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Electrical Installation
Input Cable: Synergic 7F Control to Power Wave
Synergic Type Power Sources
K648 - (Used with Power Wave 450) Consists of an 8-
conductor control cable with a 14-pin plug and a 4/0 (107
mm
2
) electrode cable with stud terminal. It is rated at 500
amps, 60% duty cycle and is available in lengths of 7 ft (2
m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
K649 - (Used with Power Wave 450/500)
Consists of an 8-
conductor control cable with a 14-pin control cable plug and a
4/0 (107mm
2
) electrode cable with Twist-Mate™ connector. It
is rated at 500 amps, 60% duty cycle and is available in lengths
of 7 ft (2 m), 17 ft (5 m),
25 ft (7.6 m),
33 ft (10 m) and 50 ft (15
m).
K642 (Control Cable Only) - Consists of an 8
conductor control cable with a 14-pin control cable
plug, without electrode cable, and is available in
lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10
m) and 50 ft (15 m).
K643 (Control Cable Extension) - Consists of an 8
conductor control cable with 14-pin connectors on
each end for extending the control cable between the
power source and the control cables. Available in
lengths of 17 ft (5 m), 25 ft (8 m), 33 ft (10 m) and 50
ft (15 m).
With input power disconnected from the power
source, install the input cable per connection diagram
M17770 in the rear of this manual and follow exactly
the instructions on the diagram or perform the
following:
1) Connect the end of the control cable with the 14-
pin cable plug to the mating receptacle on the
power source.
2) Connect the electrode lead of that same cable end
to the power source output terminal of the desired
polarity.
3) Connect the 14-socket plug of the control cable to
the mating receptacle on the bottom of the control
box.
4) If not using a single continuous electrode cable
from the Power Source to Wire Feed Unit, bolt the
electrode lead from the power source to the
electrode lead to the wire feed unit using the nut
and bolt supplied with the K680 Control to Feed
Unit cable assembly.
Work Cable
Connect a work lead of sufficient size and length (per
the following table) 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.
* For pulse welding applications, the next larger cable
size is recommended.
Copper Work Cable Size, AWG *
Up to 100 ft Length (30m)
Current
60% Duty
Cycle
300 Amps
400 Amps
500 Amps
00 (67 mm
2
)
000 (85 mm
2
)
000 (85 mm
2
)
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• When inching with gun trigger, electrode
and drive mechanism are “hot” to work
and ground.
• Turn OFF welding power source before
installing or changing drive roll and/or
guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
WARNING
Observe all additional Safety Guidelines detailed
throughout this manual.