06 welding leads, 06 welding leads -5 – Tweco 500P PowerMaster User Manual
Page 29
POWERMASTER 500, 500P, 350
Manual No. 0-4749
3-5
INSTALLATION
3.06 Welding Leads
Connect the welding leads to the output bus bar
terminals of the power source. Selection of the proper
size of welding leads should be based upon both the
rated current capacity of the wire as well as the voltage
drop on the cable. When considering voltage drop, the
entire loop (electrode plus work lead) must be
considered.
50 Feet (15.2 m)
100 Feet (30.5 m)
150 Feet (45.7 m)
200 Feet (61.0 m)
250 Feet (76.2 m)
100
#4 (20 mm
2
)
#4 (20 mm
2
)
#2 (35 mm
2
)
#1 (50 mm
2
)
#1 (50 mm
2
)
150
#3 (25 mm
2
)
#3 (25 mm
2
)
#1 (50 mm
2
)
#1/0 (50 mm
2
)
#2/0 (70 mm
2
)
200
#2 (35 mm
2
)
#2 (35mm2)
#1/0 (50 mm
2
)
#2/0 (70 mm
2
)
#3/0 (95 mm
2
)
250
#1 (50 mm
2
)
#1 (50 mm
2
)
#2/0 (70 mm
2
)
#3/0 (95 mm
2
)
#4/0 (120 mm
2
)
300
#1/0 (50 mm
2
)
#1/0 (50 mm
2
)
#3/0 (95 mm
2
)
#4/0 (120 mm
2
)
2 - #2/0
2 - (70 mm
2
)
350
#2/0 (70 mm
2
)
#2/0 (70 mm
2
)
#4/0 (120 mm
2
)
2 - #2/0
2 -(70 mm
2
)
2 - #2/0
2 - (70 mm
2
)
400
#3/0 (95 mm
2
)
#3/0 (95 mm
2
)
#4/0 (120 mm
2
)
2 - #2/0
2 - (70 mm
2
)
2 - #3/0
2 - (95 mm
2
)
450
#3/0 (95 mm
2
)
#3/0 (95 mm
2
)
#4/0 (120 mm
2
)
2 - #3/0
2 - (95 mm
2
)
2 - #3/0
2 - (95 mm
2
)
500
#4/0 (120 mm
2
)
#4/0 (120 mm
2
)
2 - #2/0
2 - (70 mm
2
)
2 - #3/0
2 - (95 mm
2
)
2 - #4/0
2 - (120 mm
2
)
550
#4/0 (120 mm
2
)
#4/0 (120 mm
2
)
2 - #2/0
2 - (70 mm
2
)
2 - #4/0
2 - (120 mm
2
)
2 - #4/0
2 - (120 mm
2
)
600
#4/0 (120 mm
2
)
#4/0 (120 mm
2
)
2 - #3/0
2 - (95 mm
2
)
2 - #4/0
2 - (120 mm
2
)
2 - #4/0
2 - (120 mm
2
)
TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS
(ELECTRODE LEAD PLUS WORK LEAD)
Avg. Welding
Amps
Refer to Table 3-3 as a basic guideline to the required
copper cable sizes.
As a general rule, the welding cables should be kept as
short as possible and placed close together. Try to avoid
coiling up the cables if possible. A damaged or frayed
cable should not be used, and all connections must be
properly tightened.
NOTE: Lead size shown is for 194°F (90°C) cable insulation, 86°F (30°C) ambient, and not over 4.5 volts lead drop.
Table 3-3 Lead Circuit Lengths by Welding Amps