Finaltechwrit&CADproj

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Andrew Obenshain
CAD Project Fall 2016
Comparison of Three Lever Designs
Introduction:
The goal is to determine which lever design is the best. Each design was created using the same
materials so the overall cost and mass can be determined.
In this case the decision variable is:
Material: Changing this for the respective designs will affect the cost, mass, and the
contact force.
Contact Force: The magnitude of reactive forces due to 50 lbsf (222.22 N)
applied to the handles of the lever systems.
Once the best lever is chosen, the next step would be to change the materials to optimize the cost,
mass, and contact force of the chosen system. This step is not taken in this case. Our only
objective is to determine the best lever of the three.
The properties used to compare the systems are;
1. Overall cost: Based on the cost per unit mass of component materials. This quantity is
denoted “TC”. For n materials, the total cost is equal to:
TC = ∑Cn mn S.T: mn (mass of material n in system) and
Cn (Cost per unit mass of material n)
2. Overall Mass: Determined be summing the individual masses of the components.
Confirmed through Solid Works ™ mass properties of the assembly of the system under
study. Total mass (TM) is equal to:
TM = ∑mcn S.T: mcn (Mass of component n)
3. Contact Force: This will be determined using Solid Works ™ motion analysis. 50 lbf
will be applied to the handles of the levers. Oak branch sizes of (1/8, ¼, ½, and 1)” are
placed between the blades. The magnitude of the contact forces are presented graphically
later in this report.

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Conclusions:
Below is a table comparing the contact force leveled out between each design and branch three;
System Leveled force after initial contact (lb)
Simple Lever 600
Old School Lever 480
New School Lever 580
It should be noted that the solid body contact between the branch and the different blades was set
to steel (dry). If left as acrylic the blade tended to go straight through the branch.
Total Mass of Each System
Total Cost of Each System
Plain Carbon Steel at .7dollars per kg
Natural Rubber at 2.40 dollars per kg
System Total Cost (U.S. Dollars)
Simple Lever 4.52
Old School Lever 4.95
New School lever 5.09
System Total Mass (kg) Total Mass (lbm)
Simple Lever 5.24 11.56
Old School Lever 5.89 12.98
New School Lever 6.08 13.40

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Simple Lever:
This system is the cheapest and lightest of the three. The downfall is the contact force. If there
are thick branches that need to be cut efficiently and effectively, the simple lever is not the ideal
choice.
Old School Lever:
Slightly more expensive and heavy, this system pumps out a decent contact force for what force
is applied to the handles. As the force input to contact force ratio increases, it is safe to assume
that the complexity of manufacturing will increase.
New School lever:
The third system has the highest contact force. This means it is the best choice for cutting thick
branches with less effort. It is the most expensive, has the greatest mass, and will take the longest
to create.
Choose the system that is best for the given situation. For instance, if we want the shortest
manufacturing time, go with the simple lever.
In our case, we want the system that will cut the branches the most efficiently. To determine
which system to choose we analyzed the contact force between the blades and the branches. The
new school lever had the highest magnitude of contact force and is therefore the best option.

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Introduction
Purpose
The SOP will serve as safety training while using the welding machines. It must train students to
be aware of the dangers and to use safe procedures during welding.
Scope
This document covers the safety and operational procedures for the Invertec V275-S and V450-
PRO welding machines. It was written for those with basic to expert knowledge on using
welding machines.
Context
The Standard/Safety Operating Procedures (SOPs) will be used in a welding training facility.
The students are tested in the safety standards at the beginning of their training sessions. This
document is a type of handbook for reference during welding operations on the field or in the
training booth.

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Safety Operating Procedures
Invertec V275-S & V450-PRO
(Welding Machine)
Note: The safety procedures for both the V275-S and V450-PRO are identical.
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects, and other
reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
The Above For Gasoline Engines
Arc welding can be hazardous. Protect yourself and others from possible serious injury or
death. Keep children away. Pacemaker wearers should consult with their doctor before
operating.
Read and understand the following safety highlights. For additional safety information, it is
strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI
Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135
or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is
available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-
1199.
Be sure that all installation, operation, maintenance and repair procedures are performed
only by qualified individuals.

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For Engine Powered Equipment
A. Turn the engine off before troubleshooting and maintenance work unless the maintenance
work requires it to be running.
B. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
Open Flame
C. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine until fumes have been eliminated.
Moving Parts
D. Keep all equipment safety guards, covers and devices in position and in good repair.
Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
E. In some cases it may be necessary to remove safety guards to perform required
maintenance. Remove guards only when necessary and replace them when the
maintenance requiring their removal is complete. Always use the greatest care when
working near moving parts.
F. Do not put your hands near the engine fan. Do not attempt to override the governor or
idler by pushing on the throttle control rods while the engine is running.
G. To prevent accidentally starting gasoline engines while turning the engine or welding
generator during maintenance work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Hot Surface
H. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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Electric and Magnetic Fields
A. Electric current flowing through any conductor causes localized Electric and Magnetic
Fields (EMF). Welding current creates EMF fields around welding cables and welding
machines
Magnetic Field
B. EMF fields may interfere with some pacemakers, and welders having a pacemaker should
consult their physician before welding.
C. Exposure to EMF fields in welding may have other health effects which are now not
known.
D. All welders should use the following procedures in order to minimize exposure to EMF
fields from the welding circuit:
a. Route the electrode and work cables together - Secure them with tape when
possible.
b. Never coil the electrode lead around your body.
c. Do not place your body between the electrode and work cables. If the electrode
cable is on your right side, the work cable should also be on your right side.
d. Connect the work cable to the work-piece as close as possible to the area being
welded.
e. Do not work next to welding power source.

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Electric Shock
Electric Shock
A. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
B. Insulate yourself from work and ground using dry insulation. Make certain the insulation
is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under
electrically hazardous conditions (in damp locations or while wearing wet clothing;
on metal structures such as floors, gratings or scaffolds; when in cramped positions
such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental
contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
C. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun are also electrically “hot”.
D. Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.
E. Ground the work or metal to be welded to a good electrical (earth) ground.
F. Maintain the electrode holder, work clamp, welding cable and welding machine in good,
safe operating condition. Replace damaged insulation.
G. Never dip the electrode in water for cooling.
H. Never simultaneously touch electrically “hot” parts of electrode holders connected to
two welders because voltage between the two can be the total of the open circuit voltage
of both welders.
Fall Hazard
I. When working above floor level, use a safety belt to protect yourself from a fall should
you get a shock.
J. Also see Items 6.c. and 8.

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Arc Rays
Welding Area
A. Use a shield with the proper filter and cover plates to protect your eyes from sparks and
the rays of the arc when welding or observing open arc welding. Headshield and filter
lens should conform to ANSI Z87. I standards.
B. Use suitable clothing made from durable flame-resistant material to protect your skin and
that of your helpers from the arc rays.
C. Protect other nearby personnel with suitable, non-flammable screening and/or warn them
not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

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Fumes and Gases
Fumes and Gases
A. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes
and gases. When welding, keep your head out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or cadmium plated steel and other metals
or coatings which produce highly toxic fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be
required. Additional precautions are also required when welding on galvanized steel.
B. The operation of welding fume control equipment is affected by various factors including
proper use and positioning of the equipment, maintenance of the equipment and the
specific welding procedure and application involved. Worker exposure level should be
checked upon installation and periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
Toxic Gas
C. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
D. Shielding gases used for arc welding can displace air and cause injury or death. Always
use enough ventilation, especially in confined areas, to insure breathing air is safe.
E. Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from your welding distributor or
from the manufacturer.
F. Also see item 1.b.

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Welding and Cutting Sparks
Open Flame
A. Remove fire hazards from the welding area. If this is not possible, cover them to prevent
the welding sparks from starting a fire. Remember that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Avoid
welding near hydraulic lines. Have a fire extinguisher readily available.
B. Where compressed gases are to be used at the job site, special precautions should be used
to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard
Z49.1) and the operating information for the equipment being used.
C. When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create a fire hazard.
D. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken
to insure that such procedures will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have been “cleaned”. For
information, purchase “Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from
the American Welding Society (see address above).
E. Vent hollow castings or containers before heating, cutting or welding. They may explode.
F. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such
as leather gloves, heavy shirt, cuff-less trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places. Always wear safety glasses
with side shields when in a welding area.
G. Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area
increase the possibility of the welding current passing through lifting chains, crane cables
or other alternate circuits. This can create fire hazards or overheat lifting chains or cables
until they fail.
H. Also see item 1.c.
I. Read and follow NFPA 51B “Standard for Fire Prevention during Welding, Cutting and
Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
J. Do not use a welding power source for pipe thawing.

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Cylinders
Explosion
A. Use only compressed gas cylinders containing the correct shielding gas for the process
used and properly operating regulators designed for the gas and pressure used. All
hoses, fittings, etc. should be suitable for the application and maintained in good
condition.
B. Always keep cylinders in an upright position securely chained to an undercarriage or
fixed support.
C. Cylinders should be located:
a. Away from areas where they may be struck or subjected to physical damage.
b. A safe distance from arc welding or cutting operations and any other source of
heat, sparks, or flame.
D. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch
a cylinder.
E. Keep your head and face away from the cylinder valve outlet when opening the cylinder
valve.
F. Valve protection caps should always be in place and hand tight except when the
cylinder is in use or connected for use.
G. Read and follow the instructions on compressed gas cylinders, associated equipment,
and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.

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Electrically Powered Equipment
Electric Shock
A. Turn off input power using the disconnect switch at the fuse box before working on the
equipment.
B. Install equipment in accordance with the U.S. National Electrical Code, all local codes
and the manufacturer’s recommendations.
C. Ground the equipment in accordance with the U.S. National Electrical Code and the
manufacturer’s recommendations.
Refer to http://www.lincolnelectric.com/safety for additional safety information.

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Standard Operating Procedures
Invertec V275-S
(Welding Machine)
Read and understand this entire section before operating your machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
Figure 13 Electric Shock
• Do not touch electrically live parts such as output terminals or internal wiring.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
Figure 14 Fumes and Gases
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.

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WELDING, CUTTING and GOUGING SPARKS can cause fire or explosion
Figure 15 Open Flame
• Keep flammable material away.
• Do not weld, cut or gouge on containers that have held combustibles.
ARC RAYS can burn.
Figure 16 Arc Flash
• Wear eye, ear and body protection.
Only qualified personnel should operate this equipment.
Observe all safety information throughout this manual.

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Figure 17 Invertec V275-S
GENERAL DESCRIPTION
The Invertec V275-S is a 275 amp arc welding power source that utilizes single or three phase
input power, to produce constant current output. The welding response of this Invertec has been
optimized for stick (SMAW) and TIG (GTAW).
OPERATIONAL FEATURES
The Invertec V275-S provides continuous total range output current adjustment, selectable
welding modes and local or remote output control. Welding characteristics can be controlled via
an arc force control. Additionally, starting characteristics can be adjusted via a “hot start”
control.
WELDING CAPABILITY
The Invertec V275-S is rated at 275 amps, 35% duty cycle (based on a 10 minute cycle). It is
also rated at 200 amps, 100% duty cycle, and 250 amps, 60% duty cycle.
LIMITATIONS
The V275-S is not recommended for pipe thawing.
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the V275-S.

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1. POWER SWITCH - Place the lever in the “ON” position to energize the machine. When the
power is on the output will be energized in STICK (SMAW) mode and TIG (GTAW) if the
remote is set to local control. At power up the thermal Light and Fan will turn on for
approximately 3 seconds.
2. OUTPUT CONTROL - This controls the output current. Control is provided over the entire
output range of the power source with (1) turn of the control knob. This control may be adjusted
while under load to change power source output. When using remote control this function
becomes the limit setting.
3. LOCAL/REMOTE SWITCH - Place in the “LOCAL” position to allow output adjustment at
the machine. Place in the “REMOTE” position to allow output adjustment at remote pot or
amptrol. In Remote, the machine output control pot is the limit setting for remote control.
4. MODE SWITCH CC -Stick (SMAW) Use this mode for all stick welding. Output energized
when machine is on.
TIG (GTAW) Optimized for touch start use. Short circuit current is limited to approximately 20
amps to aid in touch starting.
In TIG (GTAW) mode, the Local/Remote switch also controls if the output is energized.
Table 1
MODE LOCAL/REMOTE SWITCH OUTPUT
GTAW LOCAL ENERGIZED
GTAW REMOTE CONTROL BY
REMOTE ARC SWITCH
SMAW LOCAL & REMOTE ENERGIZED

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5. HOT START - Controls the amount of starting energy in CC Stick (SMAW). The Hot Start
can be either turned on or off. When on, it provides a striking current at 160% of the set current
or 275A whichever is larger then quickly reverts to the set current in 0.4 second.
6. ARC FORCE - This control functions in CC Stick SMAW modes to adjust the Arc Force.
The arc is soft at the minimum settings and more forceful or driving at the maximum settings.
Higher spatter levels may be present at the maximum settings. Full range is from -10(Soft) to
+10(Crisp)
7. OUTPUT TERMINALS - These quick disconnect terminals provide connection points for
the electrode and work cables. Refer to Output Connection in the Installation chapter for proper
cable sizes. For positive polarity welding connect the electrode cable to the positive terminal and
the work cable to the negative terminal. To weld negative polarity, reverse the electrode and
work cables.
8. THERMAL SHUTDOWN INDICATOR - This light will illuminate if an internal
thermostat has been activated. Machine output will return after the internal components have
returned to a normal operating temperature. See Thermal Protection later in this Operation
chapter.
9. 6-PIN REMOTE RECEPTACLE (Refer to Output Connection in the Installation chapter.)
10. POWER LIGHT - This Light will illuminate when the power switch is in the “ON”
position.
CONSTANT CURRENT PROCESSES
MANUAL ARC WELDING (STICK)*
The Invertec may be utilized as a manual DC arc welder with the electrode cable, work cable,
and electrode holder being the only equipment required. AIR CARBON ARC CUTTING* Air
carbon arc cutting may be performed with the Invertec within its output rating using 3/16”
diameter carbon rods. Output cables, an air carbon arc electrode cable assembly, and a source of
compressed air are required.

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TIG WELDING*
The Invertec V275-S is capable of touch start TIG welding. An electrode cable, work cable, TIG
torch, and gas supply with regulator are required. Refer to Accessories section of this manual.
Touch starting is done as follows:
1. Place the shield cup edge on the work piece.
2. Rock the tungsten down to touch.
3. Trigger the output, if using remote control.
4. Gently rock back the tungsten from the workpiece.
Note: The short circuit current is limited to 20 amps to aid in touch starting. Panel output control
becomes the current limit setting when in remote control.
Note: Operating this machine with the output control set to maximum may cause the machine to
phase back and the arc to go out. This occurs because the welding current exceeded 300 amps
and the machine’s protection circuitry activated. Turn the output control down to correct this
condition.
PARALLEL OPERATION
The Invertecʼs are operable in parallel. For best results, the currents of each machine should be
reasonably well shared. As an example, with two machines set up in parallel for a 300 amp
procedure, each machine should be set to deliver approximately 150 amps, not 200 amps from
one and 100 amps from the other. This will minimize nuisance feedback conditions. In general,
more than two machines in parallel will not be effective due to the voltage requirements of
procedures in that power range.
To set machine outputs, start with output control pots and arc force pots in identical positions.
Adjust outputs and arc forces to maintain current sharing while establishing the proper output
current.
OVERLOAD PROTECTION
The machine is electrically protected from producing high output currents. Should the output
current exceed 300A, an electronic protection circuit will reduce the current to less than 200A.
The machine will continue to produce this low current until the protection circuit is reset. Reset
occurs when the output load is removed.
Note: When TIG welding with the Output Knob at or above 275 Amps the Arc may go out.

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THERMAL PROTECTION
Thermostats protect the machine from excessive operating temperatures. Excessive temperatures
may be caused by a lack of cooling air or operating the machine beyond the duty cycle and
output rating. If excessive operating temperature should occur, the thermostats will prevent
output voltage or current.
Thermostats are self-resetting once the machine cools sufficiently.
FAN
The cooling fan on the V275-S operates once 15 amps of welding current are drawn and for 7
minutes after the output current has stopped flowing.
The fan will also run anytime the machine has over heated.
POWER-UP SEQUENCE
At power up the thermal light (and Power light on codes 11164 and above) turns on and the fans
run for approximately 3 seconds. This is the pre-charge time for the main capacitors. After this
time the fans and thermal light turn off and the pre-charge relay closes to apply full line power to
the capacitors. At this time the machine is ready to weld.

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Standard Operating Procedures
Invertec V450-PRO
(Welding Machine)
SAFETY PRECAUTIONS
Warning
ELCTRIC SHOCK can kill
Figure 18 Electric Shock
• Do not touch electrically live parts or electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous
Figure 19 Fumes and Gases
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
WELDING SPARKS can cause fire or explosion.
Figure 20 Open Flame
• Keep flammable material away.
• Do not weld on closed containers.

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ARC RAYS can burn eyes and skin.
Figure 21 Arc Flash
• Wear eye, ear and body protection.
See additional warning information at front of this operator’s manual.

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Figure 22 Invertec V450-PRO
GENERAL DESCRIPTION
The INVERTEC® V450-PRO offers multi-process CV, CC, and DC welding and is rated 570
amps, 43 volts at a 60% duty cycle.
DUTY CYCLE
The V450-Pro is rated at 570 amps, 60% duty cycle (based on a 10 minute cycle). It is also rated
at 450 amps, 100% duty cycle.

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OPERATIONAL FEATURES and CONTROLS:
UPPER CONTROL PANEL
1. ON, OFF- SWITCH
2. AMPS Meter
• Prior to STICK or TIG operation (current flow), the meter displays preset current value
(either +/- 2 amps or +/- 3% (e.g. 3 amps on 100), whichever is greater).
• Prior to CV operation, the meter displays four dashes indicating non-presettable AMPS.
• During welding, this meter displays actual average amps.
• After welding, the meter holds the actual current value for 5 seconds. Output adjustment
while in the "hold" period results in the "prior to operation" characteristics stated above.
The displays blink indicating that the machine is in the "Hold" period.
3. VOLT METER
• Prior to CV operation (current flow), the meter displays desired preset voltage value
(+/- .5V).
• Prior to STICK or TIG operation, the meter displays the Open Circuit Voltage of the
Power Source or four dashes if the output has not been turned on.
• During welding, this meter displays actual average volts.
• After welding, the meter holds the actual voltage value for 5 seconds. The displays blink
indicating that the machine is in the "Hold" period.
• Output adjustment while in the "hold" period results in the "prior to operation"
characteristics stated above.
4. OUTPUT CONTROL
• Output control is conducted via a single turn potentiometer.
• Adjustment is indicated by the meters as stated above.
• When in TIG modes, this control sets the maximum welding current. Full depression of a
foot or hand Amptrol results in the preset level of current.

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5. WELD TERMINALS-REMOTE / ON
• Two status lights indicate the location of trigger control as determined by the "WELD
TERMINALS" push button.
• If trigger control is local "weld terminals on", the ON display will be lit.
• If trigger control is remote "weld terminals remotely controlled", the REMOTE display
will be lit.
• The unit will power up in "pre-determined preferred" trigger modes.
 STICK = ON
 CV = REMOTE
 TIG = REMOTE if remote output controls are attached to the machine.
 TIG = 0N if remote output controls are not attached to the machine.
 For all versions, these trigger modes can be over-ridden (switched) with the WELD
TERMINALS push button. When changed, the unit will power up in the configuration it
was in when it was last powered down.
6. THERMAL
• This status light indicates when the power source has been driven into thermal overload.
If the output terminals were "ON", the "ON" light will blink indicating that the output
will be turned back on once the unit cools down to an acceptable temperature level. If the
unit was operating in the "REMOTE" mode, the trigger will need to be opened before or
after the thermal has cleared and closed after the machine has cooled down to an
acceptable temperature to establish output.
7. CONTROL-REMOTE / LOCAL
• Two status lights indicate the location of output control as pre-determined by the power
sources auto-configure system.
• The LOCAL display will be lit when control is at the power source.
• The REMOTE display will be lit when a remote pot/control is detected.
These Output Control configurations can be overridden (switched) with the CONTROL
push button. When changed, the unit will power up in the configuration it was in when it
was last powered down.
Hidden Middle Control Panel – Process Set up Panel
The middle control panel is removable to allow for upgrades (see Field Installed
Options/Accessories). Additionally, this panel is hidden by an access door to provide protection
to the controls.

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8. WELD MODE SELECT - STANDARD (See Figure B.1) The Mode Control
button selects from the following welding modes.
CC-Stick Soft: The Stick Soft process features continuous control ranging from 5 to 570 amps.
This mode was intended for most SMAW applications, and Arc Gouging.
• Arc Gouging: Setting the output of the Stick Soft mode to 570 amps or setting the arc
control to maximum will enable the arc-gouging mode. The actual output current will
depend on the size of carbon used. The recommended maximum size carbon is
3/8"(9.5mm).
• The Hot Start control regulates the starting current at arc initiation. Hot Start can be
adjusted from minimum (0), with no additional current added at arc start, to maximum
(10), with double the preset current or 570 amps (max of machine) added for the first
second after arc initiation.
• The Arc Control regulates the Arc Force to adjust the short circuit current. The
minimum setting (-10) will produce a "soft" arc and will produce minimal spatter. The
maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking
CC-STICK CRISP: The Stick Crisp mode features continuous control from 5 to 570 amps with
a crisp shorting response optimized for E6010 type electrodes.
• Arc Gouging: Setting the output of the Crisp mode to 570 amps or setting the arc control
to maximum will enable the arc-gouging mode. The actual output current will depend
on the size of carbon used. The recommended maximum size carbon is 3/8"(9.5mm).
• The Hot Start control regulates the starting current at arc initiation. Hot Start can adjust
starting current up or down by 25% of the preset value. The recommended setting for
Hot Start is 5 where the initial current is equal to the preset current.
• The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum
setting (-10) will produce a "soft" arc and will produce minimal spatter. The maximum
setting (+10) will produce a "crisp" arc and will minimize electrode sticking.

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TIG GTAW: The TIG mode features continuous control from 5 to 570 amps. The TIG mode can be
run in either the TIG touch start or high frequency (optional equipment required) assisted start mode.
• The Hot Start control selects the starting mode desired. A setting of less than 5, the TIG lift
start mode is selected. The OCV is controlled below 10v and the short circuit "TIG touch"
current is maintained at 25 amps independent of the preset current.
When the tungsten is lifted, an arc is initiated and the output is regulated at the preset value. Hot
start settings between 0 and 5 regulate the arc initiation current. A setting of 5 results in the most
positive arc initiation. A setting of 0 reduces hot start.
• Hot Start settings between 5 and 10, select high frequency assisted starting TIG mode. In
this range, the OCV of the machine is controlled between 50 and 70 volts. If using the
Lincoln K9301 TIG Module, set the hot start to 10 for maximum OCV.
• The Arc Control is not used in the TIG mode.
CV-WIRE: The CV-WIRE mode features continuous control from 10 to 40 volts. This mode was
intended for most GMAW, FCAW, and MCAW applications.
• The Hot Start control is not used in the CV-WIRE mode.
• The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and
results in a soft arc. Low pinch settings are preferable for welding with gas mixes
containing mostly inert gases. At the maximum setting (+10), maximizes pinch effect and
results in a crisp arc. High pinch settings are preferable for welding FCAW and GMAW
with CO2.
CV-INNERSHIELD: The CV-INNERSHIELD mode features continuous control from 10 to 45
volts. This mode was designed for self-shielded flux cored wires that require tight voltage control.
• The Hot Start control is not used in the CV-INNERSHIELD mode.
• The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and
results in a soft arc. At the maximum setting (+10), maximizes pinch effect and results in a
crisp arc. Most self-shielded wires work well at an Arc Control setting of 5.

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8A. WELD MODE SELECT-FOR MACHINES EQUIPPED
WITH OPTIONAL ADVANCED PROCESS PANEL (See Figure
B.2 UPPER AND MIDDLE SECTION) See (WELD MODE
DETAILS) in this section.
To program welding modes; Select knob is used to Scroll through all Welding modes. The
Memory button is used to store and access Welding modes into locations M1 thru M8.
Modes: In addition to the 5 welding modes described in SECTION 7, the Advance Process
Panel allows you to select the Following additional modes.
• Constant Power Mode
o In the Power Mode; the work point will be in the Volts window. The Amp
window will have CP displayed indicating Constant Power. Once current starts
flowing and during the 5 second “Hold” feature the displays will show Volts
and Amps respectively.
• Gouge Mode
o The gouging mode is specifically designed for carbon arc gouging with
electrodes up to 3/8”.
• Pulsed Modes
o In Pulse Modes; the work point will be in the Amps window and should be set
close to the wire feed speed of the wire feeder in inches per minute. The Volts
window will have SPd displayed indicating Wire Feed Speed. Once current starts
flowing and during the 5 second “Hold” feature the displays will show amps and
volts.
o Pulse Mode features that are displayed while selecting a Welding pulse mode are
listed below;
 Steel - .030”, .035”, .045”, .052”, 1/16” – Argon Blends
 Stainless Steel - .030”, .035”, .045” – Argon Blends & Helium/Argon
Blends
 Aluminum - .035”, 3/64”, 1/16” – 4043 & 5356
 Metal Core - .045”, .052”, 1/16” – Argon Blends
 Nickel - .035”, .045” – Argon/Helium blends

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MEMORY SELECTIONS:
The MEMORY button and SELECT knob are used together to select a welding process and store
it in memory (M1 thru M8). The SELECT knob scrolls through the, welding process modes and
memory M1 thru M8. The MEMORY button stores the welding process in memory.
• SELECT button" (The right button) selects between the "Hot Start" and "Arc Control".
The < will indicate the active feature shown below.
Right Digital Window
o "Hot Start" (-10 to 0 +10)
o "Arc Control" (0 to 10) <
• The ADJUST knob adjusts the desired settings for the Hot Start or Arc Control feature that
is active.
WELDING PROCESS MODES AVAILABLE
• Stick SMAW
• TIG GTAW
• Gouge CAG
• CV MIG GMAW CV Flux Core
• Pulse MIG
ELECTRODE MATERIAL
• Steel
• Metal Core
• Stainless
• Aluminum
• Nickel

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EXAMPLE OF SAVING WELDING MODES TO MEMORY
The following example is how to select Pulse MIG using .035 steel and store it into memory.
1. Turn the Select knob until welding process is displayed.
RIGHT WINDOW LEFT WINDOW
Pulse MIG Argon Blends
Steel .035
2. Wait two seconds and the right window will display Arc Control on the second line on
the right side.
Pulse MIG Argon Blends
Steel .035 Arc Cntrl ### <
3. SPd is displayed in the upper right Volts window. The left Amps window matches the
desired wire feed speed that is set on the wire feeder. Adjust the Output knob until
desired number is displayed.
4. Start welding. If the arc length is too short turn the Output knob up. If the arc length is
too long turn the Output knob down.
The Arc Control which is displayed in the right digital window can be used to fine-tune the arc
length and characteristics.
5. After all adjustments have been made press and hold the Memory button until the display
changes. The right and the left window will display a memory position, let’s say M1(or
turn knob to select memory of your choice. To store in M1 push the Memory button
again to save the Pulse Mig mode to memory M1.
6. The display in the digital windows read as follows:
M1 Pulse MIG Argon Blends
Steel .035 Arc Cntrl 1.2
7. To save a second welding mode to a memory position of your choice, turn the Select
knob until the desired welding process mode is displayed in right digital window. Then
follow steps 2 thru 6.
8. Adjust the output control to the correct wire feed setting and the V450-PRO is ready to
weld again. (Note: The wire feed speed setting is not stored in memory and will need to
be reset.)
9. Adjust the Arc Control and note that the M1 goes away indicating that the V450-PRO
settings no longer match what is stored in memory. Going back to the original settings
will not bring the M1 back. You will need to push the Memory button to recall the
original settings in M1.
Note: After all memory’s M1 thru M8 are used and the welder needs to store another welding
process, a new welding process will overwrite what was originally in the memory and will read,
Save to MEM
M1 Overwrite
M1 which stored Pulse Mig is overwritten with the new welding process.

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WELD MODE DETAILS:
Table 2
Mode Range
Stick Soft 55 - 570 amps
Comments: The stick soft mode is the best selection for general stick applications. Arc Control
= Arc Force Hot Start = Initial hot start current (min = start a match set amps, Max. = greatest
hot start current) during hot start, arc force is set at high and is fast response. For gouging
applications: Turn current up to 570 amps.
Stick Crisp 55 - 570 amps
Comments: The stick crisp mode features an aggressive arc force routine well suited for Exx10,
Exx11 series electrodes. Arc Control = Arc Force Hot Start = Initial hot start current (Mid range
= welding current and will vary up and down with knob control.) During hot start, arc force is set
at high and is fast response. For gouging applications: Turn current up to 570 amps.
GTAW (Tig mode) 5 - 570 amps
Comments: The tig mode produces a soft, steady constant current waveform for either touch
start or high frequency assisted start DC GTAW applications. Hot Start = Min to Mid range =
Touch start with low OCV Mid to Max range = High frequency assisted starting with adjustable
OCV up to 70 volts.
GMAW - CV 10 - 45 volts
Comments: The GMAW - CV mode is the best selection for general MIG welding, Metal core,
and gas shielded applications. Arc Control = Pinch (Min = min pinch, softest arc), (Max = max
pinch, crispest arc)
FCAW-SS 10 - 45 volts
Comments: The FCAW-SS mode is designed for Self- Shielded Inner shield products that
require tight voltage control. For example; the NR 203 series or NR 207) Arc Control = Pinch
(Min = min pinch, softest arc), (Max = max pinch, crispest arc,)

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ADVANCED PULSE PANEL WELDING PROGRAMS
Table 2 continued
Gouging 60 – 570 amps
Comments: The gouging mode is specifically designed for carbon arc gouging with electrodes
up to 3/8”.
GMAW – Power 0.1 – 20 KW
Comments: The GMAW – power mode is similar in operation to other GMAW modes. The
power mode features a very stable short arc performance which is especially good when welding
small diameter (.025 and .030 steel and stainless) wires for low procedures. The short arc steel
and stainless applications, a fast response for spray applications, and a drooper type spray mode
characteristic for Aluminum.
Table 3
PULSE PROGRAMS: *IPM (INCHES PER MINUTE)
MODE IPM*
.030 Steel 75 – 800
.035 Steel 50 – 800
.045 Steel 60 – 800
.052 Steel 60 – 750
1/16 Steel 60 – 600
.045 Metal Core 60 – 700
.052 Metal Core 60 – 500
1/16 Metal Core 60 – 500
.030 Stainless Ar Blends 100 – 800
.030 Stainless He Ar CO2 100 – 800
*Continue to next page.

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MODE IPM*
.035 Aluminum 4043 125 – 700
.035 Aluminum 5356 130 – 750
3/64 Aluminum 4043 85 – 600
3/64 Aluminum 5356 85 – 700
1/16 Aluminum 4043 55 – 300
1/16 Aluminum 5356 65 – 400
Comments: The V450 pulse programs are non-synergic and allow independent control of the
wire feed speed and the arc length. The Output Control Knob on the V450, adjusts an “SPD”
value. Similar to trim, the “SPD” value indicates the relative arc length setting. The value of
“SPD” is meant to be a starting point at which to set the arc length relative to the wire feed
speed. Depending on the application, the “SPD” value can be adjusted to obtain the desired arc
length.
The “SPD” value displayed on the V450 may not match the actual wire feed speed!
The operation of the Arc Control knob on the V450 is similar to the Power Wave series. As Arc
Control is increased, the frequency is increased and the background reduced. Decreasing Arc
Control will reduce frequency and increase background current. Arc Control acts to fine tune the
arc plasma to the specific application. Preferred gas selections:
Steel Argon Blends = Argon with CO2 additions from 2 to 20 % or Oxygen additions
from 2 to 5%.
Stainless Argon Blends = Argon with Oxygen additions up to 2%
Stainless He Ar CO2 = ~ 90% Helium, 7 1/2 % Argon 2 1/2 CO2 Aluminum 100% Argon
.035 Nickel Alloys (Non Adaptive) 60 - 700
.045 Nickel Alloys (Non Adaptive) 60 - 600
Coments: The Nickel Alloy pulse programs are non-adaptive. The operator sets the output
control knob to deliver the correct arc length at desired wire feed speed and stick out. While
welding, the operator manipulates the stick out to maintain the correct arc length. This method of
operation produces very stable arc performance considering the nature of nickel alloys. Preferred
gas: Argon/Helium Blends = for the best results add helium to the argon base from 0-25%.
Table 3 continued

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PULSE ON PULSE
Table 4
MODE IPM*
.035 4043 (4x Pulse on Pulse) 125 - 600
3/64 4043 (4x Pulse on Pulse) 85 - 400
1/16 4043 (4x Pulse on Pulse) 65 – 315
.035 5356 (5x Pulse on Pulse) 140 - 700
3/64 5356 (5x Pulse on Pulse) 100 - 550
1/16 5356 (5x Pulse on Pulse) 75 - 360
Comments: Arc Control = Pulse on Pulse frequency.
For faster travel speed welds, the arc control should be increased. For larger puddle, slower
travel speeds, the arc control should be decreased.
LN-10/DH-10 Wire Feeder Compatibility Note:
The LN-10 and DH-10 feeders can be used to pulse weld and in the power mode with the panel.
The displays on the LN-10 & DH-10 do not show the wire feed speed or power.
9. SERIAL PORT FOR SOFTWARE UPDATES
10. HOT START and ARC CONTROL
Features have different functions depending on the welding Mode that is active. Each feature is
described under the welding mode heading. (See Item 8 or 8A for specified Mode Operations)
(See Figure B.1 or B.2)
LOWER CASE PANEL
The output studs, Meter Polarity switch and remote connector are located on the lower case
front.
11. Both Output terminals are "STUD” connectors.
12. The METER POLARITY switch is located above the output connectors. The switch
provides a work connection for wire feeder voltmeters. Place the switch in the position of the
electrode polarity indicated by the decal. The switch does not change the welding polarity.
13. 6-pinMS-style connector for remote control.
14.14-PINMS-style connector for wire and remote control.

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15. AUXILIARY POWER
• 115VAC, 42VAC and 24VAC power is available from the 14-pin MS-style connector.
• 42 VAC supply is rated at 10 amps.
• 24 VAC supply is rated at 10 amps.
• 115VAC outlet rated at 15* amps.
* Earlier models used a 10 amp circuit breaker.
REMOTE CONTROL SELECTION
The INVERTEC® V450-PRO has auto sensing of remote output controls. If after connecting or
removing a remote, the INVERTEC® V450-PRO did not configure the way you would like the
local or remote control settings can be changed by pushing the OUTPUT CONTROL or WELD
TERMINAL button. (A user cannot select between the 6 and 14 pin MS-style connectors.)
CVmodes:
• The remote will default to the 14-pin MS-style connector if a remote is connected. If no
remote is connected to the 14pin MS-style connector then the remote will default to the
6pin MS-style connector if a remote is connected to it.
• In all of the CV modes, the WELD TERMINAL control will default to REMOTE.
TIG mode
• The remote will default to the 6-pin MS-style if a remote control is connected to the 6-pin
MS-style and to the 14-pin MS-style connector. If a remote is not connected to the 6-pin
MS-style connector then the remote will default to the 14-pin MS-style connector if a
remote is connected.
• If a remote control is connected to any of the MSstyle connectors the WELD
TERMINAL control will default to REMOTE. If there are not any remote control devices
attached the WELD TERMINAL control will default to ON.
CC-Stick modes
• The remote will default to only the 6-pin MS-style connector if a remote is connected to
it.
• The WELD TERMINAL control will default to ON with or without a remote connected.
Types of Remote OUTPUT CONTROL
• The INVERTEC® V450-PRO’s Output Control can be controlled by either a
potentiometer connected between 77 & 75 with the wiper connected to 76 or a 0V to 10V
DC supply connected between 76 & 75. (76 needs to be positive)
• 14-Pin Ms-style connector lead 75 is pin G, lead 76 is pin F and lead 77 is pin E.
• 6-Pin Ms-style connector lead 75 is pin C, lead 76 is pin B and lead 77 is pin A.

of 47
Potentiometer Control
• The total resistance should be between 2000 ohms (2K) and 10,000 ohms (10K)
• The machine output will be at minimum when lead 76 (wiper) is at the end of the
potentiometer that is connected to 75. The machine’s output will increase as the wiper of
the potentiometer is moved to the end that is connected to 77. (Note: In TIG mode,
moving the lead 76 (wiper) to lead 77 would produce the current that has been set by the
INVERTEC® V450-PRO’s front panel Output Control.)
• Remotes of this type offered by Lincoln Electric are the K857, K812 and K870.
Voltage Control
• The supply should be an isolated supply. (Not referenced to earth ground, any auxiliary
power from the INVERTEC® V450-PRO or the welding output) The supply should be
capable of supplying at least 20mA.
• 0 volts supplied to 76 will set the INVERTEC® V450-PRO to minimum output for the
mode that has been selected while 10 volts supplied to 76 will set the INVERTEC®
V450-PRO to the maximum output for the mode. (Note: In TIG mode, 10 volts supplied
to lead 76 would produce the current that has been set by the INVERTEC® V450-PRO’s
front panel Output Control.)
Types of Remote WELD TERMINAL Control
• The INVERTEC® V450-PRO’s Weld Terminals can be controlled from each of the MS-
style connectors. The circuit has a nominal OCV of 15VDC and requires a dry contact
closure (less than 100 ohms) to activate the output of the INVERTEC® V450PRO.
• 14-Pin MS-style connector, the Weld Terminals is controlled from pin C (lead 2) and pin
D (lead 4). Pin C is positive.
• 6-Pin MS-style connector, the Weld Terminals are controlled from pin D (lead 2) and pin
E (lead 4). In the 6-pin MS-style connector pin D is positive.
LIMITATIONS
• The V450-Pro is not recommended for processes other than those listed.
• The V450-Pro can only be used with the recommended equipment and options.
RECOMMENDED PROCESSES
Properly equipped, the INVERTEC® V450-PRO supports GMAW-P, FCAW, SMAW, GTAW
and CAC-A processes for a variety of materials, including mild steel, stainless steel, cored wires,
and aluminum.

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Conclusions
There are many safety and standard operating procedures (SOPs) for the welding
industry. The machines in question are the Lincoln Invertec V275-S and V450-PRO. This
document brings together the main operation aspects for both machines to serve as a reference
for individuals in the industry.
The safety procedures given are applicable in any welding situation. All welding
machines will have similar if not the same safety protocol. The standard operating procedures
given are less universal. Given the type of machine being used the location or the programming
may be different. The general theory behind these operations will be similar but the practice may
not be.
Welding takes a huge role in many industries. This includes manufacturing, oil,
construction, and the list goes on. That being said, the procedures have an influence on the other
industries. Another point to make is the safety procedures will likely be similar in any industry.
If a machine is being used whether it is a welding, milling, or any other machine, there will be
safety precautions regarding electricity.
The responsibility of knowing and being familiar with the stated procedures falls onto the
individual. There is no need for memorization but familiarization is key. We must know where to
look for answers. If there is any doubt, please look into your questions. It is not worth lives to
follow through on an operation you are not familiar with.
Recommendations
We recommend that you read through SOPs such as this one to begin familiarizing
yourself with correct operating procedures in your industry. This will provide with general
knowledge on the procedures as well as refer you to more sources of information.
When reading make sure to absorb the information as much as possible. At first it helps
to focus on why the precaution may be there. Try to answer where the issue or danger originates
from. We said that there is no need to memorize. What we mean is that we do not expect you to
quote some regulation from the proper book and give the exact location in the book. We do
however, expect that you will recognize a problem when you see it. Please note that regulations
can and do change.

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Works Cited
Operator`s Manual Invertec V275-S. Cleveland: Lincoln Global, 2011. Print
Operator`s Manual Invertec V450-Pro. Cleveland: Lincoln Global, 2009. Print
Guide for the Design of a Welder Training Facility. Miami: American Welding Society, 1998.
Print
Safe Practices. Miami: American Welding Society, 1988. Print
29 CFR 1926 OSHA Construction Regulations. Davenport: Mancomm, 2015. Print

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Appendix A
Image 23
Invertec V275-S
1. POWER SWITCH
2. OUTPUT CONTROL
3. LOCAL/REMOTE SWITCH
4. MODE SWITCH
5. HOT START
6. ARC FORCE
7. OUTPUT TERMINALS
8. THERMAL SHUTDOWN
INDICATOR
9. 6-PIN REMOTE
RECEPTACLE
10.POWER LIGHT

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Appendix B
Image 24
Invertec 450-PRO

of 47
ANDREW OBENSHAIN 47
1. ON, OFF-SWITCH
2. AMPS METER
3. VOLT METER
4. OUTPUT CONTROL
5. WELD TERMINALS-REMOTE/ON
6. THERMAL
7. CONTROL-REMOTE/LOCAL
8. WELD MODE SELECT – STANDARD
9. SERIAL PORT FOR SOFTWARE UPDATES
10.HOT START and ARC CONTROL
11.“STUD CONNECTORS”
12.METER POLARITY
13.6-PIN
14.14-PIN
15.AUXILIARY POWER

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