Miller Electric OM-494 manual Selecting Weld Cable Sizes, 150 ft 200 ft 250 ft, Put terminals

Page 30

5-15. 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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Terminals

 

 

 

 

 

 

 

 

 

 

Y Turn off power before

Welding

10 − 60%

60 − 100%

 

 

 

 

 

 

 

connecting to weld out-

Duty

Duty

 

10 − 100% Duty Cycle

 

 

put terminals.

Amperes

 

 

 

Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YDo not use worn, dam- aged, undersized, or poorly spliced cables.

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)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

700

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

4 ea. 4/0

(2x70)

(2x95)

(2x120)

(3x95)

(3x120)

(3x120)

(4x120)

 

 

 

 

 

 

 

 

 

 

 

 

 

800

4/0 (120)

2 ea. 2/0

2 ea. 3/0

2 ea. 4/0

3 ea. 4/0

3 ea. 4/0

4 ea. 4/0

4 ea. 4/0

(2x70)

(2x95)

(2x120)

(3x120)

(3x120)

(4x120)

(4x120)

 

 

 

 

 

 

 

 

 

 

 

 

 

*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.

 

( ) = mm2 for metric use

S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

OM-494 Page 26

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Contents Visit our website at OM-494191 862P January ProcessesDescription Dual-Operator Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesSymbols And Definitions − DefinitionsDimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications DescriptionAC Generator Power Fuel ConsumptionOverheating Exceeding duty cycle can damage unit and void warrantyDuty Cycle And Overheating Reduce Duty Cycle MinutesCV/DC Mode CC/DC − Single ModeCC/DC − Dual Mode Volt-Ampere Curves− Installation Installing Welding GeneratorRead and follow all instruc Activating The Dry Charge BatteryDo not overfill battery cells ChargerConnect − Cable Last Connecting The BatteryInstalling Exhaust Pipe Top View Tools Needed 1/2Engine Prestart Checks Fuel Do not use gasoline. Gaso Line will damage engineOil Unexpected Weld Output can cause injury or fire Safety Information For Connecting To Weld Output TerminalsWeld Output Terminals Welder a Left Side Welder B Right SideWelder a Left Side Do not exceed machine duty cycleStop engine Do not exceed machine duty cycle Connect electrode holder cables to Elec- trode receptaclesWhen switch is in Straight position Place optional Polarity switches in ReVerse position when using CV weld re Switches are set correctly. See SectionConnect wire feeder cables to Negative − terminals Connect wire feeder cables to CV recep- taclesBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft Put terminalsRemote 14 Receptacle Information Installing Ether Cylinder Optional Ether Starting AidAfter installing cylinder, wait at Socket InformationRemote 14 Receptacle Connections Dual Operator OperationSee -3for weld control descriptions − Operating the Welding GeneratorEngine Controls If light goes on, stop engine and check engine beltWeld Controls See Section Weld Control Descriptions See Section Do not switch under load or with out- put onDo not switch under load CV weld output for MIG is only available− Maintenance & Troubleshooting − Operating Auxiliary EquipmentEvery 250 h Every 100 hEvery 200 h Every 500 hMaintenance Label To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseServicing Fuel And Lubrication Systems Servicing Optional Ether Starting Aid Adjusting Engine SpeedWeld/Power 1850 CylinderMax Tools Needed 11/16 To adjust belt tensionChecking And Replacing Alternator Belt Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Inspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed 3/8Circuit Protection Thermostats TP3 And TP4 Internal − Not ShownTroubleshooting WeldingRepair or replace wire feeder Factory Authorized Service Agent check main rectifier SR2Factory Authorized Service Agent check main rectifier SR3 Formers T5 thru T10, and control board PC1 or PC5Generator Power EngineOM-494 − Electrical Diagrams Circuit Diagram For Welding Generator210 657-A − RUN-IN Procedure WetstackingMent damage may occur Check oil level frequently dur Run-In Procedure Using Load Bank4exceed duty cycle or equip- ment damage may occur Ing run-in add oil if neededBank/grid Run-In Procedure Using Resistance GridProcedure at less than From flammablesSelecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer FrameEarth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated Electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 311 103 96−SEE -2 101 25−SEE FIG 9104748 57−SEE FIG 78−SEE FIG Item Dia Part Description Quantity Mkgs 189 Front Panel Front Panel -1Item Side Control Panels − Welder B Right Side Shown Side Control Panels -1Item Side Control Panels Generator Rectifier Assembly OM-494 Page Service Your distributor also givesSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s
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