4-6. Weld Output Terminals And Selecting Cable Sizes
! ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
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| Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit | |||||||
| Weld Output |
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| Terminals |
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| connecting to weld out- |
| 150 ft | 200 ft | 250 ft | 300 ft | 350 ft | 400 ft | ||
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| 100 ft (30 m) or Less | |||||||
! | Do not use worn, dam- | (45 m) | (60 m) | (70 m) | (90 m) | (105 m) | (120 m) | |||
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| aged, undersized, | or |
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| poorly spliced cables. |
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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) | |
| 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) | |
+ | 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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| 600 | 3/0 (95) | 4/0 (120) | 2 ea. 2/0 | 2 ea. 3/0 | 2 ea. 4/0 | 3 ea. 3/0 | 3 ea. 4/0 | 3 ea. 4/0 | |
| (2x70) | (2x95) | (2x120) | (3x95) | (3x120) | (3x120) | ||||
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*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. |
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( ) = mm2 for metric use |
***For distances longer than those shown in this guide, call a factory applications representative at