Miller Electric Big Blue 251D Selecting Weld Cable Sizes, 150 ft 200 ft 250 ft, Put terminals

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5-7. 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)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*This chart is a general 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 Description ProcessesVisit our website at OM-480128 576AC January Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Symbols And Definitions− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Exceeding duty cycle can damage unit and void warranty Curve shows typical fuel use under weld or power loadsFuel Consumption Duty Cycle And OverheatingVolt-Ampere Curves AC Generator PowerOptional AC Power Plant Curves − Installation Installing Welding GeneratorConnecting The Battery Engine Prestart Checks Installing Muffler PipeStop engine and let cool Fuel Do not use gasoline. GasolineConnecting To Weld Output Terminals Installing Ether Cylinder Optional Ether Starting Aid150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsControls See Section − Operating the Welding GeneratorRemote A/V Control Description Of Front Panel Controls See SectionStop engine and fix trouble if either light goes on Do not use Ether if engine is running− Operating Auxiliary Equipment Volt Duplex And Optional Gfci ReceptaclesX 15 a + 120 V x 10 a = 3.0 kVA/kW OM-480 240 V 15 a AC Receptacle RC1 Volt Duplex Receptacle OptionalCircuit Breakers CB1 And CB2 X 10 a + 120 V x 5 a = 3.0 kVA/kWConnecting Optional AC Power Plant 240 Volt Twistlock Receptacle Optional − Maintenance and Troubleshooting Maintenance Label Servicing Air Cleaner To change oil and filter Servicing Fuel And Lubrication SystemsTo replace primary fuel filter To replace secondary fuel filterAdjusting Engine Speed Standard ModelsModels With Automatic Idle Optional Full Empty Overload Protection Servicing Optional Ether Starting AidTroubleshooting Inspecting And Cleaning Optional Spark ArrestorStop engine and let cool. Reinstall cleanout plug WeldingCheck connections to ac power plant see Section Generator PowerEngine Maximum see SectionCircuit Diagram For Welding Generator − Electrical Diagram− RUN-IN Procedure WetstackingWelding Generator Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-in− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-480 125 124 123 122 − Parts List120 121 117 1162526 126 Dia Part Description Quantity Mkgs 128 111 Panel, Front w/Components -1ItemPanel, Front w/Components -1Item 111 Cont’d Generator Generator -1Item Includes 114Page Page Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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