Appropriate cable size (in copper) depending on the required length. Both the lengths of the positive and negative cables must be taken into account.
For example, if 100 feet of grounding cable and 100 feet for the electrode door are used for a 200A application, a 1/0 gauge cable is required.
| – | 100ft (30m) or less | 100ft (30m) or less | 150ft (45m) | 200ft (60m) | 250ft (70m) | 300ft (90m) | 350ft (105m) | 400ft (120m) |
| Welding Amperage | 10-60% duty cycle AWG (mm²) | 60-100% duty cycle AWG (mm²) | 10-100% duty cycle AWG (mm²) | |||||
| 100 | 4 (20) | 4 (20) | 4 (20) | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 1/0 (60) |
| 150 | 3 (30) | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 3/0 (95) |
| 200 | 3 (30) | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 4/0 (120) |
| 250 | 2 (35) | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2X 2/0 (2×70) | 2 CH. 2/0 (2×70) |
| 300 | 1 (50) | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2x 2/0 (2×70) | 2x 3/0 (2×95) | 2 CH. 3/0 (2×95) |
| 350 | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2x 2/0 (2×70) | 2x 3/0 (2×95) | 2x 3/0 (2×95) | 2 CH. 4/0 (2×120) |
| 400 | 1/0 (60) | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2x 2/0 (2×70) | 2x 3/0 (2×95) | 2 CH. 4/0 (2×120) | 2 CH. 4/0 (2×120) |
| 500 | 2/0 (70) | 3/0 (95) | 4/0 (120) | 2x 2/0 (2×70) | 2x 3/0 (2×95) | 2x 4/0 (2×120) | 3x 3/0 (3×95) | 3x 3/0 (3×95) |
| 600 | 3/0 (95) | 4/0 (120) | 2x 2/0 (2×70) | 2x 3/0 (2×95) | 2x 4/0 (2×120) | 3x 3/0 (3×95) | 3x 4/0 (3×120) | 3 CH. 4/0 (3×120) |
| 700 | 4/0 (120) | 2x 2/0 (2×70) | 2x 3/0 (2×95) | 2x 4/0 (2×120) | 3x 3/0 (3×95) | 3x 4/0 (3×120) | 4x 3/0 (4×95) | 4x 3/0 (4×95) |
| 800 | 4/0 (120) | 2x 2/0 (2×70) | 2x 3/0 (2×95) | 2x 4/0 (2×120) | 3x 3/0 (3×95) | 4x 3/0 (4×95) | 4x 4/0 (4×120) | 4 CH. 4/0 (4×120) |
