Weld Output Terminals And Selecting Cable Sizes - Miller XMS 403 Owner's Manual

3-9. Weld Output Terminals And 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
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 be-
fore connecting to
weld output termi-
nals.
!
Do not use worn,
damaged, under-
sized, or poorly
spliced cables.
Positive Positive
receptacle receptacle
TIG/Stick MIG
Gas
Negative receptacle
MIG/TIG/Stick
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.
OM-244 243 Page 12
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
30 m (100 ft) or Less
10 − 60% 60 − 100%
Duty
Welding
Cycle Cycle
Amperes
2
mm (AWG) mm
100 20 (4)
150 30 (3)
200 30 (3)
250 35 (2)
300 50 (1) 60 (1/0)
350 60 (1/0) 70 (2/0)
400 60 (1/0) 70 (2/0)
500 70 (2/0) 95 (3/0)
600 95 (3/0) 120 (4/0)
Not Exceeding***
45 m 60 m
(150 ft) (200 ft)
Duty
2
(AWG)
20 (4) 20 (4) 30 (3)
30 (3) 35 (2) 50 (1)
35 (2) 50 (1) 60 (1/0)
50 (1) 60 (1/0) 70 (2/0)
70 (2/0) 95 (3/0)
95 (3/0) 120 (4/0)
95 (3/0) 120 (4/0)
2x70
120 (4/0)
(2 ea. 2/0)
2x70 2x95
(2 ea. 2/0) (2 ea. 3/0)
70 m 90 m 105 m
(250 ft) (300 ft) (350 ft)
10 − 100% Duty Cycle
2
mm (AWG)
35 (2) 50 (1) 60 (1/0)
60 (1/0) 70 (2/0) 95 (3/0)
70 (2/0) 95 (3/0) 120 (4/0)
2x70
95 (3/0) 120 (4/0)
(2 ea. 2/0)
2x70 2x95
120 (4/0)
(2 ea. 2/0) (2 ea. 3/0)
2x70 2x95 2x95
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 3/0)
2x70 2x95 2x120
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 4/0)
2x95 2x120 3x95
(2 ea. 3/0) (2 ea. 4/0) (3 ea. 3/0)
2x120 3x95 3x120
(2 ea. 4/0) (3 ea. 3/0) (3 ea. 4/0)
Milan Ref. S-0007-G 2009−08
120 m
(400 ft)
60 (1/0)
95 (3/0)
120 (4/0)
2x70
(2 ea. 2/0)
2x95
(2 ea. 3/0)
2x120
(2 ea. 4/0)
2x120
(2 ea. 4/0)
3x95
(3 ea. 3/0)
3x120
(3 ea. 4/0)