Miller Electric Big Blue 600D Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

4-5. Connecting To Weld Output Terminals

			Tools Needed:			1 Positive (+) Weld Output Terminals
						2 Negative (–) Weld Output Terminals
				3/8, 7/8 in		For Direct Current Electrode Positive
						(DCEP), connect work cable to Negative
						(–) terminal and electrode holder cable to
						Positive (+) terminal.
						For Direct Current Electrode Negative
1					2	(DCEN), reverse cable connections.
						To prevent overheating and damage, two
						terminals are provided for each polarity in
						case more than one cable is needed to
						carry current to a single arc (see Section
						4-6). This unit is not designed to supply
						multiple arcs.
							Ref. ST-134 687-B / ST-174 733
4-6. 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)
600	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	3 ea. 3/0	3 ea. 4/0	3 ea. 4/0
			(2x70)	(2x95)	(2x120)	(3x95)	(3x120)	(3x120)
700	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	3 ea. 3/0	3 ea. 4/0	3 ea. 4/0	4 ea. 4/0
		(2x70)	(2x95)	(2x120)	(3x95)	(3x120)	(3x120)	(4x120)
800	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	3 ea. 4/0	3 ea. 4/0	4 ea. 4/0	4 ea. 4/0
		(2x70)	(2x95)	(2x120)	(3x120)	(3x120)	(4x120)	(4x120)
900	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	3 ea. 3/0
	(2x70)	(2x95)	(2x120)	(3x95)
1000	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	3 ea. 3/0
	(2x70)	(2x95)	(2x120)	(3x95)

*Chart is a 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.
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