Miller Electric Big Blue 600D Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

Page 19

4-5. Connecting To Weld Output Terminals

 

 

 

Tools Needed:

 

1 Positive (+) Weld Output Terminals

 

 

 

 

2 Negative (–) Weld Output Terminals

 

 

 

 

 

 

 

 

 

 

3/8, 7/8 in

 

For Direct Current Electrode Positive

 

 

 

 

 

 

(DCEP), connect work cable to Negative

 

 

 

 

 

 

(–) terminal and electrode holder cable to

 

 

 

 

 

 

Positive (+) terminal.

 

 

 

 

 

 

 

 

For Direct Current Electrode Negative

1

 

 

 

 

2

(DCEN), reverse cable connections.

 

 

 

 

 

 

 

 

 

 

 

 

 

To prevent overheating and damage, two

 

 

 

 

 

 

 

 

 

 

 

 

terminals are provided for each polarity in

 

 

 

 

 

 

case more than one cable is needed to

 

 

 

 

 

 

carry current to a single arc (see Section

 

 

 

 

 

 

4-6). This unit is not designed to supply

 

 

 

 

 

 

multiple arcs.

 

 

 

 

 

 

 

 

 

Ref. ST-134 687-B / ST-174 733

4-6. 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)

 

 

 

 

 

 

 

 

 

 

 

 

 

900

2 ea. 2/0

2 ea. 3/0

2 ea. 4/0

3 ea. 3/0

 

 

 

 

(2x70)

(2x95)

(2x120)

(3x95)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1000

2 ea. 2/0

2 ea. 3/0

2 ea. 4/0

3 ea. 3/0

 

 

 

 

(2x70)

(2x95)

(2x120)

(3x95)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Chart is a guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), 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-E–

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

 

 

 

 

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Contents
Processes OM-481Description From Miller to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumé ES ET LES GAZ peuvent ê tre dangereux Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation UN Choc É Lectrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES PIÈ CES Chaudes peuvent provoquer des brû lures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sé curitéInformation sur les champs é lectromagné tiques LE Soudage À L’ARC risque de provoquer des interfé rencesDefinitions SpecificationsSymbols And Definitions Weld, Power, And Engine SpecificationsDo not exceed operating angles Dimensions, Weights, And Operating AnglesDo not move or operate unit where it could tip Fuel Consumption100% Duty Cycle At 600 Amperes AC Generator PowerExceeding duty cycle can damage unit and void warranty Duty Cycle And Overheating Volt-Ampere Curves For Constant Current CC Mode For Constant Voltage CV ModeInstalling Welding Generator InstallationConnecting The Battery Engine Prestart Checks Installing Exhaust Pipe And Rain CapSelecting Weld Cable Sizes Connecting To Weld Output TerminalsSocket Remote 14 Receptacle RC3 InformationStop engine Terminal Strip 3T ConnectionsOpen right side door Terminal Strip 3T Strain Relief Front Panel Controls Do not switch under loadDo not run engine until problem is fixed Operating the Welding GeneratorExample Of Remote Amperage Control Operating Auxiliary EquipmentVolt Duplex Gfci Receptacles 50 h Maintenance & TroubleshootingRoutine Maintenance Volt Duplex Receptacle Optional500 h 100 h200 h 250 hMaintenance Label Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterServicing Fuel And Lubrication Systems Overload Protection Adjusting Engine SpeedTo replace belt To adjust belt tensionChecking And Replacing Engine Belt Servicing Optional Spark ArrestorSpeed Control Lever Overspeed Shutdown Valve Adjusting Overspeed Shutdown ValveWelding TroubleshootingEngine Generator Power TroubleCircuit Diagram For Welding Generator Electrical Diagram194 139-B Wetstacking RUN-IN ProcedureWelding Generator From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammablesSelecting Equipment Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible66 71 74 73 Parts List60Fig Dia Part Description Mkgs Quantity Shunt Panel, Front w/Components Panel, Front w/Components -1 Item 13 14 23 22 21 2524 Panel, Front Lower w/ComponentsPanel, Front Lower w/Components -1 Item Control Box -1 Item Generator -1 Item OM-481 Page Page Your distributor also gives ServiceSupport Miller Electric Mfg. Co Owner’s Record
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