Selecting Weld Cable Sizes | Miller Electric 400P, 500 X specs

5-9.

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

!

Stop engine

before

Welding

10 − 60%

60 − 100%

connecting to

weld

Duty

Duty

10 − 100% Duty Cycle

output terminals.

Amperes

Cycle

Cycle

!Do 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
	250		2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x70)
									(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
	300		1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x95)
								(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
	350		1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x95)	(2x120)
							(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
	400		1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x120)	(2x120)
							(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
	500		2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x120)	(3x95)	(3x95)
						(2x70)	(2x95)	(2x120)	(3x95)	(3x95)

	*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.

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

	1	1 Remote Amperage Adjust
	1	Receptacle RC13
		Receptacle RC13

Connect optional remote control to

RC13 (see Section 6-3).

Ref. 154 862-A / 048 720-K / 803 602

OM-4421 Page 27

Image 33

Miller Electric 400P, 500 X manual Selecting Weld Cable Sizes, 150 ft 200 ft 250 ft, Connecting to Weld, Output terminals

Contents

Processes OM-4421215 075QDescription File Engine Drive From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDecrot1/07 Decrotsound6/05 Manufacturer European Contact Notified Body Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burns Buildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosion Compressed Air Hazards Engine Hazards HOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injury 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 Indique des instructions spécifiques LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe DES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peu LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Principales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicaux − Definitions − 50 h StdStd Manufacturer’s Rating Labels Some symbols are found only on export products Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV Models Fuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes Optional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load Installing Welding Generator − InstallationLocation/Airflow Clearance Grounding1 Using Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust Pipe Connecting The Battery Activating The Dry Charge Battery If Applicable Engine Prestart Checks Coolant Recovery Tank Stick and TIG Welding Connecting To Weld Output TerminalsMIG and Fcaw Welding Stop engine Selecting Weld Cable Sizes Connecting to Weld150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Socket Connecting To Remote 14 Receptacle RC14 On CC/CV Models OM-4421 Front Panel Controls For CC Models See Section − Operating Welding Generator − CC Models To Start Engine Starting ControlsEngine Gauges And Meters Weld Controls Remote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4421 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models Voltage/Amperage Adjust Switch And Remote 14 Receptacle Electric shock can kill14 AC/DC Voltmeter Optional Process/Contactor Switch Settings Process/Contactor Switch On CC/CV Models Example Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models Optional Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en If a Supplementary Three-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 Maintenance Label − Maintenance & Troubleshooting Routine Maintenance Checking Generator Brushes To clean air filter Servicing Air Cleaner Inspecting And Cleaning Optional Spark Arrestor Muffler Weld/Power Speed Adjustment Adjusting Engine SpeedEngine Speed No Load Standard Model Idle Speed Ad- justment To change oil and filter Servicing Fuel And Lubrication SystemsTo replace primary fuel filter While draining fuel tank Overload Protection Welding − CC Models Troubleshooting Welding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator Power Engine Welding Symbols Circuit Diagram For CC Welding Generator − Electrical Diagrams 223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Keep exhaust and pipe awayFrom flammables Specifications section in this Run-In Procedure Using Resistance GridJust generator A/V control so Manual Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Electrically Bond Generator How Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = Watts Approximate 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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 128 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models -1Item Control Box Assembly − CC/CV Models TD1 214 3634 Panel, Front w/Components − CC Models Panel, Front w/Components − CC Models -1Item 40 39 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1Item 170 34 36 27 26 Hardware is common Not available unless listed 602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses PLG4 Harness, receptacle auxiliary power export models includesPage 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