ESAB Heavy Duty CC/CV Semiautomatic Solid-State Control Wire Feeder Model 2460 User manual

Brand: ESAB

Model: Heavy Duty CC/CV Semiautomatic Solid-State Control Wire Feeder Model 2460

Category: Welding System

Type: 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

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

IMPORTANT: Readtheseinstructionsbeforeinstalling,operating,orservicingthissystem.

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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

430429-249

Table of Contents

December 1, 1997 Revised

April14, 2005 Revised 1-1

430429-249

INTRODUCTION

How To Use This Manual

This Owner’s Manual usually applies to just the under-

lined 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, includ-

ing the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING,

CAUTION, and NOTE may appear. Pay particular atten-

tion 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 cer-

tain operating procedures.

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 Ther-

mal Arc web site listed below and clicking on the Litera-

ture Library link:

http://www.thermadyne.com/tai

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. Equip-

ment which does not have a control panel such as gun

and cable assemblies is identified only by the specifica-

tion 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 in-

voice to make sure it is complete and inspect the equip-

ment for possible damage due to shipping. If there is any

damage, notify the carrier immediately to file a claim. Fur-

nish 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.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER

WEARERSKEEPAWAY UNTILCONSULTING YOUR DOCTOR.DONOT LOSETHESEINSTRUCTIONS.READOPERATING/INSTRUC-

TION 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:

SAFETY IN WELDING AND CUTTING. This publication and

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 serv-

icing 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.

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. Repair or 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 WELDING SAFETY INSTRUCTIONS AND WARNINGS

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.

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.

ARC WELDING can be hazardous.

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

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

—

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

Electrode Size

Metal Thickness

or Welding Current

All

Under 300 Amp

300 to 400 Amp

Over 400 Amp

Filter

Shade

No.

3or4

4or5

5or6

4or5

5or6

6or8

Filter

Shade

No.

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

May 8, 1996 2-1

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The

flying sparks and hot metal, weld spatter, hot work-

piece, 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.

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 SPARKSANDHOTMETALcan

cause injury.

Chipping and grinding cause flying metal. As welds

cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields rec-

ommended.

2. Wear proper body protection to protect skin.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pres-

sure. 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, mechani-

cal shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining

them to a stationary support or equipment cylinder rack to prevent

falling or tipping.

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, asso-

ciated equipment, and CGA publication P-1 listed in Safety

Standards.

ENGINES can be hazardous.

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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.

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.

4. Read the Material Safety Data Sheets (MSDSs) and the manu-

facturer’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.

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

2-2 May 8, 1996

STEAM AND PRESSURIZED HOT

COOLANT can burn face, eyes, and

skin.

The coolant in the radiator can be very hot and under

pressure.

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.

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 Superinten-

dent 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, Ameri-

can 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 High-

way, 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 Pro-

tection, 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.

SPARKS can cause BATTERY GASES

TO EXPLODE; BATTERY ACID can

burn eyes and skin.

Batteries contain acid and generate explosive gases.

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.

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.

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.

ENGINE FUEL can cause fire or

explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks 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.

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,

Biological Effects

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:

About Pacemakers:

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

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

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

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

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

practical.

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.)

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

May 8, 1996 2-3

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ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

2-4 May 8, 1996

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DES PIECES EN MOUVEMENT PEU-

VENT 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.

3. Seules des personnes qualifiées doivent démonter des protec-

teurs 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 mou-

vement; 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.

DESETINCELLES PEUVENTFAIREEX-

PLOSER UN ACCUMULATEUR;

L’ELECTROLYTE D’UN ACCUMU-

LATEUR PEUT BRULER LA PEAU ET

LES YEUX.

Les accumulateurs contiennent de l’électrolyte

acide et dégagent des vapeurs explosives.

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.

LA VAPEUR ET LE LIQUIDE DE RE-

FROIDISSEMENT BRULANT SOUS

PRESSION PEUVENT BRULER LA

PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut

être brûlant et sous pression.

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 Held Hazardous 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 Asso-

ciation canadienne de normalisation, Standards Sales, 276 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Pro-

tection, 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.

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC

Instruction 830002

2-4 8-V-96

DESCRIPTION OF EQUIPMENT

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 weld-

ing 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 con-

stant-voltage or constant-current type welding ma-

chine. 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 connec-

tions 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 a given dial selection on the feeder. If either

the power source voltage setting or the feeder set-

ting 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 in-

crease 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 re-

duces 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,

430429-249

DESCRIPTION OF EQUIPMENT

May 22, 1997 Revised 3-1

depending upon which wire feed rate is desired. See

Table 3-1 for correlation of numbers.

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 as-

sembly. The drive motor 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.

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

Motor 24 V DC

Gun Circuit 11 V DC or 24 V AC

(option)

Speed Range of Wire

20.4:1 drive gear ratio — 40 to 600 IPM

(inches/minute)

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 base-

plate. 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 sub-

ject model configuration.

Options

The options available with this unit are as follows:

SPEC. MODEL

FEED

ROLLS

WIRE FEED

RATE

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

Table 3-1

430429-249

DESCRIPTION OF EQUIPMENT

3-2 May 22, 1997 Revised

ITEM DESCRIPTION

6877A-1

6877A-2

6877B-1

6877B-2

KIT, CONTACTOR WITH GV

KIT, CONTACTOR LESS GV

KIT, CONTACTOR WITH GV AND MEGA-ARC REMOTE CONTROL

376809-1

376809-2

376809-3

376809A-1

376809A-2

376809A-3

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

376809-4

376809-5

376809-6

376809A-4

376809A-5

376809A-6

KIT, VOLT AND IPM METERS

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

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

376847

376810-1

376810-2

376847

376810-1

376810-2

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

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

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

376810-3

376810-4

376810-5

376810-3

376810-4

376810-5

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

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

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

376810-6

376810-7

376810-8

376810-6

376810-7

376810-8

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

CABLE CONTROL 6 FT.

CABLE, “Y” MEGA-ARC 6 FT.

376810-9

373059A

376510

376810-9

373059A

376510

CABLE, EXT 6 PIN 50 FT.

CABLE, EXT 6 PIN 100 FT.

CABLE, EXT 6 PIN 25 FT.

376511-1

376511-2

376511-3

376511-1

376511-2

376511-3

CABLE, EXT 6 PIN 75 FT.

CABLE, 19 PIN–10 PIN 10 FT.

CABLE, 10 PIN–LEAD 10 FT.

376511-4

376512-1

376513-1

376511-4

376512-1

376513-1

CABLE, 19 PIN–6 PIN 15 FT.

CABLE, 19 PIN–6 PIN 25 FT.

CABLE, 19 PIN–6 PIN 50 FT.

376514-1

376514-2

376514-3

376514-1

376514-2

376514-3

CABLE, 19 PIN–6 PIN 75 FT.

CABLE, 19 PIN–6 PIN 100 FT.

FRAME, SKID

376514-4

376514-5

493263

376514-4

376514-5

493263-1

KIT, HANDLE

KIT, CASTOR

EYE, LIFTING

375994

375605-2

375104

375994A

375605A-2

375104A

MOUNTING, SWIVEL

KIT, SPOOL

ADAPTER, SPOOL 10 LB.

375606-2

374831A

375585

375606A-2

374831A

375585-1

ADAPTER, SPOOL 15 LB.

ADAPTER, COIL 14 LB.

COVER, SPOOL 30 LB.

375584

375942

375582-2

375584-1

375942A

375582A-2

ADAPTER, COIL 60 LB.

KIT, REEL, WIRE

COVER, COIL 60 LB./SUPPORT/LIFTING EYE

407142

374819A

375733-1

407142A

374819A

375733A-1

NOTE:For installationandoperationinstructionsforthe aboveoptions,see thedrawingsandinstructions

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.)

430429-249

DESCRIPTION OF EQUIPMENT

May 22, 1997 Revised 3-3

This page intentionally left blank.

430429-249

DESCRIPTION OF EQUIPMENT

3-4 May 22, 1997 Revised

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 elec-

trode (welding wire) is electri-

cally “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 weld-

ing current.

WhenusingaCC powersource,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.

430429-249

OPERATION

May 22, 1997 Revised 4-1

This page intentionally left blank.

430429-249

OPERATION

4-2 May 22, 1997 Revised

PARTS LIST

Equipment Identification

All identification numbers as described in the In-

troduction 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 the equipment are listed except for commer-

cially available hardware, bulk items such as wire,

cable, sleeving, tubing, etc., and permanently at-

tached 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, quan-

tity, 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 right-

most 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 appro-

priate 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

430429-249

Troy, Ohio 45373 PARTS LIST

November 2, 1999 Revised 5-1

Figure 5-1 Wire Feeder Assembly

430429-249

PARTS LIST Troy, Ohio 45373

5-2 June 18, 1999 Revised

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

4-Roll Drive, 40-600 IPM 1 A

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

4-Roll Drive, 20-300 IPM 1 B

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

4-Roll Drive, 40-600 IPM 1 C

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

4-Roll Drive, 20-300 IPM 1 D

1 376783B . Box - Control Assembly

(For Details See Figure 5-2) 1 AB

376783B-1 . Box - Control Assembly

(For Details See Figure 5-2) 1 CD

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

(For Details See MPL-224) 1 A

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

(For Details See MPL-224) 1 C

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

(For Details See MPL-224) 1 B

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

(For Details See MPL-224) 1 D

3 375769-1 . Base 1 AB

375769-4 . Base 1 CD

4 374818A-1 . Support - Wire Spool Assembly

(For Details See I-169) 1 AB

374818A-9 . Support - Wire Spool Assembly

(For Details See I-169) 1 CD

— 376827 List - Field Installable Options Ref. All

5 870087-1 Label - Thermal Arc 2 All

6 870194-1 Cable - Assy 1 All

— Not Illustrated

Item Part Description Qty Application

No Number per Code

Assy

Parts List for Figure 5-1

430429-249

Troy, Ohio 45373 PARTS LIST

November 2, 1999 Revised 5-3

Figure 5-2 Control Box Assembly

430429-249

PARTS LIST Troy, Ohio 45373

5-4 June 18, 1999 Revised

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

Item Part Description Qty Application

No Number per Code

Assy

Parts List for Figure 5-2

430429-249

Troy, Ohio 45373 PARTS LIST

November 2, 1999 Revised 5-5

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

Item Part Description Qty Application

No Number per Code

Assy

Parts List for Figure 5-2

430429-249

PARTS LIST Troy, Ohio 45373

5-6 June 18, 1999 Revised

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ESAB Heavy Duty CC/CV Semiautomatic Solid-State Control Wire Feeder Model 2460 User manual

Brand: ESAB

Model: Heavy Duty CC/CV Semiautomatic Solid-State Control Wire Feeder Model 2460

Category: Welding System

Type: User manual

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ESAB Heavy Duty CC/CV Semiautomatic Solid-State Control Wire Feeder Model 2460 User manual

ESAB Heavy Duty CC/CV Semiautomatic Solid-State Control Wire Feeder Model 2460 User manual

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