Selecting Cable Sizes; Weld Output Terminals - Miller MigMatic S400i Owner's Manual

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%
Duty
Welding
Cycle
Amperes
2
mm (AWG)
100 20 (4)
150 30 (3)
200 30 (3)
250 35 (2)
300 50 (1)
350 60 (1/0)
400 60 (1/0)
500 70 (2/0)
600 95 (3/0)
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, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.

4-3. Weld Output Terminals

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
45 m (150
ft)
60 − 100%
Duty Cycle
2
mm (AWG)
20 (4) 20 (4)
30 (3) 35 (2)
35 (2) 50 (1)
50 (1) 60 (1/0)
60 (1/0) 70 (2/0)
70 (2/0) 95 (3/0)
70 (2/0) 95 (3/0)
95 (3/0) 120 (4/0)
120 (4/0) 2x70 (2x2/0)
3
1
Not Exceeding***
70 m (250
60 m (200 ft)
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)
95 (3/0) 120 (4/0)
120 (4/0) 2x70 (2x2/0)
120 (4/0) 2x70 (2x2/0)
2x70 (2x2/0) 2x95 (2x3/0)
2x95 (2x3/0) 2x120 (2x4/0)
2
90 m (300 105 m (350
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) 2x95 (2x3/0)
2x95 (2x3/0) 2x95 (2x3/0)
2x95 (2x3/0) 2x120 (2x4/0) 2x120 (2x4/0)
2x120 (2x4/0) 3x95 (3x3/0)
3x95 (3x3/0) 3x120 (3x4/0) 3x120 (3x4/0)
Milan Ref. S-0007-M 2017−08
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged,
undersized, or repaired cables.
1 Electrode Weld Output Terminal
(−) Negative Weld Output Terminal
2 Work Weld Output Terminal
(+) Positive Weld Output Terminal
3 Remote 14 Receptacle
Ref. 956172374_4_A
OM-287504 Page 13
120 m (400
ft)
60 (1/0)
95 (3/0)
120 (4/0)
2x70 (2x2/0)
2x95 (2x3/0)
2x120 (2x4/0)
3x95 (3x3/0)