Mixing #1 and 2/0 welding cable

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I currently have 25' of #1 welding lead I've been using off of my Ranger 250gxt.  I just acquired 200' of 2/0 cable in 100' sections. I was wonder where it would be best to put my current #1 cable. I wanted to cut that stuff up to connect my Ranger to my lead reels and keep the 100' sections in tact. I have yet to use a rod over 1/8". I might in the future step it up one size and run a 5/32. Would it make a difference if I put the #1 on the machine to reel side or on the stinger side? If it's gonna cause extra resistance on the machine to stinger side I'll just buy a couple feet of 2/0 to run it that to my reels instead. Thanks in advance for any information.Lone Star Mobile Welding, LLC2006 Ram 3500Lincoln Ranger 250GXTHypertherm 30 AirK2000 CAG ESAB Rebel 215ic Milwaukee mag drillDewalt dry cut sawMilwaukee metal cutting circular sawMilwaukee M18 Fuel Chisholm Lead Reels
Reply:Its all about resistance, if you put the thinner cable on the machine end then your gonna have increased resistance from machine to stinger. Always put it from heaviest to lightest gauge from machine to stinger. This way the 1 gauge is only having more resistance at the very end. The 1 I'd keep for the stinger so you have more control and less weight on the stringer.  Alot of people use 2-4 gauge on the stinger for this purpose.
Reply:Originally Posted by iongarIts all about resistance, if you put the thinner cable on the machine end then your gonna have increased resistance from machine to stinger. Always put it from heaviest to lightest gauge from machine to stinger. This way the 1 gauge is only having more resistance at the very end. The 1 I'd keep for the stinger so you have more control and less weight on the stringer.  Alot of people use 2-4 gauge on the stinger for this purpose.
Reply:I've done close to the same on my machine, but 125' leads of 2/0AWG from the machine, then another 20' of 1AWG to the stinger. I have "Jackson" twist connectors so connections are quick and easy. I did this setup as I plan to attempt to short cycle air arc with my machine yet I, like you, only use 1/8" welding rod most times. Added resistance at a given current draw results in rapid heating of the conductors. Larger cable has less resistance per circular mil than smaller cable of the same composition.SlobPurveyor of intimate unparalleled knowledge of nothing about everything.Oh yeah, also an unabashed internet "Troll" too.....
Reply:Originally Posted by iongarIts all about resistance, if you put the thinner cable on the machine end then your gonna have increased resistance from machine to stinger. Always put it from heaviest to lightest gauge from machine to stinger. This way the 1 gauge is only having more resistance at the very end. The 1 I'd keep for the stinger so you have more control and less weight on the stringer.  Alot of people use 2-4 gauge on the stinger for this purpose.
Reply:Originally Posted by Welder DaveSeveral years ago I was involved in an argument on this topic on another forum. I was saying the smaller cable goes after the bigger cable and the electrical guys got into a big frenzy and said it makes no difference electrically where the smaller cable goes because it's all the same circuit. It doesn't matter if the resistance is at the machine or the stinger it's the same in the overall circuit. Apparently the heat generated from the arc back to the cable makes no difference. The reason to use smaller cable at the stinger is because it's lighter and easier to handle.
Reply:I tried to argue that you'd lose voltage/current right of the bat by having the smaller cable at the machine but they weren't hearing any of it. It got to calling me all kinds of names but in practice you never see smaller extension cables put on ahead of larger ones.
Reply:Originally Posted by Welder DaveI tried to argue that you'd lose voltage/current right of the bat by having the smaller cable at the machine but they weren't hearing any of it. It got to calling me all kinds of names but in practice you never see smaller extension cables put on ahead of larger ones.
Reply:They might say its wrong but my csa/aws textbook begs to differ.
Reply:Why not keep the 2/0 for a work lead...   Keep a nice length of #1 for a stinger extension on the end of your 2/0 using a Tweco jack.     2/0 on a stinger is a lot of weight to hold when your poking around with a only 3/32" rod.
Reply:Originally Posted by BilldacatWhy not keep the 2/0 for a work lead...   Keep a nice length of #1 for a stinger extension on the end of your 2/0 using a Tweco jack.     2/0 on a stinger is a lot of weight to hold when your poking around with a only 3/32" rod.
Reply:Its hard to explane it to some people so I have found its not worth the efiert some times.This is the way I tell it and hope it helps people under stand.You can run 230 volts through 22 gauge wire(very small) as well as 000 size wire (very large)You can only run 2 amps through the 22 gauge wire but 500 amps through the 000www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:Although I don't see the electrical sense in it, I have been told by experienced welders that considerably more current ends up going through the ground cable.  In theory this doesn't seem like it could be true, but they insisted in a welding environment it was the case. So I know they would put the heavy cable on the ground with a good connection.  Electrical law say's current is the same anywhere in a circuit, but I thought I would pass it on.
Reply:Yes put something smaller connected to the stinger.I don't know how moveable a big stinger connected to 1 gauge wire or bigger would be. I wouldn't want to find out.For the work lead, just use the heavy stuff, since you can clamp it and forget it and wont have to worry about it heating up so much.old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:Originally Posted by mad welder 4Yes put something smaller connected to the stinger.I don't know how moveable a big stinger connected to 1 gauge wire or bigger would be. I wouldn't want to find out.For the work lead, just use the heavy stuff, since you can clamp it and forget it and wont have to worry about it heating up so much.
Reply:Originally Posted by BilldacatWhy not keep the 2/0 for a work lead...   Keep a nice length of #1 for a stinger extension on the end of your 2/0 using a Tweco jack.     2/0 on a stinger is a lot of weight to hold when your poking around with a only 3/32" rod.
Reply:It might depend on polarity but generally other than the stinger, you run the same size cable for both leads. A good ground on the work is imperative though.