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A-6
WELDING TERMINALS
The Ranger® 250 is equipped with a toggle switch for select-
ing "hot" welding terminal when in the "WELD TERMINALS
ON" position or "cold" welding terminal when in the "REMOTE-
LY CONTROLLED" position.
WELDING OUTPUT CABLES
With the engine off connect the electrode and work cables to
the output studs. The welding process dictates the polarity of
the electrode cable. These connections should be checked
periodically and tightened with a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengths for rated
current and duty cycle. Length refers to the distance from the
welder to the work and back to the welder. Cable diameters
are increased for long cable lengths to reduce voltage drops.
TABLE A-1
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100 Ft. (0-31 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
CABLE INSTALLATION
Install the welding cables to your RANGER® 250 as follows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals.
3. Connect the electrode holder and work cables to the weld
output terminals. The terminals are identified on the case
front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the "work")
is properly connected to the work clamp and cable.
6. Check and tighten the connections periodically.
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate from
one another.
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AUXILIARY POWER RECEPTACLES
The auxiliary power of the RANGER® 250 consists of two 20
Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp
120/240 VAC (14-50R) receptacle. The 240 VAC receptacle
can be split for single phase 120 VAC operation.
INSTALLATION
The auxiliary power capacity is 10,500 Watts Peak, 9500
Watts Continuous of 60 Hz, single phase power. The auxiliary
power capacity rating in watts is equivalent to volt-amperes at
unity power factor. The max permissible current of the 240
VAC output is 40 Amps. The 240 VAC output can be split to
provide two separate 120 VAC outputs with a max permissible
current of 40 Amps per output to two separate 120 VAC
branch circuits (these circuits cannot be paralleled). Output
voltage is within ± 10% at all loads up to rated capacity. All
auxiliary power is protected by circuit breakers.
The 120 V auxiliary power receptacles should only be used
with three wire grounded type plugs or approved double insu-
lated tools with two wire plugs. The current rating of any plug
used with the system must be at least equal to the current
capacity of the associated receptacle.
NOTE: The 240 V receptacle has two 120 V circuits, but are of
opposite polarities and cannot be paralleled.
STANDBY POWER CONNECTIONS
Cable Size for
The RANGER® 250 is suitable for temporary, standby or
250 Amps
emergency power using the engine manufacturerʼs recom-
100% Duty Cycle
mended maintenance schedule.
1 AWG
The RANGER® 250 can be permanently installed as a stand-
1 AWG
by power unit for 240 VAC, 3 wire, single phase, 40 amp ser-
vice. Connections must be made by a licensed electrician who
1/0 AWG
can determine how the 120/240 VAC power can be adapted to
the particular installation and comply with all applicable electri-
cal codes.
1. Install the double-pole, double-throw switch between the
2. Take necessary steps to assure load is limited to the capac-
3. Install a 50 amp, 120/240 VAC plug (NEMA Type 14-50) to
4. Plug this cable into the 50 Amp, 120/240 Volt receptacle on
RANGER® 250
power company meter and the premises disconnect. Switch
rating must be the same or greater than the customerʼs
premises disconnect and service over current protection.
ity of the RANGER® 250 by installing a 40 amp, 240 VAC
double pole circuit breaker. Maximum rated load for each
leg of the 240 VAC auxiliary is 40 amperes. Loading above
the rated output will reduce output voltage below the allow-
able - 10% of rated voltage which may damage appliances
or other motor-driven equipment and may result in over-
heating of the RANGER® 250 engine and/or alternator
windings.
the double-pole circuit breaker using No. 6, 4 conductor
cable of the desired length. (The 50 amp, 120/240 VAC
plug is available in the optional K802R plug kit or as part
number T12153-9.)
the RANGER® 250 case front.
A-6
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