A-7
INSTALLATION
FX360XL
reCOMMenDeD eleCTrODe anD WOrk CaBle
sIZes FOr arC WelDInG
Connect the electrode and work cables between the appropriate
output studs of the FX360XL per the following guidelines:
• Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode
cable between the wire drive input power connector 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 A.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 voltage drop.
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F OR 75°C)**
Amperes
PERCENT
DUTY CYCLE
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
200
60
2
2
2
1
1/0
200
100
2
2
2
1
1/0
225
20
4 or 5
3
4 or 5
1
1/0
225
40 & 30
3
3
3
1
1/0
250
30
3
3
3
1
1/0
250
40
2
2
2
1
1/0
250
60
1
1
1
1
1/0
250
100
1
1
1
1
1/0
300
60
1
1
1
1/0
1/0
350
100
2/0
2/0
2/0
2/0
2/0
350
60
1/0
1/0
1/0
2/0
3/0
400
60
2/0
2/0
2/0
3/0
4/0
400
100
3/0
3/0
3/0
3/0
4/0
500
60
2/0
2/0
2/0
3/0
4/0
** 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).
TABLE A.1
