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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.
Amps
Watts 120 V
2 .5
300
5
600
7 .5
900
10
1200
15
1800
20
2400
25
3000
30
3600
40
4800
Total Cable Length *
Maximum Welding Current
100 A
150 A
200 A
250 A
* Total cable length is the sum of the ground and electrode cable lengths .
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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
handle off of the electrode holder,
and slide it over the welding cable .
TABLE 2 - ExTENSION CORDS
Maximum Recommended Lengths (in feet)
Watts 240 V
#8 Wire
600
1200
1800
2400
3600
4800
175
6000
150
7200
125
9600
90
TABLE 3 - WELDING CABLES
0 - 20 feet (0 - 6 m)
Recommended Sizes of Copper Welding Cables
6 AWG (15 mm
2
)
6 AWG (15 mm
2
)
4 AWG (20 mm
2
)
3 AWG (25 mm
2
)
figure 1
figure 2
3 .
4 .
#10 Wire
#12 Wire
1000
600
500
300
350
200
250
150
150
100
125
75
100
60
65
20 - 40 feet (6 - 12 m)
6 AWG (15 mm
2
)
3 AWG (25 mm
2
)
2 AWG (35 mm
2
)
2 AWG (35 mm
2
)
8
Wire
Handle
Sleeve
Cable Setscrew
Handle Phillips Head Screw
Electrode Holder
Loosen the set screw on the bottom
of the electrode holder .
Insert the welding cable / wire
sleeve into the back of the brass
body of the electrode holder .
#14 Wire
#16 Wire
375
200
125
100
65
50
40 - 60 feet (12 - 18 m)
4 AWG (20 mm
2 AWG (35 mm
1 AWG (40 mm
1/0 AWG (55 mm
Welding
Cable
250
125
100
50
2
)
2
)
2
)
2
)
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