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FLEXTEC 650x
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 650x 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).
AMPERES
PERCENT
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
600
60
600
80
600
100
650
60
650
80
700
100
800
80
800
100
** 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).
TABLE A.1
OUTPUT CABLE GUIDELINES
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
(RUBBER COVERED COPPER - RATED 167°F or 75°C)**
0 to 50Ft.
50 to 100Ft.
(0 to15m)
(15 to 30m)
2
2
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
3/0
2-1/0
2-1/0
3/0
2-1/0
2-2/0
3-1/0
2-3/0
The following recommendations apply to all output polarities and
weld modes:
• Select the appropriate size cables per the "Output Cable
Guidelines" (See Table A.1). 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.
100 to 150 Ft.
(30 to 46m)
2
2
2
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
3/0
3/0
2-1/0
2-1/0
2-1/0
2-1/0
3/0
4/0
2-1/0
2-1/0
2-2/0
2-3/0
3-1/0
3-1/0
2-3/0
2-3/0
A-6
INSTALLATION
150 to 200 Ft.
200 to 250 Ft.
(46 to 61m)
(61 to 76m)
1
1/0
1
1/0
1
1/0
1
1/0
1
1/0
1
1/0
1/0
2/0
2/0
3/0
2/0
3/0
3/0
4/0
3/0
4/0
3/0
4/0
4/0
2-3/0
2-2/0
2-3/0
2-2/0
2-3/0
2-2/0
2-3/0
2-2/0
2-3/0
2-3/0
2-4/0
2-3/0
2-4/0
2-3/0
2-4/0
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