. A complete Parts List is available at wwwHobartWelders.com
5-9. Selecting Weld 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.
Weld Output
Terminals
! Turn off power before connecting to weld output terminals.
!Do not use worn, damaged, under- sized, or poorly spliced cables.
| Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit | ||||||||
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| 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) | ||
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Welding | 10 − 60% | 60 − 100% |
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Duty | Duty |
| 10 − 100% Duty Cycle |
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Amperes |
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Cycle | Cycle |
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100 | 4 (20) | 4 (20) | 4 (20) | 3 (30) | 2 (35) | 1 (50) |
| 1/0 (60) | 1/0 (60) |
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150 | 3 (30) | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) |
| 3/0 (95) | 3/0 (95) |
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200 | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) |
| 4/0 (120) | 4/0 (120) |
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250 | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) |
| 2 ea. 2/0 | 2 ea. 2/0 |
| (2x70) | (2x70) | |||||||
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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 |
(2x70) |
| (2x95) | (2x95) | ||||||
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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) | |||||
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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) | |||||
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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) | ||||
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*This chart is a general guideline and may not suit all applications. If cables overheat, 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. |
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( ) = mm2 for metric use |
***For distances longer than those shown in this guide, call a factory applications representative at 800−332−3281.
Notes
Work like a Pro!
Pros weld and cut safely. Read the safety rules at the beginning of this manual.