OM-495 Page 31
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5-10. Connecting To Weld Output Terminals

802 311-A
Tools Needed:
3/4 in
2
1
Stop engine.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
For Stick and TIG welding Direct Current
Electrode Positive (DCEP), connect elec-
trode holder cable to Positive (+) terminal
on left and work cable to Negative (−) ter-
minal 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 Pos-
itive (+) terminal on left and work cable to
Negative (−) terminal on right. Use Pro-
cess/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 ter-
minal on left and work cable to Work termi-
nal on right.

5-11. 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
(45 m) 200 ft
(60 m) 250 ft
(70 m) 300 ft
(90 m) 350 ft
(105 m) 400 ft
(120 m)
Weld Output
Terminals
Stop engine before
connecting to weld out-
put terminals.
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle 10 − 100% Duty Cycle
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
(2x70) 2 ea. 2/0
(2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0
(2x95) 2 ea. 3/0
(2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0
(2x95) 2 ea. 3/0
(2x95) 2 ea. 4/0
(2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0
(2x95) 2 ea. 4/0
(2x120) 2 ea. 4/0
(2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0
(2x70) 2 ea. 3/0
(2x95) 2 ea. 4/0
(2x120) 3 ea. 3/0
(3x95) 3 ea. 3/0
(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.