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4-5. Connecting to Weld Output Terminals
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4-6. Selecting Weld Cable Sizes*
Weld Output
Terminals
Y Turn off power before
connecting to weld out-
put terminals.
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), 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, call a factory applications representative at 920-735-4505.
OM-4408 Page 18
2
1
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
100 ft (30 m) or Less
10 – 60%
60 – 100%
Welding
Duty
Duty
Amperes
Cycle
Cycle
100
4 (20)
4 (20)
150
3 (30)
3 (30)
200
3 (30)
2 (35)
250
2 (35)
1 (50)
300
1 (50)
1/0 (60)
350
1/0 (60)
2/0 (70)
400
1/0 (60)
2/0 (70)
500
2/0 (70)
3/0 (95)
Y Stop engine.
1
2
For Stick welding Direct Current
Electrode Positive (DCEP), connect
the electrode holder cable to Positive
(+) weld output terminal and work
cable to the Negative (–) output termi-
nal.
For TIG welding, Direst Current Elec-
trode Negative (DCEN), connect the
TIG torch cable to the Negative (–)
weld output terminal and the work
cable to the positive (+) output termi-
nal.
For MIG welding (DCEP), connect
the MIG gun cable to the Positive (+)
weld output terminal and the work
cable to the Negative (–) output termi-
nal.
The polarity selection depends on the
specific process chosen. Consult
your distributor/dealer.
Not Exceeding***
150 ft
200 ft
250 ft
(45 m)
(60 m)
(70 m)
10 – 100% Duty Cycle
4 (20)
3 (30)
2 (35)
2 (35)
1 (50)
1/0 (60)
1 (50)
1/0 (60)
2/0 (70)
1/0 (60)
2/0 (70)
3/0 (95)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
3/0 (95)
4/0 (120)
(2x70)
2 ea. 2/0
3/0 (95)
4/0 (120)
(2x70)
2 ea. 2/0
2 ea. 3/0
4/0 (120)
(2x70)
(2x95)
Positive (+) Weld Output
Terminal
Negative (–) Weld Output Ter-
minal
803 125
300 ft
350 ft
400 ft
(90 m)
(105 m)
(120 m)
1 (50)
1/0 (60)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
3/0 (95)
4/0 (120) 4/0 (120)
2 ea. 2/0
2 ea. 2/0
4/0 (120)
(2x70)
(2x70)
2 ea. 2/0
2 ea. 3/0
2 ea. 3/0
(2x70)
(2x95)
(2x95)
2 ea. 3/0
2 ea. 3/0
2 ea. 4/0
(2x95)
(2x95)
(2x120)
2 ea. 3/0
2 ea. 4/0
2 ea. 4/0
(2x95)
(2x120)
(2x120)
2 ea. 4/0
3 ea. 3/0
3 ea. 3/0
(2x120)
(3x95)
(3x95)
S-0007-E–
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