Generator Or Inverter Requirements; Selecting Cable Sizes - Miller Multimatic 255 Owner's Manual

5-5.

Generator Or Inverter Requirements

1
5-6.

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 2 )
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.
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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
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)
2
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)
Set Engine Control Switch to Run
position, not Run/Idle.
Set generator Voltage/Amperage
Control to 10 (or max) for maxi-
mum auxiliary power.
For maximum output, Miller recommends a
12 kW or greater generator.
Generator Settings, if applicable.
1 Engine Control Switch Setting
2 Generator Amperage/Voltage
Setting
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)
OM-278174 Page 21
Control
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)