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33
Selecting the Correct Welding Current
PLATE THICKNESS (IN) ELECTRODE DIAMETER (IN) CURRENT SETTING
UP TO 3/16” 1/16” 50-100
UP TO 1/4” 3/32” 100-150
ABOVE 1/8” 1/8” 125-175
ABOVE 1/4” 5/32” 150-200
Selecting the Correct Welding Current
Measure the thickness of the metal you are welding and then refer to the table below to select the
proper electrode size and current setting.
Welding Cable Selection
The table below shows the current carrying capacity of various lengths and gauges of standard cop-
per welding cable. Whenever possible, refer to the cable manufacturer’s recommendations.
Always allow a considerable safety margin when selecting welding cables. The cable’s length and
gauge (diameter), along with the material it is made from, all combine to determine how much
current it can safely carry.
An undersize welding cable will oer unacceptable high resistance to current ow. This high resis-
tance will shorten the service life of the generator/welder, and can even make the welding cables
become hot enough to cause painful burns.
CABLE GAUGE CABLE DIA
LENGTH IN FEET*
0-50 ft. 50-100 ft. 100-250 ft.
CURRENT CAPACITY AMPERES
1 .644 250 200 170
2 .604 200 195 --
NOTE: The cable lengths given in the table above are the combined lengths of the negative
and positive cables.
Welding Duty Cycle
The duty cycle is the percent of time that the welder can be operated in a given 10 minute period.
For example, at a rated output of 140 amperes, the EW-190’s duty cycle is 40%. This means that at
140 amperes, welding can be performed for a total of 5 minutes out of every 10 minute period. The
duty cycle is longer at lower operating currents, and shorter at higher currents.
Current 190A 170A 140A 100A Below 80A
Rate 15% 25% 40% 65% 100%
Do not operate the welder beyond its duty cycle; doing so will decrease the performance and ser-
vice life of the generator/welder.
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