Welder circuit termination question

[thecj3man]

I am running a new circuit to power my welding machine. The welder has a max input of 100 amps at 230 volts and a 60% maximum duty cycle. Looking through my borrowed code book it seems that I can utilize #4 copper since the 60% duty cycle factors into the equation. This machine will be directly connected with no plug in or receptacle and will be located 20 ft from the breaker panel.

My question is about making the connection inside the box. I had initially thought about using split bolts. Then I started reading up on the Polaris style connectors. Aside from the cost difference, is one style of connection better or worse than the other? Are there any other alternatives worth mentioning?

Thanks,
WAP

 

[Norcal]

Other then a bit higher cost Polaris or competitive connectors are better then split bolts.

 

[rockwithjason]

I haven't looked a prices in a while, how does a 100a disconnect compare to the connectors? you may find that a more satisfying install

 

[sberry]

What model welder?

 

[theoldwizard1]

They both do the same job and are "approved". The split bolt require 2 wrappings of GOOD quality electrical tape (3M 88 or 3M linerless splicing tape).

BTW, like sberry, I am curious about the model of welder. It must be a BEAST !

 

[Norcal]

I haven't looked a prices in a while, how does a 100a disconnect compare to the connectors? you may find that a more satisfying install

This is not a bad idea.

 

[thecj3man]

Thanks for the information. I had not considered a 100 amp disconnect, thank you for the idea. I am going to call around and see what I can find locally.

The welder is a Airco 300 Amp AC/DC Heliwelder. It is probably a mid 70s or Early 80s vintage machine, but it still works like a champ.

This is not my welder, but I happened to find one just like it on eBay so you can see what it looks like.

http://www.ebay.com/itm/Airco-300-Amps-AC-DC-Heliwelder-Tig-Welder-/261744702494

 

[TractorJeff]

My Dial-Arc is rated similar. I don't run it Full Tilt so I have it on a 50 amp rated circuit.

 

[thecj3man]

When this welder was still installed in my dad' shop it was on a 50 amp circuit. He only had 60 amp service to the whole building so it was a pain in the rear anytime we wanted to do any copper or serious aluminum work.

This was one of the deciding factors in putting a separate 200 amp service in my shop. I may never need to run it wide open, but I want to go ahead and provide the juice should I need it.

 

[buening]

The disconnect is the way to go IMO. Easy to wire and doesn't need any special connectors since your welder cord goes into the breaker. It also gives you a way of disconnecting power should you ever have an issue with the welder and need to kill power immediately beyond its own power switch.

 

[BD1]

You could use a fused discount too .

 

[brewchief]

If you think you might ever want to remove and reinstall the welder then I would use either the polaris connectors or a disconnect, peeling tape off split bolts to reuse will take the fun out of a day.

 

[sberry]

These will run from smaller circuits but if his is the case you cant over breaker and under wire. Some allowed up to 125 service and some 100. If a wire smaller than the min is used it needs a breaker to protect it for thermal.