Correct Cable for Welder

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I have a hobart 140amp DC generator welder with 100% duty cycle.  I'm trying to extend the leads, since I got this unit used I'm not sure if it has the original leads.  The charts say for up to 150 amp DC no further then 50' you can use #6 awg, but that's only with 30% duty cycle.Do you think I'm still safe with #6 or should I go one step thicker?  I'm not a pro welder but I also don't want to cause problems by choosing a wire that's too thin.Thanks,Matt
Reply:None of the charts I looked at even listed #6. Smallest listed was #4 and it was listed at 100 ft for 150 amps. Remember these charts assume total length, that's both ground and stinger, so 100ft of cable is 2 50 ft runs. http://www.iewc.com/~/media/Files/PD...Ampacities.pdfCable size gets larger the longer the runs need to be. 150 amps at 400 ft is 3/0 cable for example. many guys use the heavier cable to extend the light gauge leads. That lets them use an easy flexible stinger and ground of light gauge cable and use the heavy stuff for the long runs when needed. They simply use quick connects to hook it all up..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Sounds good, I should definitely be safe with #3.  I was looking at this lincoln chart:http://www.lincolnelectric.com/en-us...ng-cables.aspxIt's the last chart at the very bottom.  It says (unless I'm reading it wrong) 150 A at 40% duty cycle less then 50ft is #6 - You would not need #3 until you exceeded 100ft.#6 is obviously much cheaper but if #3 makes more sense I'll go with that.  The welder as I received it has #6 already on it.Matt
Reply:2 gauge, $1.07 per foot plus shipping,  4 gauge is .73 per foot:https://www.facebook.com/pages/Elect...22082121139733"USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Wow, I wish it was that cheap here in Canada.
Reply:The correct size cable for your needs may be determined not by your current needs but rather by your future needs. If you think you will be needing longer/ larger leads in the future it may be foolish to not buy them now instead of buying small/ short leads now and having to purchase larger/ longer leads later. The only down side to longer/ larger leads are the up front cost and the weight if you have to carry them very far. If you upgrade machines at a later date just keep your larger/ longer leads. Also remember that lead prices never seem to go down. I don't know about shipping but Electron Beam Technology in Illinois has smoking hot prices on lead and weekly sales. Hope this helps.