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Work Voltage Sensing
The Power Waves are shipped from the factory with
the work sense lead enabled.
For processes requiring work voltage sensing, con-
nect the (21) work voltage sense lead from the Power
Wave to the work. Attach the sense lead to the work
as close to the weld as practical. Enable the work volt-
age sensing in the Power Wave as follows:
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
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1. Turn off power to the power source at the discon-
nect switch.
2. Remove the front cover from the power source.
3. The control board is on the left side of
the power source. Locate the 8-position
DIP switch and look for switch 8 of the
DIP switch.
4. Using a pencil or other small object,
slide the switch right to the OFF position
if the work sense lead is NOT connect-
ed. Conversely, slide the switch left to
the ON position if the work sense lead is
present.
5. Replace the cover and screws. The PC board will
“read” the switch at power up, and configure the
work voltage sense lead appropriately.
Electrode Voltage Sensing
Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead must be connected at the wire
feeder.
A-7
INSTALLATION
POWER WAVE 455/R
A-7
5. Replace the cover and screws. The PC board will
“read” the switch at power up, and configure the
work voltage sense lead appropriately.
VOLTAGE SENSING
The best arc performance occurs when the Power
Waves have accurate data about the arc conditions.
Depending upon the process, inductance within the
electrode and work lead cables can influence the volt-
age 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.
If the voltage sensing is enabled but the sense
leads are missing or improperly connected,
extremely high welding outputs may occur.
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Do not tightly bundle the work sense lead to the work
lead.
The ELECTRODE sense lead (67) is built into the
K1795 control cable. The WORK sense lead (21) con-
nects to the Power Wave at the four-pin connector
located underneath the output stud cover. Enable the
voltage sense leads as follows:
TABLE 2
Process Electrode Voltage Work Voltage
Sensing 67 lead * Sensing 21 lead
GMAW 67 lead required 21 lead optional**
GMAW-P
67 lead required 21 lead optional**
FCAW 67 lead required 21 lead optional**
STT 67 lead required 21 lead required**
GTAW
Voltage sense at studs Voltage sense at studs
SAW 67 lead required 21 lead optional**
* The electrode voltage 67 sense lead is part of to the
control cable to the wire feeder.
** For consitent weld quality work voltage sensing is
recommended.
WARNING
O
N
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CAUTION