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9
Recommended Electrode and Work Cable Sizes for Arc
Welding
Connect the electrode and work cables between the
appropriate output studs of the Flextec 350x CE 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).
The following recommendations apply to all output
polarities and weld modes:
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.
(See table 1)
Tabulated below are 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.
Table 1
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**
AMPERES
PERCENT
DUTY
CYCLE
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES
0 to 15m
15 to 30m
30 to 46m
46 to 61m
61 to 76m
200 60
35mm2 35mm2 35mm2 50mm2 70mm2
200 100
35mm2 35mm2 35mm2 50mm2 70mm2
225 20
25mm2 35mm2 25mm2 50mm2 70mm2
225
40 & 30
35mm2 35mm2 35mm2 50mm2 70mm2
250 30
35mm2 35mm2 35mm2 50mm2 70mm2
250 40
35mm2 35mm2 50mm2 50mm2 70mm2
250 60
50mm2 50mm2 50mm2 50mm2 70mm2
250 100
50mm2 50mm2 50mm2 50mm2 70mm2
300 60
50mm2 50mm2 50mm2 70mm2 70mm2
350 100
70mm2 70mm2 70mm2 70mm2 95mm2
350 60
70mm2 70mm2 70mm2 70mm2 95mm2
400 60
70mm2
70mm2
70mm2
95mm2 120mm2
400 100
70mm2
95mm2
95mm2
95mm2 120mm2
500 60
70mm2
70mm2
95mm2
95mm2 120mm2
** 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).