4-7. Connecting Weld Cable

From Wire Feeder

1

2

 

 

 

Rear View

!

Turn Off wire feeder and

 

 

welding power source. Stop

 

 

engine on welding

 

 

generator.

 

1

User-Suppled Weld Cable

 

Follow wire manufacturer’s recom-

 

mendations for weld cable polarity.

2User-Suppled Male Connector

3User-Suppled Female Connector

Push female connector over male connector, and turn 1/4 turn clock- wise.

3

804 004-A

4-8. Weld Cable Sizes

 

 

 

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

 

Weld Output

 

 

Not Exceeding***

 

 

 

 

 

 

 

 

 

 

 

 

 

Terminals

 

 

 

 

 

 

 

 

! Turn off power before

 

 

 

 

 

 

 

 

connecting to weld out-

 

150 ft

200 ft

250 ft

300 ft

350 ft

400 ft

 

put terminals.

 

100 ft (30 m) or Less

!

Do not use worn, dam-

(45 m)

(60 m)

(70 m)

(90 m)

(105 m)

(120 m)

 

 

 

 

 

 

 

 

 

aged, undersized,

or

 

 

 

 

 

 

 

 

poorly spliced cables.

 

 

 

 

 

 

 

 

Welding

10 − 60%

60 − 100%

 

 

 

 

 

 

 

 

Duty

Duty

 

10 − 100% Duty Cycle

 

 

 

Amperes

 

 

 

 

Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 overheats, 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-1500-19 Page 18

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Miller Electric 12VS manual Connecting Weld Cable, Weld Cable Sizes