
4-7. Connecting Weld Cable
From Wire Feeder
1 | 2 | |
|
|
|
Rear View | ! | Turn Off wire feeder and |
|
| welding power source. Stop |
|
| engine on welding |
|
| generator. |
| 1 | |
| Follow wire manufacturer’s recom- | |
| mendations for weld cable polarity. |
2
3
Push female connector over male connector, and turn 1/4 turn clock- wise.
3
804
4-8. Weld Cable Sizes
|
|
| Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit | |||||||
| Weld Output |
|
| Not Exceeding*** |
|
|
| |||
|
|
|
|
|
|
|
|
| ||
| Terminals |
|
|
|
|
|
|
|
| |
! Turn off power before |
|
|
|
|
|
|
| |||
| connecting to weld out- |
| 150 ft | 200 ft | 250 ft | 300 ft | 350 ft | 400 ft | ||
| put terminals. |
| 100 ft (30 m) or Less | |||||||
! | Do not use worn, dam- | (45 m) | (60 m) | (70 m) | (90 m) | (105 m) | (120 m) | |||
| ||||||||||
|
|
|
|
|
|
| ||||
| aged, undersized, | or |
|
|
|
|
|
|
| |
| poorly spliced cables. |
|
|
|
|
|
|
|
| Welding | 10 − 60% | 60 − 100% |
|
|
|
|
|
|
|
| Duty | Duty |
| 10 − 100% Duty Cycle |
|
| ||||
| Amperes |
|
|
| ||||||
| Cycle | Cycle |
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
| ||
|
|
|
|
|
|
|
|
|
|
|
100 | 4 (20) | 4 (20) | 4 (20) | 3 (30) | 2 (35) | 1 (50) |
| 1/0 (60) | 1/0 (60) | |
|
|
|
|
|
|
|
|
|
|
|
150 | 3 (30) | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) |
| 3/0 (95) | 3/0 (95) | |
|
|
|
|
|
|
|
|
|
|
|
200 | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) |
| 4/0 (120) | 4/0 (120) | |
|
|
|
|
|
|
|
|
|
|
|
250 | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) |
| 2 ea. 2/0 | 2 ea. 2/0 | |
| (2x70) | (2x70) | ||||||||
|
|
|
|
|
|
|
|
| ||
|
|
|
|
|
|
|
|
|
|
|
300 | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2 ea. 2/0 |
| 2 ea. 3/0 | 2 ea. 3/0 | |
(2x70) |
| (2x95) | (2x95) | |||||||
|
|
|
|
|
|
|
| |||
|
|
|
|
|
|
|
|
|
|
|
350 | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2 ea. 2/0 | 2 ea. 3/0 |
| 2 ea. 3/0 | 2 ea. 4/0 | |
(2x70) | (2x95) |
| (2x95) | (2x120) | ||||||
|
|
|
|
|
|
| ||||
|
|
|
|
|
|
|
|
|
|
|
400 | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2 ea. 2/0 | 2 ea. 3/0 |
| 2 ea. 4/0 | 2 ea. 4/0 | |
(2x70) | (2x95) |
| (2x120) | (2x120) | ||||||
|
|
|
|
|
|
| ||||
|
|
|
|
|
|
|
|
|
|
|
500 | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2 ea. 2/0 | 2 ea. 3/0 | 2 ea. 4/0 |
| 3 ea. 3/0 | 3 ea. 3/0 | |
(2x70) | (2x95) | (2x120) |
| (3x95) | (3x95) | |||||
|
|
|
|
|
| |||||
|
|
|
|
|
|
|
|
|
|
|
*This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. |
|
( ) = mm2 for metric use |
***For distances longer than those shown in this guide, call a factory applications representative at