Electrical Connections

A-5	INSTALLATION	A-5

When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the Amphenol, the auto-sensing circuit in the Ranger 250 automatically switches the OUTPUT control from con- trol at the welder to remote control .

The 14 pin connector is used to directly connect a wire feeder or TIG Module (K930-2) control cable. In the CV-WIRE mode, the Ranger 250 auto-sensing cir- cuit automatically makes the Ranger 250 Output Control inactive and the wire feeder voltage control active when the control cable is connected to the 14 pin connector.

NOTE: When a wire feeder with a built in welding volt- age control is connected to the 14 pin connector, do not connect anything to the 6 pin connector.

MACHINE GROUNDING

Because this portable engine driven welder

creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.)

The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

WELDING TERMINALS

The Ranger 250 is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.

WELDING OUTPUT CABLES

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.

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:

1)Be grounded to the frame of the welder using a grounded type plug.

2)Be double insulated.

WARNING

Cable Length

0-100Ft. (0-31meters)

100-150 Ft. (30-46 meters)

150-200 Ft. (46-61 meters)

Cable Size for

250Amps

100% Duty Cycle

1 AWG

1AWG 1/0 AWG

Do not ground the machine to a pipe that carries explosive or combustible material.

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When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When this engine driven welder is con- nected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the sec- tion entitled "Standby Power Connections" as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat- ed joints, or to the metal framework of a building which has been effectively grounded.

TABLE A-1

CABLE INSTALLATION

Install the welding cables to your RANGER 250 as fol- lows.

1.The gasoline 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.

RANGER 250