WITH GV
1
KIT, CONTACTOR LESS GV
2
KIT, CONTACTOR WITH GV AND MEGA-ARC REMOTE CONTROL
3
KIT, CONTACTOR LESS GV AND MEGA-ARC REMOTE CONTROL
4
KIT, CONTACTOR WITH GV AND MEGA-MIG REMOTE CONTROL
5
KIT, CONTACTOR LESS GV AND MEGA-MIG REMOTE CONTROL
6
KIT, VOLT AND IPM METERS
7
KIT, MEGA-MIG, R.C. 15 FT.
8
KIT, MEGA-MIG, R.C. 25 FT.
9
KIT, MEGA-MIG, R.C. 50 FT.
10
KIT, MEGA-MIG, R.C. 75 FT.
11
KIT, MEGA-MIG, R.C. 100 FT.
12
KIT, MEGA-ARC, R.C. 25 FT.
13
KIT, MEGA-ARC, R.C. 50 FT.
14
KIT, MEGA-ARC, R.C. 75 FT.
15
KIT, MEGA-ARC, R.C. 100 FT.
16
CABLE CONTROL 6 FT.
17
CABLE, “Y” MEGA-ARC 6 FT.
18
CABLE, EXT 6 PIN 50 FT.
19
CABLE, EXT 6 PIN 100 FT.
20
CABLE, EXT 6 PIN 25 FT.
21
CABLE, EXT 6 PIN 75 FT.
22
CABLE, 19 PIN–10 PIN 10 FT.
23
CABLE, 10 PIN–LEAD 10 FT.
24
CABLE, 19 PIN–6 PIN 15 FT.
25
CABLE, 19 PIN–6 PIN 25 FT.
26
CABLE, 19 PIN–6 PIN 50 FT.
27
CABLE, 19 PIN–6 PIN 75 FT.
28
CABLE, 19 PIN–6 PIN 100 FT.
29
FRAME, SKID
30
KIT, HANDLE
31
KIT, CASTOR
32
EYE, LIFTING
33
MOUNTING, SWIVEL
34
KIT, SPOOL
35
ADAPTER, SPOOL 10 LB.
36
ADAPTER, SPOOL 15 LB.
37
ADAPTER, COIL 14 LB.
38
COVER, SPOOL 30 LB.
39
ADAPTER, COIL 60 LB.
40
KIT, REEL, WIRE
41
COVER, COIL 60 LB./SUPPORT/LIFTING EYE
42
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
430429-249
DESCRIPTION OF EQUIPMENT
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3-4 May 22, 1997 Revised
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
430429-249
OPERATION
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4-2 May 22, 1997 Revised
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