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FLEXTEC
®
500X
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
®
500X 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
A-11
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
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