Miller Electric Big 40G manual Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

Models: Big 40G

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4-5. Connecting To Weld Output Terminals

 

Open left side door.

 

1

Bracket

3

Route cables through bracket.

 

 

 

2

Positive (+) Weld Output

 

 

Terminal

2

3

Negative (–) Weld Output Ter-

 

 

minal

 

For Stick welding Direct Current

 

Electrode Positive (DCEP), con-

 

nect work cable to (–) terminal and

 

electrode holder cable to (+)

 

terminal.

For Direct Current Electrode Nega-

Left Sidetive (DCEN), reverse cable connections.

If equipped with optional polarity switch, connect electrode holder cable to Electrode (–) terminal and work cable to Work (+) terminal.

For MIG and FCAW welding with

CV option, connect work cable to

(–) terminal and wire feeder cable to

(+) terminal

Close door.

1

Tools Needed:

3/4 in

 

 

 

 

 

 

 

 

ST-800 162-A

 

 

 

 

 

 

 

 

 

 

 

4-6. Selecting Weld Cable Sizes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Total Cable (Copper) Length In Weld Circuit Not Exceeding

 

 

 

 

 

 

 

 

 

 

 

 

 

Welding

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)

 

Amperes

 

 

 

 

 

 

 

 

 

 

 

 

 

10 – 60%

60 – 100% Duty

 

 

10 – 100% Duty Cycle

 

 

 

 

Duty Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

4

4

4

3

2

1

1/0

1/0

 

 

 

 

 

 

 

 

 

 

 

150

3

3

2

1

1/0

2/0

3/0

3/0

 

 

 

 

 

 

 

 

 

 

 

200

3

2

1

1/0

2/0

3/0

4/0

4/0

 

 

 

 

 

 

 

 

 

 

 

250

2

1

1/0

2/0

3/0

4/0

2-2/0

2-2/0

 

 

 

 

 

 

 

 

 

 

 

300

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

 

 

 

 

 

 

 

 

 

 

 

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

 

 

 

 

 

 

 

 

 

 

 

400

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

 

 

 

 

 

 

 

 

 

 

 

500

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-3/0

 

 

 

 

 

 

 

 

 

 

 

*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. Contact your

distributor for the mm2 equivalent weld cable sizes.

S-0007-E

OM-477 Page 16

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Miller Electric Big 40G manual Connecting To Weld Output Terminals, Selecting Weld Cable Sizes, 100 ft 30 m Or Less