When using inverter type power sources like the
Power Waves, use the largest welding (electrode
and work) cables that are practical. At least 2/0
copper wire - even if the average output current
would not normally require it. When pulsing, the
pulse current can reach very high levels. Voltage
drops can become excessive, leading to poor weld-
ing characteristics, if undersized welding cables
are used.
------------------------------------------------------------------------

Most welding applications run with the electrode being

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

trode cable between the wire feeder and the positive

(+) output Twist-Mate terminal on the power source.

Connect the other end of the electrode cable to the

wire drive feed plate. The electrode cable lug must be

against the feed plate. Be sure the connection to the

feed plate makes tight metal-to-metal electrical con-

tact. The electrode cable should be sized according to

the specifications given in the output cable connections

section. Connect a work lead from the negative (-)

power source output Twist-Mate terminal to the work

piece. The work piece connection must be firm and

secure, especially if pulse welding is planned.

For additional Safety information regarding the elec-

trode and work cable set-up, See the standard "SAFE-

TY INFORMATION" located in the front of the

Instruction Manuals.

Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
-----------------------------------------------------------------------

NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as

in some Innershield applications, reverse the output

connections at the power source (electrode cable to

the negative (-) Twist-Mate terminal, and work cable

to the positive (+) Twist-Mate terminal.

When operating with electrode polarity negative the

"Electrode Sense Polarity" DIP switch must be set to

the "Negative" position on the Wire Drive Feed Head

PC Board. The default setting of the switch is positive

electrode polarity. Consult the Power Feed instruction

manual for further details.

VOLTAGE SENSING

The best arc performance occurs when the

PowerWaves have accurate data about the arc condi-

tions. Depending upon the process, inductance within

the electrode and work lead cables can influence the

voltage apparent at the studs of the welder. Voltage

sense leads improve the accuracy of the arc conditions

and can have a dramatic effect on performance.

Sense Lead Kits (K940-10, -25 or -50) are available for

this purpose.

If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
extremely high welding outputs may occur.
------------------------------------------------------------------------

The ELECTRODE sense lead (67) is built into the con-

trol cable, and is automatically enabled for all semi-

automatic processes. The WORK sense lead (21) con-

nects to the Power Wave at the four pin connector. By

default the WORK voltage is monitored at the output

stud in the POWER WAVE 355/405. For more informa-

tion on the WORK sense lead (21), see"Work Voltage
Sensing” in the following paragraph.

CAUTION

Advertising

Popular Brands

Popular manuals