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Hi woodache, I owned one of those a few years ago. I don't remember it being 250 amps, though. I think the one I had was 240 (AC) and I can't remember what the DC went up to, so maybe it was a different model. Isn't yours a graduated amperage welder (you turn a crank or slide a lever to set the amperage, rather than clicking on fixed settings?) If so, you have a lot more than a 20% duty cycle at all but the highest settings---which you are unlikely to use much, if at all. A welder like that often indicates the 100% duty cycle range on the face of the machine. This will be around 100 amps AC and 70 amps DC (and all lower settings, of course.) My understanding is that the factor which limits the duty cycle is the heat generated by the electronics. In a machine with an infinitely adjustable amperage setting system, the same internal conductors carry the current at every setting. Because less heat if generated at lower settings than higher ones, higher duty cycles are possible for lower settings. The reason Lincoln buzzbox welders have a 20% duty cycle at every setting is because they use different sized internal conductors for each individual amperage the transformer is tapped for. All the best, Stan
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