INSTALLATION | ||
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WELD CABLE SIZE
Table A.1 located below are copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the dis- tance 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.
COAXIAL WELD CABLE
(See Table A.2)
Coaxial welding cables are specially designed welding cables for pulse welding or STT™ welding. Coaxial weld cables feature low inductance, allowing fast changes in the weld current. Regular cables have a higher inductance which may distort the pulse or STT™ wave shape. Inductance becomes more severe as the weld
To install:
1.Turn the input power off at the welding power source.
2.Connect one end of the center lead to the power source electrode connection, and the other end to the wire feed- er electrode connection.
3.Connect the outer lead bundle to the power source work connection, and the other end to the work piece. Minimize the length of any work lead extension for best results.
4.Insulate all connections.
FIGURE A.5
Work
cables become longer.
Coaxial cables work best for high performance waveforms and when:
•long cables are present.
•the cables are housed in a metal tray.
Power Source
Work Electrode
Electrode |
Wor |
Coaxial Weld Cable
A coaxial weld cable is constructed with multiple small leads wrapped around one large lead. The large inner lead connects to the electrode stud on the power source and the electrode connec- tion on the wire feeder. The small leads combine together to form the work lead, one end attached to the power source and the other end to the work piece. See Figure A.5
ElectrodeWorkWire Feeder
TABLE A.2
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**
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| COAXIAL CABLE LENGTH |
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AMPERES | DUTY | 0 to 25Ft. | 25 to 50Ft. | 50 to 75 Ft. | 75 to 100 Ft. |
| CYCLE | (0 to7.6M) | (7.6 to 15.2M) | (15.2 to 22.9M) | (22.9 to 30.5M) |
250 | 100% | 1 | 1 | 1 | 1 |
300 | 60% | 1 | 1 | 1 | 1/0 |
350 | 60% | 1/0 | 1/0 | ||
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TABLE A.1
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
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| CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES | ||||
AMPERES | PERCENT |
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| DUTY | 0 to 50Ft. | 50 to 100Ft. | 100 to 150 Ft. | 150 to 200 Ft. | 200 to 250 Ft. |
| CYCLE | (0 to15M) | (15 to 30M) | (30 to 46M) | (46 to 61M) | (61 to 76M) |
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200 | 60 | 2 | 2 | 2 | 1 | 1/0 |
200 | 100 | 2 | 2 | 2 | 1 | 1/0 |
225 | 20 | 4 or 5 | 3 | 2 | 1 | 1/0 |
225 | 40 & 30 | 3 | 3 | 2 | 1 | 1/0 |
250 | 30 | 3 | 3 | 2 | 1 | 1/0 |
250 | 40 | 2 | 2 | 1 | 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 | 2/0 |
325 | 100 | 2/0 | 2/0 | 2/0 | 2/0 | 3/0 |
350 | 60 | 1/0 | 1/0 | 2/0 | 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 | 3/0 | 3/0 | 4/0 |
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**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).