Any benefit to using heavier leads?

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I have two sets of leads for my welder.  One is cable size 1 and the other is cable size 1/0.   Both sets are 50' work and 50' stinger.   All our machines are max 250 amps.   We have all our welders and leads set up with tweako cam quick connects.    Is there any advantage to using the heavier set as my daily use leads?  Or should I put them on my service truck where I won't have to wrestle them as much.    I also have a 40' 1/0 extension lead that goes with that set.Thermal Arc  Power-Tech 10/270  stick welderLincoln buzz-boxPurox O/A setupNothing is foolproof to a sufficiently talented fool
Reply:I would personally use the larger set. Bigger wire = less resistance and amp loss. It may not make a noticeable differance on lower settings but you should see the differance if your working near the max output!Current acts like water for the most part. If you put a garden hose on a fire hydrant you get tons of pressure but no volume. Hook op a 10" pipe and you will get as much volume as possible with less pressure.The pressure in the water hose would equal heat in a wire. So .. Bigger wire = more current with less heat.I hope that makes some kind of sense!Real welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:Your machines are max 250amps.  But what amperage are you typically welding with?  50-125 amps, only stick welding, you're probably fine with thinner leads, under 100' for the whole circuit.  For higher amps, longer duty cycle, or longer runs, I'd use the heavier leads.  If you switch to a solid wire spray transfer or flux core you should definitely consider the heavier leads.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:only if you weld for exercise.
Reply:I used to carry 150' of 2/0 ground and 150' 2/0 lead with 125'of 1/0  plus my 10 ' super flex wip. I was almost always 100' or more from the machine ,also had 150' remote , bigger is better , If you want to order wire some company will imprint your name on the wire
Reply:#2 is plenty for your needs.  I have 60' lead and 40' ground on a 250 amp Miller.  Anything heavier and you will tire sooner.  It is different with a big engine drive where you run long distances from your machine.
Reply:If you are using one 50' set, the #1 will work fine. If you need 100' of lead you connect the 1/0 lead to the #1 lead. Simple.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:I say go big as possible on the work lead since you aren't constantly handling it.My favorite one has about 15 feet of 3ga spliced to 10 feet of 4ga with a stinger on the end, does all the smaller stuff. Then for bigger stuff I have 1 and 2ga stinger leads.I like being able to swap stinger leads so I am not using a 2ga cable on a 250 amp stinger to hold a 1/8 inch electrode.But the 20ft 1ga "500amp" work clamp usually is my work clamp for everything.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:Now I feel pretty silly with my 15' 2/0 work clamp lead! I'll say it was free.