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Use Table 3-2
as
a
guide
for
selecting
the
Correct
welding
cable
size
(or the
anticipated
maximum weld
current
that will
be used.
Table 3-2 takes into
account
the total cable
for the
weld
circuit. This
means
the combined
length
of
th~
Elec
trode cable that connects the Electrode Holder
to
the weld
ing.
power
source
and the Work cable between
the
welding
power
source
and the
work
piece.
For
example:
If the Elec
trode cable is 75 feet
long
and the work cable is 25 feet
long,
you
would select the size cable from Table 3-2 that is
recom
mended for
100 feet
at
the maximum amperage that will be
used. In the
case
of
a
maximum
anticipated
weld
current
of
250
amperes,
1/0
weld cable would be
recommended for
both the Electrode and Work cables.
Table 3-2.
Secondary
Cable Size
Welding
Amperes
Total
Length
Of Cable
(copper)
in
Weld Circuit
50
100
100
150
200
250
4
4
2
2
1
1
1/0
1/0
NOTE:
A.
5OFEETOR LESS
B.
CABLE
SIZE
IS
BASED
ON
DIRECTCURRENT
(DC),
30% DUTY CYCLE AND EITHER
A
4
VOLTS
OR
LESS
DROP
OR
A
CURRENT
DENSITY
OF
NOT OVER
300 CIRCULAR MILS
PER
AMP.
C.
WELD
CABLE
INSULATION
WITH
A
VOLTAGE
RATING
TO
WITHSTAND
THE
OPEN
CIRCUIT
VOLTAGE
(O.C.V.)
OF
THE
WELDING
POWER
SOURCE
MUST BE
USED
WHILE
MOST
WELDING
POWER
SOURCES
HAVE
AN
OPEN
CIRCUIT
VOLTAGE
OF
LESS
THAN
100
VOLTS,
SOME
WELDING POWER SOURCES OF SPECIAL DESIGN
MAY
HAVE
HIGHER
OPEN CIRCUIT VOLTAGE.
Two
ac
(yellow)
receptacles
and
two
(black
&
red)
recep
tacles
are
provided
on
the lower
portion
of
the
front
panel
for
making secondary
connections.
Plugs
for these
receptacles
are
provided.
Connect
the
weld
cables
to
these
plugs
as
follows:
1.
Remove
3/4
inch of insulation from
one
end of the
welding
cable.
2.
Clamp
the
welding
cable in
a
vise with
the
uninsulated
end
protruding upward
out
of
the
vise
approximately
1-3/4
inches.
3.
Place
the steel
tie wire
approximately
1/4
inch
(B)
from the end of the insulation.
4.
Make
a
half
turn
around the cable
bringing
the
looped
ends of
the tie wire
together.
5.
Insert
a
rod
of
approximately
3/8
inch
diameter
through
the
two
looped
ends of the tie wire.
6.
Twist
the
tie
wire
(B)
until
the entire tie wire
is
twisted and is
tight
around the insulation of the weld
ing
cable.
7.
Clip
off the
looped
ends of the tie wire.
8.
Bend the twisted tie wire
over
along
the side
(C)
of
the
uninsulated
portion
of the
welding
cable.
9.
Wrap
the
strip
of
copper foil
tightly
around the unin
sulated end
of the
welding
cable and the twisted tie
wire
(D).
10.
Place the
jack plug
on
the end of the
welding
cable
and
push
it
Onto
the
welding
cable
over
the copper foil
(E).
11.
Insert the
1/4-20
set
screws
into the
center
and
upper
holes in the
jack plug
and
tighten.
A'~
B
E
~
--
-~__
C
F
AA-901 024-4
Figure
3-4. Jack
Plug
Installation
12.
Remove the
welding
cable from the vise and insert the
jack plug
into the fiber sleeve.
13.
Slide the fiber
sleeve
over
the
jack plug
and
welding
cable until the hole
in
the fiber sleeve lines
up
with the
8/32
inch hole
in
the
jack plug.
14.
Insert the
8/32
inch self
tapping
screw
(F) through
the
hole
in
the
fiber sleeve
into the
plug. Tighten
the
screw
with
a
screw
driver. Connect
a
work
clamp
to
one
of the unused ends of
one
of the cables. Connect
an
electrode holder
to
the unused end of the other
welding
cable. The
method of
connecting
the cables
to
the w.ork
clamp
and electrode holder will
depend
on
the manufacturers
design.
To obtain dc
straight polarity
weld current, the Work cable
should be
plugged
into the
positive
(red) receptacle
on
the
front
of
the machine. The
Electrode cable should be
plugged
into
the
negative
(black) receptacle.
To obtain dc
reverse
polarity
weld current, the above
connec
tions should be reversed,
For
ac
weld current, the Work and Electrode cables need
only
to
be
plugged
into
the
two
ac
(yellow) receptacles.
SECTION
4
-
OPERATION
Never,
under any
circumstances,
operate
the
welding
power
source
with the
cover
removed. In addition
to
a
safety hazard, improper cooling
may result in
damage
to
the
welding
transformer and
the
welding
power
source
components.
Warranty
is void if the
welding
power
source
is
operated
with the wrapper removed.
4-1.
RANGE SELECTOR SWITCH
(Figure
4-1)
A
RANGE SELECTOR
Switch,
located
on
the
front control
panel,
is
provided
to
select either
a
HIGH
or
LOW
amperage
range
when
welding
with
ac or
dc. When this switch is
placed
in the HIGH
position
(up),
an
ac
range
of 105-325
amperes
or
a
dc range of
70-250
amperes
will be available. When in
the LOW
position (down),
an
ac
range
of 25.125
amperes
or
a
dc range of
20-95
amperes will
be available. Exact amperage
selection within the range selected
may
be made
by adjusting
the Fine
Current
Control,
the function
of which
will be
ex
plained
iii
paragraph
4-2.
4-2.
FINE
CURRENT CONTROL & CURRENT INDI
CATOR
(Figure
4-1)
Figure
4-1. Front Panel View
CAUTION
I
I
FINE
CURRENT
CONTROL~
I
CURRENT
INDICATOR
DC SECONDARY
RECEPTACLES
AC
SECONDARY
RECEPTACLES
AA-gol
972-2
OM-313
Page
7
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