Lincoln Electric 11124, 11226 manual Electrode and Work, Connections

A-15		INSTALLATION		A-15
ELECTRODE AND WORK			For parallel applications with excessive electrode
CONNECTIONS			cable lengths, a common bus connection should be
			used. The common electrode connection serves to
General Guidelines			minimize voltage drops associated with resistive loss-
			es in the electrode path. It should be made of copper,
The unique switching structure of the Power Wave			and located as close as possible to the power
AC/DC 1000 allows it to produce DC positive, DC			sources. (See "Connection Diagram – Parallel
negative or AC output waveforms without reposition-			Machines")
ing the work and electrode leads. Additionally, no DIP
switch changes are required to switch between the dif-			Work Connections
ferent polarities. All of this is controlled internally by			Connect a work lead of sufficient size and length (Per
the Power Wave AC/DC 1000, and based exclusively			Table 1) between the "work" stud (located beneath the
on the weld mode selection.			spring loaded output cover on the top, front of the
The following recommendations apply to all output			machine) and the work piece. For convenience, the
			work lead can be routed along the left cable tray, and
polarities and weld modes:			out the back of the machine. Be sure the connection
• Select the appropriate size cables per the			to the work makes tight metal-to-metal electrical con-
			tact.
"Output Cable Guidelines" below. Excessive volt-
age drops caused by undersized welding cables			For parallel and/or multiple arc applications with
and poor connections often result in unsatisfactory			excessive ground path lengths, a common work con-
welding performance. Always use the largest weld-			nection bus should be used. The common work con-
ing cables (electrode and work) that are practical,			nection serves to minimize voltage drops associated
and be sure all connections are clean and tight.			with resistive losses in the ground paths. It should be
Note: Excessive heat in the weld circuit indicates			made out of copper, and located as close as possible
			to the power sources (See Common Connection
	undersized cables and/or bad connections.		Diagram).

• Route all cables directly to the work and wire	Common Connection Diagram
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.

TABLE A.1 - Output Cable Guidelines				COMMON CONNECTION
Total Cable Length				(LOCAT ED CLOSE TO
ft (m)	Duty Cycle	Number of	Cable Size	POWER SOURCES)
Electrode and Work		Parallel Cables	Copper
Combined				WORK PIECE
0 (0) to 250 (76.2)	80%	2	4/0 (120 mm2)
0 (0) to 250 (76.2)	100%	3	3/0 (95 mm2)

Electrode Connections

Connect an electrode cable of sufficient size and length (Per Table A.1) to the "electrode" stud on the power source (located behind the cover plate on the lower left side). For convenience, the cable can be routed down through the two holes in the left cable tray before being connected to the output terminals. Connect the other end of the electrode cable to the wire drive feed plate on the wire feeder. Be sure the connection to the feed plate makes tight metal-to- metal electrical contact.

POWER WAVE® AC/DC 1000