3-8. Weld Output Terminals And Selecting Cable Sizes
YTurn off power before connecting to weld out- put terminals.
YDo not use worn, dam- aged, undersized, or poorly spliced cables.
Negative
Stainless Steel/
Aluminum
All Other
Materials
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| Total Cable (Copper) Length In Weld Circuit Not Exceeding |
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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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| 10 − 100% Duty Cycle |
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Amperes | Duty Cycle | Duty Cycle |
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100 | 4 | 4 | 4 | 3 | 2 | 1 | 1/0 | 1/0 |
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150 | 3 | 3 | 2 | 1 | 1/0 | 2/0 | 3/0 | 3/0 |
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200 | 3 | 2 | 1 | 1/0 | 2/0 | 3/0 | 4/0 | 4/0 |
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250 | 2 | 1 | 1/0 | 2/0 | 3/0 | 4/0 | ||
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300 | 1 | 1/0 | 2/0 | 3/0 | 4/0 | |||
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350 | 1/0 | 2/0 | 3/0 | 4/0 | ||||
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400 | 1/0 | 2/0 | 3/0 | 4/0 | ||||
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500 | 2/0 | 3/0 | 4/0 | |||||
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600 | 3/0 | 4/0 | ||||||
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700 | 4/0 | |||||||
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*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. Contact your distributor for the mm2 equivalent weld cable sizes.
3-9. Connecting Weld Output Cables
4
1
Do not place
anything between weld cable terminal and copper bar.
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Tools Needed: | 3 |
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3/4 in (19 mm) |
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803
YTurn off power before connecting to weld output terminals.
YFailure to properly connect weld cables may cause excessive heat and start a fire, or damage your ma- chine.
Correct Installation
1Weld Output Terminal
2Supplied Weld Output Terminal Nut
3Weld Cable Terminal
4Copper Bar
Remove supplied nut from weld output ter-
Incorrect Installation
minal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable terminal and copper bar. Make
sure that the surfaces of the weld cable terminal and copper bar are clean.