Extension Cord for Welder

[BJ42LX]

I need a 240V extension cord for my welder. It's a Miller 211.

The 211 can use either 120VAC or 240VAC. The (short!) power cord coming off the unit has a proprietary adapter where you can screw on either a standard 120V/15A plug (NEMA 1-15P) or a 240V/50A plug (NEMA 6-50: think electric dryer plug).

You can see the adapters here, if you're interested:
http://store.cyberweld.com/mimvpmpl.html

The welder easily runs on 120VAC for sheet metal and stock up to 1/8" thick. I've got a project in the works where I may need the extra capacity of 240VAC.

I have plenty of power in the garage. I currently have a 240V/40A circuit (with 8 AWG wire in the wall) for my compressor. That receptacle is a NEMA 6-20 style. I'd like to use that outlet for my welder, if possible.

So, ideally, I'd like to have a 50' extension cord with NEMA 6-20 plug on the one end and a NEMA 6-50 receptacle on the other. Problem is I can't seem to find a 6-50 receptacle suitable for use on an cord. Google says everything available is for wall-mount and is usually 90-degrees.

The Miller manual suggests 12 AWG is sufficient for this run (the lead on the welder is 12 AWG), but I'd like to go with 10 AWG to minimize voltage drop.

Obviously, no one makes an extension cord like this. Short of making my own, does anyone have any better ideas about how to put this together? Especially if I can eliminate the wonkiness of the 6-50 receptacles.

 

[MP&C]

Go to your local electrical supply store, they should have all the components for you to make your extension cord.

 

[gte718p]

I was in a similar situation for my plasma cutter. The only reasonably priced option I could find was to make my own. 220 volt extension cords just don't seem to exist except for RV shore power plugs. Those are ridiculously expensive. I ended up making my own.

I see two options. The welder doesn't care what the plug voltage is, only line voltage. Take a good quality extension cord and cut the wall end off and wire in a 220 dryer plug.
Down side is now you have a single use cord, and if you forget and plug your 120 tools in its going to be interesting, so make sure you mark it well.

Option Two: I found good quality drier outlets with their own cases at my local electrical supply store. Combined with some high quality wire for a nice little extension cord. A good fine stranded wire is essential for a flexible cord. I went with 12 gauge on my 75 foot extension cord. Voltage drop is minimal. Good quality plugs are essential.

 

[K2Orion]

Make a "jumper" of sorts.
A 6-50 90* receptacle mounted to your welder or cart with a short pigatil coming out with your choice of male plug on the end. 6-20 would be my choice. Then use the cord you make/buy to go from the welder to the wall. Then you don't have a ******* cord thats only good for 1 use.

 

[Alchymist]

All my lower current 240 volt tools are set up on NEMA 6-15R. If you use the 6-20R receptacles, will take either 6-15 or 6-20 plugs, on 20 amp circuit.

 

[sberry]

The 6-50 R is not a dryer plug, it is a 2 pole 3 wire grounding type. Wire 12 or better, at 240 the V drop at 50 ft isnt anything you would notice, the main reason to go to 10 would be the cord may be useful for other machines.

 

[theoldwizard1]

Pass & Seymour 50A, 250V, NEMA 6-50R, 2 Pole, 3 Wire, Grounding, D0653 Gator Grip Connector

 

[fourjeepin]

I was trying to find the ends myself for my welder for a few years. When I found them, they were always very expensive. I ended up buying a 25 foot extension off of eBay. It wasn't cheap, but cheaper and better than cobbling something together.

This approach would only solve half of your problem. I would also suggest building the short adapter cord. Either that or switching your tools to a common plug. For safety, probably best to use the higher amp 6-50, even though you don't like this one. I did this to my old Lincoln tombstone so i didn't have to wire two types of outlets and so it could use the extension cord I purchased for my Miller.

 

[BJ42LX]

If you use the 6-20R receptacles, will take either 6-15 or 6-20 plugs, on 20 amp circuit.

I like that 6-20R duplex receptacle. I wouldn't have to unplug the compressor when using the welder.

Wire 12 or better, at 240 the V drop at 50 ft isnt anything you would notice, the main reason to go to 10 would be the cord may be useful for other machines.

I may go with 12 anyway. Miller recommends it and there's decent savings between 12 and 10 wire. Copper is stupid expensive these days. Stupid expensive.

Pass & Seymour 50A, 250V, NEMA 6-50R, 2 Pole, 3 Wire, Grounding, D0653 Gator Grip Connector

THAT is the receptacle I need for an extension cord. But $50. That hurts more than paying for copper.

I would suggest ... switching your tools to a common plug. For safety, probably best to use the higher amp 6-50, even though you don't like this one.

Yeah, common plug is the clean way to go in this case. I may just have to swallow hard and do it.

 

[just1more]

I also have a Miller 211. I had a 50 foot extension cord from my old Century welder. It has had a surface mount dryer recepticle on it for at least 20 years with no problems. I had to change the end when I bought the 211 and I went back to the surface mount again.
You just need to be a bit careful with it.

...dont be afraid to make your own, its usually cheaper.

 

[JerryC]

Same dilemma as you, same welder and same compressor outlet. I ended up changing the outlet to a 50A and changing the plug on the compressor to match.

I agonized over that for a week, it took just minutes to do. The 50A outlet fit in same box as the 6-20, all I needed was a new faceplate.

 

[countryss]

where in NY are you? General welding with multiple spots on Long Island have them. I may be able to get my hands on a homeade 10ga 220v cable with dryer end on it.

 

[BJ42LX]

I'm in Western New York. I was going to hit the local electrical supply on Monday. I'm sure they could set me up with all the parts. I suppose I could check with my welding supplier as well.

Or,

I could just get this, change the receptacle in the wall and the plug on my compressor:

http://www.ebay.com/itm/140832823701

They also offer a 50 footer, but at 8 AWG that's going to be a lot of cable to manage in the garage.

 

[mjb]

I had some 10ga SO left over and made one.

Made one to go from twist lock to welder.

I made this one if I ever need to run the Dynasty 200 on 115v.

The connectors are not cheap, but considering that extension cords tend to get kicked and thrown around, I wanted them to be durable.

 

[shawnspeed]

Do you have a Menards close??? They have a 25' welder cord for that same size welder...I found that is was about 20 bucks cheaper than the cord I put together that was only 20' long....and the ends were molded in & weather tight....Shawn

 

[JerryC]

I could just get this, change the receptacle in the wall and the plug on my compressor:

http://www.ebay.com/itm/140832823701

They also offer a 50 footer, but at 8 AWG that's going to be a lot of cable to manage in the garage.

I bought my M211 from them and got that same extansion cord. It's thick and doesnt bend easily. It took me a while to get it to lay straight when I took it of out the box. i basically had to bend it down the entire length to get it back straight. Probably made worse by the near freezing temps. I would get two 25's instead of one 50' if you plan to roll it up between uses.

 

[BDAZSVT]

Rural King also sells them

 

[BJ42LX]

I had some 10ga SO left over and made one.

I bought my M211 from them and got that same extansion cord. It's thick and doesnt bend easily.

Jerry, looks like that one is made with a plastic casing which is going to be very stiff as you found. It looks like mjb's cable is rubber, which is much more pliable even in cold weather.

Decisions, decisions.

 

[JerryC]

Jerry, looks like that one is made with a plastic casing which is going to be very stiff as you found. It looks like mjb's cable is rubber, which is much more pliable even in cold weather.

Decisions, decisions.

I think that is correct, it appears to be plastic cased.

 

[lmwilco1]

Can you tell me the manufacture and part number of the 250v 50A receptacle that you used? I tried to find one at the local electrical supply and they did not have one.

Louis

I had some 10ga SO left over and made one.


I made this one if I ever need to run the Dynasty 200 on 115v.

The connectors are not cheap, but considering that extension cords tend to get kicked and thrown around, I wanted them to be durable.

 

[KCarGuy]

I always get calls from Friends and Family about welding repairs.

I throw my 220VAC welder in the van and do the repair at their houses.

I made a 100 foot cord (3-10) with the Female Receptacle on one end and 3 Insulated Spring Clamps on the other.
I simply open up there Electrical box, clamp onto the ground and (fused) power legs...and Plug in my Welder.
Quick, Easy and One Cord.

 

[theoldwizard1]

Pass & Seymour 50A, 250V, NEMA 6-50R, 2 Pole, 3 Wire, Grounding, D0653 Gator Grip Connector

THAT is the receptacle I need for an extension cord. But $50. That hurts more than paying for copper.

Regardless of their size, good quality connectors are ALWAYS expensive.

Can you simply replace the compressor outlet box with a double box or add another box. Then install a 6-30R or 6-50R in the new box for your extension cord.

Above 20A locking plugs and receptacles seem to be more popular and therefore more cost effective.



If timing is not critical, you will save a lot of money by buying the same name brand parts on eBay that you would buy at your local electrical supply house.

 

[sberry]

I agree, add an outlet or better yet another circuit,,, maybe to location that is more ideal, all this is just a cobble in the end for the most part especially if this is some kind of permanent situation on property you own.

 

[E.Marquez]

This is what i used for my extension cord used with a Hobart Iron Man 250
http://store.cyberweld.com/primpowplug.html
http://store.cyberweld.com/primpowrec.html
and 50ft of 10ga SJOOW Cable. I have checked for lin loss with the welder cranked way up and zapping 1/2 plate... I’m very comfortable with my creation and it's been in use about 12 years now.

 

[BMW Rider]

I bought a 25' cord for my 211 from Princess Auto. They also have a 50' version available. I got mine when it was on sale for much less than the regular price. They had the 50' on sale as well at that time, but 25' was all I needed.

 

[mjb]

Can you tell me the manufacture and part number of the 250v 50A receptacle that you used? I tried to find one at the local electrical supply and they did not have one.

Louis

I got it from McMaster-Carr. http://www.mcmaster.com/#catalog/118/787/=ktolyh

The part number: 7120K83

 

[Sureshot]

It also depends on how much you plan to do. Is this a one time project, light duty?

I asked an electrician friend if I could borrow a chunk of cable to weld some tabs on some metal fence posts I had pounded in. He told me for the low duty cycle and temporary thing I was doing to just use some 14-2 I had on hand into the front of the panel. It worked fine for that small job with my tombstone welder.

 

[srmofo]

I just made an extension cord last week for my stuff. Ive got the hobart 210 and it has the same style plugs on it, but I always run it on 220v.

Anyway, I used #8 wire because I like to overdo things and I found it cheap. MENARDS IS THE PLACE TO GO FOR HEAVY GUAGE CORD. They dont sell it in bulk but they do sell it in pre-packaged lengths ranging from #6 to #12 and from 25',50', and 100' lengths.

I paid $42 for 25' #8 made in USA woods rubber cord ,but I had a 10% coupon. This same stuff is over $3/ft at home depot or lowes. The 6-50R is inside a Bell outdoor box ( $5 , #5324 ) and had cord strain relief from home depot ( 2 for $6, #051411216948). I had the plug and receptacle already

The only thing I am having an issue with is finding a cover for it. I just havent had time to get to the local electrical supply house. In the meantime I just bought a plastic blank cover and drilled the correct size hole in it with a forstener bit.

Yes it was a real PITA to install it into that box, but it works well and is water tight and wont blow apart if it gets dropped unlike those wall mounted receptacles that only have 1 tiny screw holding the cover on. I installed the receptacle 'upside down' so the cord could keep going in the same direction since those 6-50 plugs have the ground pin on the top.

Menards also had the same chinese welding PLASTIC cord pictured above in a 20' length for $70. Thats the same amount (little more actually) I am into my cord for and I have an extra 5' of higher quality cord.

 

[theoldwizard1]

... MENARDS IS THE PLACE TO GO FOR HEAVY GUAGE CORD. They dont sell it in bulk but they do sell it in pre-packaged lengths ranging from #6 to #12 and from 25',50', and 100' lengths.

Good to know ! They are opening a Menards within a couple of mile of my house this spring !!

The 6-50R is inside a Bell outdoor box ( $5 , #5324 ) ...

Images of that box show an "extra" hole in the back. What did you plug that with ?

 

[srmofo]

It actually has 3 holes. They come with plugs to fill in unnecessary holes. You just need to add sealant to threads to make it water proof

 

[sberry]

Take some pipe foam, wrap around box and tape on. Will stand some abuse.

 

[alan camby]

http://www.amazon.com/dp/B002IZ99G6/?tag=atomicindus08-20

http://store.cyberweld.com/230voexco25.html?utm_medium=shoppingengine&utm_source=productads

another option

 

[R.Anderson]

I use 10/4 SJOOW with a L14-30 plug and two 120v and two 240v one 100' and one 25'. That way I can use my plasma cutter, welder, grinders, drills, lights, saws, etc. off the same extension cord out of my shop or off my trailer's generator. E-bay was the cheapest place to buy the 10/4 SJOOW and the plugs and receptacles. I choose SJOOW because of the cold temperatures here in Wisconsin.

 

[sberry]

It also depends on how much you plan to do. Is this a one time project, light duty?

I asked an electrician friend if I could borrow a chunk of cable to weld some tabs on some metal fence posts I had pounded in. He told me for the low duty cycle and temporary thing I was doing to just use some 14-2 I had on hand into the front of the panel. It worked fine for that small job with my tombstone welder.

This is true to some extent, legally the tombstone can run on a 12 with 50A breaker.

. That way I can use my plasma cutter, welder, grinders, drills, lights, saws, etc. off the same extension cord out of my shop or off my trailer's generator. E-bay was the cheapest place to buy the 10/4 SJOOW

Ideally would be to have 20A overcurrent protection for tool circuits,, you could run 180 mig on 20A and same for a 375 plasma.

 

[R.Anderson]

I agree on the 20A over current protection. I have a couple of those push to reset breakers that I should wire in for the 120 outlets. I run a Miller passport plus and Everlast PP205 both can be ran on 30A 240v.

 

[Hammer1963]

I always get calls from Friends and Family about welding repairs.

I throw my 220VAC welder in the van and do the repair at their houses.

I made a 100 foot cord (3-10) with the Female Receptacle on one end and 3 Insulated Spring Clamps on the other.
I simply open up there Electrical box, clamp onto the ground and (fused) power legs...and Plug in my Welder.
Quick, Easy and One Cord.

A simple brilliant idea.Of course, you hope no fool tampers with the opened breaker panel.

 

[sberry]

Does the Passport come with a 50A plug?

 

[R.Anderson]

Yes it can plug into A 230v 50a outlet but also a standard 115v 20a
The MVP (Milller's Multi-Voltage Plug) allows you to plug into either 115v or 230v

 

[R.Anderson]

Ah I know what ya getting at lol I'm using L-10-30 plugs and outlets for 230/240. I made a adapter for my passport to plug in to it.

 

[sberry]

I was going to ask engineer how they got around providing a 14 cord that can be plugged in to 50A, it has its own thermal so the machine internals are fine but the 180 class wire feeders that come with 50A have a 12 cord which is the code and or nema minimum for it. My Maxstar is the same, comes with 14,,, seems I asked this,,, maybe I plain forgot?