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INSTALLATION
A-5 A-5
POWER FEED® 25M
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WELD CABLE SIZE
Table A.1 located below are copper cable sizes recom-
mended for different currents and duty cycles. Lengths
stipulated 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 minimizing
cable drop.
COAXIAL WELD CABLE
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 weld cables are recommended for all pulse and
STT™ welding, especially when the total weld cable
length (electrode cable + work cable) exceeds 50 feet
(7.6m).
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 connection 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
EElleecctrtrooddee
WWoorrkk
W
Woorrkk
ElectrodeElectrode
WWorkork
ElectrodeElectrode
WWorkork
Power 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
FIGURE A.5