Hobart Welding Products OM-945 Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

5-8. Connecting To Weld Output Terminals

4

1

Do not place anything between weld cable terminal and copper bar.

2

3

Correct Installation Incorrect Installation

YStop engine.

YFailure to properly connect weld cables may cause ex- cessive heat and start a fire, or damage your machine.

1Weld Output Terminal

2Supplied Weld Output Terminal Nut

3Weld Cable Terminal

4Copper Bar

Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against cop- per bar. Do not place anything be- tween weld cable terminal and copper bar. Make sure that the surfaces of the weld cable termi- nal and copper bar are clean.

Tools Needed: 3/4 in

803 778-A / Ref. 226 427-A

5-9. Selecting Weld Cable Sizes*

			Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
					Not Exceeding***
			100 ft (30 m) or Less		150 ft	200 ft	250 ft	300 ft	350 ft	400 ft
					(45 m)	(60 m)	(70 m)	(90 m)	(105 m)	(120 m)
	Weld Output	Welding	10 − 60%	60 − 100%
			Duty	Duty		10 − 100% Duty Cycle
	Terminals	Amperes
			Cycle	Cycle
		100	4 (20)	4 (20)	4 (20)	3 (30)	2 (35)	1 (50)	1/0 (60)	1/0 (60)
		150	3 (30)	3 (30)	2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	3/0 (95)
		200	3 (30)	2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	4/0 (120)
Y Turn off power before
									2 ea. 2/0	2 ea. 2/0
connecting to weld		250	2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)
									(2x70)	(2x70)
output terminals.
Y Do not use worn, dam-
		300	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 3/0
aged, undersized, or
								(2x70)	(2x95)	(2x95)
poorly spliced cables.
		350	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 3/0	2 ea. 4/0
							(2x70)	(2x95)	(2x95)	(2x120)
		400	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	2 ea. 4/0
							(2x70)	(2x95)	(2x120)	(2x120)
		500	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	3 ea. 3/0	3 ea. 3/0
						(2x70)	(2x95)	(2x120)	(3x95)	(3x95)

*This chart is a general guideline and may not suit all applications. If cable overheating occurs, 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.
( ) = mm2 for metric use	S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 1-800-332-3281.

OM-945 Page 17