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A-5
Connect the one end of the electrode cable, to the
power source output terminal of the desired polarity.
Connect the other end of the electrode cable to the
connection bar at the front of the wire drive feed plate
using the provided bolt and lockwasher. The
trode cable lug must be against the feed plate. Be
sure the cable, connection bar, and gun adapter bush-
ing all make tight metal-to-metal electrical contact.
The Electrode cable should be sized according to the
specifications given in the work cable connections
section.
WORK CABLE CONNECTIONS
Connect a work lead of sufficient size and length (per
the following table) between the proper output termi-
nal on the power source and the work. Be sure the
connection to the work makes tight metal-to-metal
electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths, bundle the electrode and ground
cables together where practical, and do not coil
excess cable.
Minimum work and electrode cables sizes are as fol-
lows:
Current
Minimum Copper Work Cable Size, AWG
60% Duty
Up to 100 ft Length (30m)
Cycle
400 Amps
500 Amps
600 Amps
When using an inverter type power source, use the
largest welding (electrode and ground) cables that are
practical. At least 2/0 copper wire — even if the aver-
age 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 welding characteristics, if undersized welding
cables are used.
INSTALLATION
e l e c -
2/0 (67 mm
2
)
3/0 (85 mm
2
)
3/0 (85 mm
)
2
POWER FEED 10
WIRE DRIVE GEAR RATIO (HIGH
OR LOW SPEED)
The speed range capability and drive torque of the
Power Feed 10 wire drive can be easily and quickly
changed by changing the external drive gear. The
Power Feed 10 is shipped with both a high speed and
a low speed gear. As shipped from the factory, the low
speed (high torque) gear is installed on the feeder. If
this is the desired gear ratio, no changes need to be
made.
SELECTING THE PROPER GEAR RATIO
See the Technical Specifications at the front of this
section for feed speed and wire size capabilities with
high and low speed gear ratios. To determine whether
you should be using the high or low speed ratio use
the following guidelines:
- If you need to operate at wire feed speeds above
800 IPM (20 m/m), you will need to install the high
speed gear (large 30 tooth, 1.6 inch(41mm) diameter
gear).
- If you do not need to run at wire feed speeds in
excess of 800 IPM (20 m/m), you should use the low
speed gear (small, 20 tooth, 1.1 inch(28mm) diame-
ter gear). Using the low speed ratio will provide the
maximum available wire driving force.
Note: If you are feeding only small diameter wires you
may, at your option, install the high speed ratio.
CHANGING THE WIRE DRIVE RATIO
Changing the ratio requires a gear change and a PC
board switch change. The Power Feed 10 is shipped
with both a high speed and a low speed gear. As
shipped from the factory, the low speed (high torque)
gear is installed on the feeder. For identification pur-
poses, the low speed (high torque) gear has 20 teeth
and is 1.1 inches(28mm) in diameter. The high speed
gear has 30 teeth and is 1.6 inches(41mm) in diame-
ter.
WARNING
Power down the Power Feed by turning off its
companion Power Wave power source. For maxi-
mum safety, disconnect the control cable from the
Power Feed.
------------------------------------------------------------------------
A-5
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