Section 5 − Recommended Setup Procedures; Selecting Weld Cable Sizes - Miller Axcess 300 Owner's Manual

SECTION 5 − RECOMMENDED SETUP PROCEDURES

5-1. Selecting Weld Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Output
Terminals
!
Turn off power before
connecting to weld
output terminals.
!
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
Positive Negative
*
)
Ref. 803 669-A
This chart is a general guideline and may not suit all applications. If cable overheats, 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 rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
.
In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding characteris-
tics with undersized cables. A recommendation for weld cable size is a minimum of 2/0 for 300 ampere welding power sources and 4/0 for 450
ampere welding power sources when total cable length is less than 100 ft (30m).
OM-216 967 Page 22
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
100 ft (30 m) or Less
10 − 60% 60 − 100%
Welding
Duty
Amperes
Cycle
100 4 (20)
150 3 (30)
200 3 (30)
250 2 (35)
300 1 (50) 1/0 (60)
350 1/0 (60) 2/0 (70)
400 1/0 (60) 2/0 (70)
500 2/0 (70) 3/0 (95)
600 3/0 (95) 4/0 (120)
2 ea. 2/0
700 4/0 (120)
2 ea. 2/0
800 4/0 (120)
Not Exceeding***
150 ft 200 ft
(45 m) (60 m)
Duty
Cycle
4 (20) 4 (20) 3 (30)
3 (30) 2 (35) 1 (50)
2 (35) 1 (50) 1/0 (60)
1 (50) 1/0 (60) 2/0 (70)
2/0 (70) 3/0 (95)
4/0
3/0 (95)
(120)
4/0
3/0 (95)
(120)
2 ea. 2/0
4/0 (120)
(2x70)
2 ea. 2/0 2 ea. 3/0
(2x70) (2x95)
2 ea. 3/0 2 ea. 4/0
(2x70) (2x95) (2x120)
2 ea. 3/0 2 ea. 4/0
(2x70) (2x95) (2x120)
250 ft 300 ft 350 ft
(70 m) (90 m)
(105 m)
10 − 100% Duty Cycle
2 (35) 1 (50) 1/0 (60)
1/0 (60) 2/0 (70) 3/0 (95)
4/0
2/0 (70) 3/0 (95)
(120)
4/0 2 ea. 2/0
3/0 (95)
(120) (2x70)
4/0 2 ea. 2/0 2 ea. 3/0
(120) (2x70) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70) (2x95) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0
(2x70) (2x95) (2x120)
2 ea. 3/0 2 ea. 4/0 3 ea. 3/0
(2x95) (2x120) (3x95)
2 ea. 4/0 3 ea. 3/0 3 ea. 4/0
(2x120) (3x95) (3x120)
3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
(3x95) (3x120) (3x120)
3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
(3x120) (3x120) (4x120)
Ref. S-0007-G 2009−08
400 ft
(120 m)
1/0 (60)
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)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)