5-7. Connecting to Weld Output Terminals
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1Negative (−) Weld Output Terminal
2Positive (+) Weld Output Terminal
For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative (−) terminal and electrode holder cable to Positive (+) terminal.
For Direct Current Electrode Nega- tive (DCEN), reverse cable connections.
Tools Needed: 
3/4 in
2
Ref. 202
5-8. Selecting Weld Cable Sizes*
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| Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit | ||||||||
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| Not Exceeding*** |
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| 100 ft (30 m) or Less | 150 ft | 200 ft | 250 ft | 300 ft |
| 350 ft | 400 ft | |
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| (45 m) | (60 m) | (70 m) | (90 m) |
| (105 m) | (120 m) | ||
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| Terminals |
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Y Turn off power before | Welding | 10 − 60% | 60 − 100% |
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connecting to weld out- | Duty | Duty |
| 10 − 100% Duty Cycle |
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put terminals. | Amperes |
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Cycle | Cycle |
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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) | ||
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150 | 3 (30) | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 3/0 (95) | ||
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200 | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 4/0 (120) | ||
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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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*This chart is a general guideline and may not suit all applications. If cable overheating occurs, 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
