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Electrical Installation
WARNING
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts such as output terminals or internal wiring.
•When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground.
•Turn OFF welding power source before installing or changing drive roll and/or guide tubes.
•Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.
•Only qualified personnel should perform this installation.
Observe all additional Safety Guidelines detailed throughout this manual.
Input Cable: Synergic 7F Control to Power Wave Synergic Type Power Sources
K648 - (Used with Power Wave 450) Consists of an 8- conductor control cable with a
K649 - (Used with Power Wave 450/500) Consists of an 8- conductor control cable with a
K642 (Control Cable Only) - Consists of an 8 conductor control cable with a
K643 (Control Cable Extension) - Consists of an 8 conductor control cable with
With input power disconnected from the power source, install the input cable per connection diagram M17770 in the rear of this manual and follow exactly the instructions on the diagram or perform the following:
1)Connect the end of the control cable with the 14- pin cable plug to the mating receptacle on the power source.
2)Connect the electrode lead of that same cable end to the power source output terminal of the desired polarity.
3)Connect the
4)If not using a single continuous electrode cable from the Power Source to Wire Feed Unit, bolt the electrode lead from the power source to the electrode lead to the wire feed unit using the nut and bolt supplied with the K680 Control to Feed Unit cable assembly.
Work Cable
Connect a work lead of sufficient size and length (per the following table) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight
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| Copper Work Cable Size, AWG * |
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| 60% Duty |
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| Cycle |
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| Up to 100 ft Length (30m) |
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| 300 Amps |
| 00 (67 mm2) | ||||
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| 400 Amps |
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| 000 (85 mm2) |
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| 500 Amps |
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| 000 (85 mm2) |
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*For pulse welding applications, the next larger cable size is recommended.
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