Selecting Cable Sizes; Connecting Weld Output Cables - 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%
Welding
Duty Cycle
Amperes
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.
( ) = mm 2 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 Weld Output Cables

1
3
4
5
3/4 in. (19 mm)
wrench
crescent wrench
nutdriver
chippinghammer
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Complete Parts List is available at www.MillerWelds.com
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***
150 ft (45 m)
60 - 100%
Duty Cycle
2 ) AWG (mm 2 )
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)
Complete Parts List available at www.MillerWelds.com
6
200 ft (60 m) 250 ft (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)
4/0 (120) 2x2/0 (2x70)
4/0 (120) 2x2/0 (2x70)
2
350 ft
300 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
2x3/0 (2x95)
(2x120)
Stop engine.
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
�
Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces 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 termi-
nal. Slide weld cable terminal onto weld out-
put terminal and secure with nut so that weld
cable terminal is tight against copper bar.
OM-279836 Page 27
400 ft
(120 m)
1/0 (60)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0
(2x120)
2x4/0
(2x120)