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HTP MIG 2400 User Manual

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2400 Owner’s Manual
HTP America, Inc. 3200 Nordic Road Arlington Heights, IL 60005-4729
1-800-USA-WELD 847-357-0700 FAX: 847-357-0744 www.usaweld.com
Model 60240-24
America Inc.
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HTP MIG 2400 Specifications

General IconGeneral
BrandHTP
ModelMIG 2400
CategoryWelding System
LanguageEnglish

Summary

MANUFACTURER'S WARRANTY

Introduction

Safety Suggestions

Essential safety precautions for electric arc welding, including personal protective equipment and workplace safety.

Electrical Connection

Line Voltage Adjustment

Instructions for setting the welder's line voltage adjustment for optimal performance.

Front Panel Controls

Wire Feed Rate Control

Explains how to adjust the wire feed rate for optimal welding sound and performance.

Weld Time Control

Details the weld time knob for spot welding mode, controlling weld duration.

Digital Display Mode Selector

Describes the switch to select display of welding voltage or amperage.

Digital Display Unit

Explains the digital display for monitoring welding voltage or amperage.

Main Power On-Off Switch

Controls the input power to the welder, illuminating an indicator and activating the fan.

Welding Mode Switch

Allows selection between 'seam' welding and 'continuous' welding modes.

Thermoswitch Indicator Light

Indicates when the duty cycle has been exceeded, warning of overheating.

Welding Gun Adapter Flange

Houses the adapter block and connects to the front panel of the welder.

Welding Gun Adapter Block

Connects the welding gun to the machine, housing power, wire, gas, and trigger wires.

Course Power Adjustment

Controls welding current with four settings, influencing amperage based on wire diameter.

Fine Power Adjustment

Provides six heat settings within each coarse setting, offering 24 total heat settings.

Power Output Receptacles

Connects the ground cable and welding gun lead, controlling machine polarity.

Welding Gun Lead Connection

Transmits power from the output receptacle to the welding gun.

Controls in the Wire Feed Compartment

Burnback Time Adjustment

Controls the duration welding current is applied after the wire feed stops.

Wire Feed Accelerator Settings

Adjusts how fast the wire drive motor accelerates to the set wire feed rate.

Feeding the Welding Wire

Spool Installation and Wire Feeding

Guides on installing spools, feeding wire through guides, and setting pressure roller tension.

Wire Drive Brake Tension

Adjusting the brake tension to control spool rotation after trigger release.

Preventing Bird Nesting

Explains how to adjust the drive roll and pressure roller to prevent wire tangling.

Adjusting the Welding Machine

Power Setting and Wire Feed Tuning

Guide on setting power and wire feed for optimal arc sound and penetration.

Arc Sound Indicators

Describes how arc sounds (hissing, cracking, sizzling) indicate wire feed rate issues.

Seam Welding

Seam Welding Technique

Instructions for tacking and performing continuous seam welds using the correct gun angle.

Weld Direction (Push vs. Pull)

Explains the impact of gun angle and travel direction on weld characteristics.

Stitch Welding

Stitch Welding Procedure

Method for creating overlapping spot welds for thin or warped materials.

Metal Shrinking

Shrinking Attachment Use

Instructions for using the optional attachment for metal shrinking.

Spot Welding

Spot Welding Setup and Execution

Steps for punch-and-flange, setting power, and executing spot welds.

Hole Filling

Hole Filling Process

Steps for building up and filling holes using multiple weld puddles.

Welding Aluminum

Aluminum Welding Considerations

Advice on wire, gun, spool guns, and technique for welding aluminum.

Welding Muffler Pipe

Muffler Pipe Welding Technique

Instructions for tacking and welding muffler pipes, including gun angle and speed.

Broken Stud Removal

Exhaust Manifold Stud Removal

Method for removing broken studs from exhaust manifolds using the welder.

Welding Cast Iron

Cast Iron Welding Techniques

Guidance on gas, wire, preheating, and welding cracks in cast iron.

Maintenance and Service

Nozzle Reamer Use

Describes the nozzle reamer for cleaning welding gun tips and nozzles.

Spatter Build Up Symptoms

Illustrates signs of spatter accumulation affecting nozzle and weld quality.

Spatter Damage to Swan Neck

Shows how spatter can damage the welding gun's swan neck, requiring replacement.

Changing the Contact Tip

Procedure for removing and replacing worn contact tips in the welding gun.

Changing the Gas Nozzle

Instructions for removing and installing gas nozzles for optimal gas coverage.

Changing the Drive Roll

Steps to remove and install drive rolls for different wire sizes.

Replacing the Printed Circuit Board (PCB)

Guide for safely unplugging and replacing the welder's main circuit board.

Setting the Pressure on the Pressure Roller

Pressure Roller Adjustment Procedure

Detailed steps for adjusting pressure roller tension to ensure consistent wire feed.

Testing and Changing the Liner

Liner Inspection and Replacement

Procedure to test the welding gun liner for friction and replace it if necessary.

Monthly Maintenance

Wire Drive System Checks

Periodic checks of the guide tube and inlet wire guide for alignment.

Welding Cable Care

Guidelines to prevent damage to the welding cable from running over or pulling.

Transformer and Internal Component Cooling

Explains the thermoswitch protection and cooling fan operation.

Shield Gas Requirements

Details shield gas types and flow rates for various welding materials.

Welding Wire

Welding Wire Selection Guide

Chart listing available welding wire types, part numbers, and applications.

Mig 2400 Settings for Steel Wire

Steel Wire Settings Chart

Comprehensive table of heat settings, wire feed rates, and material thicknesses for different steel wires.

HTP MIG 2400 Wiring Diagram

Electrical Schematics Overview

Presents the internal electrical wiring diagram of the MIG 2400 welder.

Parts List – MIG 2400

Main Unit Components

Lists and illustrates the various internal parts of the MIG 2400 welder with corresponding numbers.

24 Series Welding Gun Parts Breakdown

24 Series Gun Components

Illustrates and lists the parts for the 24 Series welding gun.

Parts Breakdown – #1 Style Welding Gun

#1 Style Gun Components

Illustrates and lists the parts for the #1 Style welding gun.

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