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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-
Current
Minimum Copper Work Cable Size, AWG
60% Duty
Up to 100 ft Length (30m)
Cycle
400 Amps
500 Amps
600 Amps
lows:
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 DUAL
WIRE DRIVE GEAR RATIO (HIGH
OR LOW SPEED)
The speed range capability and drive torque of the
Power Feed 10 Dual wire drive can be easily and
quickly changed by changing the external drive gear.
The Power Feed 10 Dual is shipped with both a high
speed and a low speed gear. As shipped from the fac-
tory, 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 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 diameter 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 Dual 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 identifica-
tion purposes, the low speed (high torque) gear has
20 teeth and is 1.1 inches in diameter. The high speed
gear has 30 teeth and is 1.6 inches in diameter.
WARNING
Power down the Power Feed by turning off its com-
panion PowerWave power source. For maximum
safety, disconnect the control cable from the Power
Feed.
------------------------------------------------------------------------
A-5
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