Connecting To Weld Output Terminals; Selecting Weld Cable Sizes - Miller Electric Blue Star 6000 Owner's Manual

5-7. Connecting To Weld Output Terminals

Tools Needed:
3/4 in

5-8. Selecting Weld Cable Sizes*

Weld Output
Terminals
Y Stop
engine 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.
1
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)
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2
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)
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.
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)
OM-499 Page 17
196 914 / 495 178
400 ft
(120 m)
1/0 (60)
3/0 (95)
2 ea. 2/0
(2x70)
S-0007-E