Durable Electrode Holders?

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Hi,My name is Paul, I'm an electrician who works in a Sugar Mill over in Australia and I maintain Lincoln DC600 (and other large Miller, WIA etc machines).I'm not sure how many of you guys would deal with the larger welders, but it doesn't hurt in asking.The Story/ Problem / Question:We have boiler makers who use wet arcing electrodes to reface the rollers (things that grind the sugar cane) and usually run the welders at 400 to 500A, these are stick welders btw.Up until a few years ago we were able to buy Lincoln Cooltong 400A electrode holders (though they could take much more than their rated 400A), which featured a metal strip for a spring, instead of a coil. Unfortunately these are no longer made.We now have to use these crappy 600A Cigweld holders that have a coiled steal spring that is held onto the handpiece by two plastic caps. Now although the handpiece is rated at 600A you only have to run it at 200 to 300A to melt the plastic caps after a few days use which causes the spring to drop out and the electrode holder is then useless.Does anyone know of anywhere that sells durable high rating electrode holders that have a spring that is a steel strip instead of a coil?Thankyou.
Reply:Your boilermakers will probably balk, but I would look at the Bernard Short Stub holders, probably the 600 Amp rated holder.
Reply:I finally settled on Jackson holders a long time ago for durability in the situations I used them in and they took quite a beating.  That said, a 400 amp holder was the largest I ever needed.
Reply:I would suggest a Duro stinger for not having a coil spring but personally I use LincolnT-300 stingersI know I may be burnt up, but your ol' lady likes 'em crispy!Member Pipeliners Union 798
Reply:Thanks for the input.The Duro holder looks really promising, I'm going to order a few and give them to our "butchers" to see how they hold up.We are currently trialing a Lenco HT-50, it holds the big rods fairly decently compared to the CIG holders although not as good as the old Cooltongs... I personally give it a week in the factory before I think it will melt.Thanks again.Last edited by nIMrOD888; 08-18-2009 at 07:19 PM.
Reply:The Duro holder turned out to be a failure, it doesn't even have a spring it just relies on the flex in the pincer arms to hold the rod in place.So far the HT-50 has been the best.Anyone got anymore ideas, still trying to source sellers for the other suggested electrode holders as it is hard to find in Aus.
Reply:Try Tweco?- If you can jump across it you can weld it!  - anonymous old boilermaker
Reply:The short stub style holder is the obvious solution.  The screw clamp action makes sure you have a good electrical connection reducing resistance and resulting heat.  Changing rods takes more time but worth the inconvenience.  I would like to suggest that one reason you are having trouble getting electrode holders with high amperage ratings is the changing times.  I find it interesting that stick electrodes would be used for hard facing a large area.  Someone has not thought about cost.
Reply:If you want something that will hold up forever, just use carbon guns  we use them for 5/32 and 3/16 wire pretty frequently."Real power is an arcair hand torch with a piece of 3/4 inch carbon and 1500 amps.  You feel like Zeus throwing a lightning bolt."
Reply:Bernard short stub ! No question.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720
Reply:The reason we use stick welders for hard facing is because not every roller can be accessed with a wirefeeder, we use a weldalloy auto arcing box for the rollers that are able to be accessed. We also cannot stop and take apart the mills as they need to be running all the time while the factory is operating (there are 5 rollers in each of the 6 mills, all of which weigh around 8 tonnes each).Just had a talk with the boiler makers and they say that the short stub type holder would not be suitable for use, as it is too restrictive for the places they need to use the stick welder. Also the electrode being used is 6mm so it isn't exactly the easiest welding rod to bend, especially when you go through 30 an hour.I also asked about the carbon guns, and there is only one boiler maker out of the lot who actually likes the things (I've not yet had a look at ours, didn't even know we had any).Thanks for your input though, I think you are right about the changing times.
Reply:on wirefeeders....you can get flexible necks for them....we're able to get wire feeders in a lot of places they shouldnt go because of those wonderful gadgets."Real power is an arcair hand torch with a piece of 3/4 inch carbon and 1500 amps.  You feel like Zeus throwing a lightning bolt."
Reply:2010 Update:Just finished another season of crushing and the original Lenco HT-50 electrode holders I put into service at the end of last year are still going strong. A fair bit of the insulation on the ends is burnt off but the jaw strength is still very good.Would highly recommend them if you are looking at big stick welding.
Reply:Check out tweco. I've had good luck with all of mine. Im not sure if they make one rated for those amps but its worth a look.Edit: oops I just noticed this is an old thread.