Welding Output Cables

A-6	INSTALLATION	A-6

With the engine off connect the electrode and work cables to the output studs. The welding process dic- tates the polarity of the electrode cable. These con- nections should be checked periodically and tightened with a 3/4" wrench.

Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.

TABLE A-1

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

The auxiliary power capacity is 10,000 watts Peak, 9500 Watts Continuous of 60 Hz, single phase power. The auxil- iary power capacity rating in watts is equivalent to volt- amperes at unity power factor. The max permissible current of the 240 VAC output is 40 Amps. The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 40 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paral- leled). Output voltage is within ± 10% at all loads up to rated capacity. All auxiliary power is protected by circuit breakers.

The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the cur- rent capacity of the associated receptacle.

Cable Length

0-100Ft. (0-30 meters)

100-150 Ft. (30-46m meters)

150-200 Ft. (46-61 meters)

Cable Size for

305Amps

100% Duty Cycle

1/ 0 AWG

2 / 0 AWG

3 / 0 AWG

NOTE: The 240 V receptacle has two 120 V circuits, b u t are of opposite polarities and cannot be paralleled.

STANDBY POWER CONNECTIONS

The RANGER 305G is suitable for temporary, standby or emergency power using the engine manufacturer’s recom- mended maintenance schedule.

CABLE INSTALLATION

Install the welding cables to your RANGER 305G as follows.

1.The engine must be OFF to install welding cables.

2.Remove the flanged nuts from the output terminals.

3.Connect the electrode holder and work cables to the weld output terminals. The terminals are identi- fied on the case front.

4.Tighten the flanged nuts securely.

5.Be certain that the metal piece you are welding (the “work”) is properly connected to the work clamp and cable.

6.Check and tighten the connections periodically.

CAUTION

•Loose connections will cause the output termi- nals to overheat. The terminals may eventually melt.

•Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.

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AUXILIARY POWER RECEPTACLES

The auxiliary power of the RANGER 305G consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.

The RANGER 305G can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 40 amp service. Connections must be made by a licensed elec- trician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes.

•Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the cus- tomer’s premises disconnect and service over current pro- tection.

•Take necessary steps to assure load is limited to the capacity of the RANGER 305G by installing a 40 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 40 amperes. Loading above the rated output will reduce output voltage below the allowable - 10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the RANGER 305G engine and/or alternator windings.

•Install a 50 amp, 120/240 VAC plug (NEMA Type 14-50) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit or as part number T12153-9.)

•Plug this cable into the 50 Amp, 120/240 Volt receptacle on the RANGER 305G case front.

RANGER 305G