Lincoln Electric IM850-A manual Electrode and Work Connections, Remote Sense Lead Specifications

A-4 INSTALLATION A-4

ELECTRODE AND WORK

CONNECTIONS

Due to the Power Wave AC/DC”s ability to produce either a DC positive, DC negative or AC output the elec- trode 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 polar- ities:

Connect a work lead of sufficient size (Per Table A.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 per- formance. 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 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 through the oval hole in the left cable tray before being connected to the output terminals. Connect the other end of the electrode cable to the nozzle. Be sure the connection makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in Table A.1.

TABLE A.1 - Output Cable Guidelines

Total Cable Length
ft (m)	Duty Cycle	Number of	Cable Size
Electrode and Work		Parallel Cables	Copper
Combined
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 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.

REMOTE SENSE LEAD SPECIFICATIONS

The Power Feed 10S has sense lead connections at the Connection Box mounted to the motor. These sense leads are critical to the accuracy of the Power Wave welding process. Ring terminals are provided at the ends of the leads. These leads must be extended to the Work piece and the Electrode respectively. The lead marked "TO WORK" should be extended and connected to the work piece, while the lead marked "TO ELECTRODE" should be extended and connect- ed to the nozzle. These connections 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 connec- tion, then insulate the connection with electrical tape. Proper care should be taken to protect the sense leads from becoming disconnected or damaged. The loss of a sense lead connection can adversely affect welding performance.

There are several different sense lead configurations that can be used depending on the application. The ELECTRODE sense lead (67) and the WORK sense lead (21) are built into the wire drive control cable. The system has multiple sense lead configurations available. Consult the power source manual on how to configure the power source DIP switches for the sense leads.

CAUTION

Excessive voltage drops at the work piece con- nection often result in unsatisfactory pulse weld- ing performance.

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POWER FEED 10S