Selecting Cable Sizes; Weld Output Terminals - Miller Bobcat 260 Diesel Owner's Manual

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)
* 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.
5-7.

Weld Output Terminals

1
259 707 / 258 070-A
OM-286506 Page 28
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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)
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)
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)
Stop engine.
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
Turn off power before connecting
to weld output terminals.
Do not use worn, damaged, under-
sized, or repaired cables.
1 World Weld Output Terminal
2 Electrode Weld Output Terminal
Connect work cable to Work terminal.
Connect electrode holder cable or electrode
weld cable to Electrode terminal for Stick
and MIG welding.
Connect torch cable to Electrode terminal for
TIG welding.
Use Process Selector switch to select type
of weld output (see Section 6-1).
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See Sections 6-3 thru 6-5 for typical
process connections
settings.
400 ft
(120 m)
1/0 (60)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
and control