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5-4. Weld Output Terminals And 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
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Output
Terminals
!
Turn off power be-
fore connecting to
weld output termi-
nals.
!
Do not use worn,
damaged,
under-
sized,
or
poorly
spliced cables.
+
−
Output Receptacles
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).
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
100 ft (30 m) or Less
10 − 60%
60 − 100%
Duty
Welding
Cycle
Cycle
Amperes
AWG
AWG (mm
2
(mm
)
100
4 (20)
150
3 (30)
200
3 (30)
250
2 (35)
300
1 (50)
1/0 (60)
350
1/0 (60)
2/0 (70)
400
1/0 (60)
2/0 (70)
500
2/0 (70)
3/0 (95)
600
3/0 (95)
4/0 (120)
Not Exceeding***
150 ft
200 ft
(45 m)
(60 m)
Duty
2
)
4 (20)
4 (20)
3 (30)
3 (30)
2 (35)
1 (50)
2 (35)
1 (50)
1/0 (60)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
3/0 (95)
4/0 (120)
2x2/0
4/0 (120)
(2x70)
2x2/0
2x3/0
(2x70)
(2x95)
250 ft
300 ft
350 ft
(70 m)
(90 m)
(105 m)
10 − 100% Duty Cycle
2
AWG (mm
)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
2/0 (70)
3/0 (95)
2/0 (70)
3/0 (95)
4/0 (120) 4/0 (120)
2x2/0
3/0 (95)
4/0 (120)
(2x70)
2x2/0
2x3/0
4/0 (120)
(2x70)
(2x95)
2x2/0
2x3/0
2x3/0
(2x70)
(2x95)
(2x95)
2x2/0
2x3/0
2x4/0
(2x70)
(2x95)
(2x120)
2x3/0
2x4/0
3x3/0
(2x95)
(2x120)
(3x95)
2x4/0
3x3/0
3x4/0
(2x120)
(3x95)
(3x120)
Ref. S-0007-J 2011−07
OM-234 202 Page 15
400 ft
(120 m)
1/0 (60)
3/0 (95)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
2x4/0
(2x120)
3x3/0
(3x95)
3x4/0
(3x120)
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