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2-11. Selecting Cable Length and Size
Weld cable length and size are very important. A power source is often penalized by the use of too small a cable or too
long a cable system. The following chart will serve as a guide to selecting cable size and lengths in relation to the stud
diameter and approximate amperage.
A voltage drop will occur between the power source terminals and the stud gun due to cable resistance. Cables must
be of sufficient size to allow the necessary voltage to be available at the stud gun. Avoid more than a 5 volts drop in the
cables.
Cable connections and splices are another area to consider. Make the best possible electrical and mechanical con-
nections. Use commercially available welding cable connectors, making certain the right size is used for cable size
being used. Since the time cycle is so short, any arcing in a poor connection will prevent satisfactory stud weld-
ing.
400
350
300
250
200
150
100
50
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2100
2/0
4/0
2-4/0
Use multiple 4/0 cables or
500 mcm cable or larger.
No. 1
Cable Size
Area
1/4”
5/16”
3/8”
7/16”
1/2”
5/8”
3/4”
7/8”
1”
Arc Stud Size & W
elding Current (Shank Size)
TOTAL CABLE LENGTH (FT)
(Ground And Electrode
)
