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A-4
INSTALLATION
POWER WAVE® 405M
A-4
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.
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.
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The ELECTRODE sense lead (67) is built into the
control cable, and is automatically enabled for all
semi-automatic processes. The WORK sense lead
(21) connects to the POWER WAVE® at the four pin
connector. By default the WORK voltage is monitored
at the output stud in the POWER WAVE® 405M. For
more information on the WORK sense lead (21), see
"Work Voltage Sensing” in the following paragraph.
Enable the voltage sense leads as follows:
TABLE A.1
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
GTAW
Voltage sense at studs Voltage sense at studs
GMAW
Voltage sense at studs Voltage sense at studs
SAW 67 lead required 21 lead optional
CAC-C
Voltage sense at studs Voltage sense at studs
* The electrode voltage 67 sense lead is integral to
the control cable to the wire feeder.
Work Voltage Sensing
The standard POWER WAVE® 405M’s default to the
work stud (work sense lead disabled)
For processes requiring work voltage sensing, con-
nect the (21) work voltage sense lead (K940) from the
POWER WAVE® work sense lead receptacle to the
work piece. Attach the sense lead to the work piece
as close to the weld as practical, but not in the return
current path. Enable the work voltage sensing in the
POWER WAVE®. (See Dip Switch Settings and
Locations in Installation Section of this manual.)
CAUTION
ELECTRODE VOLTAGE SENSING
Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead is internal to the cable to the
wire feeder and always connected when a wire feeder
is present.
Important: The electrode polarity must be config-
ured at the feed head for all semi-automatic
processes. Failure to do so may result in extreme-
ly high welding outputs.
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CAUTION