Lead size?

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Just a little future planning. My welder is capable of 575A @ 50% duty cycle. Using it at that range would be very far and few between. Right now I own four 50' sections of 1/0. I like to always be as prepared as possible, so in the future I will purchase two 50' sections of heavier lead in case I want to run some big carbons.Looking at different tables, there are vast differences in the neccessary size of the leads.From the Lincoln Commander 500 owners manual: 100' would be 3/0From a Tweco ground clamp box: 100' would be 4/0From the Arcair Air Carbon Arc Guide: 100' would be 2 - 2/0'sFrom the Airgas Radnor products catalog: 4/0 would not be enough to handle 500A at 100'From a Miller Big Blue 500 Owners Manual: 100' would be 3/0So, Lincoln and Miller seem to be the same. I was hoping to get away with 3/0 because of cost and weight. Anybody have any real results from actual use?"Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:100 ft (total length) of 4/0 stranded copper at 500 amps should give you a voltage drop of 2.6 volts. 3 volts at 575 amps.That gives 1719 watts of resistance heating over that 100 ft of cable at 575 amps.  That can heat things up!100 ft of 3/0 standed copper at 500 amps should give you a voltage drop of 3.4 volts.  3.8 volts at 575 amps.That gives 2185 watts of resistance heating over that 100 ft of cable.  Again, that can heat things up!Make sure to lay out the cable and not leave it coiled (on a spool/reel OR on the ground).Oh, and those voltage drops are just from the cable resistance, and don't take into account anything else.  Like the connections to the machine or the electrode holder or the work clamp.  So you could be losing from 4-10 volts with the cable and some 'bad' connections.  Make sure all the connections are clean and good!  The best laid schemes ... Gang oft agley ...
Reply:the Tweco box says Not Recommended for lengths 200' and over... Even 4/0.But for under 2-hundy, 4/0 is obviously gonna handle anything you throw at it...Makes my #2 lead at home look silly. lol, but Im only welding pipe at 85-105 amps. I may never touch 210 amps, let alone 500!!!Lincoln Power MIG 210 MP ( boat anchor )Lincoln Weld-Pac 100 HDHobart IronMan 230Cutmaster 42Jackson NexGenSumner Ultra ClampsDWM120
Reply:yep!  every where you look , different answers.  I went thought the samething.  All I can say, if you need cables. Call http://www.trystar.com/   great price, super nice to deal with and they even put your companys name on the leads for free, lots of colors too.Good luck DayeLast edited by tigmusky; 03-22-2011 at 08:27 PM.Pound to fit, paint to match
Reply:As long as the cable are unreeled you can match the 50% duty cycle rating to your leads sense your welder is rated at 50% duty cycle. That enough current to make any grindings near your leads to dance around.Tough as nails and damn near as smart