Secondary Output Connections; Tig Welding; Welding Current - ESAB MTS 3500i Mode D'emploi

SEctIoN 2

2.5 Secondary output connections

WARNINg
Two male plug connectors are supplied with the MTS 3500i (see Figure 2-4). To assemble the connectors onto each of your
welding cables, refer to the following instructions:
1. Slip the insulating boot over the end of the cable.
2. Strip the wire approximately 1-1/2" (37 mm) from the end.
3. Place the ferrule over the stripped wire end.
4. Place the male connector over the ferrule and tighten the two Allen screws until they are flush with the connec-
tor.
5. Slide the insulating boot over the assembly.
Refer to Tables 2-2 and 2-3 and Figures 2-4, 2-5, 2-6, and 2-7 when attaching welding cables and optional equipment to the
MTS 3500i.
Particular attention should be paid to the electrical resistance in the welding circuit; especially, the work and work cable and
when using a water-cooled torch. High resistance in the welding circuit can cause performance deterioration (loss of "heat"
input, popping of weld puddle, bushy arcs, etc.). It is recommended that the power source/wire feeder and workpiece be
placed as close together as possible to limit this resistance. Make sure that the work cable (ground) is large enough, kept
as short as possible, properly insulated, securely connected to the workpiece, and that all connections are clean and tightly
secured. If the work circuit includes mechanical fixtures, ship structure, robot fixtures, etc., make sure that the circuit is secure
and presents a low resistance path to the flow of weld current. Also, the power cable on a water-cooled torch is normally
subject to gradual deterioration and increasing resistance due to corrosion which leads to the poor performance described
above. To assure good torch performance, the water-cooled power cable should be replaced periodically.
Electrode
Work
Welding
current
* Total cable length includes work and electrode cables. Cable size is based on direct current, insulated copper conductors, 100% duty cycle, and a
voltage drop of 4 or less volts. The welding cable insulation must have a voltage rating that is high enough to withstand the open circuit voltage of the
machine.
** The supplied male output connectors will not accept anything smaller than #2 gauge (35 mm) cable.
ELEctRIc SHocK cAN KILL! Before making any connections to the power source
output terminals, make sure that all primary power input power is deenergized (oFF)
at the line (wall) disconnect switch or circuit breaker.
table 2-2. typical output connections
MIg Welding
(DcRP)
positive (+)
negative (-)
table 2-3. Recommended Welding cable Sizes - AWg (mm
total Length (Feet) of cable in Welding circuit*
50 100
(13 m) (25 m)
100 6 (16)** 4 (25)**
150 4 (25)** 3 (30)**
200 3 (30)** 1 (50)
250 2 (35) 1/0 (50)
300 1 (50) 2/0 (70)

tIg Welding

Stick Welding
(DcSP) (DcSP or DcRP)
positive (+) DCRP
negative (-)
negative (-) DCSP
negative (-) DCRP
positive (+)
positive (+) DCSP
150 200
(38 m) (51 m)
3 (30)** 2 (35)
1 (50) 1/0 (50)
1/0 (50) 2/0 (70)
2/0 (70) 3/0 (95)
3/0 (95) 4/0 (120)
17
INStALLAtIoN
)
2
250
(64 m)
1 (50)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)