Lincoln Electric FLEXTEC 500 P Operator's Manual page 23

FLEXTEC™ 500 P
RECOMMENDED ELECTRODE AND WORK
CABLE SIZES FOR ARC WELDING
General Guidelines
Connect the electrode and work cables between the appropriate
output studs of the Flextec™ 500 P per the following guidelines:
• Most welding applications run with the electrode being positive
(+). For those applications, connect the electrode cable between
the wire drive feed plate 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.
PERCENT
AMPERES DUTY
CYCLE
200 60
200 100
250 30
250 40
250 60
250 100
300 60
300 100
350 40
400 60
400 100
500 60
• 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.
OUTPUT CABLE GUIDELINES
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]**
0 TO 50 FT 50 TO 100 FT
2 2
2 2
3 3
2 2
1 1
1 1
1 1
2/0 2/0
1/0 1/0
2/0 2/0
3/0 3/0
2/0 2/0
B-6
100 - 150 FT 150 - 200 FT
2 1
2 1
2 1
1 1
1 1
1 1
1 1/0
2/0 2/0
2/0 2/0
2/0 3/0
3/0 3/0
3/0 3/0
INSTALLATION
200 - 250 FT
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0