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SECTION 4 − RECOMMENDED SETUP PROCEDURES
4-1. Selecting Weld Cable Sizes*
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Weld Output
Terminals
Y Turn off power before
connecting to weld out-
put terminals.
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
P
Positive
iti
Negative
N
ti
*
)
This chart is a general guideline and may not suit all applications. If cable overheating occurs, use next size larger cable.
*
**Cable should be sized for Peak Amperage (Apk) for pulse welding applications.
***Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
2
( ) = mm
for metric use
****For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
NOTE
Weld Cable Size*** and Total Cable (Copper) Length in Weld Circuit
100 ft (30 m) or Less
10 − 60%
60 − 100%
Welding
Duty
Amperes**
Cycle
100
4 (20)
150
3 (30)
200
3 (30)
250
2 (35)
300
1 (50)
350
1/0 (60)
400
1/0 (60)
500
2/0 (70)
600
3/0 (95)
700
4/0 (120)
800
4/0 (120)
In pulse welding applications using inverter power sources, peak currents can
result in extreme voltage drops producing poor welding characteristics with
undersized cables. A recommendation for weld cable size is a minimum of 2/0 for
300 ampere welding power sources and 4/0 for 450 ampere welding power
sources when total cable length is less than 100 ft (30m).
Not Exceeding****
150 ft
200 ft
(45 m)
(60 m)
Duty
Cycle
4 (20)
4 (20)
3 (30)
3 (30)
2 (35)
1 (50)
2 (35)
1 (50)
1/0 (60)
1 (50)
1/0 (60)
2/0 (70)
1/0 (60)
2/0 (70)
3/0 (95)
4/0
2/0 (70)
3/0 (95)
(120)
4/0
2/0 (70)
3/0 (95)
(120)
2 ea. 2/0
3/0 (95)
4/0 (120)
(2x70)
2 ea. 2/0
2 ea. 3/0
4/0 (120)
(2x70)
(2x95)
2 ea. 2/0
2 ea. 3/0
2 ea. 4/0
(2x70)
(2x95)
(2x120)
2 ea. 2/0
2 ea. 3/0
2 ea. 4/0
(2x70)
(2x95)
(2x120)
350 ft
250 ft
300 ft
(105
(70 m)
(90 m)
m)
10 − 100% Duty Cycle
2 (35)
1 (50)
1/0 (60)
1/0 (60)
2/0 (70)
3/0 (95)
4/0
2/0 (70)
3/0 (95)
(120)
4/0
2 ea. 2/0
3/0 (95)
(120)
(2x70)
4/0
2 ea. 2/0
2 ea. 3/0
(120)
(2x70)
(2x95)
2 ea. 2/0
2 ea. 3/0
2 ea. 3/0
(2x70)
(2x95)
(2x95)
2 ea. 2/0
2 ea. 3/0
2 ea. 4/0
(2x70)
(2x95)
(2x120)
2 ea. 3/0
2 ea. 4/0
3 ea. 3/0
(2x95)
(2x120)
(3x95)
2 ea. 4/0
3 ea. 3/0
3 ea. 4/0
(2x120)
(3x95)
(3x120)
3 ea. 3/0
3 ea. 4/0
3 ea. 4/0
(3x95)
(3x120)
(3x120)
3 ea. 4/0
3 ea. 4/0
4 ea. 4/0
(3x120)
(3x120)
(4x120)
OM-211 434 Page 17
400 ft
(120
m)
1/0 (60)
3/0 (95)
4/0
(120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)
S-0007-E
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