INSTALLATION | ||
ELECTRODE AND WORK CONNECTIONS GENERAL GUIDELINES |
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Connect the electrode and work cables between the appropriate output studs of the POWER WAVE® i400 and the robot weld cell per the connection diagrams included in this document. Size and route the cables per the following.
•Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source. Connect a work lead from the negative
•When negative electrode polarity is required, such as in some Innershield applications, reverse the out- put connections at the power source (electrode cable to the negative
CAUTION
Negative electrode polarity operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode Polarity attribute to be set. See the Remote Sense Lead Specification section of this document for further details.
For additional Safety information regarding the elec- trode and work cable
•Select the appropriate size cables per the “Output Cable Guidelines” in Table A.1. Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance. Always use the largest welding cables (electrode and work) that are practical, and be sure all connections are clean and tight.
Note: Excessive heat in the weld circuit indicates undersized cables and/or bad connections.
•Route all cables directly to the work and wire feeder, avoid excessive lengths and do not coil excess cable. Route the electrode and work cables in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit.
•Always weld in a direction away from the work (ground) connection.
In Table A.1 are copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop.
TABLE A.1
OUTPUT CABLE GUIDELINES
| Percent | CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES | ||||
Amperes | Duty | (RUBBER COVERED COPPER - RATED 75°C)** |
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Cycle |
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| 0 to 50 Ft. | 50 to 100 Ft. | 100 to 150 Ft. | 150 to 200 Ft. | 200 to 250 Ft. |
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200 | 60 | 2 | 2 | 2 | 1 | 1/0 |
200 | 100 | 2 | 2 | 2 | 1 | 1/0 |
225 | 20 | 4 or 5 | 3 | 2 | 1 | 1/0 |
225 | 40 & 30 | 3 | 3 | 2 | 1 | 1/0 |
250 | 30 | 3 | 3 | 2 | 1 | 1/0 |
250 | 40 | 2 | 2 | 1 | 1 | 1/0 |
250 | 60 | 1 | 1 | 1 | 1 | 1/0 |
250 | 100 | 1 | 1 | 1 | 1 | 1/0 |
300 | 60 | 1 | 1 | 1 | 1/0 | 2/0 |
325 | 100 | 2/0 | 2/0 | 2/0 | 2/0 | 3/0 |
350 | 60 | 1/0 | 1/0 | 2/0 | 2/0 | 3/0 |
400 | 60 | 2/0 | 2/0 | 2/0 | 3/0 | 4/0 |
400 | 100 | 3/0 | 3/0 | 3/0 | 3/0 | 4/0 |
500 | 60 | 2/0 | 2/0 | 3/0 | 3/0 | 4/0 |
**Tabled values are for operation at ambient temperatures of 40°C and below. Applications above 40°C may require cables larger than recommended, or cables rated higher than 75°C.
POWER WAVE® i400