Weld Cable Sizes; Coaxial Weld Cable - Lincoln Electric POWER FEED 25M Operator's Manual

A-4
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
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.
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
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**
AMPERES
250
300
350
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
AMPERES PERCENT
DUTY
CYCLE
200 60
200 100
225 20
225 40 & 30
250 30
250 40
250 60
250 100
300 60
325 100
350 60
400 60
400 100
500 60
** 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).
All manuals and user guides at all-guides.com
INSTALLATION
DUTY
0 to 25Ft.
(0 to7.6M)
CYCLE
100%
1
1
60%
1/0
60%
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
0 to 50Ft.
50 to 100Ft.
(0 to15M) (15 to 30M)
2
2
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
POWER FEED™ 25M
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.
W W o o r r k k
Power Source Power Source
W W ork ork Electrode Electrode
Coaxial Weld Cable Coaxial W
TABLE A.2
COAXIAL CABLE LENGTH
25 to 50Ft.
50 to 75 Ft.
(7.6 to 15.2M)
(15.2 to 22.9M)
1
1
1/0
TABLE A.1
100 to 150 Ft.
(30 to 46M)
2 2
2
2
3 2
3 2
3
2
2 1
1 1
1
1
1 1
2/0 2/0
1/0
2/0
2/0 2/0
3/0 3/0
2/0
3/0
FIGURE A.5
W W o o r r k k
E E l l e e c c tr tro o d d e e
eld Cable
Electrode Electrode
Wire Feeder Wire Feeder
W W ork ork
75 to 100 Ft.
(22.9 to 30.5M)
1
1
1/0
1
--
--
150 to 200 Ft. 200 to 250 Ft.
(46 to 61M) (61 to 76M)
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
A-4
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0