Help selecting lead size

admin

I am looking for some real world advice on selecting lead size. These will be for a 300 amp stick welder and the leads will be around 100 feet total (60' stinger / 40' ground). While my machine is 300 amps I don't think I have ever used over 200 amps and really the vast majority of my work is under 150 amps. I have looked at several charts and see different recommendations from 2 to 1 to 1/0. Just wondering what I need. Obviously the smaller wire is cheaper and easier to handle but I don't want to limit my capabilities of my machine.
Reply:Make them 50ft lengths with twist locks at the ends that way in the future you can add more length as needed. Go with 1/0
Reply:Welcome Aboard,Just as you cant be too rich or too good looking, cables can't be too heavy a gauge.Yes, heavy wire costs more; but every thing in my life is a compromise.Many choose to use the fat wire, with a lighter gauge Whip at the end.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:Originally Posted by Firemanmike69Make them 50ft lengths with twist locks at the ends that way in the future you can add more length as needed. Go with 1/0
Reply:1/0 it is then. Is that flexible orange cable worth the extra cost? It is about 25 cents more a foot or $25 for my 100' of lead.Last edited by Drilldo; 02-02-2014 at 08:17 PM.
Reply:I don't think so ,at least not for your main cable. I would use the 1-0 with LC40 connecters on each end and then a 10 foot ground of 1-0 with a 300 amp clamp and then 15-25 feet of number 1 cable with a 250 amp electrode holder.Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.