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A-6
INSTALLATION
RANGER 250
A-6
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
CABLE INSTALLATION
Install the welding cables to your RANGER 250 as fol-
lows.
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 identi-
fied 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.
• Loose connections will cause the output termi-
nals 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.
------------------------------------------------------------------------
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.
The auxiliary power capacity is 9,000 Watts Peak, 8500
Watts Continuous of 60 Hz, single phase power. The auxil-
iary power capacity rating in watts is equivalent to volt-
amperes at unity power factor. The max permissible current
of the 240 VAC output is 35 Amps. The 240 VAC output can
be split to provide two separate 120 VAC outputs with a max
permissible current of 35 Amps per output to two separate
120 VAC branch circuits (these circuits cannot be paral-
leled). 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
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.
NOTE: The 240 V receptacle has two 120 V circuits, but are
of opposite polarities and cannot be paralleled.
STANDBY POWER CONNECTIONS
The RANGER 250 is suitable for temporary, standby or
emergency power using the engine manufacturer’s recom-
mended maintenance schedule.
The RANGER 250 can be permanently installed as a stand-
by power unit for 240 VAC, 3 wire, single phase, 35 amp
service. Connections must be made by a licensed electri-
cian who can determine how the 120/240 VAC power can
be adapted to the particular installation and comply with all
applicable electrical codes.
1. Install the double-pole, double-throw switch between the
power company meter and the premises disconnect.
Switch rating must be the same or greater than the cus-
tomer’s premises disconnect and service over current
protection.
2. Take necessary steps to assure load is limited to the
capacity 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 35 amperes. Loading
above the rated output will reduce output voltage below
the allowable - 10% of rated voltage which may damage
appliances or other motor-driven equipment and may
result in overheating of the RANGER 250 engine and/or
alternator windings.
3. Install a 50 amp, 120/240 VAC plug (NEMA Type 14-50)
to the double-pole circuit breaker using No. 6, 4 conduc-
tor 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.)
4. Plug this cable into the 50 Amp, 120/240 Volt receptacle
on the RANGER 250 case front.
CAUTION
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 Size for
250 Amps
100% Duty Cycle
1 AWG
1 AWG
1/0 AWG