Miller Electric Big Blue 251D Selecting Weld Cable Sizes, 150 ft 200 ft 250 ft, Put terminals

5-7. 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
Y Turn off power before		Welding	10 − 60%	60 − 100%
connecting to weld out-			Duty	Duty		10 − 100% Duty Cycle
put terminals.		Amperes
			Cycle	Cycle

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)
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 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.
( ) = mm2 for metric use	S-0007-E−

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

OM-480 Page 17