Connecting To Weld Output Terminals; Selecting Weld Cable Sizes - Miller Electric 185 Owner's Manual

5-6. Connecting To Weld Output Terminals

6
3
anything between
weld cable terminal
4
5
Correct Installation

5-7. Selecting Weld Cable Sizes*

Weld O tp t Weld Output
Terminals
Stop engine before
connecting to weld connecting to weld
output terminals.
Do not use worn, dam- Do not use worn dam-
aged, undersized, or
poorly spliced cables.
This chart is a general guideline and may not suit all applications. If cables overheat, 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.
2
( ) = mm for metric use
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-4415 Page 20
2
Do not place
and copper bar.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
100 ft (30 m) or Less
10 − 60% 60 − 100%
Welding
Duty Duty
Amperes
Cycle Cycle
100 4 (20) 4 (20)
150 3 (30) 3 (30)
200 3 (30) 2 (35)
250 2 (35) 1 (50)
300 1 (50) 1/0 (60)
.
Complete Parts List available at www.MillerWelds.com
1
Incorrect Installation
Not Exceeding***
150 ft 200 ft 250 ft
(45 m) (60 m) (70 m)
10 − 100% Duty Cycle
4 (20) 3 (30) 2 (35)
2 (35) 1 (50) 1/0 (60)
1 (50) 1/0 (60) 2/0 (70)
1/0 (60) 2/0 (70) 3/0 (95)
2/0 (70) 3/0 (95) 4/0 (120)
1 Positive (+) Weld Output
Terminal
2 Negative (−) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode nega-
tive (DCEN), reverse cable con-
nections.
Failure to properly connect weld
cables may cause excessive
heat and start a fire, or damage
your machine.
3 Weld Output Terminal
4 Supplied Weld Output
Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against cop-
per bar. Do not place anything
between weld cable terminal
and copper bar. Make sure that
the surfaces of the weld cable
terminal and copper bar are
clean.
Tools Needed:
3/4 in
803 596−B / 803 778-A
300 ft 350 ft 400 ft
(90 m) (105 m) (120 m)
1 (50) 1/0 (60) 1/0 (60)
2/0 (70) 3/0 (95) 3/0 (95)
3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0
4/0 (120)
(2x70) (2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70) (2x95) (2x95)
S-0007-F