Thermal Dynamics Plasma Cutter Cord Modification

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Ok, I touched on this before in another thread. My problem is that the Cutmaster 101 requires an 80amp breaker to feed a 50amp plug for a unit that draws 76 amps at full load.-I just don't care for the 50amp plug at the working end of an 80amp breaker.Here is my solution to the problem. For now. The Appleton connectors were in excess of $1200.00 for male and female and a housing.-I cut the end off, put new male ends on, put heat shrink on the cable, and connected them to the female ends to use! I saw this done in Las Vegas at a trade show. That is how everything in there was connected.-See 2nd post for the final pics.And thanks for looking. Attached ImagesLincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:And now the end product! Attached ImagesLincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:That is a good idea.  What size was the original cord?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:When you get up in that range in the amps, another good solution is a service disconnect box or even just a junction box (if within sight of a disconnect) with insulated bolt lugs (bugs) to make the connections.Favorite right now is a Miller Syncro 200.Tons of tools and I blame at least one of them when things don't go right.
Reply:Is the insulation on those rated to 240V? Personally I would not have done it, because if they come apart for some reason theres a posibbility of a short. The femal ends really arent recessed in as much as they should be for that voltage.But if you feel comfortable with it then use it.
Reply:Neat job, but isn't the 50 amp plug ok, due to the duty cycle of the cutter?How big is the wire from the cutter? Is it rated for 80 amps at 100%?Miller EconotigCutmaster 38Yes ma'am, that IS a screwdriver in my pocket!
Reply:Were you referring to temporary power for the convention facilities in Las Vegas?  We've both worked MANY of those shows and assembled countless of those cords.  But that really has little in common with a low-duty-cycle-limited shop machine.  A 50A plug here is pretty much standard operating procedure; see NEC Article 630.BUT IT'S YOUR MACHINE = YOUR CHOICE.Tanky, I know what you mean about the copper/brass not being very much recessed on a female end, but yes, that is the intended voltage for these products.  It is rare that you would have any of these laying around unless they were fully hooked up before being powered.  This is because it is very dangerous to connect and disconnect these devices while under load, and it says so plainly in many locations. We would still carry around voltage testers before touching just about anything.
Reply:Another thing that is SOP here for using those is to reverse the ground and neutral directions.  Only the hots would be a female on the line side.
Reply:Okay, answers to questions:DavidR: The original cord on the machine was 6/3, I used 4/3 S/O cable.Phila.Renewal: The short S/O cord hangs from a 12 X 12 junction box with a cable sock which supports the hanging cord. It is a short distanc, 15ft to the circuit breaker. I thought about putting a disconnect at the junction box but actually decided against it due to the proximity of the breaker.Tanky321: I did this as a temporary solution. I concede that you have a valid point. But the connectors are twist locks and coming apart is a remote possibility. I never connect or disconnect HOT and feel that the risk is minimal.JoeH: It seems that the NEC accepts the original plug due to duty cycle rating. I checked the code. It is completely legal and acceptable. I just don't like it. No other reason. The original cord on the cutter was 6/3. The unit is rated for 100% duty cycle at 40amps of cutting power. The duty cycle is reduced at full output of 80amps of cutting power.  Mac702: Yes, those are the ones I am speaking of. Yep, I checked the NEC code. Since I am not running a shop with employees, I did it my way. I am sure I would catch hell if I had OSHA come by but I just don't want a 50amp plug doing 76amp duty even at a reduced duty cycle.Mac702: That is a great idea! Reversing the ground directions. I didn't even think of that. Thanks!Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain