INSTALLATION |
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WELD CABLE SIZE
Table A.1 located below are copper cable sizes recom- mended 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.
COAXIAL WELD CABLE
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 cables become longer.
Coaxial weld cables are recommended for all pulse and STT™ welding, especially when the total weld cable length (electrode cable + work cable) exceeds 50 feet (7.6m).
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 connection 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
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FIGURE A.5 | Work |
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Power Source
Work Electrode
Electrode |
Wor |
Coaxial Weld Cable
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ElectrodeWorkWire Feeder
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).
