Longer welding leads or input power cable extension?

[E.Marquez]

I want to be able to move my Hobart ironman 250 farther away from the 240v 50 amp receptacle.

Say 25-35 feet.

Longer power cord extension?
Longer mig gun and ground leads?
Combined little of both?

 

[Ft.ValloniaStreaker]

You'll be better off making an extension cord, if you heading outside you might want to spend a little extra $ and got weather proof ends. I had my son make me one for a 4-H project.

 

[Dr.JohnnyFever]

I would almost always go with longer (and appropriately sized) power cord.

Usually, extending the part of the system that has the highest voltage is the most economical approach. Only so many electrons can cram themselves down a given diameter of copper wire. It is better to send fewer electrons at a higher potential.

 

[Kirbot]

Longer extension cord.

I really can't think of any possible reason to use longer leads, unless you actually need to get further away from the machine for some reason... (like going up a ladder)

 

[shawhite]

Extension cord would definitely be the cheaper alternative

 

[Buckgnarly]

MIG wire can only be pushed so far in the gun lead. Not even sure they make MIG leads that long. Best (and only?) bet is an extension cord for the welder.

 

[Angry welder]

Just keep in mind that while your are extending your extension cord for your power supply. That main power runs are sized for the length of pull from the panel or breaker box and for the amount of amp draw required for the wire itself. So if your planning to extend your extension cable 25-30 feet and your using 8ga. wire from the panel box. Then you will have to step up wire size and maybe circuit breaker size to accommodate the amount or wire for that run.

 

[Nele]

just make an extension, i just made 100ft extension with 6ga cable for 220v

 

[strutaeng]

Option 1 is really the only feasible one.

Have you looked to see if you can get a longer gun for your machine? Perhaps a Bernard 20' gun would work, but that's just 5 extra feet over your existing gun.

Make yourself an extension chord with connectors from the hardware store or buy a pre-made one. Research cable gages, amp draw and duty cycle of your welder...

I have an Ironman 210 that I keep mainly close to my garage receptacle. If I need to get across the garage or to my back yard, out of my shed comes my old buzzbox with of 50' of leads.

Good luck

 

[Loscaldazar]

I'd make an extension cord no doubt.

If you need to buy wire, I've found (http://www.wireandcabletogo.com/) is usually the cheapest, and they have some great options too. I just ordered 50FT of SOOW 10/3 wire and it was at my door just 3 business days later. Saved $30 over any local store, even when shipping was factored in. Since they have such a great selection, you can also make a much nicer extension cord than you could buy. Most extension cords will be SJ (severe junior service aka 300V rating, which the voltage isn't the bad part) that are made out of a cheaper more plastic outer coating. If you buy an SO or SOOW you get a nice industrial grade rubber compound. Some SOOW wires are even submersible they are so well insulated and made!

 

[E.Marquez]

Thanks all.

I have other welder options besides the "big One" but sometimes thats what I need or want to use.

I have a 15" mig lead now...and yes I know one can not just run out and buy a 50' one.

I was thinking combo of longer mig lead or spool gun and an extension cord OR just longer extension cord.

Was pretty sure the better idea was just a cord.... but you never know what's out there unless you ask.

I'm thinking 30ft of 8/3 SOOW .. but maybe go up to 6AWG? or is that overkill.
How much voltage loss can a welder work with?

 

[zkling]

For a mig* and tig machine, longer input power cord is usually the best option.

*barring a spool gun, even then I feel it is best to have the shortest length necessary to keep the gas line protected. A good 10/3 or what have you power cord can really take a thrashing without damage.

 

[e30bradley]

I built a 50 ft extension cord for my 190 amp 220v welder. I have since chopped a few feet off to use for something else so its about 45ft 3/10 wire. I've used the welder cranked all the way up and it runs good and doesn't make the cable hot or trip the breaker. I hope it runs as good as it would plugged into the wall but I don't know since I've really only used it through the extension.

 

[Loscaldazar]

A voltage drop calculator may be useful to find the gauge of wire you want to use. Usually you want less than a 3% voltage drop if possible. *deleted previous comments about amperage, had a major brain fart*
http://www.calculator.net/voltage-drop-calculator.html

Also, look in your owner's manual for what extension cord you need to use. Most welders have this information in their owner's manual because for these beasts, it is important that they have the proper gauge extension cord so you aren't popping breakers, starting fires, etc. I just bought a Hobart Handler 140 and it had a small chart that listed lengths of extension cords and what gauge wire it should be. Very useful!

 

[Dr.JohnnyFever]

A voltage drop calculator may be useful to find the gauge of wire you want to use. Usually you want less than a 3% voltage drop if possible. Don't know the exact specs of your welder, so I just used 300 Amps (I would guess that it being a ironman "250" it is probably 250 amps, but I added 20% margin of safety) for the load current, and at 35 feet you'll have a 3.18% voltage drop. I might use 8 gauge wire if my specs are correct.

An Ironman 250 draws 35A at 230V.

 

[Loscaldazar]

An Ironman 250 draws 35A at 230V.

Ahhh... right. Brain fart there. I was going off the output amps...not what it draws
My bad....

 

[E.Marquez]

A voltage drop calculator may be useful to find the gauge of wire you want to use. Usually you want less than a 3% voltage drop if possible. *deleted previous comments about amperage, had a major brain fart*
http://www.calculator.net/voltage-drop-calculator.html

Also, look in your owner's manual for what extension cord you need to use. Most welders have this information in their owner's manual because for these beasts, it is important that they have the proper gauge extension cord so you aren't popping breakers, starting fires, etc. I just bought a Hobart Handler 140 and it had a small chart that listed lengths of extension cords and what gauge wire it should be. Very useful!

My Ironman 250 is a few years old now... and a bit different then a current model 230.

but I opened up the owners manual just to see what it had to say on the subject (thanks for the reminder)
While there is no verbiage discussing extension cord... it does have a section on power supply.
Yes, at 230v it pulls 35 amps as already mentioned. The manual calls for a minimum of 10AWG wire and a Max Recommended Input Conductor Length In Feet" of 94 feet' So the answer was there all along... in digits on the same laptop I typed the question.

Add to that data a few calcs for voltage drop... and clearly 8/3 SOOW is more then enough for a 30-50ft extension cord.

Now to find plugs and receptacles for it.
Cyberweld has a 230 Volt Extension Cord features 25' or 50' of 8/3 power cable with lighted NEMA 6.50 (pin) male (plug) and female (receptacle) at each end. at a good price all things considered... but it uses a NEMA 6.50 setup.. and my welder and 230v outlet in use already are NEMA 10-50.

So I have to change the in use plugs to NEMA 6-50 or make a cord using NEMA 10-50

 

[Buckgnarly]

A tip I used for my own setup was to NOT make a 50' cord, but make two 25' cords. I have one extension on my HH175 and one on my MM210. Makes connecting one easy in the garage, and in the rare case I need the full 50' I pull the other from the other machine. Just a thought!

Oh yeah, used the SOO 8 gauge, makes for a flexible and durable cord!

 

[E.Marquez]

http://www.wireandcabletogo.com/
50ft of 8/3 SOOW ($82.50) and make two cords. Most times one is all i'll need.. so I'll have a back up and or the capability to go 50ft when needed.

Anyone have a source for a NEMA 6-50 recepticle that is designed for a cord? not a wall mount? preferable a straight on (in?) design not the typical 90deg

Or thinking two 25" cords from cyberweld
http://store.cyberweld.com/230voexco25.html
Its a bit more $$ but it gets me a nice pre made molded on plug in rubber vs hard plastic (all I can find so far) then buy a single Nema 6-50 recepticle for the wall and im done.

$144 from cyberweld and an $18 recep, $12 90deg plug from darn near any place and im done.

 

[bigdave39355]

http://www.wireandcabletogo.com/
50ft of 8/3 SOOW ($82.50) and make two cords. Most times one is all i'll need.. so I'll have a back up and or the capability to go 50ft when needed.

Anyone have a source for a NEMA 6-50 recepticle that is designed for a cord? not a wall mount? preferable a straight on (in?) design not the typical 90deg

Or thinking two 25" cords from cyberweld
http://store.cyberweld.com/230voexco25.html
Its a bit more $$ but it gets me a nice pre made molded on plug in rubber vs hard plastic (all I can find so far) then buy a single Nema 6-50 recepticle for the wall and im done.

$144 from cyberweld and an $18 recep, $12 90deg plug from darn near any place and im done.

i was looking for the same thing, just got a mm252.

torchking on ebay has those cords (25') for 63.50 shipped.

 

[Buckgnarly]

Hobart makes a straight on female end. Got mine from TSC.

Get SOO wire, it is WAY more flexible than those premade cords. I have a premade also, it pisses me off trying to wind it nicely...even worse in cold!

 

[E.Marquez]

i was looking for the same thing, just got a mm252.

torchking on ebay has those cords (25') for 63.50 shipped.

NICE

http://www.ebay.com/itm/25-220-Volt...263?pt=LH_DefaultDomain_0&hash=item339a3e3567

Thanks great find.. yes that makes even a better deal than making my own... Mcmaster carr has the plugs I want but they are $55 EACH

 

[E.Marquez]

Hobart makes a straight on female end. Got mine from TSC.

Get SOO wire, it is WAY more flexible than those premade cords. I have a premade also, it pisses me off trying to wind it nicely...even worse in cold!

The advantage to STW is it is a bit more cut resistant .. something to consider when you're dragging cable around a metal fab shop. Tends to be lots of sharp edges all over.
I have a SOOW 15" homemade cord now.. and yes while flexible, the jacket has lots of cuts from 10 years of abuse.

 

[E.Marquez]

Hobart makes a straight on female end. Got mine from TSC.

Thanks, I noticed that,,, but what about a straight on 6-50 recepticle? Seen one of those?

 

[Buckgnarly]

Thanks, I noticed that,,, but what about a straight on 6-50 recepticle? Seen one of those?

Like this?

http://www.galco.com/buy/Arrow-Hart...id=6709N-CWD&gclid=CL_ezKj4o8QCFYYkgQodMkQA8g

 

[E.Marquez]

Like this?

http://www.galco.com/buy/Arrow-Hart...id=6709N-CWD&gclid=CL_ezKj4o8QCFYYkgQodMkQA8g

Yes but damn $41 each...
That cost is driving me to a premade cord

 

[evintho]

Made a 25' extension cord for my Ironman 210. The cable was picked up at a garage sale for $5. It's the power supply cable for a motorhome so they can hook up to electrical at campgrounds. 10/3 wire. Got the plug and receptacle ends off Amazon for $20. Another $5-$6 for the box and cover. Works great!