Selecting Cable Sizes; Connecting To Remote Receptacle - Miller Big Blue 500 Pro Owner's Manual

5-8. 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%
Duty
Welding
Cycle
Amperes
2
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)
500 2/0 (70)
600 3/0 (95)
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, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.

5-9. Connecting To Remote Receptacle

.
Accessories depend
on unit capabilities.
OR
.
Complete Parts List available at www.MillerWelds.com
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
150 ft
(45 m)
60 − 100%
Duty Cycle
2
AWG (mm )
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)
3/0 (95) 4/0 (120)
4/0 (120) 2x2/0 (2x70)
*The remaining sockets
are not used.
.
24 VOLTS AC
REMOTE
CONTROL
Rmt14_1 2010−04
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)
4/0 (120) 2x2/0 (2x70)
4/0 (120) 2x2/0 (2x70)
2x2/0 (2x70) 2x3/0 (2x95)
2x3/0 (2x95) 2x4/0 (2x120)
Socket*
Not all models have contactor control. See description of front panel controls and
circuit diagram.
A 24 volts AC. Protected by supplementary protector.
B Contact closure to A completes 24 volt AC contactor
control circuit.
C Output to remote control:+10 volts DC in MIG mode;
0 to +10 volts DC in Stick or TIG mode.
D Remote control circuit common.
OUTPUT
E DC input command signal: 0 to +10 volts from min.
to max. of remote control with Voltage/Amperage
Adjust control at maximum.
F Current feedback: 1 volt per 100 amperes.
H Voltage feedback: 1 volt per 10 arc volts.
G Circuit common for 24 volt AC circuit.
NEUTRAL
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) 2x3/0 (2x95)
2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
2x4/0 (2x120) 3x3/0 (3x95)
3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
Ref. S-0007-M 2017−08
Socket Information
OM-278739 Page 29
400 ft
(120 m)
1/0 (60)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)