Recommended Work Cable Sizes For Arc Welding; General Guidelines - Lincoln Electric PIPEFAB Series Operator's Manual

PIPEFAB™ WELDING SYSTEM

RECOMMENDED WORK CABLE SIZES FOR ARC WELDING

GENERAL GUIDELINES

• Select the appropriate size cables per the "Output Cable Guidelines" below. Excessive voltage drops
caused by undersized welding cables and poor connec�ons o�en result in unsa�sfactory welding
performance. Always use the largest welding cables (electrode and work) that are prac�cal, and be
sure all connec�ons are clean and �ght.
NOTE: Excessive heat in the weld circuit indicates undersized cables and/or bad connec�ons.
• 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 direc�on away from the work (ground) connec�on.
Table A.1 shows copper cable sizes recommended for different currents and duty cycles. Lengths
s�pulated 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 - RECOMMENDED CABLE SIZES - RUBBER COVERED COPPER - RATED 167°F (75°C)[1]
PERCENT
DUTY
AMPERES
CYCLE
200 100
250 100
300 100
400 100
450 100
500 60
550 40
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
50 TO 100
0 TO 50 FT.
FT.
2 2
1 1
2/0 2/0
3/0 3/0
3/0 3/0
2/0 2/0
2/0 2/0
A-27
CABLES
100 TO 150 150 TO 200
FT. FT.
2 1
1 1
2/0 2/0
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
2–3/0
4/0
4/0