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4-2. Selecting 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 30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine
cable size.
30 m (100 ft) or Less
10 − 60%
60 − 100%
Duty
Welding
Duty Cycle
Cycle
Amperes
mm
2
mm
(AWG)
100
20 (4)
150
30 (3)
200
30 (3)
250
35 (2)
This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
*
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
4-3. Weld Output Terminals
4-4. Typical Connections For Stick (SMAW) Welding
OM-233 381 Page 12
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
45 m (150
60 m (200 ft)
ft)
2
(AWG)
20 (4)
20 (4)
30 (3)
35 (2)
35 (2)
50 (1)
50 (1)
60 (1/0)
2
Not Exceeding***
70 m (250
90 m (300
ft)
10 − 100% Duty Cycle
2
mm
(AWG)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
70 (2/0)
70 (2/0)
95 (3/0)
1
105 m (350
120 m (400
ft)
ft)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
120 (4/0)
120 (4/0)
2x70 (2x2/0)
2x70 (2x2/0)
Milan Ref. S-0007-L 2015−02
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, un-
dersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
.
For welding output terminal connec-
tions see Section 4-4 for typical
connection processes
output term1 2015−02 / 804 944
ft)
60 (1/0)
95 (3/0)
120 (4/0)
804 961
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