What size lead

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To run a CAC 250amp at the end of a 100ft run, what size cable ?ThanksAnything worth doing is worth doing RIGHT
Reply:I would go with #1/0.  I tried some #2 at 15' and it gets hot at 150 amps.  Welding supply told me it would carry 200 amps 50'.  They are full O crap.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I'm always afraid to go small now after burning up #1/0 cable running wire at 29.5v...  But sorry, I don't have a real answer for ya.  I know how expensive that stuff is and I know nobody wants to spend an extra hundred and fifty bucks to bump it up a size.
Reply:I was planning on going with 1/0. Can't find a chart to figure loss with so was hoping I wouldn't need 2/0...that get heavy...lolAnything worth doing is worth doing RIGHT
Reply:Called the welding supply store.  They said #1/0.  That is what they supply for all their rental equipment when the customer is running 250amps AC or DC.
Reply:Olddad,For 250A for a 200'  (100' x 2 = 200') run charts recommend 2/0.  Remember you've go to figure the "total length" of cable.  For 100' or less, same chart recommends 1 ga.There may be an easier way to look it up yourself but I got that from the chart that comes with the Miller Dialarc.If you want to print it, go to the Miller site, go to service (I think), then go to owners manuals.  Dialarc 250, page 11 has the chart.If I was smarter with the computer I could probably link it.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:I keep 100' of 1/0 on the truck for a 250amp machine, and I have never had a problem with it even when the machine is maxed.  I think you would be fine with a 1/0 cable.  Just my personal experience.  Not sure if it would be right on a chart or not.....I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:I asked the welding supply if it was suitable for heavy use and they said yes, so I don't know if they are right or Miller.  Miller may just want to cover their *** from lawsuit in case someone has a slightly damaged lead and somebody is injured as a result of it electrocuting someone or causing a fire.Plus, the welding shop naturally would want to sell the more expensive leads, but they said #1/0.  So I don't think they would offer something less when they could make the big money on #2/0.
Reply:To do a calculation you need a voltage.  Do you know what voltage you will be at?Me!
Reply:Stick welding is about 32 volts across the arc.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I'll just go with the 1/0. I've always used that but wanted reassurance I'd be covered at that distance. Jackson earns his beans off that truck, if it works for him I shouldn't have any problem. Thank you all.Anything worth doing is worth doing RIGHT
Reply:You might be able to get away with the 1/0 if you keep duty cycles low. If you start pushing higher duty cycles you are going to heat up the cables and increase the resistance of the cables, this will cause you to drop voltage. This will make your power source have to put out more voltage at the studs to try and maintain the same current at the arc. In the end you will be pulling more kilowatts of the machine. If you are looking at 200 feet in the whole welding circuit (100 ft lead + 100 ft ground) a 2/0 will handle it up to 60% duty cycle.Also consider that when gouging you are using high voltages, make sure that your machine has an OCV high enough to compensate for voltage loss and voltages at the arc.Last edited by reddoggoose; 08-21-2007 at 10:32 AM.Arguing with a Welding Engineer is like wrestling with a pig... after a while you realize the pig likes it
Reply:I have 2/0 for everything, except for my stick whip with stinger on it. That is 1 or 1/0 to keep it light.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:Hey Olddad,Our pipeline weldors all have 2/0 with the 1/0 whips on the stingers.  That is easy to do since the money is not coming out of their pockets.  I think if I were you, I would go with 2/0 to keep the heat down as mentioned.  I know copper is extremely high, but I would hate to see you have to upgrade because it wasn't adequate.  Although, I'm sure you could unload 200 ft of 1/0 pretty fast with minimal loss if needed.As mentioned it also depends on your amperage and duty cycle.  I have seen (and got to grind) our weldors run beads for 8 hours straight on hot taps and sleeves.This probably doesn't help your decision and its your money and not mine.  Just thought I would throw my 2 cents in.Thanks,JasonMillermatic 210 w/ SpoolgunMiller 375 ExtremeMiller Trailblazer 250GMiller AEAD 200-LEVictor Journeyman O/A
Reply:Not trying to argue, but rather than trying to cover their butts, I suspect Miller is trying to insure that their customers obtain maximum performance from their welding machines.As in a chain, a welding system is only as good as it's weakest link.Only the welder can determine where he's going to be running his machine and what kind of duty cycle it will be subjected to.  Wire to me is like machines--you can't use amps you didn't buy.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:Well, as I said, this will be for a CAC run to my hard-wired Lincoln. A new possibility has arisen and West Baden Iron stated what I'd need if I go that route. SO, I'll go ahead and get the 2/0 and if I have need to run a stinger later I'll just make up a 1/0 20 ft quick-connect pigtail to hook to the 2/0.Anything worth doing is worth doing RIGHT