Recommended Work Cable Sizes - Lincoln Electric POWER WAVE S500 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
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 out-
put connections at the power source (electrode cable
to the negative (-) stud, and work cable to the posi-
Negative electrode polarity operation WITHOUT
tive (+) stud).
CAUTION
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.
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For additional Safety information regarding the elec-
"SAFETY INFORMATION" located in the front of this
trode and work cable set-up, See the standard
General Guidelines
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).
® S500
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-8
• Select the appropriate size cables per the
"Output Cable Guidelines" below. Excessive volt-
age drops caused by undersized welding cables and
poor connections often result in unsatisfactory weld-
ing 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