Lincoln Electric IM850 POWER FEED 10S - Manual (Page 14)

A-4 INSTALLATION
POWER FEED 10S
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
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.
Excessive voltage drops at the work piece con-
nection often result in unsatisfactory pulse weld-
ing performance.
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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
Total Cable Length
ft (m)
Electrode and Work
Combined
0 (0) to 250 (76.2)
0 (0) to 250 (76.2)
Duty Cycle
80%
100%
Number of
Parallel Cables
2
3
Cable Size
Copper
4/0 (120 mm 2 )
3/0 (95 mm 2 )