Longer cables on Lincoln welder?

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I have a Lincoln square wave 175 that is tig and stick. I would like to replace the small short welding leads (#4) with some larger cables about 40 feet long for my stick welding. Is there a problem with this?Dale
Reply:I would go with #2.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I think what he was saying  was that the original cables were #4. Not that he was going to replace them with #4.No there should not be a problem
Reply:My point, #4 is pretty small for 175 amps once you go beyond 50' 40+40=80'DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:when you have a longer lead you will encounter a voltage drop, so you might have to set the welder a few amps higher than you normally would.Go hot, or go home!
Reply:In addition to calculating the voltage drop at given cable lengths--as already mentioned;remember you're dealing with an upwards of maybe only 30 volts. The lower thevoltage the more effect voltage drop can have.It is most helpful to verify that the selected, new cable strand bundle will fit inside theintended connectors--without cutting strands.......been there, dun' that.Anymore, for fitting or re-attaching cables, I tightly compress the copper strands, thenrosin core, sweat solder the ends, immediately cooling with water to save melting thecable covering. This really helps to prevent cable pullout from the connectors and improvesconductivity.      Prior to inserting this soldered, trimmed end into the connector (usually Tweco's or variationthereof), I coat the recess of the connector with copper based conductive grease (Thomas & Betts--Koppershield--available from electrical contractor supply). Doing this stops heat oxidation of the copper, which then creates more and more resistanceduring use. One noticeable effect is HOT WELD LEADS, when they appear to be properly sized.I also coat the male and female connections of the disconnect with the same copper grease,since they're completely shielded from outside grit, by their construction and the heavy rubbercovers.Last edited by dave powelson; 04-28-2009 at 05:42 PM.Reason: added commentBlackbird
Reply:Check out the chart.  (From the Bible as always)One thing to consider is the machine duty cycle compared to the amount of time you will actually welding.On a 100% duty cycle machine, you can get by with smaller cables rated at the amps you normally weld, if YOUR duty cycle (Actual time that you actually intend to weld) is less than the machine's duty cycle.Also remember that most cable sizing charts are TOTAL LENGTH OF LEADS.  STINGER LEAD PLUS WORK LEAD.  40 foot leads, as most people think of them, is simply 40 feet from the machine.  The leads are actually 80 feet long for sizing purposes.  Out and back is the total length Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Go to a heavier cable, and Let 'Er Rip....I use a Lincoln PowerMig 350MP at work with Shell-Ryn Cable Reels, and over 200' or #2/0 Cable and everything works just fine for SMAW and CAC-A.I use a PTA 26FV Tig torch and a seperate 20' #2/0 work lead (ground) cable because I am DCEN for Carbon and Stainless Steel.No reason something similiar shouldn't work for you.Later,Jason
Reply:also consider that if you want 40 feet now you will certainly want 75 or 100 soon enough...