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A-6
WELDING OUTPUT CABLES
With the engine off, route the electrode and work
cables thru the strain relief bracket provided on the
front of the base and connect to the terminals provid-
ed. These connections should be checked periodically
and tightened if necessary.
Listed in Table A.1 are copper cable sizes recom-
mended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable voltage drop.
Table A.1 Combined Length of Electrode and Work
Cables.
TOTAL COMBINED LENGTH OF ELEC-
TRODE AND WORK CABLES
AMPS
Up to 150
@100%
FT.
Duty Cycle
500
3/0 AWG
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.).
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
a) be grounded to the frame of the welder using a
grounded type plug,
b) be double insulated.
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 insulated
INSTALLATION
150-200 FT.
200-250 FT.
3/0 AWG
4/0 AWG
or
COMMANDER 500 CUMMINS
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the
front of the welder.
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the COMMANDER 500
CUMMINS is 12,000 watts of 60 Hz, single phase
power. The auxiliary power capacity rating in watts is
equivalent to volt-amperes at unity power factor. The
maximum permissible current of the 240 VAC output is
50 A. The 240 VAC output can be split to provide two
separate 120 VAC outputs with a maximum permissible
current of 50 A per output to two separate 120 VAC
branch circuits. The output voltage is within ± 10% at
all loads up to rated capacity.
NOTE: The 120/240V receptacle has two 120V outlets
of different phases and cannot be paralleled.
The Commander has two 20 Amp-120VAC (5-20R)
duplex receptacles and one 50 Amp-120/240 VAC (14-
50R) receptacle. The 120/240 VAC receptacle can be
split for single phase 120 VAC operation. The 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.
STANDBY POWER CONNECTIONS
The COMMANDER 500 CUMMINS is suitable for tem-
porary, standby or emergency power using the engine
manufacturer's recommended maintenance schedule.
The COMMANDER 500 CUMMINS can be perma-
nently installed as a standby power unit for 240 volt-3
wire, 50 amp service. Connections must be made by a
licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular
installation and comply with all applicable electrical
codes. The following information can be used as a
guide by the electrician for most applications. Refer to
the connection diagram shown in Figure A.2.
1. Install the double-pole, double-throw switch between
the power company meter and the premises discon-
nect.
Switch rating must be the same or greater than the
customer's premises disconnect and service over cur-
rent protection.
A-6
symbol is provided on the
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