Welder Operation - Campbell Hausfeld GW4502 Operating Instructions And Parts Manual

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
2
6 AWG (15 mm )
2
6 AWG (15 mm )
2
4 AWG (20 mm )
2
3 AWG (25 mm )
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)
2
6 AWG (15 mm )
2
3 AWG (25 mm )
2
2 AWG (35 mm )
2
2 AWG (35 mm )
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
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