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3-10. Weld Output Terminals and 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.
Weld Output
Terminals
!
Turn off power be-
fore connecting to
weld output termi-
nals.
!
Do not use worn,
damaged,
under-
sized,
or
poorly
spliced cables.
Welding
Amperes
Electrode
Work
Weld Output
Weld Outpu
Terminals
Terminals
Requires cable lugs with
5/8 in diameter holes.
15/16 in.
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)
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
100 ft (30 m) or Less
10 − 60%
60 − 100%
Duty
Duty
Cycle
Cycle
2
AWG (mm
)
AWG (mm
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)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
700
4/0 (120)
(2x70)
2 ea. 2/0
800
4/0 (120)
(2x70)
2 ea. 2/0
2 ea. 3/0
900
(2x70)
(2x95)
2 ea. 2/0
2 ea. 3/0
1000
(2x70)
(2x95)
2 ea. 3/0
2 ea. 4/0
1250
(2x95)
(2x120)
Not Exceeding***
150 ft
200 ft
250 ft
(45 m)
(60 m)
(70 m)
10 − 100% Duty Cycle
2
)
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)
2 ea. 2/0
2 ea. 3/0
2 ea. 4/0
(2x70)
(2x95)
(2x120)
2 ea. 3/0
2 ea. 4/0
3 ea. 3/0
(2x95)
(2x120)
(3x95)
2 ea. 3/0
2 ea. 4/0
3 ea. 4/0
(2x95)
(2x120)
(3x120)
2 ea. 4/0
3 ea. 3/0
(2x120)
(3x95)
2 ea. 4/0
3 ea. 3/0
(2x120)
(3x95)
3 ea. 3/0
4 ea. 3/0
(3x95)
(4x95)
300 ft
350 ft
(90 m)
(105 m)
2
AWG (mm
)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
2 ea. 2/0
4/0 (120)
(2x70)
2 ea. 2/0
2 ea. 3/0
(2x70)
(2x95)
2 ea. 3/0
2 ea. 3/0
(2x95)
(2x95)
2 ea. 3/0
2 ea. 4/0
(2x95)
(2x120)
2 ea. 4/0
3 ea. 3/0
(2x120)
(3x95)
3 ea. 3/0
3 ea. 4/0
(3x95)
(3x120)
3 ea. 4/0
3 ea. 4/0
(3x120)
(3x120)
3 ea. 4/0
4 ea. 4/0
(3x120)
(4x120)
Ref. S-0007-G 2009−08
OM-2221 Page 15
400 ft
(120 m)
1/0 (60)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)
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