OM-4417 Page 16
5-7. Connecting To Weld Output Terminals
803 596−B / 803 778-A
1 Positive (+) Weld Output
Terminal
2 Negative (−) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode nega-
tive (DCEN), reverse cable con-
nections.
Failure to properly connect
weld cables may cause ex-
cessive heat and start a fire,
or damage your machine.
3 Weld Output Terminal
4 Supplied Weld Output
Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against cop-
per bar. Do not place anything be-
tween weld cable terminal and
copper bar. Make sure that the
surfaces of the weld cable termi-
nal and copper bar are clean.
Tools Needed:
3/4 in
6
4
5
Do not place
anything between
Correct Installation Incorrect Installation
3
weld cable terminal
and copper bar.
1
2
5-8. 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
(45 m) 200 ft
(60 m) 250 ft
(70 m) 300 ft
(90 m) 350 ft
(105 m) 400 ft
(120 m)
W ld O t t
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle 10 − 100% Duty Cycle
Weld Output
Terminals 100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
Terminals
Turn off power before
connectin
g
to weld out- 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
connecting to weld out
-
put terminals.
Do not use worn dam-
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
Do not use worn, dam-
aged, undersized, or
poorly spliced cables. 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 2/0
(2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0
(2x95) 2 ea. 3/0
(2x95)
* 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.