User's Manual

Output connections on some POWER WAVE®s are
made via 1/2-13 threaded output studs located
beneath the spring loaded output cover at the bottom
of the case front.
Most welding applications run with the electrode being
positive (+). For those applications, connect the elec-
trode cable between the wire feeder and the positive
(+) output Twist-Mate terminal on the power source.
Connect the other end of the electrode cable to the
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical con-
tact. The electrode cable should be sized according to
the specifications given in the output cable connec-
tions section. Connect a work lead from the negative
(-) power source output Twist-Mate terminal to the
work piece. The work piece connection must be firm
and secure, especially if pulse welding is planned.
For additional Safety information regarding the elec-
trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
Instruction Manuals.
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
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NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.
When operating with electrode polarity negative the
"Electrode Sense Polarity" DIP switch must be set to
the "Negative" position on the Wire Drive Feed Head
PC Board. The default setting of the switch is positive
electrode polarity. Consult the Power Feed instruction
manual for further details.
A-3
INSTALLATION
POWER WAVE® 405M
A-3
OUTPUT CABLES, CONNECTIONS AND
LIMITATIONS
Connect a work lead of sufficient size and length (per
table A.1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths and do not coil excess cable.
When using an inverter type power source like the
POWER WAVE®s, use the largest welding (elec-
trode and work) cables that are practical. At least
2/0 copper wire - even if the average output cur-
rent would not normally require it. When pulsing,
the pulse current can reach very high levels.
Voltage drops can become excessive, leading to
poor welding characteristics, if undersized weld-
ing cables are used.
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CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING
For Pulse Welding processes, cable inductance will
cause the welding performance to degrade. For the
total welding loop length less than
50 ft.(15.24m), tradi-
tional welding cables may be used without any effects
on welding performance. For the total welding loop
length greater than
50 ft.(15.24m)), the K1796 Coaxial
Welding Cables are recommended. The welding loop
length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See
Figure A.3).
For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length
less than
50 ft.(15.24m). (See Figure A.4.)
CAUTION
CAUTION
B
A
C
FIGURE A.3
POWER
WAVE
WORK
A
C
B
POWER
WAVE
FIGURE A.4
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
C
A
B
WORK
SLIDING
WORK