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A-5
UNDERCARRIAGE MOUNTINGS
MOUNTING HOLE LOCATIONS
NOTE: MOUNTING SCREWS CA
N NOT PROTR UDE MORE THAN
0.5 INCHES INSIDE THE MACHINE.
1/4-20 NUT (4 PLACES)
11.84
OUTPUT CABLES, CONNECTIONS AND
LIMITATIONS
Connect a work lead of sufficient size and length
between the proper output terminal 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 and do not coil excess cable.
CAUTION
When using an inverter type power source like the
PowerWaves, 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
welding 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 connec-
tions 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.
INSTALLATION
3.50
5.50
10.00
4/01
M19527
POWER WAVE 355/405
CAUTION
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 condi-
tions and can have a dramatic effect on performance.
Sense Lead Kits (K940-10, -25 or -50) are available for
this purpose.
CAUTION
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 infor-
mation on the WORK sense lead (21), see"Work
Voltage Sensing" in the following paragraph.
A-5
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