Welder leads

[Anonymous-0]

Well like usual I cant find the info elsewhere so I am turning to you kind folks. I have a Lincoln AC/DC (250 v) welder and it seems like the leads are never as long as I need them. Much as I would like one, a truck mounted Generator/Welder is not in the cards. How long can I make the leads without to much drop (causing heat) in the leads? Thanks, Bob

 

[wayne2]

Comes to mind my ol fab guy I think had two extra lines scabed on the hot one at joints looked scary-thats when we left him alone-he was usually p_ssed-next day was always bettar-I miss that ol Boy. Wayne

 

[Anonymous-0]

Forgot to mention that this one is wired in, not plug in so harder to "extend" length as needed.

 

[RAB]

Are we talking welding leads or the supply leads? Either way, if you double the cross sectional area you can double the length with the same power loss. So if you double the diameter of the conductor you can go four times the current with the same power loss. When you can't lift the electrode holder you will wonder whether it was all worth it!
Now, don't you turn up the welder if the power is down? If you just double the length of your present leads and double the amount of heat lost in the leads it will be dissipated over twice the length, so should not get any hotter. Remember power loss is I*I*R, so is proportional to the resistance (R) where I is the current you are using for welding. Soooo, as long as your welding leads do not overheat at full current, they will not overheat if longer - just your maximum current will be less. Therefore not a problem. Just don't coil up the leads when you don't need the extra reach! Simple really but remember as temperature rises so does the resistance (in most materials), so if used for extended periods continuously, some leads are barely big enough for the job in the first place. You could also consider changing conductor material in your leads if appropriate.
RAB

 

[pork]

RAB is correct in his reply, however, ill add a little more to it. i run a fab shop and portable welding service. with "one-aut"(1-0) cable you should be able to reach any job. ive connected as much as 250 feet without any considerable power loss. if your welding with one-eighth rods youll be fine. i purchace welding lead in 50 or 100 feet sections and use quick-connects to add on as needed. this also makes it easy to move cable to another welder without having to drag all the cable around. as far as the weight issue, he's right there to, however most iron workers and field welders(myself included) use an electrode whip thats about 10-12 feet long.this section of cable can be a couple of sizes smaller to cut down on weigh. put a quick connect on the end and it will slip on any cable you have. make sure the end of all cable toward the work is the female end so if the welder is running while youre adding more cable, it wont ground out.

 

[wayne2]

Cut the lines!!!

 

[Anonymous-0]

You can run leads a long way. There are charts on most welder sites that tell the size needed for different lengths. You may have to turn up your amps a little to compensate for the longer leads but on big construction projects 500 foot cables aren't uncommon. Dave

 

[Mike Van]

Bob, I"ve got the same welder - Years ago I put 50" of 1/0 wire on for the electrode holder & close to that for the ground. It works fine, I took mine apart and did the wiring right where I took the #2 out. I can"t remember if there were spades crimped on the ends or what? For 1/0 you can make your own spades from 1/2" copper tube, solder them on, flaten the end & drill a 3/8" hole & there"s the spade. The wire is not cheap.