Lincoln Electric IM559 Electrical Installation, Work Cable, Current, Amps 00 67 mm2 000 85 mm2

A-9 INSTALLATION A-9

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 and could remain energized several seconds after the gun trigger is released.

•Turn OFF input power at welding power source before installation 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

NOTE: CSAnrtl certification of the Synergic 7 models is with input cable assemblies identified by carton date codes 010161, or above. These assemblies have grounding lead continituity between the 14-pin plug pin B and the 8-socket plug pin E per diagram below.

B=GND

E=GND

14-PIN PLUG, FRONT VIEW 8-PIN PLUG, FRONT VIEW

K648 - (Used with Power Wave 450) Consists of an 8-con- ductor control cable with a 14-pin plug and a 4/0 (107 mm2) electrode cable with stud terminal. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).

K649 - (Used with Power Wave 450/500) Consists of an 8- conductor control cable with a 14-pin control cable plug and a 4/0 (107mm2) electrode cable with Twist-Mate™ connector. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).

K642 (Control Cable Only) - Consists of an 8 conductor control cable with a 14-pin control cable plug, without electrode cable, and is available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).

K643 (Control Cable Extension) - Consists of an 8 conductor control cable with 14-pin connectors on each end for extending the control cable between the power source and the control cables. Available in lengths of 17 ft (5 m), 25 ft (8 m), 33 ft (10 m) and 50 ft (15 m).

With input power disconnected from the power source, install the input cable per connection diagram S22015 in the rear of this manual and follow exactly the instructions on the diagram or perform the follow- ing:

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 14-socket plug of the control cable to the mating receptacle on the bottom of the control box.

4)If not using a single continuous electrode cable from the Power Source to the 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. Insulate connection with elec- trical tape.

Work Cable

Connect a work lead of sufficient size and length (per the following table) between the proper output termi- nal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact.

Current
	Copper Work Cable Size, AWG *
60% Duty
Cycle	Up to 100 ft Length (30m)
300 Amps	00 (67 mm2)
400 Amps	000 (85 mm2)
500 Amps	000 (85 mm2)

*For pulse welding applications, the next larger cable size is recommended.

SYNERGIC 7F & FH