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A-3
SAFETY PRECAUTION
ELECTRIC SHOCK can
kill.
• Only qualified personnel should
perform this installation.
• Turn off the input power to the power source at
the disconnect switch or fuse box before work-
ing on this equipment. Turn off the input power
to any other equipment connected to the weld-
ing system at the disconnect switch or fuse
box before working on this equipment.
• Do not touch electrically hot parts.
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WELD CAbLE SIzING
Minimum work and electrode cables sizes are as follows:
TAbLE A.1
(Current (60% Duty Cycle)
400 Amps
500 Amps
600 Amps
NOTE: K1796 coaxial welding cable is recommended
to reduce the cable inductance in long distance Pulse
or STT applications up to 300 amps.
WELD CAbLE CONNECTION
Connect a work lead of sufficient size and length (Per
Table A.1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths and do not coil excess cable.
RECOMMENDED CAbLE SIzES (RUbbER COVERED COPPER - RATED 75°C)**
Percent
Duty
Amperes
Cycle
325
100
350
60
400
60
400
100
500
60
**
Tabled values are for operation at ambient temperatures of 40°C and below. Applications above 40°C may require cables larger than
recommended, or cables rated higher than 75°C.
INSTALLATION
MINIMUM COPPER
WORK CAbLE SIzE AWG
Up To-100 Ft. Length (30 m)
2/0 (67 mm2)
3/0 (85 mm2)
3/0 (85 mm2)
TAbLE A.2
CAbLE SIzES FOR COMbINED LENGTHS OF ELECTRODE AND WORK CAbLES
0 to 50 Ft.
50 to 100Ft.
0 to 15 m
15 to 31 m
2/0
2/0
1/0
1/0
2/0
2/0
3/0
3/0
2/0
2/0
POWER FEED™ 10M SINGLE WIRE FEEDER
CAUTION
When using an inverter type power source like the
Power Waves, use the largest welding (electrode
and work) cables that are practical. At least 2/0
copper wire - even if the average output current
would not normally require it. When pulsing, the
pulse current can reach very high levels. Voltage
drops can become excessive, leading to poor
welding characteristics, if undersized welding
cables are used.
------------------------------------------------------------------------
WELD CAbLE SIzES
Table A.2 has the copper cable sizes recommended
for different currents and duty cycles. Lengths stipu-
lated 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 mini-
mizing voltage in the welding circuit.
ELECTRODE LEAD
Most welding applications run with the electrode being
positive (+). For those applications, connect the elec-
trode cable between the wire feeder and the positive
(+) output stud on the power source. Connect the lug
at the other end of the electrode cable to the wire
drive feed plate. Be sure the connection to the feed
plate makes tight metal-to-metal electrical contact.
The electrode cable should be sized according to the
specifications given in the work cable connections
Table A.1. Connect a work lead from the negative (-)
power source output stud to the work piece. The work
piece connection must be firm and secure, especially
if pulse welding is planned.
150 to 200 Ft.
100 to 150 Ft.
31 to 48 m
48 to 61 m
2/0
2/0
2/0
3/0
3/0
A-3
200 to 250 Ft.
61 to 76 m
2/0
3/0
2/0
3/0
3/0
4/0
3/0
4/0
3/0
4/0
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