Ground Cable Size

admin

I need to replace the ground cable on a Lincoln 255.  Max output is 300 amps at about 20% duty cycle.  I have pulled all the charts I can find on welding cable size.  Most assume either 60%-100% duty cycle and have 50-100ft as the smallest length.  What size cable would you use for a 15ft ground?  I was thinking 1 AWG.
Reply:The more the merrier!!...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Here's a decent page: http://www.powerstream.com/Wire_Size.htm1 gauge is fine. 1/0 will be a little better but it's more important to have good contact with the ground clamp.
Reply:Thanks guys.  I ordered some 1/0 AWG.Lincoln Powermig 255Hypertherm Powermax 45Thermal Arc 161SOxweld 24R OA TorchStill Looking for an Old Round Top Idealarc 250
Reply:You probably know this already but WTH.  Connecting the cable is important.  Strip the ends carefully.  Don't nick/cut the outer strands.  Clean the ends really well.  I like to use a solvent, acetone is good (I also use a conduction enhancer but I'm crazy).  I like to use a strain relief at the connection like one or two layers of heatshrink tubing.  If you are crimping on a ring terminal, do a good crimp.  If you have a compression screw terminal  I like to find some copper tubing that the cable will just fit in and then crank the hell out of the screw.  The tubing prevents the screw from tearing up the strands.  The goal is to crush all the strands together so tightly that air (oxygen) can not penetrate into the strands and cause oxidation/corrosion.Do not solder/braze/weld the cable ends.  This will actually weaken the connection (well, you could do this but you would really have to engineer the connection and it would be more trouble than it's worth.  Trust me on this!).
Reply:Originally Posted by solidstateDo not solder/braze/weld the cable ends.  This will actually weaken the connection (well, you could do this but you would really have to engineer the connection and it would be more trouble than it's worth.  Trust me on this!).
Reply:Is this the crimping tool that you guys are talking about:http://www.weldingcable.us/LENCO-Swe...Tool_p_27.htmlLincoln Powermig 255Hypertherm Powermax 45Thermal Arc 161SOxweld 24R OA TorchStill Looking for an Old Round Top Idealarc 250
Reply:Originally Posted by morgaj1Is this the crimping tool that you guys are talking about:http://www.weldingcable.us/LENCO-Swe...Tool_p_27.html
Reply:1/0  is overkill#2 would be fineEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:A crimp joint is only superior if you use a proper ultra high pressure crimp tool that compresses around the entire crimp sleeve.  To do it correctly requires different sized jaws for different sized cables and lugs.For large welding size cables, a proper commercial crimper will  have a long compound lever system to generate the many tons of force required, just like a set of bolt cutters. It actually crushes the copper wire and sleeve completely solid, so no moisture or air can get  into the joint to oxidize.Something like this:Cheers,  Tony._________________________________Transmig 310 + Argoshield LightOxy acetyleneOxy propanePrehistoric stick welder_________________________________
Reply:Originally Posted by WarpspeedA crimp joint is only superior if you use a proper ultra high pressure crimp tool that compresses around the entire crimp sleeve.  To do it correctly requires different sized jaws for different sized cables and lugs.For large welding size cables, a proper commercial crimper will  have a long compound lever system to generate the many tons of force required, just like a set of bolt cutters. It actually crushes the copper wire and sleeve completely solid, so no moisture or air can get  into the joint to oxidize.Something like this:
Reply:i just use a pair of bolt cutters to crimp them cable ends... seems to work for me
Reply:Originally Posted by solidstateYeah, but a crimper like that costs over 200 bucks.  Kind of pricey for occasional use.  .