Lincoln Electric IM10024 manual Electrode Connections, Remote Sense Lead Specifications

A-9 INSTALLATION A-9

ELECTRODE CONNECTIONS

Because the Power Wave® AC/DC 1000 SD can pro- duce either a DC positive, DC negative or AC output the electrode and work connections do not need to be reversed for the different polarities. Additionally no DIP switch changes are required to switch between the dif- ferent polarities. All of this is controlled internally by the Power Wave® AC/DC. The following directions apply to all polarities:

Connect the electrode cable(s) to the "ELECTRODE" stud(s) on the power source . Connect the other to the contact assembly at the Wire Drive. Be sure the con- nection makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in Table A.1.

On the Power Wave® 1000 SD, the Electrode NOTE: studs are on the lower left rear corner of the machine. On older units they are on the lower left front corner. On those machines, the cables can be routed through the oval hole in the cable tray before being connected to the

output terminals.

TABLE A.1 - Output Cable Guidelines

Total Cable Length		Parallel Cables	Copper
Electrode and Work	Duty Cycle
ft (m)		Number of	Cable Size
Combined
0 (0) to 250 (76.2)	80%	2	4/0 (120 mm2)
0 (0) to 250 (76.2)	100%	3	3/0 (95 mm2)

When using inverter type power sources like the Power Wave®, use the largest welding (electrode and work) cables that are practical. When using AC appli- cations the current can reach very high levels. Voltage drops due to cable resistance can become excessive, leading to poor welding characteristics if undersized welding cables are used.

REMOTE SENSE LEAD SPECIFICATIONS
The MAXsa™ 22 & 29 Wire Drives				has an		ELEC-
TRODE sense	lead extending from			the connection
box that is mounted to the motor. This sense						lead is
critical to the accuracy of the Power Wave® welding
process. A ring	terminal is provided at the end of the
lead. This lead	must be extended and connected to
the electrode connection at the nozzle. This connec-
tion should be made as close to the				welding		arc as
possible. Use at least		a 12 AWG wire with			a	proper
sized ring terminal. Use a screw with a lock washer
and nut to make the connection, then insulate the con-
nection with electrical tape.			Proper care should be
taken to protect the sense lead from becoming discon-
nected or damaged. The loss of a sense lead connec-
tion can adversely affect welding performance. The
system may have multiple sense lead configurations
available. Consult the power source manual on how to
configure the power source for the sense leads.
NOTE: The WORK sense lead (21) for the MAXsa™
22 & 29	Wire Drives		system is typically con-
nected	at the	back	of the Power		Wave®
AC/DC 1000 SD. If the MAXsa™ wire drive is
to be used in an older system, (PF10A and/or
K2344-X) the		WORK sense		lead	must be
brought	out of	the motor connection			box and
connected to the workpiece.

MAXsa™ 22 & 29 WIRE DRIVES