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WORK CABLE CONNECTIONS | SELECTING THE PROPER GEAR RATIO | ||
Connect a work lead of sufficient size and length (per the following table) between the proper output termi- nal on the power source and the work. Be sure the connection to the work makes tight
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, bundle the electrode and ground cables together where practical, and do not coil excess cable.
Minimum work and electrode cables sizes are as fol- lows:
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| Minimum Copper Work Cable Size, AWG |
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| 60% Duty |
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| Up to 100 ft Length (30m) |
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| 500 Amps |
| 3/0 (85 mm2) | ||||
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| 600 Amps |
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| 3/0 (85 mm2) |
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When using an inverter type power source, Use the largest welding (electrode and ground) cables that are practical. At least 3/0 (85 mm2) copper wire — even if the average output current 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 welding cables are used.
WIRE DRIVE GEAR RATIO (HIGH OR LOW SPEED)
The speed range capability and drive torque of the Power Feed 11 wire drive can be easily and quickly changed by changing the external drive gear. The Power Feed 11 is shipped with both a high speed and a low speed gear. As shipped from the factory, the high speed (low torque) gear is installed on the feed- er. If this is the desired gear ratio, no changes need to be made.
See the Technical Specifications at the front of this section for feed speed and wire size capabilities with high and low speed gear ratios. To determine whether you should be using the high or low speed ratio use the following guidelines:
-When operating at wire feed speeds above 625 IPM (15.9 m/m), you must have the high speed gear (large 30 tooth, 1.6 inch diameter gear) installed.
-When operating at wire feed speeds below 625 IPM (15.9 m/m), you must have the low speed gear (small 17 tooth, .95 inch diameter gear) installed for all wire sizes because using the low speed ratio pro- vides the maximum available wire feeding force. Note: If you are feeding only .045” (1.2 mm) diame- ter and smaller wires you may, at your option, use the factory installed high speed ratio.
CHANGING THE WIRE DRIVE RATIO
Changing the ratio requires a gear change and a PC board switch change. The Power Feed 11 is shipped with both a high speed and a low speed gear. As shipped from the factory, the high speed (low torque) gear is installed on the feeder. For identification pur- poses, the low speed (high torque) gear has 17 teeth and is .95 inches in diameter. The high speed gear has 30 teeth and is 1.6 inches in diameter. See Figure A.2.
WIRE
FEEDER
PHILLIPS | DRIVE |
HEAD SCREW | GEAR |