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See Section 3-8 to select proper cable size. Use shortest cables possible. Do not use damaged cables. 2 Terminal Lug Use lugs of proper amperage capacity and hole size for connecting to work clamp, electrode holder, and weld output terminals. 3 Insulated Electrode Holder Install according to manufacturer’s instructions. 4 Work Clamp Install onto work cable. OM-201 444 Page 15 3-8. Weld Cable Sizes Welding Amperes Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) 10 To 60% Duty Cycle 60 Thru 100% Duty Cycle 10 Thru 100% Duty Cycle 100 150 200 250 300 350 400 500 600 4 3 3 2 1 1/0 1/0 2/0 3/0 4 3 2 1 1/0 2/0 2/0 3/0 4/0 4 2 1 1/0 2/0 3/0 3/0 4/0 2-2/0 3 1 1/0 2/0 3/0 4/0 4/0 2-2/0 2-3/0 2 1/0 2/0 3/0 4/0 2-2/0 2-2/0 2-3/0 2-4/0 1 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 3-3/0 1/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 3-3/0 3-4/0 1/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0 3-3/0 3-4/0 *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E 3-9. Connecting To Weld Output Terminals Ref. ST-800 040 Tools Needed: Use ONLY one negative weld output terminal at a time. 1 2 3 3/4 in 1 Positive (+) Weld Output Terminal 2 A Negative (–) Weld Output Terminal (Low Range) 3 B Negative (–) Weld Output Terminal (High Range) For DC Electrode Positive (DCEP), connect work cable to negative (–) terminal that supplies desired amperage range. Connect electrode holder cable to positive (+) terminal. For DC Electrode Negative (DCEN), reverse cable connections. OM-201 444 Page 16 3-10. Remote Amperage Control Receptacle 1 2 1 Remote Amperage Control Receptacle RC1 2 Keyway To connect remote amperage control to receptacle, insert plug and turn clockwise until tight. Ref. ST-800 040 3-11. Electrical Service Guide 50 Hertz Models 500 Amp Model Input Voltage 220 380 440 Input Amperes At Rated Output 103 60 51 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 Normal Operating 3 100 125 60 70 5060 Min Input Conductor Size In AWG/Kcmil 4 8 8 Max Recommended Input Conductor Length In Feet (Meters) 193 (59) 258 (79) 346 (105) Min Grounding Conductor Size In AWG/Kcmil 6 8 10 Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications. 2 “Time-Delay” fuses are UL class “RK5” . 3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above). OM-201 444 Page 17 3-12. Connecting Input Power A. Placing Jumper Links Tools Needed: 3/8 in ssb5.1 2/92 – Ref. ST-800 042 12 Jumper links allow operation on different input voltages and are factory set for the highest input voltage. Check input voltage available at site. Open rear panel access door to check jumper links. 1 Input Voltage Label – Only One Is On Unit Look at jumper links and compare link position with unit label. 2 Input Voltage Jumper Links Move links to match input voltage. For example, use 230 volts position when 230 volts input power is available. Close door or go on to 3-12B. 220 VOLTS S-021 148-A L1 L2 L3 380 VOLTS L1 L2 L3 440 VOLTS L1 L2 L3 OM-201 444 Page 18 B. Connecting Input Power 1 9 3 4 8 5 3 2 7 6 Tools Needed: Connect GND/PE Conductor First. Connect GND/PE Conductor First. Have only qualified persons make this installation. Open rear panel access door. 1 Line Disconnect Device Of Proper Rating 2 Input Conductors 3 Grounding Conductor Select size and length using 3-11. Conductor rating must comply with national, state, and local electrical codes. Use lugs of proper amperage capacity and correct hole size. 4 Strain Relief Connector Insert conductors through strain relief. 5 Input Terminal Board 6 Line Terminals 7 Welding Power Source Ground Terminal Connect grounding conductor to ground terminal first. Then connect input conductors to line terminals. 8 Disconnect Device Ground Terminal Install and connect grounding conductor and input conductors in conduit or equivalent to deenergized line disconnect device. Connect grounding conductor first, then line input conductors. Be sure grounding conductor goes to an earth ground. Close rear panel door. 9 Overcurrent Protection Select type and size using 3-11. Install into deenergized line disconnect device (fused disconnect switch shown). 3/8, 7/16, 1/2 in ssb2.4 1/94 – ST-800 042-A OM-201 444 Page 19 SECTION 4 – OPERATION 4-1. Controls 1 Power Switch 2 Amperage Adjustment Control (see Section 4-2) 3 Remote Amperage Control Receptacle (See Section 3-10) 4 Circuit Breaker CB1 (See Section 5-2) 5 Remote Amperage Switch (See Section 4-3) 122 043 2 13 4 5 4-2. Amperage Adjustment Control 1 1 Amperage Adjustment Control Use control to adjust amperage within range for Negative Weld Output terminal (see Section 3-9). Use A (inner) scale for low amperage range and B (...