leads and whips

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hi,allI got a new miller bobcat 225 .  looking to get some leads, 50' a side for now the master plan would be 100' a side with 2 whips. I looked at a bunch of charts and no two are the same.  so I'm running with what the miller manual shows.  200' @200 amps 1/0 .  does that sound about right.  If I got 2 15' foot whips would 4 be ok??  what about this UltraFlex Orange cable. good idea for whips?  welding supply looks to have the best prices. heres the shopping list.30'   #4 Welding Cable  Orange 100' 1/0 Welding Cable Yellow 2   Tweco Terminals 45* for the machine1   GC-300 Amp Hi Copper Ground Clamp (Tweco) 2   Tweco 1-MPC Complete Set Cable Connectors 1   Tweco A-316 250A Electrode Holder any input would be very appreciatied.   dos or don'ts  whip length, UltraFlex, where to buy?thanks, Daye
Reply:I have 200 feet of 1/0 on my machine and my whips are 1 guage for 200 amps I would probably go with at least a 2 guage but maybe some one will correct me. I have heated up my cords before on my old bobcat gouging so spend the extra money and don't have to worry about it. I have ultra flexs for my whips and not on my leads and you can really tell the difference. THe ultra is like a extension cord when you go to wind them up and the regular leads are like a frozen garden hose. The list looks but are you doing lugs from the machine to the 1/0 lead or are you going to have a quick connect from there to the leads and another quick connect at the whips?Vantage 300 kubota ,miller 304 xmt ,lincoln ln 25 pro , ranger 305 G, plenty of other tools of the trade to make the sparks fly.
Reply:If you buy 50' a side now - what will you do when you decide to put on 100' a side?I don't like the idea of buying cables that are not the right length (you said you wanted 100') then splicing them.....Good luck man
Reply:I was thinking about these Cable Connector Socket  every 50' and than the 45* Cable Connector Socket on the machine.Daye Attached Images Attached ImagesTWmanarc.pdf (91.3 KB, 39 views)
Reply:Originally Posted by tigmuskyI was thinking about these Cable Connector Socket  every 50' and than the 45* Cable Connector Socket on the machine.Daye
Reply:Tigmusky, I did the same as you are wanting. I have four 50' lenghts of 1/0. I don't always need 100' so why carry them. I use the Tweco MPC2 connectors, they are more common by me. Also I wrap a couple inches of red electrical tape around two of the leads. This is so if I am switching ground clamps or from a stinger to a wire feeder, I don't have to trace the cables. "No tape" always goes to the work piece. You don't need a long whip on your ground clamp, just use a foot or two of the 1/0. The smaller whip is just for the stinger so your hand is not fighting the heavier cable and thats the area which will get the most abuse. I don't want to cut off parts of the 50'ers. ten to fifteen foot of whip is plenty."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:I have Lenco quick connects on my cables.  Lenco, and probably the others make those quick connects with different colored covers.  I have red and black quick connects, and red and black cables.  You can also get your cables jacketed in any color you want.  Trystar makes and excellent welding cable, here in the USA.  Not the cheapest stuff you can buy but double jacketed and guaranteed flexible down to -75C(where I'd never be welding anyway).  I got a sample from them and they printed my name on the cable every foot.  Nice for keeping your leads seperated from the crowd.I have a few 50' lengths, a set of 25' lengths, and a set of 10' whips for stinger and ground clamp.  Stinger is #1 cable, but ground clamp is still 1/0.  1/0 cable 100' out and back will be ok as long as you're running stick, under 200 amps.  Chances are the time you spend chipping slag and wire brushing will be more than enough to allow the cable to cool down.  Pay more attention to your cables if you're going to be running wire or gouging, where the cables don't get time to cool down.I've heard a few people swear by coating the cable connections with Koprshield.  Stuff's not cheap but it's supposed to prevent oxidation and increased resistance at connections.  I haven't bought any yet because I haven't had a problem with leads overheating.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:thanks guys,I put an order in at welding supply for some of the stuff.  not overly helpful.  I'll wait to get the stuff before I bash em.Daye
Reply:yep!  welding supply = ahole.  great prices ,but you don't want to talk to the sales people.  talk about junkyard dogs.On the other hand, this place Trystar cables out of Fairbault MN. Was A+ top notch.  This guy ( don't recall his name)  Super helpful. I got cables (any color and my name on them) connectors , ground clamp and stinger with Free shipping .  I highly recommend this place.  They also sell on E-bay.I think they would of assembled them, but I said that I wanted to.  Heres a few picsDaye Attached ImagesLast edited by tigmusky; 01-27-2011 at 09:41 PM.
Reply:Your embossed name looks like a brand name.  If one didn't know any better . . . Good move on the anti-sieze on the set screws.  Odd size if you have to drill them out and you'll thank yourself in a couple years if you need to take them apart.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55Your embossed name looks like a brand name.  If one didn't know any better . . . Good move on the anti-sieze on the set screws.  Odd size if you have to drill them out and you'll thank yourself in a couple years if you need to take them apart.
Reply:Are you going to list what you bought and the prices? It would be nice to have for reference."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:Originally Posted by Stick-manAre you going to list what you bought and the prices? It would be nice to have for reference.
Reply:Thanks for posting the invoice from your trystar order.  The cable prices are actually less than I'd have guessed.  I haven't ordered from them yet, but I did meet with some Trystar folks at Fabtech.  They sent me a sample of cable that impressed the hell out of me. Originally Posted by tigmuskyhere ya go
Reply:Instead of color coating my leads to reduce the mix up between hot and ground, I simply flip flopped the twist quick connects making the hot cable the female to reduce any unwanted arc striking. I bought a 250' spool for $560.00 last spring.I like the name printed on the leads.
Reply:I was looking for the proper size cable and discovered different charts can say very different things.http://www.pacificcabling.com/Specia...rage_chart.htmLincolin Power Wave 450, Lincoln Powermig 255, Lincoln Pro Mig 140, Lincoln Squarewave Tig 275, Miller Big 40 G(with Hobart Hefty suitcase), Thermal Arc 95S and Esab PCM875 in an already full machine shop.
Reply:I would guess that those charts are all dependent on the duty cycle used in the calculations.  Charts made using the assumption of 100% duty cycle will show a need for much heavier cables for any given length of run.Tables based on 60% duty cycle (or less) will say you need a lot less cable as they allow time for heat to dissipate.That's my guess anyway.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Originally Posted by tigmuskyyep!  welding supply = ahole.  great prices ,but you don't want to talk to the sales people.  talk about junkyard dogs.On the other hand, this place Trystar cables out of Fairbault MN. Was A+ top notch.  This guy ( don't recall his name)  Super helpful. I got cables (any color and my name on them) connectors , ground clamp and stinger with Free shipping .  I highly recommend this place.  They also sell on E-bay.I think they would of assembled them, but I said that I wanted to.  Heres a few picsDaye