SAF ETY Precautions, Electrode Routing | Lincoln Electric K1780-1

A-2

INSTALLATION

A-2

SAF

ETY PRECAUTIONS

ELECTRODE ROUTING

WARNING

The electrode supply may be either from reels, Readi-

ELECTRIC SHOCK can kill.

Reels, spools, or bulk packaged drums or reels.

• Do not bend the conduit more than 45°, and to use

• Only qualified personnel should

Observe the following precautions:

the minimum amount of conduit necessary for the

perform this installation.

wire reel to connect to the wire feeder.

• Turn off the input power to the power source at

• The electrode is "hot" while welding and must be

the disconnect switch or fuse box before work-

insulated from the boom, conduit and wire payoff

ing on this equipment. Turn off the input power

structure.

to any other equipment connected to the weld-

• If more than one wire feed unit shares the same

ing system at the disconnect switch or fuse

boom and are not sharing the some power source

box before working on this equipment.

output stud, their wire and reels must be insulated

• Do not touch electrically hot parts.

from each other as well as insulated from their

• Always connect the Power Wave grounding lug

mounting structure.

door) to a proper safety (Earth) ground.

ELECTRODE AND WORK CABLE CON-

(located inside the reconnect input access

NECTIONS

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Most welding applications run with the electrode being

positive (+). For those applications, connect the elec-

MOUNTING OF THE PF10/R

trode cable between the wire feeder and the positive

(+) output stud on the power source (located beneath

Mount the wire drive unit by means of the 4 holes in

the spring loaded output cover near the bottom of the

the

bottom of the wire drive base. Note that the gear-

case front).

box assembly is electrically “hot” when welding.

Therefore, make certain the gearbox does not come in

A work lead must be run from the negative (-) power

contact with the structure on which the unit is mount-

source output

stud to the work piece. The work piece

ed. The wire feed unit should be mounted so that the

connection must be firm and secure, especially if

drive rolls are in a vertical plane to prevent the accu-

pulse welding is planned. Excessive voltage drops at

mulation of dirt in the drive roll area. Do not bend the

the work piece connection often result in unsatisfacto-

conduit more than 45°.

ry pulse welding performance.

Connect a work lead of sufficient size and length (per

TABLE 1) between the proper output terminal on the

FIGURE A.1

power source and the work. Be sure the connection

tact. To avoid interference problems with other equip-

to the work makes tight metal-to-metal electrical con-

ment and to achieve the best possible operation, route

all cables directly to the work or wire feeder. Do not

7.11

bundle the electrode and work leads tightly together.

Avoid excessive lengths and do not coil excess cable.

1.77

Use K1796 Coaxial welding cables wherever possible.

Minimum work and electrode cables sizes are as follows:

TABLE 1

1.97

.22 DIA.

3.05

MINIMUM COPPER WORK

CABLE SIZE, AWG

(2 Places)

Current (60% Duty Cycle)

Up To-100 Ft. Length (30 m)

400 Amps

2/0 (67 mm2)

500 Amps

3/0 (85 mm2)

.25 DIA.

600 Amps