Cable Size

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I'm having trouble determining which weld cable size I would need for 12' leads, 300amps at 100% duty cycle? I'm not exactly sure what goes into the equation to figure everything out.
Reply:Wow, that's heavy duty power!With 100% duty cycle and leads that short, there is no equation.My tables for single conductor wire, continuous current suggest:- 3/0 is good for 260 - 310 amps, depending upon whose value you accept- 4/0 is good for 300 - 360 amps, depending upon whose value you acceptSo, to be good to go, it looks like 4/0 may be your best bet.I'm not an electrician, so don't hold me to those values... but that summarizes what I was able to find from various wire & cable manufacturers.Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:As short as the leads are I wouldn't be afraid of 2/0 leads. And who's going to be running that 100% of the time.  Even robot welding has breaks for parts to move and repositioning. If you're burning rod I'd say you're going to have to be busting your hump to exceed 70% arc time. Changing rods, chipping slag, repositioning all count as cooling time.Tough as nails and damn near as smart
Reply:The problem im facing is that i dont need i don't need 100ft plus leads, and everything over 12' just seems just unnecessary for welding out of a garage in close proximity to the work piece but i still want to be able to utilize the machine to its fullest capabilities (tb302). I don't know whats considered the norm as far as length but maybe i'll be better off finding something in the middle and use a smaller size cable.
Reply:Go to a longer lead length and leave it out of the way of grinder crap and stuff. My leads are 50 ft and my machine NEVER moves.Miller thunderbolt 250Decastar 135ERecovering tool-o-holic ESAB OAI have been interested or involved in Electrical, Fire Alarm, Auto, Marine, Welding, Electronics ETC to name a just a few. So YES you can own too many tools.
Reply:Take a look at this.http://www.pacificcabling.com/Specia...rage_chart.htmRemember when the table says 100', it means 50' of stinger and 50' of work clamp cable combined, not 100' of each. It's listing 1/0 for 100' @ 300 amps, and shorter I'd bet you could go even smaller. Also unless you are doing some serious heavy welding or gouging, I doubt you'd ever max out that TB. Most usually run 1/8" rod, maybe 5/32". If you are running 1/4" rods, I'd like to see picts of the project!.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:I would get 50' and cut it 30' for the electrode and 20' for the ground.  2/0 should be more than enough.  I don't know what you will weld that you need 300 amps, and the other posters are correct about the 100%
Reply:I don't know who here has actually welded, but a 12' 4/0 cable????? or even a 2/0, that is ridiculously huge for 12'. Point #1, if you are asking about cable size then I can nigh guarantee you that you will NOT be welding at 300 amps! You will likely be welding at at 75 to 150 amps most all the time. I use two whips that are 10 - 15 foot long with my stinger and work clamp on them, they are a #1 cable and work fine for all welding. If I am welding at higher amps they will warm up a bit. If I was welding at 300 amps I might upsize them a bit. The reason to use a light cable on the end o fyour leads is because it is easier to handle and you get less fatigued. If anyone s welding with a 4/0 cable then they are going to have arms like a gorilla after a week. Just get a couple of 15' pieces of #1 and you will be totally fine.
Reply:I'll agree with that. When i suggested 2/0 I didn't know what he was doing and I did go overboard. He might have been setting up for a production line or hobby use. you never know.Tough as nails and damn near as smart
Reply:Typical... not enough information given in the original post."which weld cable size I would need for 12' leads, 300amps at 100% duty cycle?"I read that to mean, running 300 amps continuous - all the time, like in robotic welding of spiral welded pipe.  For that, you do need 3/0 to 4/0 as the tables say.Now it turns out this is ordinarly stick welding (with rod changes) "out of a garage" and the poster "want to be able to utilize the machine to its fullest capabilities (tb302)". Interpretation = I will be welding at 120 amps most the time and rarely I might want to run 300 amps. Different Story = Different Answer!I think #1 or 1/0 would be just fine.Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Originally Posted by walkerI don't know who here has actually welded, but a 12' 4/0 cable????? or even a 2/0, that is ridiculously huge for 12'. Point #1, if you are asking about cable size then I can nigh guarantee you that you will NOT be welding at 300 amps! You will likely be welding at at 75 to 150 amps most all the time. I use two whips that are 10 - 15 foot long with my stinger and work clamp on them, they are a #1 cable and work fine for all welding. If I am welding at higher amps they will warm up a bit. If I was welding at 300 amps I might upsize them a bit. The reason to use a light cable on the end o fyour leads is because it is easier to handle and you get less fatigued. If anyone s welding with a 4/0 cable then they are going to have arms like a gorilla after a week. Just get a couple of 15' pieces of #1 and you will be totally fine.
Reply:I run 2/0 all the way out(over 500') and my 15' stinger lead is #1 to keep my arm from falling off.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:thanks for all the replys guys, even though it might of been a dumb question.
Reply:It wasn't a dumb question royalblue302... it might have beeen worded a mite clearer, that's all.For our part, maybe we should have asked for the application before providing answers.Never feel reluctant to ask a question here... after you can't find the answer in a Goggle and WeldingWeb search.  This site exists to help people... who ask questions! Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Not a dumb question.  And you've got a great machine.  On my TB302 I run 1/0 all the way, but I only carry 220' on the truck (in (4) 50' segments and (2) 10-footers) as opposed to Tozzi, and 100' of that is almost never in the loop.  150A is the most I run with that machine.  I do have about 200' of 4/0 which came with the SAM 400.  If I HAVE to, I'll use it.With an engine-driven welder, you'll probably end up wanting more lead soon anyway, so you can use your mobility to its best advantage.  Since I'm glad to spend your money for you, I'd buy 140' of whatever size lead you decide on.  I'd put 3 large Tweco QD receptacles on the welder and I'd chop the lead into 4 sections - (2) 20 footers and (2) 50 footers.  The 20 footers would be a work lead whip and a stinger whip, with Tweco large male QD's on the other ends.  Then I'd make the (2) 50 footers into extension leads, with male and female large Tweco QD's on the ends.  If I couldn't swing the cost of the (2) 50 footers right now, I'd buy one 50' and use it for the stinger, and one 20' and use it for the work clamp.  Then add in my other 50' and 20' with associated QD's when I could afford it.
Reply:one more question here, im looking at buying the suitcase x-treme 12vs wire feeder and it says recommended distance between feeder and power source is 400' (cable length)! So just to clarify than im supposed to buy 400' of cable just for that seems ridiculous to me?
Reply:I would take that to mean the maximum distance from the power source is 400'(200 out and 200 back).
Reply:Ya that makes more sense thanks,
Reply:NOT a dumb question (questions).  Maybe.But surely one that shows the OP has done ABSOLUTELY no homework on his own.If he approaches the rest of his "welding learning curve" in the same manner, he's going to have a long, uphill battle.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Originally Posted by TozziWeldingI run 2/0 all the way out(over 500') and my 15' stinger lead is #1 to keep my arm from falling off.
Reply:Originally Posted by vwguy3I would take that to mean the maximum distance from the power source is 400'(200 out and 200 back).
Reply:Originally Posted by Stick-man....On my want list is two 50' sections of 4/0.
Reply:HERE is a site with cable specs.Chart at the bottom of the page.
Reply:Originally Posted by tbone550I'll be locking the shop tonight.
Reply:Straight from the TB302 owners manual:  100ft or less, 60 to 100% duty cycle, 300 amps = 1/0That's 100ft total cable length in the weld circuit.RTFM!Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LEOriginally Posted by Stick-mantbone, quit tellin stories. I lent you that 4/0 awhile ago for that kanutin plant refit job. I'll be by to pick em up this weekend. Make sure the beer is cold!!!
Reply:Originally Posted by tbone550Be sure to bring back my nearly complete Snap-On tool set which I lent you to change your muffler bearings!