Welding Cable length / size

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I am looking to run some long welding cable. Each lead will be UP TO 250' a side. I plan on using variable lengths like 2-100' and 1-50' to allow for projects at varying lengths. I need to know how big of a wire I could use. The MAX rating on my machine is 225amps but I won't be welding that high often. And when I do, it won't be for very long at all.
Reply:I definately wouldn't use anything smaller than 2/0 for that long a run.The cable sizing charts for my machines say 400' total cable run at 200 amps = 4/0 cable size.  That is as far out as the charts cover.  Charts are included in most Miller welding machine owner's manuals.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Originally Posted by DesertRider33I definately wouldn't use anything smaller than 2/0 for that long a run.The cable sizing charts for my machines say 400' total cable run at 200 amps = 4/0 cable size.  That is as far out as the charts cover.  Charts are included in most Miller welding machine owner's manuals.
Reply:Originally Posted by FranciscoJI am looking to run some long welding cable. Each lead will be UP TO 250' a side. I plan on using variable lengths like 2-100' and 1-50' to allow for projects at varying lengths. I need to know how big of a wire I could use. The MAX rating on my machine is 225amps but I won't be welding that high often. And when I do, it won't be for very long at all.
Reply:If the price of 500' of 2/0 -4/0 wire doesn't make find a way of moving your welder dragging that much cable around will.Tough as nails and damn near as smart
Reply:Originally Posted by tresiIf the price of 500' of 2/0 -4/0 wire doesn't make find a way of moving your welder dragging that much cable around will.
Reply:It's not so much moving it closer. I was talking to a friend (who is a certified welder) and he said even 150' on each lead isn't enough for what he does. I just thought buying in bulk now would help.
Reply:I have had to run 500'+ of welding lead.  after i got it all strung out i was practically to tired to weld.   Thank god i have have a helper now a days.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:I really gave thought to everyone around here. I decided to go with 200' (100' a side) of 3/0 cable. This would allow me to push my welder to the max. If I need to get closer I will just move the welder. And in time if I need to extend the leads, I already have 3/0.