Lincoln Electric IM10133 POWER WAVE R500 - Manual (Page 12)

A-6 INSTALLATION
POWER WAVE ® R500
A-6
RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING
Connect the electrode and work cables between the
appropriate output studs of the POWER WAVE ® R500
per the following 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 posi-
tive (+) stud).
Negative electrode polarity operation WITHOUT
use of a remote work sense lead (21) requires the
Negative Electrode Polarity attribute to be set. See
the Remote Sense Lead Specification section of
this document for further details.
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For additional Safety information regarding the elec-
trode and work cable set-up, See the standard
“SAFETY INFORMATION” located in the front of this
Instruction Manual.
General Guidelines
• Select the appropriate size cables per the
“Output Cable Guidelines” below. Excessive volt-
age drops caused by undersized welding cables and
poor connections often result in unsatisfactory weld-
ing 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.
• 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.
Table A.1 shows copper cable sizes recommended 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.
CAUTION
Amperes
200
250
300
350
400
450
500
550
Percent Duty
Cycle
100
100
100
100
100
100
60
40
0 to 50 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
50 to 100 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
100 to 150 Ft.
2
1
2/0
3/0
3/0
4/0
3/0
3/0
150 to 200 Ft.
1
1
2/0
3/0
3/0
4/0
3/0
3/0
200 to 250 Ft.
1/0
1/0
3/0
4/0
4/0
2-3/0
4/0
4/0
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED
167°F (75°C)] **
OUTPUT CABLE GUIDELINES (Table A.1)
** 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).