Recommended Work Cable Sizes For Arc Welding - Lincoln Electric Power Wave S500 K2904-1 Operator's Manual

POWER WAVE ® S500
RECOMMENDED WORk CABLE SIZES fOR ARC
WELDINg
Connect the electrode and work cables between the appropriate
output studs of the POWER WAVE® S500 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).
CAUTION
Negative electrode polarity operation WITHOUT use of a
remote work sense lead (21) requires the Negative
Electrode Polarity attribute to be set. See the Remote
Sense Lead Specification section of this document for
further details.
For additional Safety information regarding the electrode and work
cable set-up, See the standard "SAFETY INFORMATION" located in
the front of this Instruction Manual.
Percent Duty
Amperes
Cycle
200
100
250
100
300
100
350
100
400
100
450
100
500
60
550
40
** 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).
OUTPUT CABLE GUIDELINES
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED
0 to 50 Ft. 50 to 100 Ft.
2 2
1 1
2/0 2/0
2/0 2/0
3/0 3/0
3/0 3/0
2/0 2/0
2/0 2/0
A-9
General Guidelines
• 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.
• 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.
Table A.1 shows copper cable sizes recommended 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.
(Table A.1)
167°F (75°C)]
100 to 150 Ft. 150 to 200 Ft.
2 1
1 1
2/0 2/0
3/0 3/0
3/0 3/0
4/0 4/0
3/0 3/0
3/0 3/0
INSTALLATION
**
200 to 250 Ft.
1/0
1/0
3/0
4/0
4/0
2-3/0
4/0
4/0