5
INSTALLATION
2.3 WELD OUTPUT CONNECTIONS
To obtain full rated output from this unit, it is necessary to select,
prepare, and install proper weld cables. Failure to comply in any
of these areas may result in unsatisfactory welding performance.
Use the following guidelnes to select weld cables:
1. Use the shortest possible cables, and place cables close
together. Excessive cable lengths may reduce or cause unit
overload due to added resistance.
2. Use weld cable with an insulation voltage rating equal to or
greater than the maximum open circuit voltage (OCV) of the
welding power source (see Table 2-A below).
3. Select welding cable size according to maximum weld output
and total length of connecting cables in weld circuit. For
example, if a 25 foot (7.5 m) electrode holder or torch cable is
used with a 25 foot (7.5 m) work cable, select the cable size
recommended in Table 2-A for 50 feet (15 m).
4. Do not use damaged or frayed cables.
1. Install terminal lugs of adequate amperage capacity and
correct stud size onto ends of cables that connect to the work
clamp and electrode holder or torch.
2. If installing electrode holder, follow manufacturer’s installa-
tion instructions. Always use an insulated electrode holder to
ensure operator safety.
3. Install work clamp onto cable.
4. Install supplied male connectors onto remaining ends of both
cables (refer to Connector Installation, page 6).
Weld Cable Selection
Weld Cable Preparation
Table 2-A
Weld Cable Sizes
Maximum Total Cable Length in Weld Circuit
Welding
Under 100 ft
150 ft
200 ft
250 ft
300 ft
250 ft
400 ft
Amperes
(Under 30 m)
(45 m)
(60 m)
(70 m)
(90 m)
(105 m)
(120 m)
10-60%
60-100%
10-100%
Duty Cycle
Duty Cycle
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
Summary of Contents for 400 GTSW AC/DC
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