Operating Instructions and Parts Manual
Generator Operation (Continued)
INSTALLATION FOR STAND-BY USE
Precautions must be taken to prevent electrical back feeding into utility systems. This requires isolation of the electrical system. To isolate the electrical system, perform the following procedures:
1.Turn off the main electrical system switch prior to connecting the welder / generators.
2.In accordance with national and local standards, a double throw transfer switch must be installed in the system.
Always shut off main power prior to
temporary connection of the welder / generators to a building electrical system.
Installation of the welder / generator
as a backup electrical source must be performed by a qualified (licensed or certified) electrical technician.
Welder Operation
(FRONT PANEL SWITCH MUST BE SET TO WELDER POSITION)
WELDING LEAD ASSEMBLIES
Welding leads assemblies are not included with all units. Use copper welding cables in the size specified in Table 3.
GROUND CLAMP (SEE FIGURE 1)
1.Strip 1/2 inch of insulation from the end of one of the welding cables.
2.Loosen hex nuts on work clamp.
3.Insert the end of the welding cable through clamp handle and slide the bare wire under the clamp block.
4.Tighten the hex nuts, securing the cable in place.
ELECTRODE HOLDER (SEE FIGURE 2)
1.Strip 1/2 inch of insulation from the end of the other welding cable. Slide the bare wire into the wire sleeve.
2.Loosen the phillips head screw a few turns. Do not remove it completely. Pull the insulated
Figure 1
Wire | Handle |
Sleeve | Welding |
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| Cable |
Cable Setscrew | |
Handle Phillips Head Screw | |
Electrode Holder | |
Figure 2 |
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3.Loosen the set screw on the bottom of the electrode holder.
handle off of the electrode holder, and slide it over the welding cable.
4.Insert the welding cable / wire sleeve into the back of the brass body of the electrode holder.
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| TABLE 2 - EXTENSION CORDS |
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| Maximum Recommended Lengths (in feet) |
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Amps | Watts 120 V | Watts 240 V | #8 Wire | #10 Wire | #12 Wire | #14 Wire | #16 Wire |
2.5 | 300 | 600 |
| 1000 | 600 | 375 | 250 |
5 | 600 | 1200 |
| 500 | 300 | 200 | 125 |
7.5 | 900 | 1800 |
| 350 | 200 | 125 | 100 |
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10 | 1200 | 2400 |
| 250 | 150 | 100 | 50 |
15 | 1800 | 3600 |
| 150 | 100 | 65 |
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20 | 2400 | 4800 | 175 | 125 | 75 | 50 |
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25 | 3000 | 6000 | 150 | 100 | 60 |
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30 | 3600 | 7200 | 125 | 65 |
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40 | 4800 | 9600 | 90 |
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| TABLE 3 - WELDING CABLES |
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Total Cable Length * | 0 - 20 feet (0 - 6 m) | 20 - 40 feet (6 - 12 m) | 40 - 60 feet (12 - 18 m) |
Maximum Welding Current |
| Recommended Sizes of Copper Welding Cables |
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100 A | 6 AWG (15 mm2) | 6 AWG (15 mm2) | 4 AWG (20 mm2) |
150 A | 6 AWG (15 mm2) | 3 AWG (25 mm2) | 2 AWG (35 mm2) |
200 A | 4 AWG (20 mm2) | 2 AWG (35 mm2) | 1 AWG (40 mm2) |
250 A | 3 AWG (25 mm2) | 2 AWG (35 mm2) | 1/0 AWG (55 mm2) |
* Total cable length is the sum of the ground and electrode cable lengths. |
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