RECOMMENDED WORk CABLE SIZES fOR ARC
WELDINg
Connect the electrode and work cables between the appropriate
output studs of the POWER WAVE® S500 per the following
guidelines:
•
Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode
cable between the wire drive feed plate and the positive (+)
output stud on the power source. Connect a work lead from
the negative (-) power source output stud to the work piece
•
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 (-) stud,
and work cable to the positive (+) stud).
Negative electrode polarity operation WITHOUT use of a
remote work sense lead (21) requires the Negative
Electrode Polarity attribute to be set. See the Remote
Sense Lead Specification section of this document for
further details.
For additional Safety information regarding the electrode and work
cable set-up, See the standard “SAFETY INFORMATION” located in
the front of this Instruction Manual.
General Guidelines
•
Select the appropriate size cables per the “Output Cable
Guidelines” below.
Excessive voltage drops caused by
undersized welding cables and poor connections often result
in unsatisfactory welding performance. Always use the
largest welding cables (electrode and work) that are practical,
and be sure all connections are clean and tight.
Note: Excessive heat in the weld circuit indicates undersized
cables and/or bad connections.
•
Route all cables directly to the work and wire feeder, avoid
excessive lengths and do not coil excess cable.
Route the
electrode and work cables in close proximity to one another
to minimize the loop area and therefore the inductance of the
weld circuit.
• Always weld in a direction away from the work (ground)
connection.
Table A.1 shows copper cable sizes recommended for different
currents and duty cycles. Lengths stipulated are the distance from
the welder to work and back to the welder again. Cable sizes are
increased for greater lengths primarily for the purpose of
minimizing cable drop.
CAUTION
Amperes
200
250
300
350
400
450
500
550
Percent Duty
Cycle
100
100
100
100
100
100
60
40
0 to 50 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
50 to 100 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
100 to 150 Ft.
2
1
2/0
3/0
3/0
4/0
3/0
3/0
150 to 200 Ft.
1
1
2/0
3/0
3/0
4/0
3/0
3/0
200 to 250 Ft.
1/0
1/0
3/0
4/0
4/0
2-3/0
4/0
4/0
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED
167°F (75°C)]
**
OUTPUT CABLE GUIDELINES
(Table A.1)
** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may
require cables larger than recommended, or cables rated higher than 167°F (75°C).
A-9
INSTALLATION
POWER WAVE
®
S500