INSTALLATION | ||
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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
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 |
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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 | ||||||
WORK sense | lead | must be | ||||
brought | out of | the motor connection | box and | |||
connected to the workpiece. |
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