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5-7. Connecting to Weld Output Terminals
5-8. Selecting Weld Cable Sizes*
Weld Output
Terminals
Y Turn off power before
connecting to weld out-
put terminals.
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
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.
2
( ) = mm
for metric use
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
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
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)
1
Not Exceeding***
150 ft
200 ft
(45 m)
(60 m)
Duty
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)
3/0 (95)
4/0 (120)
3/0 (95)
4/0 (120)
2 ea. 2/0
4/0 (120)
(2x70)
1
Negative (–) Weld Output
Terminal
2
Positive (+) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (–) terminal and electrode
holder cable
to
terminal.
For Direct Current Electrode Nega-
tive
(DCEN),
reverse
connections.
Tools Needed:
2
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)
2/0 (70)
3/0 (95)
4/0 (120) 4/0 (120)
2 ea. 2/0
3/0 (95)
4/0 (120)
(2x70)
2 ea. 2/0
2 ea. 3/0
4/0 (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)
OM-945 Page 17
Positive
(+)
cable
3/4 in
Ref. 202 069-A
400 ft
(120 m)
1/0 (60)
3/0 (95)
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)
S-0007-E–
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