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5-2. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
100 ft (30 m) or Less
10 − 60%
Duty
Welding
Cycle
Amperes
2
AWG (mm
)
100
4 (20)
150
3 (30)
200
3 (30)
250
2 (35)
300
1 (50)
350
1/0 (60)
400
1/0 (60)
500
2/0 (70)
600
3/0 (95)
This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
*
**Weld 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.
2
( ) = mm
for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
5-3. Weld Output Terminals
1
OM-217769 Page 16
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
150 ft
(45 m)
60 − 100%
Duty Cycle
2
AWG (mm
)
4 (20)
4 (20)
3 (30)
2 (35)
2 (35)
1 (50)
1 (50)
1/0 (60)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
4/0 (120)
2x2/0 (2x70)
2
Not Exceeding***
200 ft
250 ft
(60 m)
(70 m)
10 − 100% Duty Cycle
AWG (mm
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
4/0 (120)
2x2/0 (2x70)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
300 ft
350 ft
(90 m)
(105 m)
2
)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120) 2x4/0 (2x120)
2x4/0 (2x120)
3x3/0 (3x95)
3x3/0 (3x95)
3x4/0 (3x120) 3x4/0 (3x120)
Ref. S-0007-L 2015−02
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, un-
dersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
Ref. 801 192-A / output term1 2015−02
400 ft
(120 m)
1/0 (60)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
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