4-8. Connecting To Weld Output Terminals
Tools Needed:
3/4 in
1
2
YStop engine.
1Positive (+) Weld Output Terminal
2Negative
For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to Positive (+) ter- minal on left and work cable to Negative
For Direct Current Electrode Negative (DCEN), reverse cable connections.
If equipped with optional polarity switch, connect electrode holder cable to Elec- trode terminal on left and work cable to Work terminal on right.
For MIG and FCAW welding Direct Cur- rent Electrode Positive (DCEP) on CC/ CV models, connect wire feeder cable to Positive (+) terminal on left and work cable to Negative
For Direct Current Electrode Negative (DCEN), reverse cable connections.
If equipped with optional polarity switch, connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right.
802 729
4-9. 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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| Weld Output |
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| Terminals |
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Y Stop engine 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 (normally you can smell it), 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 |
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