💡 Use the lower of the two unless one causes frequent tripping.
Multiple Welders? Time to Group Them!
42-006 (2) & 42-008 (3)
RW75 Copper
Welder 1: 100A × 0.89 = 89A → #3awg
Welder 2: 40A × 1.0 = 40A → #8awg
Welder 3: 40A × 0.78 = 31.2A → #10awg
Welder 4: 20A × 0.78 = 15.6A → #14awg
Welder 5: 20A × 1.0 = 20A → #14awg
Demand Factor Formula:
100% of the 2 biggest
85% of the 3rd
70% of the 4th
60% of the rest
Calculation:
89A + 40A = 129A
31.2A × 0.85 = 26.52A
20A × 0.7 = 14A
15.6A × 0.6 = 9.36A
Total = 178.88A
Use Table 2: #3/0awg
Over-Current for Grouping
Protecting the Feeder:
Welder 1: 100A
Welder 2: 40A
Welder 3: 40A
Welder 4: 20A
Welder 5: 20A
Calculation: Pick the Welder with the largest RPC/FLA, use the appropriate multiplier, then ADD the rest. (100 × 200%) + 40 + 40 + 20 + 20 = 320A GO DOWN → 300A
Resistance Welders (42-014)
Conductor Sizing
70% of RPC for seam/auto welders
50% of RPC for manual welders
Use Table 42C for exact current & duty cycle
For groups: 100% of largest + 60% of all others
Overcurrent (42-016)
Resistance welders get more flexibility:
O/C = Up to 300% of either:
RPC (GO DOWN)
Or conductor ampacity (GO UP)
Pick whichever gives better protection.
Example:
89A × 3 = 267A
Add other welders = 373.8A
GO UP!
Use 400A breaker
Over-Current for Grouping
Protecting the Feeder:
Pick the biggest RPC
Multiply by 300%, add the rest
GO DOWN
Disconnects (42-010)
⚠️ If your welder doesn’t come with a built-in disconnect, you must install one. It needs to be rated high enough to handle the breaker you calculated in 42-008.