A-4
INSTALLATION
POWER FEED™ 25M
A-4
WELD CABLE SIZE
Table A.1 located below are copper cable sizes recommended for
different currents and duty cycles. Lengths stipulated are the dis-
tance 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.
COAXIAL WELD CABLE
(See Table A.2)
Coaxial welding cables are specially designed welding cables for
pulse welding or STT™ welding. Coaxial weld cables feature low
inductance, allowing fast changes in the weld current. Regular
cables have a higher inductance which may distort the pulse or
STT™ wave shape. Inductance becomes more severe as the weld
cables become longer.
Coaxial cables work best for high performance waveforms and
when:
• long cables are present.
• the cables are housed in a metal tray.
A coaxial weld cable is constructed with multiple small leads
wrapped around one large lead. The large inner lead connects to
the electrode stud on the power source and the electrode connec-
tion on the wire feeder. The small leads combine together to form
the work lead, one end attached to the power source and the other
end to the work piece. See Figure A.5
To install:
1. Turn the input power off at the welding power source.
2. Connect one end of the center lead to the power source
electrode connection, and the other end to the wire feed-
er electrode connection.
3. Connect the outer lead bundle to the power source work
connection, and the other end to the work piece.
Minimize the length of any work lead extension for best
results.
4. Insulate all connections.
E
Elleecctrtrooddee
WWoorrkk
WWoorrkk
E
lectrode
E
lectrode
WWo
rk
o
rk
ElectrodeElectrode
WWorkork
P
ower SourcePower Source
Coaxial WCoaxial Weld Cableeld Cable
Wire FeederWire Feeder
** 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).
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES
200
200
225
225
250
250
250
250
300
325
350
400
400
500
PERCENT
DUTY
CYCLE
60
100
20
40 & 30
30
40
60
100
60
100
60
60
100
60
0 to 50Ft.
(0 to15M)
2
2
4 or 5
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
50 to 100Ft.
(15 to 30M)
2
2
3
3
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
100 to 150 Ft.
(30 to 46M)
2
2
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
150 to 200 Ft.
(46 to 61M)
1
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
200 to 250 Ft.
(61 to 76M)
1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
TABLE A.1
TABLE A.2
FIGURE A.5
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**
COAXIAL CABLE LENGTH
AMPERES
250
300
350
DUTY
CYCLE
100%
60%
60%
0 to 25Ft.
(0 to7.6M)
1
1
1/0
25 to 50Ft.
(7.6 to 15.2M)
1
1
1/0
50 to 75 Ft.
(15.2 to 22.9M)
1
1
--
75 to 100 Ft.
(22.9 to 30.5M)
1
1/0
--
