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3-9. 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.
Positive
Positive
receptacle
receptacle
TIG/Stick
MIG
Gas
Negative receptacle
MIG/TIG/Stick
This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
*
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
OM-244 243 Page 12
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
30 m (100 ft) or Less
10 − 60%
60 − 100%
Duty
Welding
Cycle
Cycle
Amperes
2
mm
(AWG)
mm
100
20 (4)
150
30 (3)
200
30 (3)
250
35 (2)
300
50 (1)
60 (1/0)
350
60 (1/0)
70 (2/0)
400
60 (1/0)
70 (2/0)
500
70 (2/0)
95 (3/0)
600
95 (3/0)
120 (4/0)
Not Exceeding***
45 m
60 m
(150 ft)
(200 ft)
Duty
2
(AWG)
20 (4)
20 (4)
30 (3)
30 (3)
35 (2)
50 (1)
35 (2)
50 (1)
60 (1/0)
50 (1)
60 (1/0)
70 (2/0)
70 (2/0)
95 (3/0)
95 (3/0)
120 (4/0)
95 (3/0)
120 (4/0)
2x70
120 (4/0)
(2 ea. 2/0)
2x70
2x95
(2 ea. 2/0)
(2 ea. 3/0)
70 m
90 m
105 m
(250 ft)
(300 ft)
(350 ft)
10 − 100% Duty Cycle
2
mm
(AWG)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
70 (2/0)
95 (3/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
95 (3/0)
120 (4/0)
(2 ea. 2/0)
2x70
2x95
120 (4/0)
(2 ea. 2/0)
(2 ea. 3/0)
2x70
2x95
2x95
(2 ea. 2/0)
(2 ea. 3/0)
(2 ea. 3/0)
2x70
2x95
2x120
(2 ea. 2/0)
(2 ea. 3/0)
(2 ea. 4/0)
2x95
2x120
3x95
(2 ea. 3/0)
(2 ea. 4/0)
(3 ea. 3/0)
2x120
3x95
3x120
(2 ea. 4/0)
(3 ea. 3/0)
(3 ea. 4/0)
Milan Ref. S-0007-G 2009−08
120 m
(400 ft)
60 (1/0)
95 (3/0)
120 (4/0)
2x70
(2 ea. 2/0)
2x95
(2 ea. 3/0)
2x120
(2 ea. 4/0)
2x120
(2 ea. 4/0)
3x95
(3 ea. 3/0)
3x120
(3 ea. 4/0)