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Up Topic Welding Industry / General Welding Discussion / Welding Cable Size?
- - By Tamper (**) Date 03-12-2009 05:02
What size cables are you guys running? I figure somewhere around 200 feet right? But what size? is it 1/0 or 2/0?
Thanks,
Chris
Parent - - By raftergwelding (*****) Date 03-12-2009 10:49
I run 100 feet on each side with 1 on the ground side and 2 on hot side with a 50ft 4/0 whip
Parent - - By 357max (***) Date 03-12-2009 15:02
Do you mean #4 whip versus the #4/0? The #4/0 will carry 200 amps through 350 - 400 feet of cable. Total 200 feet of #1/0 is good for 200 amps. 200 amps will need #1 for 50 feet. 100 amps will need #4 for 50 - 150 feet of cable according to Miller's Trailblazer owners manual. A voltmeter will tell if the cable is too small by measuring the voltage at the output connections on the machine and at the SMAW holder and work clamp. The OM says 4 volt or less drop from the machine to the arc; that's a pretty good diagnostic if the cables and connections are indeed good. FYI - if the cables get hot from resistance (due to too small cable size) - they will get hotter through use and voltage will drop more and amperage will drop and penetration may become problematic.
Parent - - By up-ten (***) Date 03-12-2009 16:47
I would hope that's what he meant because he'd sure be tired by lunch break holding a heavy whip like that. Brother in law on a 24" was having huge issues on his root pass one day. Couldn't figure it out until his cable fell out of his stinger. It was just hanging probably by a few strands of copper so, what you mentioned at the end of your post is very true. Typically,before I start a new job, I'll take connections apart and cut old tarnished cable if its needed and make sure all is well for that first day and of course every other day. Thanks for that 357max.
Parent - By fordsux8269 (**) Date 03-12-2009 16:57
I run 100' of 1/0 on both with 20' of #2 whip on the stinger side.
Parent - By 357max (***) Date 03-12-2009 18:08
I should have posted that if GMAW or FCAW is used with a constant voltage output machine; increase the cable size by one number. This is to prevent and have "NO" voltage loss from the machine to the arc. Especially important when using the voltage sensitive flux cored wires. It also keeps the inspectors from grousing about the voltage that is showing on the machines volt meter being too high from the qualified procedure to offset the losses.
Parent - By raftergwelding (*****) Date 03-13-2009 00:38
i had that happen 1 day it weled fine but the stinger got hot as hades running 5/32 5p rod and couldnt figure out why til someone told me check for loose whip and it was loose i cut a foot off and put it back together worked fine
Parent - - By raftergwelding (*****) Date 03-13-2009 00:36
i was wrong i looked today and its 2 on the ground and 1 on the hot with a 4 50' long on the stinger i was told its a 4 its about 3/ 8- 7/16 diameter i have no troubles at all
Parent - By TozziWelding (**) Date 03-13-2009 00:39
I have 2/0 all the way out on both sides, but my whip/stinger is 15' of #2 so my arm dosen't fall off.
Parent - By J Hall (***) Date 03-13-2009 03:22
75' 1/0 hot and 75' 1/0 work, with a 25' #2 whip
Up Topic Welding Industry / General Welding Discussion / Welding Cable Size?

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