Recommended Electrode And Work Cable For Arc Welding; Output Cable Guidelines - Lincoln Electric RED-D-ARC FX450 Operator's Manual

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RECOMMENDED ELECTRODE AND
WORK CABLE SIZES FOR ARC WELDING
General Guidelines
Connect the electrode and work cables between the
appropriate output studs of the FX450 per the follow-
ing 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
positive (+) stud).
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.
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
** 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).
INSTALLATION
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
FX450 (RED-D-ARC)
• 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.
CONTROL CABLE CONNECTIONS
General Guidelines
Genuine Lincoln control cables should be used at all
times (except where noted otherwise). Lincoln cables
are specifically designed for the communication and
power needs of the FX450. Most are designed to be
connected end to end for ease of extension.
Generally, it is recommended that the total length not
exceed 100 feet (30.5 m). The use of non-standard
cables, especially in lengths greater than 25 feet, can
lead to communication problems (system shutdowns),
poor motor acceleration (poor arc starting), and low
wire driving force (wire feeding problems). Always use
the shortest length of control cable possible, and DO
NOT coil excess cable.
Regarding cable placement, best results will be
obtained when control cables are routed separate
from the weld cables. This minimizes the possibility of
interference between the high currents flowing
through the weld cables, and the low level signals in
the control cables.
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
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
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