Connecting To Weld Output Terminals; Selecting Weld Cable Sizes - Miller Electric Big Blue 602P Owner's Manual

5-8. Connecting To Weld Output Terminals

1

5-9. 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 cables overheat (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.
2
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)
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Tools Needed:
3/4 in
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)
Y Stop engine.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
For Stick and TIG welding Direct Cur-
rent Electrode Positive (DCEP), con-
nect electrode holder cable to Positive
(+) terminal on left and work cable to
Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connect electrode holder cable to Elec-
trode terminal on left and work cable to
Work terminal on right.
For MIG and FCAW welding Direct Cur-
rent Electrode Positive (DCEP) on CC/
CV models, connect wire feeder cable to
Positive (+) terminal on left and work
cable to Negative (−) terminal on right.
Use Process/Contactor switch to select
type of weld output (see Section 7-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connect wire feeder cable to Electrode
terminal on left and work cable to Work
terminal on right.
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-491 Page 21
Ref. 802 169-E
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−