Selecting Weld Cable Sizes | Miller Electric 250 specs

. A complete Parts List is available at www.MillerWelds.com

5-6. Selecting Weld Cable Sizes*

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

Not Exceeding***

Weld Output

Terminals

! Turn off power before connecting to weld output terminals.

! Do not

use

worn,

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)

damaged,

under-

sized,

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 cables overheat, 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.

Notes

. A complete Parts List is available on-line at www.MillerWelds.com

OM-217 455 Page 19

Image 23

Miller Electric 250 manual Selecting Weld Cable Sizes

Contents

2007−05−21 OM-217 455HFile Engine Drive Visit our website at From Miller to You Table of Contents 13-5 13-213-3 13-4 HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine Specifications Dimensions Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear Mounting − InstallationInstalling Welding Generator Vehicle frame. Always connect a ground wire Stop engine and let cool Installing Exhaust PipeConnecting the Battery + − Overview And Engine Prestart Checks Daily pre-start checks Engine Left Side Engine Right SideStarting engine for the first time Run-in period first 100 hours Tools Needed Do not place Connecting to Weld Output TerminalsCorrect Installation Work Weld Output Terminal Selecting Weld Cable Sizes Do not use glow plugs longer than 20 seconds Engine Control SwitchesPlace switch in Run position to operate most MIG equipment − Operating the Welding Generator Weld Output Controls Work Clamp Electrode Holder Typical Stick Welding Connections And Control SettingsTypical Settings For 7018 1/8 Electrode Stop engine Set Weld Process Selector switch to Wire − position Dcen Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + Dcep position Set Weld Process Selector switch to Wire + position Tools Needed 3/4 Work Not Used To Work Left Side View To verify Gfci is working properly Generator Power Receptacles− Operating Auxiliary Equipment At least once a month, run engine at Simultaneous Weld And Power Determining Battery Charging Current − Operating Optional Battery ChargerBattery Charge Controls Battery Charge Cable Connections Minutes Battery Charging Procedure Start Your Professional Welding Career Now Routine Maintenance − Maintenance and Troubleshooting Stop engine and let cool Oil And Fuel Maintenance Label And Engine Maintenance Activities 804 197-A / Ref 803 111-A / 227 Damage when determining whether Cleaner or with dirty element. EngineMent is not covered by the warranty Air cleaner primary element can Checking Fuel Solenoid Adjusting Engine SpeedAdjusting Fuel Solenoid Position Stop screw is factory-set and should not be adjusted Check for non-binding Adjusting Throttle SolenoidChecking Throttle Solenoid 16 mm Adjusting Weld/Power Speed Making Engine Speed AdjustmentsAdjusting Idle Speed Supplementary Protector CB8 Overload ProtectionComponent Panel Stop engine Fuse F1 Trouble Remedy Troubleshooting TablesGenerator Power Welding Engine Maintenance Display Action Current transformer CT1, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare Parts Circuit Diagram For Welding Generator − Electrical Diagrams 228 719-B OM-217 455 231 607-B Run-In And Wetstacking − RUN-IN and Wetstacking Idle − Performance DataFuel Consumption Curves US Gal./Hr AC Amperes At 120 Volts Generator Power CurveDuty Cycle Volts AC Amps Stick Mode Volt-Ampere CurvesDC Amps CC/AC Stick Mode AC Volts DC Amps MIG Mode Volt-Ampere Curve Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codes Farm/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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode Holder Electrode Movement During Welding Conditions That Affect Weld Bead Shape 16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee Joint Possible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld Test Troubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Work like a Pro Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact