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3-3.
Selecting
And
Preparing
Weld
Output
Cables
Table 3-1. Weld Cable Size*
Welding
Amperes
100
150
200
250
Total Cable
(Copper) Length
In Weld Circuit Not
Exceeding
100 ft
(30 m)
Or Less
150 ft
I
200 ft
I
250ft
I
300ft
I
3~o~
400ft
(45 m)
(60_m)
(70_m)
(90_m)
(105_m)
(120_m)
10 To 60%
Duty
Cycle
4
3
3
2
60
Thru 100%
Duty Cycle
4
3
2
1
10 Thru 100%
Duty Cycle
4
3
2
1
1/0
1/0
2
1
1/0
2/0
3/0
3/0
1
1/0
2/0
3/0
4/0
4/0
1/0
210
3/0
4/0
2-2/0
2-2/0
300
350
400
500
1
1/0
1/0
2/0
1/0
2/0
2/0
3/0
210
3/0
3/0
4/0
3/0
4/0
4/0
2-2/0
4/0
2-2/0
2-2/0
2-3/0
2-2/0
2-3/0
2-3/0
2-4/0
2-3/0
2-3/0
2-4/0
3-3/0
2-3/0
2-4/0
2-4/0
3-3/0
WeId cable size
(AWG)
is based
on
either
a
4
volts
or
less
drop
or a
current
density
of
at
least 300 circular mils per ampere.
S-0007-D
OM-22O4
Page
5
1
Weld
Output
Cable
Determine total
cable
length
In
weld circuit and maximum
welding
amperes. Use Table 3-1
to
select
proper cable size.
Use shortest cables
possible.
Do
not
use
damaged
cables.
2
Terminal
Lug
Use
lugs
of
proper
amperage
capacity
and hole size for
connect
ing
to work
clamp
or
electrode
holder.
3
Insulated Electrode I-folder
4
GTAW Torch
Install
according
to
manufacturers
instructions.
5
Work
Clamp
Install onto work cable.
6
Dinse-Type
Connector
Install onto weld cable
as
shown in
Figure
3-4.
sb62
5/94
-
S~O656
Tools Needed:
~
-r
lOft
(3 m)
For
Example,
Total Cable
Length
In Weld
Circuit
=
20 ft
(6 m)
2
Figure
3-3.
Selecting
And
Preparing
Weld
Output
Cables
3~
1
Weld
Output
Cable
1 in
2
Handle
(26 mm)
5~
3
Sleeve
Slide handle
onto
cable;
strip
cable
and install sleeve.
4
Connector
Body
4~
5
Setscrew
Tools Needed:
Insert cable with sleeve
fully
into
connector
body, tighten
setscrew,
and slide handle
over
connector.
If
job requires
cable
larger
than 3/0
AWG,
use
2
ft(610 mm)
or
shorter
piece
of 3/0 AWG cable for Dinse
Type
connector installation.
Con
nect
other end of short cable
to
the
4/0
or
larger
weld
cable.
Figure
3-4.
Dinse-Type
Connector
Assembly
ST.156
496