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OM-2221 Page 15
3-8. Weld Output Terminals and Selecting Cable Sizes
. In the table below, when multiple numbers are indicated separated by a hyphen, the number to the left of the hyphen indicates how many cables
are to be used, and the number to the right indicates the size of the cable to be used. For example, 3-3/0 indicates that 3 cables of 3/0 gauge need
to be used for electrode and work connections.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
Weld Output
Terminals
! Turn Off welding pow-
er source and discon-
nect input power be-
fore connecting to
weld output termi-
nals.
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 − 60%
Duty Cycle
60 − 100%
Duty Cycle
10 − 100% Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
Work
Weld Output
Electrode
Weld Output
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
W
e
ld O
u
t
pu
t
Terminals
Weld Output
Terminals
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
Requires cable lugs with
5/8 in diameter holes.
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
5/8 in diameter holes
.
1
5/
1
6
in
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0
15/16 in
900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0
1000 2-2/0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0
1250 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0
*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. Contact your
distributor for the mm
2
equivalent weld cable sizes. S-0007-E