Connecting Weld Output Cables; Selecting Cable Sizes - Hobart Welding Products Champion 145 Owner's Manual

5-5. Connecting Weld Output Cables

1
Tools Needed:
3/4 in. (19 mm)
!
Turn off power before connecting to
weld output terminals.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your ma-
chine.
.
Do not place anything between weld

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%
60 − 100%
Duty
Welding
Duty Cycle
Cycle
Amperes
AWG (mm
2
AWG (mm )
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.
2
( ) = mm for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
.
Complete Parts List available at www.HobartWelders.com
6
3
4
5
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
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
150 ft
(45 m)
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
Not Exceeding***
200 ft 250 ft
(60 m) (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) 2x2/0 (2x70)
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output ter-
minal. Slide weld cable terminal onto weld
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar.
300 ft 350 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)
Ref. S-0007-L 2015−02
OM-267225 Page 19
803 778-B
400 ft
(120 m)
1/0 (60)
3/0 (95)
4/0 (120)