Selecting Cable Sizes; Connecting To Weld Output Terminals - Miller Trailblazer 325 Diesel Owner's Manual

5-7. 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.
100 ft (30 m) or Less
10 − 60%
Duty
Welding
Cycle
Amperes
2
AWG (mm )
100 4 (20)
150 3 (30)
200 3 (30)
250 2 (35)
300 1 (50)
350 1/0 (60)
400 1/0 (60)
This chart is a general guideline and may not suit all applications. If cable overheats, 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, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.

5-8. Connecting To Weld Output Terminals

Tools Needed:
1
6
3
4
5
.
Complete Parts List available at www.MillerWelds.com
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
150 ft
(45 m)
60 − 100%
Duty Cycle
2
AWG (mm )
4 (20) 4 (20)
3 (30) 2 (35)
2 (35) 1 (50)
1 (50) 1/0 (60)
1/0 (60) 2/0 (70)
2/0 (70) 3/0 (95)
2/0 (70) 3/0 (95)
3/4 in.
2
Not Exceeding***
200 ft 250 ft
(60 m) (70 m)
10 − 100% Duty Cycle
AWG (mm
3 (30) 2 (35)
1 (50) 1/0 (60)
1/0 (60) 2/0 (70)
2/0 (70) 3/0 (95)
3/0 (95) 4/0 (120) 2x2/0 (2x70)
4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95)
4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95)
300 ft 350 ft
(90 m) (105 m)
2
)
1 (50) 1/0 (60)
2/0 (70) 3/0 (95)
3/0 (95) 4/0 (120)
4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
2x3/0 (2x95) 2x3/0 (2x95)
2x3/0 (2x95) 2x4/0 (2x120)
2x4/0 (2x120) 2x4/0 (2x120)
Ref. S-0007-M 2017−08
!
Stop engine.
!
Failure to properly connect
weld cables may cause ex-
cessive heat and start a fire,
or damage your machine.
.
Do not place anything between
weld cable terminal and copper
bar. Make sure that the sur-
faces of the weld cable terminal
and copper bar are clean.
1 Correct Weld Cable
Connection
2 Incorrect Weld Cable
Connection
3 Weld Output Terminal
4 Supplied Weld Output
Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against cop-
per bar.
OM-258900 Page 27
400 ft
(120 m)
1/0 (60)
3/0 (95)
4/0 (120)
803 778-B