Lincoln Electric IM718 manual Electrode and Work Cable Connections

A-6 INSTALLATION A-6

ELECTRODE AND WORK CABLE CONNECTIONS

Due to the PowerWave AC/DC’s ability to produce 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 different polarities. All of this is controlled internally by the Power Wave AC/DC. The following directions apply to all polarities:

Connect a work lead of sufficient size (Per Table 1) and length between the "work" stud (located beneath the spring loaded output cover on the front of the machine) and the work. For convenience, the work lead can be routed behind the left strain relief (under the spring loaded output cover), along the channels, and out the back of the machine. Be sure the connection to the work makes tight metal-to-metal electrical contact. The work piece connection must be firm and secure. Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance, espe- cially if pulse welding is planned. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work and wire feeder. Avoid excessive lengths and do not coil excess cable.

Connect the electrode cable between the wire feeder and the "electrode" stud on the power source (located behind the cover plate on the lower right side). For convenience, the cable can be routed through the oval hole in the rear of the machine before being connected to the output ter- minals. Connect the other end of the electrode cable to the wire drive feed plate. Be sure the connection to the feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in (Table A.1).

Suggested Copper Cable Sizes - 100 Duty Cycle Combined Length of Electrode and Work Cables (Table A.1)

Cable Length (ft (m)	Parallel Cables	Cable Size
0 (0) to 100 (30.4)	1	4/0 (120mm2)
100 (30.4) to 200 (60.8)	2	2/0 (70mm2)
200 (60.8) to 250 (76.2)	2	3/0 (95mm2)

When using inverter type power sources like the Power Wave, use the largest welding (electrode and work) cables that are practical. When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if undersized welding cables are used. NOTE: K1796 coaxial welding cable is recommended to reduce the cable inductance in long cable lengths. This is especially important when Pulse welding up to 350 amps.

CABLE INDUCTANCE, AND ITS EFFECTS ON PULSE WELDING

For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than 50 feet, traditional welding cables may be used without any effects on welding performance. For the total welding loop length greater than 50 feet, the K1796 Coaxial Welding Cables are recommended.

The welding loop length is defined as the total of elec- trode cable length (A) + work cable length (B) + work length (C) (See Figure A.3).

	FIGURE A.3
POWER
WAVE	A

C

WORK

B

For long work piece lengths, a sliding ground should be considered to keep the total welding loop length less than 50 feet. (See Figure A.4.)

	FIGURE A.4
POWER	A		A
WAVE
	C	WORK	C

B B

SLIDING GROUND

K1796 COAXIAL CABLE

MEASURE FROM END

OF OUTER JACKET OF

CABLE

FOR A DETAILED CONNECTION DIAGRAM USING K1796 COAXIAL CABLE, SEE PAGE F-4.

CAUTION

When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if under- sized welding cables are used.

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POWER WAVE AC/DC