Miller Electric Big Blue 602P Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

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5-8. Connecting To Weld Output Terminals

1

2

Tools Needed:

3/4 in

YStop engine.

1Positive (+) Weld Output Terminal

2Negative (−) Weld Output T erminal

For Stick and TIG welding Direct Cur- rent Electrode Positive (DCEP), con- nect electrode holder cable to Positive

(+)terminal on left and work cable to Negative (−) terminal on right.

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 (−) terminal on right. Use Process/Contactor switch to select type of weld output (see Section 7-3).

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.

Ref. 802 169-E

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
Y Stop engine 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 cables overheat (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

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

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